Additive manufacturing technologies of porous metal implants

Directory of Open Access Journals (Sweden)

Yang Quanzhan

2014-06-01

Full Text Available Biomedical metal materials with good corrosion resistance and mechanical properties are widely used in orthopedic surgery and dental implant materials, but they can easily cause stress shielding due to the significant difference in elastic modulus between the implant and human bones. The elastic modulus of porous metals is lower than that of dense metals. Therefore, it is possible to adjust the pore parameters to make the elastic modulus of porous metals match or be comparable with that of the bone tissue. At the same time, the open porous metals with pores connected to each other could provide the structural condition for bone ingrowth, which is helpful in strengthening the biological combination of bone tissue with the implants. Therefore, the preparation technologies of porous metal implants and related research have been drawing more and more attention due to the excellent features of porous metals. Selective laser melting (SLM and electron beam melting technology (EBM are important research fields of additive manufacturing. They have the advantages of directly forming arbitrarily complex shaped metal parts which are suitable for the preparation of porous metal implants with complex shape and fine structure. As new manufacturing technologies, the applications of SLM and EBM for porous metal implants have just begun. This paper aims to understand the technology status of SLM and EBM, the research progress of porous metal implants preparation by using SLM and EBM, and the biological compatibility of the materials, individual design and manufacturing requirements. The existing problems and future research directions for porous metal implants prepared by SLM and EBM methods are discussed in the last paragraph.

Standard test methods for rockwell hardness of metallic materials

CERN Document Server

American Society for Testing and Materials. Philadelphia

2008-01-01

1.1 These test methods cover the determination of the Rockwell hardness and the Rockwell superficial hardness of metallic materials by the Rockwell indentation hardness principle. This standard provides the requirements for Rockwell hardness machines and the procedures for performing Rockwell hardness tests. 1.2 This standard includes additional requirements in annexes: Verification of Rockwell Hardness Testing Machines Annex A1 Rockwell Hardness Standardizing Machines Annex A2 Standardization of Rockwell Indenters Annex A3 Standardization of Rockwell Hardness Test Blocks Annex A4 Guidelines for Determining the Minimum Thickness of a Test Piece Annex A5 Hardness Value Corrections When Testing on Convex Cylindrical Surfaces Annex A6 1.3 This standard includes nonmandatory information in appendixes which relates to the Rockwell hardness test. List of ASTM Standards Giving Hardness Values Corresponding to Tensile Strength Appendix X1 Examples of Procedures for Determining Rockwell Hardness Uncertainty Appendix X...

Standard test methods for rockwell hardness of metallic materials

CERN Document Server

American Society for Testing and Materials. Philadelphia

2011-01-01

1.1 These test methods cover the determination of the Rockwell hardness and the Rockwell superficial hardness of metallic materials by the Rockwell indentation hardness principle. This standard provides the requirements for Rockwell hardness machines and the procedures for performing Rockwell hardness tests. 1.2 This standard includes additional requirements in annexes: Verification of Rockwell Hardness Testing Machines Annex A1 Rockwell Hardness Standardizing Machines Annex A2 Standardization of Rockwell Indenters Annex A3 Standardization of Rockwell Hardness Test Blocks Annex A4 Guidelines for Determining the Minimum Thickness of a Test Piece Annex A5 Hardness Value Corrections When Testing on Convex Cylindrical Surfaces Annex A6 1.3 This standard includes nonmandatory information in appendixes which relates to the Rockwell hardness test. List of ASTM Standards Giving Hardness Values Corresponding to Tensile Strength Appendix X1 Examples of Procedures for Determining Rockwell Hardness Uncertainty Appendix X...

Wear resistance of layers hard faced by the high-alloyed filler metal

OpenAIRE

Dušan Arsić; Vukić Lazić; Ruzica R. Nikolic; Milan Mutavdžić; Srbislav Aleksandrović; Milan Djordjević

2016-01-01

The objective of this work was to determine the wear resistance of layers hard faced by the high-alloyed filler metal, with or without the austenite inter-layer, on parts that operate at different sliding speeds in conditions without lubrication. The samples were hard faced with the filler metal E 10-UM-60-C with high content of C, Cr and W. Used filler metal belongs into group of alloys aimed for reparatory hard facing of parts damaged by abrasive and erosive wear and it is characterized by ...

The impact of the manufacturing process on the hardness and sensory properties of milk chocolate

Directory of Open Access Journals (Sweden)

Zarić Danica B.

2012-01-01

Full Text Available The aim of this paper was to examine the impact of the manufacturing process on the textural characteristics and sensory properties of milk chocolate. The research was conducted on the samples of chocolate produced in a ball mill during 30, 60 and 90 minutes of refining, each of them being pre-crystallized at 26, 28 and 30°C. A chocolate mass of identical ingredient composition was also produced using a standard manufacturing process at the same pre-crystallization temperatures. Chocolate hardness was examined using a piece of equipment called Texture Analyser, measuring the stress intensity which leads to chocolate crushing. Sensory analysis was performed using the point scoring method. The new manufacturing process, i.e. the manufacturing of chocolate in a ball mill improves sensory properties and hardness of milk chocolate. [Projekat Ministarstva nauke Republike Srbije, br. TR 31014

Relationship between nickel and cobalt sensitization in hard metal workers

Energy Technology Data Exchange (ETDEWEB)

Rystedt, I; Fischer, T

1983-05-01

Eight hundred fifty-three hard metal workers were examined and patch tested with 20 substances from their environment, including nickel and cobalt. Nickel sensitivity was found in 2 men and 38 women. 88% of the nickel-sensitive individuals had developed a jewelry dermatitis prior to employment in the hard metal industry or before the appearance of hand eczema. 29% of the hard metal workers gave a history of slight irritant dermatitis. In the nickel sensitized group, 40% had had severe hand eczema which generally appeared 6-12 months after starting employment. In 25% of the cases, nickel sensitive individuals developed cobalt allergy, compared with 5% in the total population investigated. Most facts indicate that nickel sensitivity and irritant hand eczema precede cobalt sensitization. Hard metal workers with simultaneous nickel and cobalt sensitivity had a more severe hand eczema than those with isolated cobalt or nickel sensitivity or only irritant dermatitis. 64% of the female population had pierced ear lobes. Among the nickel allergic women, 95% had pierced ear lobes. The use of earrings containing nickel after piercing is strongly suspected of being the major cause of nickel sensitivity. Piercing at an early age seems to increase the risk of incurring nickel sensitivity.

Fracture toughness measurements of WC-based hard metals

International Nuclear Information System (INIS)

Prakash, L.; Albert, B.

1983-01-01

The fracture toughness of WC-based cemented carbides was determined by different methods. The values obtained are dependent on the procedure of measurement. Each method thoughness of hard metals mutually. (orig.) [de

Evaluation of workers exposed to dust containing hard metals and aluminum oxide.

Science.gov (United States)

Schwarz, Y; Kivity, S; Fischbein, A; Abraham, J L; Fireman, E; Moshe, S; Dannon, Y; Topilsky, M; Greif, J

1998-08-01

Fourteen worker exposed to hard metals and aluminum oxide were evaluated. Six heavily exposed workers underwent bronchoscopy and bronchoalveolar lavage, and five workers underwent transbronchial biopsy. Microchemical analysis of transbronchial biopsies showed a high lung burden of exogenous particles, especially metal related to their hard metals exposure. Lung tissue and cellular changes, which were associated with exposure to hard metal and aluminum oxide, corresponded well with the microanalytic test results. Three workers had at biopsy diffuse interstitial inflammatory changes: two of them were asymptomatic with normal chest X-ray films, and one had clinically evident disease with severe giant cell inflammation. Two other workers showed focal inflammation. The worker showing clinical disease and one asymptomatic worker with interstitial inflammatory changes had evaluated bronchoalveolar lavage fluid-eosinophilia counts. These two were father (with clinical disease) and son (asymptomatic).

Characterization of Metal Powders Used for Additive Manufacturing.

Science.gov (United States)

Slotwinski, J A; Garboczi, E J; Stutzman, P E; Ferraris, C F; Watson, S S; Peltz, M A

2014-01-01

Additive manufacturing (AM) techniques can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process.

Characterization of Metal Powders Used for Additive Manufacturing

Science.gov (United States)

Slotwinski, JA; Garboczi, EJ; Stutzman, PE; Ferraris, CF; Watson, SS; Peltz, MA

2014-01-01

Additive manufacturing (AM) techniques1 can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process. PMID:26601040

Theoretical calculations of hardness and metallicity for multibond hexagonal 5d transition metal diborides with ReB2 structure

International Nuclear Information System (INIS)

Yang Jun; Gao Fa-Ming; Liu Yong-Shan

2017-01-01

The hardness, electronic, and elastic properties of 5d transition metal diborides with ReB 2 structure are studied theoretically by using the first principles calculations. The calculated results are in good agreement with the previous experimental and theoretical results. Empirical formulas for estimating the hardness and partial number of effective free electrons for each bond in multibond compounds with metallicity are presented. Based on the formulas, IrB 2 has the largest hardness of 21.8 GPa, followed by OsB 2 (21.0 GPa) and ReB 2 (19.7 GPa), indicating that they are good candidates as hard materials. (paper)

3D metal droplet printing development and advanced materials additive manufacturing

Directory of Open Access Journals (Sweden)

Lawrence E. Murr

2017-01-01

Full Text Available While commercial additive manufacturing processes involving direct metal wire or powder deposition along with powder bed fusion technologies using laser and electron beam melting have proliferated over the past decade, inkjet printing using molten metal droplets for direct, 3D printing has been elusive. In this paper we review the more than three decades of development of metal droplet generation for precision additive manufacturing applications utilizing advanced, high-temperature metals and alloys. Issues concerning process optimization, including product structure and properties affected by oxidation are discussed and some comparisons of related additive manufactured microstructures are presented.

Laser-based additive manufacturing of metals

CSIR Research Space (South Africa)

Kumar, S

2010-11-01

Full Text Available For making metallic products through Additive Manufacturing (AM) processes, laser-based systems play very significant roles. Laser-based processes such as Selective Laser Melting (SLM) and Laser Engineered Net Shaping (LENS) are dominating processes...

An In-Depth Review on Direct Additive Manufacturing of Metals

Science.gov (United States)

Azam, Farooq I.; Rani, Ahmad Majdi Abdul; Altaf, Khurram; Rao, T. V. V. L. N.; Aimi Zaharin, Haizum

2018-03-01

Additive manufacturing (AM), also known as 3D Printing, is a revolutionary manufacturing technique which has been developing rapidly in the last 30 years. The evolution of this precision manufacturing process from rapid prototyping to ready-to-use parts has significantly alleviated manufacturing constraints and design freedom has been outstandingly widened. AM is a non-conventional manufacturing technique which utilizes a 3D CAD model data to build parts by adding one material layer at a time, rather than removing it and fulfills the demand for manufacturing parts with complex geometric shapes, great dimensional accuracy, and easy to assemble parts. Additive manufacturing of metals has become the area of extensive research, progressing towards the production of final products and replacing conventional manufacturing methods. This paper provides an insight to the available metal additive manufacturing technologies that can be used to produce end user products without using conventional manufacturing methods. The paper also includes the comparison of mechanical and physical properties of parts produced by AM with the parts manufactured using conventional processes.

Applications of Metal Additive Manufacturing in Veterinary Orthopedic Surgery

Science.gov (United States)

Harrysson, Ola L. A.; Marcellin-Little, Denis J.; Horn, Timothy J.

2015-03-01

Veterinary medicine has undergone a rapid increase in specialization over the last three decades. Veterinarians now routinely perform joint replacement, neurosurgery, limb-sparing surgery, interventional radiology, radiation therapy, and other complex medical procedures. Many procedures involve advanced imaging and surgical planning. Evidence-based medicine has also become part of the modus operandi of veterinary clinicians. Modeling and additive manufacturing can provide individualized or customized therapeutic solutions to support the management of companion animals with complex medical problems. The use of metal additive manufacturing is increasing in veterinary orthopedic surgery. This review describes and discusses current and potential applications of metal additive manufacturing in veterinary orthopedic surgery.

Process Modeling and Validation for Metal Big Area Additive Manufacturing

Energy Technology Data Exchange (ETDEWEB)

Simunovic, Srdjan [ORNL; Nycz, Andrzej [ORNL; Noakes, Mark W. [ORNL; Chin, Charlie [Dassault Systemes; Oancea, Victor [Dassault Systemes

2017-05-01

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to accelerate the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.

Nanotoxicity: emerging concerns regarding nanomaterial safety and occupational hard metal (WC-Co) nanoparticle exposure.

Science.gov (United States)

Armstead, Andrea L; Li, Bingyun

As the number of commercial and consumer products containing engineered nanomaterials (ENMs) continually rises, the increased use and production of these ENMs presents an important toxicological concern. Although ENMs offer a number of advantages over traditional materials, their extremely small size and associated characteristics may also greatly enhance their toxic potentials. ENM exposure can occur in various consumer and industrial settings through inhalation, ingestion, or dermal routes. Although the importance of accurate ENM characterization, effective dosage metrics, and selection of appropriate cell or animal-based models are universally agreed upon as important factors in ENM research, at present, there is no "standardized" approach used to assess ENM toxicity in the research community. Of particular interest is occupational exposure to tungsten carbide cobalt (WC-Co) "dusts," composed of nano- and micro-sized particles, in hard metal manufacturing facilities and mining and drilling industries. Inhalation of WC-Co dust is known to cause "hard metal lung disease" and an increased risk of lung cancer; however, the mechanisms underlying WC-Co toxicity, the inflammatory disease state and progression to cancer are poorly understood. Herein, a discussion of ENM toxicity is followed by a review of the known literature regarding the effects of WC-Co particle exposure. The risk of WC-Co exposure in occupational settings and the updates of in vitro and in vivo studies of both micro- and nano-WC-Co particles are discussed.

Manufacture and study of osmotic metallic membranes

International Nuclear Information System (INIS)

Deschamps, Richard

1970-01-01

The manufacture of metallic membranes, which are semi-permeable to salt water, was investigated. The best results were obtained with nickel which had been deposited 'in situ' on sintered nickel, whose pore spectrum was sharp. The investigation showed that in the case of metallic membranes reverse osmosis is only a filtration. The large quantities of water produced and the low salt rejection rate compared to that with cellulose acetate membranes demonstrated that metallic membranes are better suited to depollution than desalination. (author) [fr

Wear resistance of layers hard faced by the high-alloyed filler metal

Directory of Open Access Journals (Sweden)

Dušan Arsić

2016-10-01

Full Text Available The objective of this work was to determine the wear resistance of layers hard faced by the high-alloyed filler metal, with or without the austenite inter-layer, on parts that operate at different sliding speeds in conditions without lubrication. The samples were hard faced with the filler metal E 10-UM-60-C with high content of C, Cr and W. Used filler metal belongs into group of alloys aimed for reparatory hard facing of parts damaged by abrasive and erosive wear and it is characterized by high hardness and wear resistance. In experiments, the sliding speed and the normal loading were varied and the wear scar was monitored, based on which the volume of the worn material was calculated analytically. The contact duration time was monitored over the sliding path of 300 mm. The most intensive wear was established for the loading force of 100 N and the sliding speed of 1 m.s-1, though the significant wear was also noticed in conditions of the small loading and speed of 0.25 m.s-1, which was even greater that at larger speeds.

Manufacturing processes of cellular metals. Part I. Liquid route processes

International Nuclear Information System (INIS)

Fernandez, P.; Cruz, L. J.; Coleto, J.

2008-01-01

With its interesting and particular characteristics, cellular metals are taking part of the great family of new materials. They can have open or closed porosity. At the present time, the major challenge for the materials researchers is based in the manufacturing techniques improvement in order to obtain reproducible and reliable cellular metals with quality. In the present paper, the different production methods to manufacture cellular metals by liquid route are reviewed; making a short description about the main parameters involved and the advantages and drawbacks in each of them. (Author) 106 refs

Feasibility Study on 3-D Printing of Metallic Structural Materials with Robotized Laser-Based Metal Additive Manufacturing

Science.gov (United States)

Ding, Yaoyu; Kovacevic, Radovan

2016-07-01

Metallic structural materials continue to open new avenues in achieving exotic mechanical properties that are naturally unavailable. They hold great potential in developing novel products in diverse industries such as the automotive, aerospace, biomedical, oil and gas, and defense. Currently, the use of metallic structural materials in industry is still limited because of difficulties in their manufacturing. This article studied the feasibility of printing metallic structural materials with robotized laser-based metal additive manufacturing (RLMAM). In this study, two metallic structural materials characterized by an enlarged positive Poisson's ratio and a negative Poisson's ratio were designed and simulated, respectively. An RLMAM system developed at the Research Center for Advanced Manufacturing of Southern Methodist University was used to print them. The results of the tensile tests indicated that the printed samples successfully achieved the corresponding mechanical properties.

Standard hardness conversion tables for metals relationship among brinell hardness, vickers hardness, rockwell hardness, superficial hardness, knoop hardness, and scleroscope hardness

CERN Document Server

American Society for Testing and Materials. Philadelphia

2007-01-01

1.1 Conversion Table 1 presents data in the Rockwell C hardness range on the relationship among Brinell hardness, Vickers hardness, Rockwell hardness, Rockwell superficial hardness, Knoop hardness, and Scleroscope hardness of non-austenitic steels including carbon, alloy, and tool steels in the as-forged, annealed, normalized, and quenched and tempered conditions provided that they are homogeneous. 1.2 Conversion Table 2 presents data in the Rockwell B hardness range on the relationship among Brinell hardness, Vickers hardness, Rockwell hardness, Rockwell superficial hardness, Knoop hardness, and Scleroscope hardness of non-austenitic steels including carbon, alloy, and tool steels in the as-forged, annealed, normalized, and quenched and tempered conditions provided that they are homogeneous. 1.3 Conversion Table 3 presents data on the relationship among Brinell hardness, Vickers hardness, Rockwell hardness, Rockwell superficial hardness, and Knoop hardness of nickel and high-nickel alloys (nickel content o...

Additively manufactured metallic porous biomaterials based on minimal surfaces

DEFF Research Database (Denmark)

Bobbert, F. S. L.; Lietaert, K.; Eftekhari, Ali Akbar

2017-01-01

Porous biomaterials that simultaneously mimic the topological, mechanical, and mass transport properties of bone are in great demand but are rarely found in the literature. In this study, we rationally designed and additively manufactured (AM) porous metallic biomaterials based on four different...... of bone properties is feasible, biomaterials that could simultaneously mimic all or most of the relevant bone properties are rare. We used rational design and additive manufacturing to develop porous metallic biomaterials that exhibit an interesting combination of topological, mechanical, and mass...

Morphology, microstructure, and hardness of titanium (Ti-6Al-4V) blocks deposited by wire-feed additive layer manufacturing (ALM)

International Nuclear Information System (INIS)

Brandl, Erhard; Schoberth, Achim; Leyens, Christoph

2012-01-01

Highlights: ► The microstructure and hardness of deposited Ti-6Al-4V blocks are investigated. ► Hardness is influenced by post heat treatment rather than by process parameters. ► Microstructure within the prior β-grains varies to some extent from grain to grain. ► A 600 °C/4 h treatment significantly increased the average hardness. - Abstract: Additive layer manufacturing offers a potential for time and cost savings, especially for aerospace components made from costly titanium alloys. In this paper, the morphology, microstructure, chemical composition, and hardness of additive manufactured Ti-6Al-4V blocks are investigated and discussed. Blocks (7 beads wide, 7 layers high) were deposited using Ti-6Al-4V wire and a Nd:YAG laser. Two different sets of parameters are used and three different post heat treatment conditions (as-built, 600 °C/4 h, 1200 °C/2 h) are investigated. The experiments reveal elementary properties of additive manufactured Ti-6Al-4V material in correlation to process parameters and heat treatments, which are discussed comprehensively.

Cleaning Process Development for Metallic Additively Manufactured Parts

Science.gov (United States)

Tramel, Terri L.; Welker, Roger; Lowery, Niki; Mitchell, Mark

2014-01-01

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

21 CFR 178.3910 - Surface lubricants used in the manufacture of metallic articles.

Science.gov (United States)

2010-04-01

... 21 Food and Drugs 3 2010-04-01 2009-04-01 true Surface lubricants used in the manufacture of... lubricants used in the manufacture of metallic articles. The substances listed in this section may be safely used in surface lubricants employed in the manufacture of metallic articles that contact food, subject...

Metal Advanced Manufacturing Bot-Assisted Assembly (MAMBA) Process, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Tethers Unlimited, Inc. (TUI) proposes to develop the Metal Advanced Manufacturing Bot-Assisted Assembly (MAMBA) Process, a robotically managed metal press and...

Development of strength-hardness relationships in additively manufactured titanium alloys

Energy Technology Data Exchange (ETDEWEB)

Keist, Jayme S., E-mail: keist@psu.edu; Palmer, Todd A., E-mail: tap103@psu.edu

2017-05-02

A major concern for additively manufactured (AM) Ti-6Al-4V components is how AM processing parameters and post-process heat treatments impact the resulting mechanical behavior. The applicability of using microhardness measurements as a predictive tool for yield and tensile strengths of AM Ti-6Al-4V would provide a rapid and useful screening mechanism for ensuring that properties meet requirements in complex geometries. However, microhardness measurements on Ti-6Al-4V exhibit high levels of data variability due to the orientational impact of the α phase. In order to overcome this variability in hardness measurements, a methodology for aggregating microhardness data in individual builds has been developed and validated. By compiling mean microhardness values from various AM components produced by electron beam based directed energy deposition (DED), laser based DED, and laser based powder bed fusion (PBF) processes in the as-deposited and post-process heat treated conditions, strong linear correlations between strength and hardness can be developed in AM materials having a lamellar α+β microstructure. With the addition of strain hardening and α phase orientation contributions to the mean microhardness measurement, the strength-hardness correlations of AM Ti-6Al-4V followed empirically derived models, opening the possibility of using these models to predict strengths from AM components regardless of the AM process or post-process state.

Influence of chemical pretreatment of hard metal substrates for diamond deposition

International Nuclear Information System (INIS)

Buck, V.; Kluwe, H.; Schmiler, B.; Deuerler, F.

2001-01-01

Diamond coated cutting tools are of increasing importance in the fields of high speed cutting, dry machining or machining of special materials such as metal-matrix-composites. A well known problem is the poor adhesion of diamond films on hard metals due to the Co- or Ni-binder that catalyzes the formation of graphite. Several methods - such as the application of intermediate layers or mechanical or chemical pretreatment of the hard metal substrate - have been developed to overcome this effect. Usually chemical pretreatment is used in order to reduce the concentration of binder phase on the surface that is to be coated. Surprisingly pretreatment with agents such as Murakami's solution result in improved adhesion and nucleation of diamond films while the concentration of the binder phase on the surface is enhanced. This 'contradiction' can be explained by proving that the surface is converted into a very thin oxide/hydroxide film. (author)

Research on Computer Integrated Manufacturing of Sheet Metal Parts for Lithium Battery

Directory of Open Access Journals (Sweden)

Pan Wei-Min

2016-01-01

Full Text Available Lithium battery has been widely used as the main driving force of the new energy vehicle in recent years. Sheet metal parts are formed by means of pressure forming techniques with the characteristics of light weight, small size and high structural strength. The sheet metal forming has higher productivity and material utilization than the mechanical cutting, therefore sheet metal parts are widely used in many fields, such as modern automotive industry, aviation, aerospace, machine tools, instruments and household appliances. In this paper, taking a complex lithium battery box as an example, the integrated manufacturing of sheet metal parts is studied, and the digital integrated design and manufacturing process system is proposed. The technology is studied such as sheet metal design, unfolding, sheet nesting and laser cutting, CNC turret punch stamping programming, CNC bending etc. The feasibility of the method is verified through the examples of products and the integrated manufacturing of sheet metal box is completed.

Morphology, microstructure, and hardness of titanium (Ti-6Al-4V) blocks deposited by wire-feed additive layer manufacturing (ALM)

Energy Technology Data Exchange (ETDEWEB)

Brandl, Erhard, E-mail: erhard.brandl@eads.net [EADS Innovation Works, Metallic Technologies and Surface Engineering, D-81663 Munich (Germany); Schoberth, Achim, E-mail: achim.schoberth@eads.net [EADS Innovation Works, Metallic Technologies and Surface Engineering, D-81663 Munich (Germany); Leyens, Christoph, E-mail: christoph.leyens@tu-dresden.de [Technical University of Dresden, Institute of Materials Science, Chair of Materials Technology, Berndt-Bau, Helmholtzstr. 7, D-01062 Dresden (Germany)

2012-01-15

Highlights: Black-Right-Pointing-Pointer The microstructure and hardness of deposited Ti-6Al-4V blocks are investigated. Black-Right-Pointing-Pointer Hardness is influenced by post heat treatment rather than by process parameters. Black-Right-Pointing-Pointer Microstructure within the prior {beta}-grains varies to some extent from grain to grain. Black-Right-Pointing-Pointer A 600 Degree-Sign C/4 h treatment significantly increased the average hardness. - Abstract: Additive layer manufacturing offers a potential for time and cost savings, especially for aerospace components made from costly titanium alloys. In this paper, the morphology, microstructure, chemical composition, and hardness of additive manufactured Ti-6Al-4V blocks are investigated and discussed. Blocks (7 beads wide, 7 layers high) were deposited using Ti-6Al-4V wire and a Nd:YAG laser. Two different sets of parameters are used and three different post heat treatment conditions (as-built, 600 Degree-Sign C/4 h, 1200 Degree-Sign C/2 h) are investigated. The experiments reveal elementary properties of additive manufactured Ti-6Al-4V material in correlation to process parameters and heat treatments, which are discussed comprehensively.

Materials and Manufacturing Processing; Special Issue on Hard Carbon Films

Science.gov (United States)

1993-01-01

AZ 85721 G. SMOLIK, P.O. Box 1625, Idaho National Engineering Laboratory, Idaho Falls, ID 83415 J.B. TERRELL, Reynolds Metals Company, P.O. Box 27003 ...18%Si alloy using inserts of ISO SPGN120308 and HEHN532FN. The damage to diamond films after cutting was examined by SEM and micro-laser Raman...uncoated cemented carbide insert corresponding to ISO K10 grade and sintered diamond insert were also used. Milling a hard carbon under dry condition The

A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process

Directory of Open Access Journals (Sweden)

Baoqiang Cong

2017-03-01

Full Text Available In order to build a better understanding of the relationship between depositing mode and porosity, microstructure, and properties in wire + arc additive manufacturing (WAAM 2319-Al components, several Al-6.3%Cu deposits were produced by WAAM technique with cold metal transfer (CMT variants, pulsed CMT (CMT-P and advanced CMT (CMT-ADV. Thin walls and blocks were selected as the depositing paths to make WAAM samples. Porosity, microstructure and micro hardness of these WAAM samples were investigated. Compared with CMT-P and thin wall mode, CMT-ADV and block process can effectively reduce the pores in WAAM aluminum alloy. The microstructure varied with different depositing paths and CMT variants. The micro hardness value of thin wall samples was around 75 HV from the bottom to the middle, and gradually decreased toward the top. Meanwhile, the micro hardness value ranged around 72–77 HV, and varied periodically in block samples. The variation in micro hardness is consistent with standard microstructure characteristics.

Application of Hard Metal Weld Deposit in the Area of Mixing Organic Materials

Directory of Open Access Journals (Sweden)

Jiří Votava

2014-01-01

Full Text Available Any machine part is subject to degradation processes. Intensive wear occurs either when two bearing surfaces come into contact or when loose particles rub the function surface of a machine part. Soil processing machines are a good example. A similar process of abrasive wear occurs also in mixing machines or lines for material transport, such as worm-conveyors. The experiment part of this paper analyses hard metal weld deposit dedicated for renovation of abrasive stressed surfaces. In order to prolong the service life of a blade disc in a mixing machine Kreis-Biogas-Dissolver, the technology of hard surfacing by an electric arc was used. Tested hard metal electrodes were applied on a steel tape class 11 373. To eliminate mixing with the base material, weld beads were applied in two layers. Firstly, the weld bead was visually analyzed on a binocular microscope. Further, weld bead as well as the base material was analyzed from the metallographic point of view, whose aim was to identify the structure of weld metal and the origin of microcracks in weld bead. Moreover, there was also measured microhardness of weld metal. Abrasive resistance was tested according to the norm ČSN 01 5084, which is an abrasive cloth test. As in the mixing process also erosion wear occurs, there was also processed a test on a Bond device simulating stress of test samples by loose abrasive particles. The abrading agents were formed by broken stones of 8–16 mm in size. Based on the results of the individual tests, the recommendation of usage hard metal electrodes for prolonging service life of machine parts will be made.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

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Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

Annealing of Co-Cr dental alloy: effects on nanostructure and Rockwell hardness.

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Ayyıldız, Simel; Soylu, Elif Hilal; Ide, Semra; Kılıç, Selim; Sipahi, Cumhur; Pişkin, Bulent; Gökçe, Hasan Suat

2013-11-01

The aim of the study was to evaluate the effect of annealing on the nanostructure and hardness of Co-Cr metal ceramic samples that were fabricated with a direct metal laser sintering (DMLS) technique. Five groups of Co-Cr dental alloy samples were manufactured in a rectangular form measuring 4 × 2 × 2 mm. Samples fabricated by a conventional casting technique (Group I) and prefabricated milling blanks (Group II) were examined as conventional technique groups. The DMLS samples were randomly divided into three groups as not annealed (Group III), annealed in argon atmosphere (Group IV), or annealed in oxygen atmosphere (Group V). The nanostructure was examined with the small-angle X-ray scattering method. The Rockwell hardness test was used to measure the hardness changes in each group, and the means and standard deviations were statistically analyzed by one-way ANOVA for comparison of continuous variables and Tukey's HSD test was used for post hoc analysis. P values of directly affected both the nanostructure and hardness of the Co-Cr alloy. Group III exhibited a non-homogeneous structure and increased hardness (48.16 ± 3.02 HRC) because the annealing process was incomplete and the inner stress was not relieved. Annealing in argon atmosphere of Group IV not only relieved the inner stresses but also decreased the hardness (27.40 ± 3.98 HRC). The results of fitting function presented that Group IV was the most homogeneous product as the minimum bilayer thickness was measured (7.11 Å). After the manufacturing with DMLS technique, annealing in argon atmosphere is an essential process for Co-Cr metal ceramic substructures. The dentists should be familiar with the materials that are used in clinic for prosthodontics treatments.

Radiation hardness of silicon detectors manufactured on wafers from various sources

International Nuclear Information System (INIS)

Dezillie, B.; Bates, S.; Glaser, M.; Lemeilleur, F.; Leroy, C.

1997-01-01

Impurity concentrations in the initial silicon material are expected to play an important role for the radiation hardness of silicon detectors, during their irradiation and for their evolution with time after irradiation. This work reports on the experimental results obtained with detectors manufactured using various float-zone (FZ) and epitaxial-grown material. Preliminary results comparing the changes in leakage current and full depletion voltage of FZ and epitaxial detectors as a function of fluence and of time after 10 14 cm -2 proton irradiation are given. The measurement of charge collection efficiency for epitaxial detectors is also presented. (orig.)

Casting technology for manufacturing metal rods from simulated metallic spent fuels

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Leeand, Y. S.; Lee, D. B.; Kim, C. K.; Shin, Y. J.; Lee, J. H.

2000-09-01

A uranium metal rod 13.5 mm in diameter and 1,150 mm long was produced from simulated metallic spent fuels with advanced casting equipment using the directional-solidification method. A vacuum casting furnace equipped with a four-zone heater to prevent surface oxidation and the formation of surface shrinkage holes was designed. By controlling the axial temperature gradient of the casting furnace, deformation by the surface shrinkage phenomena was diminished, and a sound rod was manufactured. The cooling behavior of the molten uranium was analyzed using the computer software package MAGMAsoft.

Manufacturing technology development of plasma/ion nitriding for improvement of hardness of machine components and tools

International Nuclear Information System (INIS)

Suprapto; Tjipto Sujitno; Saminto

2015-01-01

The manufacturing technology development of plasma/ion nitriding to improve of hardness of machine components and tools has been done. The development of this technology aims to improve device performance plasma nitriding double chamber and conducted with the addition of thermal radiation shield. Testing was done by testing for preheating operation (start-up), test operation for conditions nitriding and test for nitriding process. The results show that: the plasma nitriding device can be operated for nitriding process at the temperature of about 500 °C for 6 hours, using the thermal radiation shield obtained outside wall temperature of about 65 °C and shorten start-up time to about 60 minutes. The use of thermal radiation shield can also improve the efficiency of the electric power supply and increase the operating temperature for nitriding process. Test for nitriding obtained increase of hardness 1.33 times for the original camshaft (genuine parts) and 1.8 times for the imitation camshaft (imitation parts), the results are compared with after the tempering process at a temperature of 600 °C. For sample SS 304 was 2.45 times compared with before nitrided These results indicate that the development of manufacturing technology of plasma/ion nitriding to increase hardness of machine components and tools have been successfully able to increase the hardness, although still need to be optimized. Besides that, these devices can be developed to use for the process of carburizing and carbonitriding. (author)

Hard X-ray-induced optical luminescence via biomolecule-directed metal clusters†

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Pratx, Guillem; Sun, Conroy; Sakamoto, Masanori; Ahmad, Moiz; Volotskova, Olga; Ong, Qunxiang; Teranishi, Toshiharu; Harada, Yoshie

2014-01-01

Here, we demonstrate that biomolecule-directed metal clusters are applicable in the study of hard X-ray excited optical luminescence, promising a new direction in the development of novel X-ray-activated imaging probes. PMID:24463467

Final Air Toxics Standards for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources Fact Sheet

Science.gov (United States)

This page contains a December 2007 fact sheet with information regarding the National Emissions Standards for Hazardous Air Pollutants (NESHAP) for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources

Hardness variability in commercial technologies

International Nuclear Information System (INIS)

Shaneyfelt, M.R.; Winokur, P.S.; Meisenheimer, T.L.; Sexton, F.W.; Roeske, S.B.; Knoll, M.G.

1994-01-01

The radiation hardness of commercial Floating Gate 256K E 2 PROMs from a single diffusion lot was observed to vary between 5 to 25 krad(Si) when irradiated at a low dose rate of 64 mrad(Si)/s. Additional variations in E 2 PROM hardness were found to depend on bias condition and failure mode (i.e., inability to read or write the memory), as well as the foundry at which the part was manufactured. This variability is related to system requirements, and it is shown that hardness level and variability affect the allowable mode of operation for E 2 PROMs in space applications. The radiation hardness of commercial 1-Mbit CMOS SRAMs from Micron, Hitachi, and Sony irradiated at 147 rad(Si)/s was approximately 12, 13, and 19 krad(Si), respectively. These failure levels appear to be related to increases in leakage current during irradiation. Hardness of SRAMs from each manufacturer varied by less than 20%, but differences between manufacturers are significant. The Qualified Manufacturer's List approach to radiation hardness assurance is suggested as a way to reduce variability and to improve the hardness level of commercial technologies

Metal oxide multilayer hard mask system for 3D nanofabrication

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Han, Zhongmei; Salmi, Emma; Vehkamäki, Marko; Leskelä, Markku; Ritala, Mikko

2018-02-01

We demonstrate the preparation and exploitation of multilayer metal oxide hard masks for lithography and 3D nanofabrication. Atomic layer deposition (ALD) and focused ion beam (FIB) technologies are applied for mask deposition and mask patterning, respectively. A combination of ALD and FIB was used and a patterning procedure was developed to avoid the ion beam defects commonly met when using FIB alone for microfabrication. ALD grown Al2O3/Ta2O5/Al2O3 thin film stacks were FIB milled with 30 keV gallium ions and chemically etched in 5% tetramethylammonium hydroxide at 50 °C. With metal evaporation, multilayers consisting of amorphous oxides Al2O3 and Ta2O5 can be tailored for use in 2D lift-off processing, in preparation of embedded sub-100 nm metal lines and for multilevel electrical contacts. Good pattern transfer was achieved by lift-off process from the 2D hard mask for micro- and nano-scaled fabrication. As a demonstration of the applicability of this method to 3D structures, self-supporting 3D Ta2O5 masks were made from a film stack on gold particles. Finally, thin film resistors were fabricated by utilizing controlled stiction of suspended Ta2O5 structures.

Nanotoxicity: emerging concerns regarding nanomaterial safety and occupational hard metal (WC-Co nanoparticle exposure

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Armstead AL

2016-12-01

Full Text Available Andrea L Armstead,1,2 Bingyun Li1–3 1Department of Orthopaedics, School of Medicine, 2School of Pharmacy, West Virginia University, 3Mary Babb Randolph Cancer Center, Morgantown, WV, USA Abstract: As the number of commercial and consumer products containing engineered nanomaterials (ENMs continually rises, the increased use and production of these ENMs presents an important toxicological concern. Although ENMs offer a number of advantages over traditional materials, their extremely small size and associated characteristics may also greatly enhance their toxic potentials. ENM exposure can occur in various consumer and industrial settings through inhalation, ingestion, or dermal routes. Although the importance of accurate ENM characterization, effective dosage metrics, and selection of appropriate cell or animal-based models are universally agreed upon as important factors in ENM research, at present, there is no “standardized” approach used to assess ENM toxicity in the research community. Of particular interest is occupational exposure to tungsten carbide cobalt (WC-Co “dusts,” composed of nano- and micro-sized particles, in hard metal manufacturing facilities and mining and drilling industries. Inhalation of WC-Co dust is known to cause “hard metal lung disease” and an increased risk of lung cancer; however, the mechanisms underlying WC-Co toxicity, the inflammatory disease state and progression to cancer are poorly understood. Herein, a discussion of ENM toxicity is followed by a review of the known literature regarding the effects of WC-Co particle exposure. The risk of WC-Co exposure in occupational settings and the updates of in vitro and in vivo studies of both micro- and nano-WC-Co particles are discussed. Keywords: engineered nanomaterial, occupational exposure, lung disease, cancer, toxicity, particle

Measurement of fracture toughness of metallic materials produced by additive manufacturing

Science.gov (United States)

Quénard, O.; Dorival, O.; Guy, Ph.; Votié, A.; Brethome, K.

2018-04-01

This study focuses on the microstructure and mechanical properties of metallic materials produced by additive layer manufacturing (ALM), especially the laser beam melting process. The influence of the specimen orientation during the ALM process and that of two post-build thermal treatments were investigated. The identified metal powder is Ti-6Al-4V (titanium base). Metallographic analysis shows their effects on the microstructure of the metals. Mechanical experiments involving tensile tests as well as toughness tests were performed according to ASTM (American Society for Testing and Materials) norms. The results show that the main influence is that of the thermal treatments; however the manufacturing stacking direction may lead to some anisotropy in the mechanical properties.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

Science.gov (United States)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Manufacturing method for hard x-ray focusing mirrors with ellipsoidal surface

International Nuclear Information System (INIS)

Yumoto, Hirokatsu; Koyama, Takahisa; Ohashi, Haruhiko; Matsuyama, Satoshi; Yamauchi, Kazuto

2014-01-01

The aim of this study is to establishing the manufacturing method for hard x-ray nano-focusing mirrors with ellipsoidal surface. Ellipsoidal mirror optics, which can produce point focus with a mirror, has a noticeable feature of a high focusing efficiency, although an ultra-precise surface figure with an accuracy of a few nanometers is required for nano-focusing mirrors. Here, we examined the effectiveness of the manufacturing process for ellipsoidal mirrors, which is consisted of a precision grinding process, a removal process of surface roughness, and a computer-controlled shape correction. The precision processing machine for both a removal of surface roughness and a shape correction was developed. This validated the utility of removing surface roughness with a spatial wavelength of 40 μm, which is the tool mark of the grinding process. The developed process achieved the improvement of surface roughness from 1.6 nm to 0.1 nm (RMS), and the figure correction with a high accuracy of < 10 nm and a spatial resolution of < 2 mm. (author)

Qualification of laser based additive production for manufacturing of forging Tools

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Junker Daniel

2015-01-01

Full Text Available Mass customization leads to very short product life cycles, so the costs of a tool have to be amortized with a low number of workpieces. Especially for highly loaded tools, like those for forging, that leads to expensive products. Therefore more economical production processes for tool manufacturing have to be investigated. As laser additive manufacturing is already used for the production of moulds for injection moulding, this technology maybe could also improve the forging tool production. Within this paper laser metal deposition, which is industrially used for tool repair, will be investigated for the use in tool manufacturing. Therefore a mechanical characterization of parts built with different laser process parameters out of the hot work tool steel 1.2709 is made by upsetting tests and hardness measurements. So the influence of the additive manufacturing process on the hardness distribution is analysed.

Reparatory and Manufacturing Hard-Facing of Working Parts Made of Stainless Steels in Confectionary Industry

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S. Rakic

2012-09-01

Full Text Available In this paper, for the sake of improving the reparatory hard-facing technology is especially analyzed reparatory hard-facing of tools for manufacturing compressed products in confectionary industry. Those products are being made of a mixture consisting of several powdery components, which is compressed under high pressure. In that way the connection between particles is realized, thus achieving certain hardness and strength of the confectionary product. The considered tool is made of high-alloyed stainless steel. The tool contains 30 identical working places. Besides the production process wear, on those tools, from time to time, appear mechanical damage on some of the products' shape punches, as cracks at the edges, where the products' final shapes are formed. Those damages are small, size wise, but they cause strong effect on the products' final shape. The aggravating circumstance is that the shape punch is extremely loaded in pressure, thus after the reparatory hard-facing, the additional heat treatment is necessary. Mechanical properties in the heat affected zone (HAZ are being leveled by annealing and what also partially reduces the residual internal stresses.

Microstructure-Based Counterfeit Detection in Metal Part Manufacturing

Science.gov (United States)

Dachowicz, Adam; Chaduvula, Siva Chaitanya; Atallah, Mikhail; Panchal, Jitesh H.

2017-11-01

Counterfeiting in metal part manufacturing has become a major global concern. Although significant effort has been made in detecting the implementation of such counterfeits, modern approaches suffer from high expense during production, invasiveness during manufacture, and unreliability in practice if parts are damaged during use. In this paper, a practical microstructure-based counterfeit detection methodology is proposed, which draws on inherent randomness present in the microstructure as a result of the manufacturing process. An optical Physically Unclonable Function (PUF) protocol is developed which takes a micrograph as input and outputs a compact, unique string representation of the micrograph. The uniqueness of the outputs and their robustness to moderate wear and tear is demonstrated by application of the methodology to brass samples. The protocol is shown to have good discriminatory power even between samples manufactured in the same batch, and runs on the order of several seconds per part on inexpensive machines.

Assessment of the hardness of different orthodontic wires and brackets produced by metal injection molding and conventional methods.

Science.gov (United States)

Alavi, Shiva; Kachuie, Marzie

2017-01-01

This study was conducted to assess the hardness of orthodontic brackets produced by metal injection molding (MIM) and conventional methods and different orthodontic wires (stainless steel, nickel-titanium [Ni-Ti], and beta-titanium alloys) for better clinical results. A total of 15 specimens from each brand of orthodontic brackets and wires were examined. The brackets (Elite Opti-Mim which is produced by MIM process and Ultratrimm which is produced by conventional brazing method) and the wires (stainless steel, Ni-Ti, and beta-titanium) were embedded in epoxy resin, followed by grinding, polishing, and coating. Then, X-ray energy dispersive spectroscopy (EDS) microanalysis was applied to assess their elemental composition. The same specimen surfaces were repolished and used for Vickers microhardness assessment. Hardness was statistically analyzed with Kruskal-Wallis test, followed by Mann-Whitney test at the 0.05 level of significance. The X-ray EDS analysis revealed different ferrous or co-based alloys in each bracket. The maximum mean hardness values of the wires were achieved for stainless steel (SS) (529.85 Vickers hardness [VHN]) versus the minimum values for beta-titanium (334.65 VHN). Among the brackets, Elite Opti-Mim exhibited significantly higher VHN values (262.66 VHN) compared to Ultratrimm (206.59 VHN). VHN values of wire alloys were significantly higher than those of the brackets. MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness.

Transcriptome response to copper heavy metal stress in hard-shelled mussel (Mytilus coruscus

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Meiying Xu

2016-03-01

Full Text Available The hard-shelled mussel (Mytilus coruscus has considerably one of the most economically important marine shellfish worldwide and considered as a good invertebrate model for ecotoxicity study for a long time. In the present study, we used Illumina sequencing technology (HiSeq2000 to sequence, assemble and annotate the transcriptome of the hard-shelled mussel which challenged with copper pollution. A total of 21,723,913 paired-end clean reads (NCBI SRA database SRX1411195 were generated from HiSeq2000 sequencer and 96,403 contigs (with N50 = 1118 bp were obtained after de novo assembling with Trinity software. Digital gene expression analysis reveals 1156 unigenes are upregulated and 1681 unigenes are downregulated when challenged with copper. By KEGG pathway enrichment analysis, we found that unigenes in four KEGG pathways (aminoacyl-tRNA biosynthesis, apoptosis, DNA replication and mismatch repair show significant differential expressed between control and copper treated groups. We hope that the gill transcriptome in copper treated hard-shelled mussel can give useful information to understand how mussel handles with heavy metal stress at molecular level. Keywords: Hard-shelled mussel, Heavy metal, Transcriptome, Ecotoxicity

Structural and electronic properties of OsB2 : A hard metallic material

Science.gov (United States)

Chen, Z. Y.; Xiang, H. J.; Yang, Jinlong; Hou, J. G.; Zhu, Qingshi

2006-07-01

We calculate the structural and electronic properties of OsB2 using density functional theory with or without taking into account the spin-orbit (SO) interaction. Our results show that the bulk modulus with and without SO interactions are 364 and 365GPa , respectively, both are in good agreement with experiment (365-395GPa) . The evidence of covalent bonding of Os-B, which plays an important role to form a hard material, is indicated both in charge density, atoms in molecules analysis, and density of states analysis. The good metallicity and hardness of OsB2 might suggest its potential application as hard conductors.

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems.

Science.gov (United States)

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan; Kim, Woong-Chul

2017-12-01

To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups ( P manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically.

Hard X-ray PhotoElectron Spectroscopy of transition metal oxides: Bulk compounds and device-ready metal-oxide interfaces

International Nuclear Information System (INIS)

Borgatti, F.; Torelli, P.; Panaccione, G.

2016-01-01

Highlights: • Hard X-ray PhotoElectron Spectroscopy (HAXPES) applied to buried interfaces of systems involving Transition Metal Oxides. • Enhanced contribution of the s states at high kinetic energies both for valence and core level spectra. • Sensitivity to chemical changes promoted by electric field across metal-oxide interfaces in resistive switching devices. - Abstract: Photoelectron spectroscopy is one of the most powerful tool to unravel the electronic structure of strongly correlated materials also thanks to the extremely large dynamic range in energy, coupled to high energy resolution that this form of spectroscopy covers. The kinetic energy range typically used for photoelectron experiments corresponds often to a strong surface sensitivity, and this turns out to be a disadvantage for the study of transition metal oxides, systems where structural and electronic reconstruction, different oxidation state, and electronic correlation may significantly vary at the surface. We report here selected Hard X-ray PhotoElectron Spectroscopy (HAXPES) results from transition metal oxides, and from buried interfaces, where we highlight some of the important features that such bulk sensitive technique brings in the analysis of electronic properties of the solids.

Hard X-ray PhotoElectron Spectroscopy of transition metal oxides: Bulk compounds and device-ready metal-oxide interfaces

Energy Technology Data Exchange (ETDEWEB)

Borgatti, F., E-mail: francesco.borgatti@cnr.it [Istituto per lo Studio dei Materiali Nanostrutturati (ISMN), Consiglio Nazionale delle Ricerche (CNR), via P. Gobetti 101, Bologna I-40129 (Italy); Torelli, P.; Panaccione, G. [Istituto Officina dei Materiali (IOM)-CNR, Laboratorio TASC, Area Science Park, Trieste I-34149 (Italy)

2016-04-15

Highlights: • Hard X-ray PhotoElectron Spectroscopy (HAXPES) applied to buried interfaces of systems involving Transition Metal Oxides. • Enhanced contribution of the s states at high kinetic energies both for valence and core level spectra. • Sensitivity to chemical changes promoted by electric field across metal-oxide interfaces in resistive switching devices. - Abstract: Photoelectron spectroscopy is one of the most powerful tool to unravel the electronic structure of strongly correlated materials also thanks to the extremely large dynamic range in energy, coupled to high energy resolution that this form of spectroscopy covers. The kinetic energy range typically used for photoelectron experiments corresponds often to a strong surface sensitivity, and this turns out to be a disadvantage for the study of transition metal oxides, systems where structural and electronic reconstruction, different oxidation state, and electronic correlation may significantly vary at the surface. We report here selected Hard X-ray PhotoElectron Spectroscopy (HAXPES) results from transition metal oxides, and from buried interfaces, where we highlight some of the important features that such bulk sensitive technique brings in the analysis of electronic properties of the solids.

Hard metal lung disease: a case series.

Science.gov (United States)

Mizutani, Rafael Futoshi; Terra-Filho, Mário; Lima, Evelise; Freitas, Carolina Salim Gonçalves; Chate, Rodrigo Caruso; Kairalla, Ronaldo Adib; Carvalho-Oliveira, Regiani; Santos, Ubiratan Paula

2016-01-01

To describe diagnostic and treatment aspects of hard metal lung disease (HMLD) and to review the current literature on the topic. This was a retrospective study based on the medical records of patients treated at the Occupational Respiratory Diseases Clinic of the Instituto do Coração, in the city of São Paulo, Brazil, between 2010 and 2013. Of 320 patients treated during the study period, 5 (1.56%) were diagnosed with HMLD. All of those 5 patients were male (mean age, 42.0 ± 13.6 years; mean duration of exposure to hard metals, 11.4 ± 8.0 years). Occupational histories were taken, after which the patients underwent clinical evaluation, chest HRCT, pulmonary function tests, bronchoscopy, BAL, and lung biopsy. Restrictive lung disease was found in all subjects. The most common chest HRCT finding was ground glass opacities (in 80%). In 4 patients, BALF revealed multinucleated giant cells. In 3 patients, lung biopsy revealed giant cell interstitial pneumonia. One patient was diagnosed with desquamative interstitial pneumonia associated with cellular bronchiolitis, and another was diagnosed with a hypersensitivity pneumonitis pattern. All patients were withdrawn from exposure and treated with corticosteroid. Clinical improvement occurred in 2 patients, whereas the disease progressed in 3. Although HMLD is a rare entity, it should always be included in the differential diagnosis of respiratory dysfunction in workers with a high occupational risk of exposure to hard metal particles. A relevant history (clinical and occupational) accompanied by chest HRCT and BAL findings suggestive of the disease might be sufficient for the diagnosis. Descrever aspectos relacionados ao diagnóstico e tratamento de pacientes com doença pulmonar por metal duro (DPMD) e realizar uma revisão da literatura. Estudo retrospectivo dos prontuários médicos de pacientes atendidos no Serviço de Doenças Respiratórias Ocupacionais do Instituto do Coração, localizado na cidade de S�

Stress concentration factor and stress intensity factor on hard metals in connection with the wear characteristics

International Nuclear Information System (INIS)

Dawihl, W.; Altmeyer, G.

1977-01-01

Description of a method to determine stress intensity factors on hard metals by lapping in notches of different diameter. Dependence of the values of the stress intensity factors on the size of the notch base diameter. For tungsten carbide hard metals with 6% Co, determination of a final value of 250 Nmm -3 / 2 . Characterisation of the stress intensity factor governed by the surface roughness which is decisive for the assessment of the wear-resistant behaviour. (orig.) [de

Fluid Structure Interaction Analysis in Manufacturing Metal/Polymer Macro-Composites

International Nuclear Information System (INIS)

Baesso, R.; Lucchetta, G.

2007-01-01

Polymer Injection Forming (PIF) is a new manufacturing technology for sheet metal-polymer macro-composites, which results from the combination of injection moulding and sheet metal forming. This process consists on forming the sheet metal according to the boundary of the mould cavity by means of the injected polymer. After cooling, the polymer bonds permanently to the metal resulting in a sheet metal-polymer macro-composite product. Comparing this process to traditional ones (where the polymeric and metal parts are joined together after separate forming) the main advantages are both reduction of production costs and increase of part quality. This paper presents a multi-physics numerical simulation of the process performed in the Ansys/CFX environment

Electrochemical removal of metallic implants from Technovit 9100 New embedded hard and soft tissues prior to histological sectioning.

Science.gov (United States)

Willbold, Elmar; Reebmann, Mattias; Jeffries, Richard; Witte, Frank

2013-11-01

Solid metallic implants in soft or hard tissues are serious challenges for histological processing. However, metallic implants are more frequently used in e.g. cardiovascular or orthopaedic therapies. Before clinical use, these devices need to be tested thoroughly in a biological environment and histological analysis of their biocompatibility is a major requirement. To allow the histological analysis of metallic implants in tissues especially in calcified hard tissues, we describe a method for embedding these tissues in the resin Technovit 9100 New and removing the metallic implants by electrochemical dissolution. With the combination of these two processes, we are able to achieve 5 μm thick sections from soft or hard tissues with a superior preservation of tissue architecture and especially the implant-tissue interface. These sections can be stained by classical stainings, immunohistochemical and enzymehistochemical as well as DNA-based staining methods.

Friction Stir Additive Manufacturing: Route to High Structural Performance

Science.gov (United States)

Palanivel, S.; Sidhar, H.; Mishra, R. S.

2015-03-01

Aerospace and automotive industries provide the next big opportunities for additive manufacturing. Currently, the additive industry is confronted with four major challenges that have been identified in this article. These challenges need to be addressed for the additive technologies to march into new frontiers and create additional markets. Specific potential success in the transportation sectors is dependent on the ability to manufacture complicated structures with high performance. Most of the techniques used for metal-based additive manufacturing are fusion based because of their ability to fulfill the computer-aided design to component vision. Although these techniques aid in fabrication of complex shapes, achieving high structural performance is a key problem due to the liquid-solid phase transformation. In this article, friction stir additive manufacturing (FSAM) is shown as a potential solid-state process for attaining high-performance lightweight alloys for simpler geometrical applications. To illustrate FSAM as a high-performance route, manufactured builds of Mg-4Y-3Nd and AA5083 are shown as examples. In the Mg-based alloy, an average hardness of 120 HV was achieved in the built structure and was significantly higher than that of the base material (97 HV). Similarly for the Al-based alloy, compared with the base hardness of 88 HV, the average built hardness was 104 HV. A potential application of FSAM is illustrated by taking an example of a simple stiffener assembly.

Hard X-ray nanoimaging method using local diffraction from metal wire

Energy Technology Data Exchange (ETDEWEB)

Takano, Hidekazu, E-mail: htakano@sci.u-hyogo.ac.jp; Konishi, Shigeki; Shimomura, Sho; Azuma, Hiroaki; Tsusaka, Yoshiyuki; Kagoshima, Yasushi [Center for Novel Material Science under Multi-Extreme Conditions, Graduate School of Material Science, University of Hyogo, Kamigori, Hyogo 678-1297 (Japan)

2014-01-13

A simple hard X-ray imaging method achieving a high spatial resolution is proposed. Images are obtained by scanning a metal wire through the wave field to be measured and rotating the sample to collect data for back projection calculations; the local diffraction occurring at the edges of the metal wire operates as a narrow line probe. In-line holograms of a test sample were obtained with a spatial resolution of better than 100 nm. The potential high spatial resolution of this method is shown by calculations using diffraction theory.

Targeted Structural Optimization with Additive Manufacturing of Metals

Science.gov (United States)

Burt, Adam; Hull, Patrick

2015-01-01

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

Study on the Effect of Heavy metals toxicity according to changing Hardness concentration using D.magna

Science.gov (United States)

Chun Sang, H.

2016-12-01

n order to determine and prevent the number of ecological effects of heavy metals in the materials, we have to accurately measure the heavy metals present in the water-based protection ecosystems and may determine the effects to humans. Heavy metals occurred in the industrial effluent which is a state in which the monitor, based on the emission standards are made by the Ministry of Environment and managed and waste water contained Copper, Zinc, lead, etc. These heavy metals are able to express the toxic effects only when present in the free-ions in the aqueous condition, which appears differently affected by the degree to hardness change in accordance with the season, precipitation. Generally changing hardness concentration can not precisely evaluate toxic effects of heavy metals in the water system. Anderson announced a study on bioassay for heavy metals from industrial waste water using Daphnia magna(Anderson, 1944, 1948). Breukelman published study the resitivity difference for the mercury Chloride(HgCl2). Braudouin(1974) compared the zooplankton(Daphnia sp.) acute toxicity of the different heavy metals and confirmed the sensitivity. Shcherban(1979) presented for toxicity evaluation results for the heavy metal of the Daphnia magna according to different temperature conditions. In the United States Environmental Protection Agency(EPA) established a standard test method for water fleas, managed and supervised water ecosystems, and announced the adoption of a bioassay standard method. This study was performed to evaluate acute inhibition using the Daphnia magna for the biological effect of heavy metal ions in water-based toxicity in the hardness change. Evaluation methods were conducted in EPA Water Quality process test criteria. TU(Toxic Unit), NOEC (No Observable Effect Concentration), LOEC (Lowest Observable Effect Concentration), EC50 (Median Effective Concentration) was calculated by Toxcalc 5.0 Program. Keywords : D. magna, Hardness, Toxic Unit, Heavy metal

Comprehensive hard materials

CERN Document Server

2014-01-01

Comprehensive Hard Materials deals with the production, uses and properties of the carbides, nitrides and borides of these metals and those of titanium, as well as tools of ceramics, the superhard boron nitrides and diamond and related compounds. Articles include the technologies of powder production (including their precursor materials), milling, granulation, cold and hot compaction, sintering, hot isostatic pressing, hot-pressing, injection moulding, as well as on the coating technologies for refractory metals, hard metals and hard materials. The characterization, testing, quality assurance and applications are also covered. Comprehensive Hard Materials provides meaningful insights on materials at the leading edge of technology. It aids continued research and development of these materials and as such it is a critical information resource to academics and industry professionals facing the technological challenges of the future. Hard materials operate at the leading edge of technology, and continued res...

Morphology Analysis and Process Research on Novel Metal Fused-coating Additive Manufacturing

Science.gov (United States)

Wang, Xin; Wei, Zheng ying; Du, Jun; Ren, Chuan qi; Zhang, Shan; Zhang, Zhitong; Bai, Hao

2017-12-01

Existing metal additive manufacturing equipment has high capital costs and slow throughput printing. In this paper, a new metal fused-coating additive manufacturing (MFCAM) was proposed. Experiments of single-track formation were conducted using MFCAM to validate the feasibility. The low melting alloy was selected as the forming material. Then, the effect of process parameters such as the flow rate, deposition velocity and initial distance on the forming morphology. There is a strong coupling effect between the single track forming morphology. Through the analysis of influencing factors to improve the forming quality of specimens. The experimental results show that the twice as forming efficiency as the metal droplet deposition. Additionally, the forming morphology and quality were analyzed by confocal laser scanning microscope and X-ray. The results show that the metal fused-coating process can achieve good surface morphology and without internal tissue defect.

Fluid Mechanics Of Molten Metal Droplets In Additive Manufacturing

Czech Academy of Sciences Publication Activity Database

Tesař, Václav; Šonský, Jiří

2016-01-01

Roč. 4, č. 4 (2016), s. 403-412 ISSN 2046-0546 R&D Projects: GA ČR GA13-23046S Institutional support: RVO:61388998 Keywords : additive manufacturing * droplets * molten metal Subject RIV: BK - Fluid Dynamics http://www.witpress.com/elibrary/cmem-volumes/4/4/1545

Development of casting technology for manufacturing metal rods with simulated metallic spent fuels

International Nuclear Information System (INIS)

Lee, D. B.; Lee, Y. S.; Woo, Y. M.; Jang, S. J.; Kim, J. D; Kim, C. K.; Shin, Y. J.; Lee, J. H.

1999-01-01

The advanced casting equipment based on the directional solidification method was developed for manufacturing the uranium metal rod having 13.5 mm diameter and 1,200 mm length. In order to prevent surface-shrunk holes revealed easily in course of casting the small diameter and long rods, the vacuum casting furnace has the four pre-heaters equipped with temperature controller. On the other hand, the computer simulation to estimate the defective location and to analyze the solidus behavior of molten uranium in the mold were also performed by using MAGMA Code. As a result of the experimental and theoretical study, the sound rod has successfully been manufactured

Hopper design for metallic powders used in additive manufacturing processes

CSIR Research Space (South Africa)

Visagie, N

2013-10-01

Full Text Available The influence of hopper geometry on the flow behaviour of typical metallic powders used in additive manufacturing processes is investigated. Bulk hopper theory provides a method of determining critical hopper parameters for bulk amounts...

Grain Structure Control of Additively Manufactured Metallic Materials

Directory of Open Access Journals (Sweden)

Fuyao Yan

2017-11-01

Full Text Available Grain structure control is challenging for metal additive manufacturing (AM. Grain structure optimization requires the control of grain morphology with grain size refinement, which can improve the mechanical properties of additive manufactured components. This work summarizes methods to promote fine equiaxed grains in both the additive manufacturing process and subsequent heat treatment. Influences of temperature gradient, solidification velocity and alloy composition on grain morphology are discussed. Equiaxed solidification is greatly promoted by introducing a high density of heterogeneous nucleation sites via powder rate control in the direct energy deposition (DED technique or powder surface treatment for powder-bed techniques. Grain growth/coarsening during post-processing heat treatment can be restricted by presence of nano-scale oxide particles formed in-situ during AM. Grain refinement of martensitic steels can also be achieved by cyclic austenitizing in post-processing heat treatment. Evidently, new alloy powder design is another sustainable method enhancing the capability of AM for high-performance components with desirable microstructures.

Hard X-ray photoemission spectroscopy of transition-metal oxide thin films and interfaces

International Nuclear Information System (INIS)

Wadati, H.; Fujimori, A.

2013-01-01

Highlights: •Photoemission spectroscopy is a powerful technique to study the electronic structures of transition-metal oxides. •Hard X-ray photoemission spectroscopy (HXPES) is a new type of photoemission spectroscopy which can probe bulk states. •HXPES is very suitable for studying oxide thin films such as the composition dependence and the film thickness dependence. -- Abstract: Photoemission spectroscopy is a powerful experimental technique to study the electronic structures of solids, especially of transition-metal oxides. Recently, hard X-ray photoemission spectroscopy (HXPES) has emerged as a more relevant experimental technique to obtain clear information about bulk states. Here, we describe how HXPES can be conveniently applied to study the interesting subjects on oxide thin films such as the composition dependence and the film thickness dependence of the electronic structures and the interfacial electronic structure of multilayers

Application of Contact Mode AFM to Manufacturing Processes

Science.gov (United States)

Giordano, Michael A.; Schmid, Steven R.

A review of the application of contact mode atomic force microscopy (AFM) to manufacturing processes is presented. A brief introduction to common experimental techniques including hardness, scratch, and wear testing is presented, with a discussion of challenges in the extension of manufacturing scale investigations to the AFM. Differences between the macro- and nanoscales tests are discussed, including indentation size effects and their importance in the simulation of processes such as grinding. The basics of lubrication theory are presented and friction force microscopy is introduced as a method of investigating metal forming lubrication on the nano- and microscales that directly simulates tooling/workpiece asperity interactions. These concepts are followed by a discussion of their application to macroscale industrial manufacturing processes and direct correlations are made.

Additive manufacturing of Ti-Si-N ceramic coatings on titanium

International Nuclear Information System (INIS)

Zhang, Yanning; Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

2015-01-01

Highlights: • 3D Printing or additive manufacturing of hard Ti-Si-N based ceramics coating on Ti metal substrate. • Understanding of phase transformation as a function of compositional variation. • Evaluation of influence of processing parameters and composition on wear resistance. - Abstract: In this study, Laser Engineered Net Shaping (LENS TM ) was employed towards Additive Manufacturing/3D Printing of Ti-Si-N coatings with three different Ti-Si ratios on commercially pure titanium (cp-Ti) substrate. Microstructural analysis, phase analysis using X-ray diffraction, wear resistance and hardness measurements were done on LENS™ processed 3D printed coatings. Coatings showed graded microstructures and in situ formed phases. Results showed that microstructural variations and phase changes influence coating's hardness and wear resistance directly. High hardness values were obtained from all samples’ top surface where the hardness of coatings can be ranked as 90% Ti-10% Si-N coating (2093.67 ± 144 HV 0.2 ) > 100% Ti-N coating (1846 ± 68.5 HV 0.2 ) > 75% Ti-25% Si-N coating (1375.3 ± 61.4 HV 0.2 ). However, wear resistance was more dependent on inherent Si content, and samples with higher Si content showed better wear resistance

Additive manufacturing of Ti-Si-N ceramic coatings on titanium

Energy Technology Data Exchange (ETDEWEB)

Zhang, Yanning; Sahasrabudhe, Himanshu; Bandyopadhyay, Amit, E-mail: amitband@wsu.edu

2015-08-15

Highlights: • 3D Printing or additive manufacturing of hard Ti-Si-N based ceramics coating on Ti metal substrate. • Understanding of phase transformation as a function of compositional variation. • Evaluation of influence of processing parameters and composition on wear resistance. - Abstract: In this study, Laser Engineered Net Shaping (LENS{sup TM}) was employed towards Additive Manufacturing/3D Printing of Ti-Si-N coatings with three different Ti-Si ratios on commercially pure titanium (cp-Ti) substrate. Microstructural analysis, phase analysis using X-ray diffraction, wear resistance and hardness measurements were done on LENS™ processed 3D printed coatings. Coatings showed graded microstructures and in situ formed phases. Results showed that microstructural variations and phase changes influence coating's hardness and wear resistance directly. High hardness values were obtained from all samples’ top surface where the hardness of coatings can be ranked as 90% Ti-10% Si-N coating (2093.67 ± 144 HV{sub 0.2}) > 100% Ti-N coating (1846 ± 68.5 HV{sub 0.2}) > 75% Ti-25% Si-N coating (1375.3 ± 61.4 HV{sub 0.2}). However, wear resistance was more dependent on inherent Si content, and samples with higher Si content showed better wear resistance.

Structure, properties and wear behaviour of multilayer coatings consisting of metallic and covalent hard materials, prepared by magnetron sputtering

International Nuclear Information System (INIS)

Schier, V.

1995-12-01

Novel multilayer coatings with metallic and covalent layer materials were prepared by magnetron sputtering and characterised concerning structure, properties and application behaviour. At first single layer coatings were deposited for the determination of the material properties. To evaluate relations between structure and properties of the multilayer coatings, different multilayer concepts were realised: - coatings consisting of at most 7 layers of metallic hard materials, - 100-layer coatings consisting of metallic and covalent hard materials, - TiN-TiC multilayer coatings with different numbers of layers (between 10 and 1000), - 150-layer coatings, based on TiN-TiC multilayers, with thin ( 4 C, AlN, SiC, a:C, Si 3 N 4 , SiAlON). X-rays and electron microscopic analysis indicate in spite of nonstoichiometric compositions single phase crystalline structures for nonreactively and reactively sputtered metastable single layer Ti(B,C)-, Ti(B,N)- and Ti(B,C,N)-coatings. These single layer coatings show excellent mechanical properties (e.g. hardness values up to 6000 HV0,05), caused by lattice stresses as well as by atomic bonding conditions similar to those in c:BN and B 4 C. The good tribological properties shown in pin-on-disk-tests can be attributed to the very high hardness of the coatings. The coatings consisting of at most 7 layers of metallic hard materials show good results mainly for the cutting of steel Ck45, due to the improved mechanical properties (e.g. hardness, toughness) of the multilayers compared to the single layer coatings. This improvement is caused by inserting the hard layer materials and the coherent reinforcement of the coatings. (orig.)

Practical Aspects of CALS in Design and Manufacturing of Sheet Metal Products

DEFF Research Database (Denmark)

Shpitalni, Moshe; Alting, Leo; Bilberg, Arne

1998-01-01

The transition from design to process planning and to the various stages of manufacturing is traditionally sequential. In many cases, practical problems associated with manufacturing cannot be resolved if only individual processes are examined. These problems can be overcome, however, by adopting...... with the design and manufacture of sheet metal parts. It is demonstrated that through implementation of the CALS approach, the overall process can be optimised and products can be manufactured significantly more accurately, faster and less expensively.......The transition from design to process planning and to the various stages of manufacturing is traditionally sequential. In many cases, practical problems associated with manufacturing cannot be resolved if only individual processes are examined. These problems can be overcome, however, by adopting...

Fabrication of hard cermets by in-situ synthesis and infiltration of metal melts into WC powder compacts

Directory of Open Access Journals (Sweden)

Guanghua Liu

2017-12-01

Full Text Available Hard carbide cermets are prepared by in-situ synthesis and infiltration of metal melts into WC powder compacts. Ni–W and Ni–W–Cr metal melts are in-situ synthesized from thermite reactions and infiltrated into WC powder compacts under high-gravity. During the infiltration, W in the metal melts reacts with WC to form W2C, and more W2C and W are observed at the upper parts of the cermets than the lower parts. The cermets show a maximum hardness of 15.4 GPa, which is higher than most commercial cemented carbides, although they are not fully dense and have a porosity of 15–20%.

Accelerating Industrial Adoption of Metal Additive Manufacturing Technology

Science.gov (United States)

Vartanian, Kenneth; McDonald, Tom

2016-03-01

While metal additive manufacturing (AM) technology has clear benefits, there are still factors preventing its adoption by industry. These factors include the high cost of metal AM systems, the difficulty for machinists to learn and operate metal AM machines, the long approval process for part qualification/certification, and the need for better process controls; however, the high AM system cost is the main barrier deterring adoption. In this paper, we will discuss an America Makes-funded program to reduce AM system cost by combining metal AM technology with conventional computerized numerical controlled (CNC) machine tools. Information will be provided on how an Optomec-led team retrofitted a legacy CNC vertical mill with laser engineered net shaping (LENS®—LENS is a registered trademark of Sandia National Labs) AM technology, dramatically lowering deployment cost. The upgraded system, dubbed LENS Hybrid Vertical Mill, enables metal additive and subtractive operations to be performed on the same machine tool and even on the same part. Information on the LENS Hybrid system architecture, learnings from initial system deployment and continuing development work will also be provided to help guide further development activities within the materials community.

Additive manufacturing of metals the technology, materials, design and production

CERN Document Server

Yang, Li; Baughman, Brian; Godfrey, Donald; Medina, Francisco; Menon, Mamballykalathil; Wiener, Soeren

2017-01-01

This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leadin...

Assessment of the hardness of different orthodontic wires and brackets produced by metal injection molding and conventional methods

Directory of Open Access Journals (Sweden)

Shiva Alavi

2017-01-01

Conclusion: MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness.

Micro-manufacturing: design and manufacturing of micro-products

National Research Council Canada - National Science Library

Koç, Muammer; Özel, Tuğrul

2011-01-01

.... After addressing the fundamentals and non-metallic-based micro-manufacturing processes in the semiconductor industry, it goes on to address specific metallic-based micro-manufacturing processes...

Fluid mechanics of additive manufacturing of metal objects by accretion of droplets - a survey

Science.gov (United States)

Tesař, Václav

2016-03-01

Paper presents a survey of principles of additive manufacturing of metal objects by accretion of molten metal droplets, focusing on fluid-mechanical problems that deserve being investigated. The main problem is slowness of manufacturing due to necessarily small size of added droplets. Increase of droplet repetition rate calls for basic research of the phenomena that take place inside and around the droplets: ballistics of their flight, internal flowfield with heat and mass transfer, oscillation of surfaces, and the ways to elimination of satellite droplets.

Indentation size effects in the nano- and micro-hardness of a Fe-based bulk metallic glass

Energy Technology Data Exchange (ETDEWEB)

Xu, F., E-mail: xufu@xtu.edu.cn; Ding, Y.H.; Deng, X.H.; Zhang, P.; Long, Z.L.

2014-10-01

Hardness of a Fe-based bulk metallic glass (BMG) was evaluated by both atomic force microscopy (AFM) nanoindentation (nano-hardness) and instrumented indentation with a traditional indenter setup (micro-hardness) under different maximum loads at room temperature. The nano-hardness and the micro-hardness were found to be comparable. For both of the indentation methods, indentation size effect (ISE) is detected as increase in hardness with decrease in indentation peak load. It is proposed that strain rate dependent softening, loading history and the lag between free volume creation and mechanical softening should be responsible for the ISE in this BMG. Furthermore, ISE is found to be more significant in AFM nanoindentation than in instrumented indentation. This can be explained by taking into account the effect of exerted peak load and the face angle of the indenter in a qualitative manner.

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

Science.gov (United States)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

Visual inspection technology in the hard disc drive industry

CERN Document Server

Muneesawang, Paisarn

2015-01-01

A presentation of the use of computer vision systems to control manufacturing processes and product quality in the hard disk drive industry. Visual Inspection Technology in the Hard Disk Drive Industry is an application-oriented book borne out of collaborative research with the world's leading hard disk drive companies. It covers the latest developments and important topics in computer vision technology in hard disk drive manufacturing, as well as offering a glimpse of future technologies.

Size effects in manufacturing of metallic components

DEFF Research Database (Denmark)

Vollertsen, F; Biermann, D; Hansen, Hans Nørgaard

2009-01-01

In manufacturing of metallic components, the size of the part plays an important role for the process behaviour. This is due to so called size effects, which lead to changes in the process behaviour even if the relationship between the main geometrical features is kept constant. The aim...... of this paper is to give a systematic review on Such effects and their potential use or remedy. First, the typology of size effects will be explained, followed by a description of size effects on strength and tribology. The last three sections describe size effects on formability, forming processes and cutting...... processes. (C) 2009 CIRP....

Metal organic frameworks as precursors for the manufacture of advanced catalytic materials

NARCIS (Netherlands)

Oar-Arteta Gonzalez, L.; Wezendonk, T.A.; Sun, X.; Kapteijn, F.; Gascon Sabate, J.

The use of metal organic frameworks as hard templates for the preparation of heterogeneous catalysts is thoroughly reviewed. In this critical article, the main factors to consider when using a MOF as a sacrificial template are first discussed. Then, the existing literature on the topic is reviewed,

Additive Manufacturing of Metal Structures at the Micrometer Scale.

Science.gov (United States)

Hirt, Luca; Reiser, Alain; Spolenak, Ralph; Zambelli, Tomaso

2017-05-01

Currently, the focus of additive manufacturing (AM) is shifting from simple prototyping to actual production. One driving factor of this process is the ability of AM to build geometries that are not accessible by subtractive fabrication techniques. While these techniques often call for a geometry that is easiest to manufacture, AM enables the geometry required for best performance to be built by freeing the design process from restrictions imposed by traditional machining. At the micrometer scale, the design limitations of standard fabrication techniques are even more severe. Microscale AM thus holds great potential, as confirmed by the rapid success of commercial micro-stereolithography tools as an enabling technology for a broad range of scientific applications. For metals, however, there is still no established AM solution at small scales. To tackle the limited resolution of standard metal AM methods (a few tens of micrometers at best), various new techniques aimed at the micrometer scale and below are presently under development. Here, we review these recent efforts. Specifically, we feature the techniques of direct ink writing, electrohydrodynamic printing, laser-assisted electrophoretic deposition, laser-induced forward transfer, local electroplating methods, laser-induced photoreduction and focused electron or ion beam induced deposition. Although these methods have proven to facilitate the AM of metals with feature sizes in the range of 0.1-10 µm, they are still in a prototype stage and their potential is not fully explored yet. For instance, comprehensive studies of material availability and material properties are often lacking, yet compulsory for actual applications. We address these items while critically discussing and comparing the potential of current microscale metal AM techniques. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Transition radiation in metal-metal multilayer nanostructures as a medical source of hard x-ray radiation

International Nuclear Information System (INIS)

Pokrovsky, A. L.; Kaplan, A. E.; Shkolnikov, P. L.

2006-01-01

We show that a periodic metal-metal multilayer nanostructure can serve as an efficient source of hard x-ray transition radiation. Our research effort is aimed at developing an x-ray source for medical applications, which is based on using low-energy relativistic electrons. The approach toward choosing radiator-spacer couples for the generation of hard x-ray resonant transition radiation by few-MeV electrons traversing solid multilayer structures for the energies of interest to medicine (30-50 keV) changes dramatically compared with that for soft x-ray radiation. We show that one of the main factors in achieving the required resonant line is the absence of the contrast of the refractive indices between the spacer and the radiator at the far wings of the radiation line; for that purpose, the optimal spacer, as a rule, should have a higher atomic number than the radiator. Having experimental goals in mind, we have considered also the unwanted effects due to bremsstrahlung radiation, absorption and scattering of radiated photons, detector-related issues, and inhibited coherence of transition radiation due to random deviation of spacing between the layers. Choosing as a model example a Mo-Ag radiator-spacer pair of materials, we demonstrate that the x-ray transition radiation line can be well resolved with the use of spatial and frequency filtering

Comparative study of material loss at the taper interface in retrieved metal-on-polyethylene and metal-on-metal femoral components from a single manufacturer.

Science.gov (United States)

Bills, Paul; Racasan, Radu; Bhattacharya, Saugatta; Blunt, Liam; Isaac, Graham

2017-08-01

There have been a number of reports on the occurrence of taper corrosion and/or fretting and some have speculated on a link to the occurrence of adverse local tissue reaction specifically in relation to total hip replacement which have a metal-on-metal bearing. As such a study was carried out to compare the magnitude of material loss at the taper in a series of retrieved femoral heads used in metal-on-polyethylene bearings with that in a series of retrieved heads used in metal-on-metal bearings. A total of 36 metal-on-polyethylene and 21 metal-on-metal femoral components were included in the study all of which were received from a customer complaint database. Furthermore, a total of nine as-manufactured femoral components were included to provide a baseline for characterisation. All taper surfaces were assessed using an established corrosion scoring method and measurements were taken of the female taper surface using a contact profilometry. In the case of metal-on-metal components, the bearing wear was also assessed using coordinate metrology to determine whether or not there was a relationship between bearing and taper material loss in these cases. The study found that in this cohort the median value of metal-on-polyethylene taper loss was 1.25 mm 3 with the consequent median value for metal-on-metal taper loss being 1.75 mm 3 . This study also suggests that manufacturing form can result in an apparent loss of material from the taper surface determined to have a median value of 0.59 mm 3 . Therefore, it is clear that form variability is a significant confounding factor in the measurement of material loss from the tapers of femoral heads retrieved following revision surgery.

Development of coatings for ultrasonic additive manufacturing sonotrode using laser direct metal deposition process

Energy Technology Data Exchange (ETDEWEB)

Niyanth S, Niyanth [ORNL; Dehoff, Ryan R [ORNL; Jordan, Brian H [ORNL; Babu, Sudarsanam Suresh [ORNL

2016-10-01

ORNL partnered with Fabrisonic, LLC to develop galling resistant hard facing coatings on sonotrodes used to fabricate 3D printed materials using ultrasonic additive manufacturing. The development and deployment of a coated sonotrode is expected to push the existing state of the art to facilitate the solidstate additive manufacturing of hard steels and titanium alloys. To this effect a structurally amorphous stainless steel material and cobalt chrome material were deposited on the sonotrode material. Both the deposits showed good adhesion to the substrate. The coatings made using the structurally amorphous steel materials showed cracking during the initial trials and cracking was eliminated by deposition on a preheated substrate. Both the coatings show hardness in excess of 600 HVN. Thus the phase 1 of this project has been used to identify suitable materials to use to coat the sonotrode. Despite the fact that successful deposits were obtained, the coatings need to be evaluated by performing detailed galling tests at various temperatures. In addition field tests are also necessary to test the stability of these coatings in a high cycle ultrasonic vibration mode. If awarded, phase 2 of the project would be used to optimize the composition of the deposit material to maximize galling resistance. The industrial partner would then use the coated sonotrode to fabricate builds made of austenitic stainless steel to test the viability of using a coated sonotrode.

Fluid mechanics of additive manufacturing of metal objects by accretion of droplets – a survey

Directory of Open Access Journals (Sweden)

Tesař Václav

2016-01-01

Full Text Available Paper presents a survey of principles of additive manufacturing of metal objects by accretion of molten metal droplets, focusing on fluid-mechanical problems that deserve being investigated. The main problem is slowness of manufacturing due to necessarily small size of added droplets. Increase of droplet repetition rate calls for basic research of the phenomena that take place inside and around the droplets: ballistics of their flight, internal flowfield with heat and mass transfer, oscillation of surfaces, and the ways to elimination of satellite droplets.

Determining the Effect of Material Hardness During the Hard Turning of AISI4340 Steel

Science.gov (United States)

Kambagowni, Venkatasubbaiah; Chitla, Raju; Challa, Suresh

2018-05-01

In the present manufacturing industries hardened steels are most widely used in the applications like tool design and mould design. It enhances the application range of hard turning of hardened steels in manufacturing industries. This study discusses the impact of workpiece hardness, feed and depth of cut on Arithmetic mean roughness (Ra), root mean square roughness (Rq), mean depth of roughness (Rz) and total roughness (Rt) during the hard turning. Experiments have been planned according to the Box-Behnken design and conducted on hardened AISI4340 steel at 45, 50 and 55 HRC with wiper ceramic cutting inserts. Cutting speed is kept constant during this study. The analysis of variance was used to determine the effects of the machining parameters. 3-D response surface plots drawn based on RSM were utilized to set up the input-output relationships. The results indicated that the feed rate has the most significant parameter for Ra, Rq and Rz and hardness has the most critical parameter for the Rt. Further, hardness shows its influence over all the surface roughness characteristics.

Manufacturing process and electrode properties of palladium-electroded ionic polymer–metal composite

International Nuclear Information System (INIS)

Chang, Longfei; Chen, Hualing; Zhu, Zicai; Li, Bo

2012-01-01

This paper primarily focuses on the manufacturing process of palladium-electroded ionic polymer–metal composite (IPMC). First, according to the special properties of Pd, many experiments were done to determine several specific procedures, including the addition of a reducing agent and the time consumed. Subsequently, the effects of the core manufacturing steps on the electrode morphology were revealed by scanning electron microscopy studies of 22 IPMC samples treated with different combinations of manufacturing steps. Finally, the effects of electrode characteristics on the electromechanical properties, including the sheet resistivity, the elastic modulus and the electro-active performance, of IPMCs were evaluated experimentally and analyzed according to the electrode morphology. (paper)

A bis(3-hydroxy-4-pyridinone)-EDTA derivative as a strong chelator for M3+ hard metal ions: complexation ability and selectivity.

Science.gov (United States)

Gama, Sofia; Dron, Paul; Chaves, Silvia; Farkas, Etelka; Santos, M Amélia

2009-08-21

The study of chelating compounds is very important to solve problems related to human metal overload. 3-Hydroxy-3-pyridinones (HP), namely deferiprone, have been clinically used for chelating therapy of Fe and Al over the last decade. A multi-disciplinary search for alternative molecules led us to develop poly-(3-hydroxy-4-pyridinones) to increase metal chelation efficacy. We present herein a complexation study of a new bis-(3-hydroxy-4-pyridinone)-EDTA derivative with a set of M(3+) hard metal ions (M = Fe, Al, Ga), as well as Zn(2+), a biologically relevant metal ion. Thus a systematic aqueous solution equilibrium study was performed using potentiometric and spectroscopic techniques (UV-Vis, NMR methods). These set of results enables the establishment of specific models as well as the determination of thermodynamic stability constants and coordination modes of the metal complexes. The results indicate that this ligand has a higher affinity for chelating to these hard metal ions than deferiprone, and that the coordination occurs mostly through the HP moieties. Furthermore, it was also found that this ligand has a higher selectivity for chelating to M(3+) hard metal ions (M = Fe, Al, Ga) than Zn(2+).

TSCA Chemical Data Reporting Fact Sheet: Reporting Manufactured Chemical Substances from Metal Mining and Related Activities

Science.gov (United States)

This fact sheet provides guidance on the Chemical Data Reporting (CDR) rule requirements related to the reporting of mined metals, intermediates, and byproducts manufactured during metal mining and related activities.

Dome style heavy wall steel casting manufactured by metallic core mould system

International Nuclear Information System (INIS)

Yamamoto, Shiro; Saeki, Keiji; Hirose, Yutaka; Takebayashi, Kazunari; Kawasaki, Masatoshi

1986-01-01

Semi-spherical thick walled steel castings are one of the main products of Nippon Chutanko K.K., but there have been the problems of internal defects peculiar to large thick walled steel castings, and the various improvements have been carried out so far for the manufacturing method, but still some of those remains. Based on the anxiety about the reliability of large steel castings, the conversion to forging has been studied. For the purpose of thoroughly improving the internal quality of thick walled steel castings to compete with forgings, on the basis of the operating experience of chills, the development of the casting techniques changing cores completely to metallic cores has been advanced. After the preliminary experiment using models, a semi-spherical thick walled steel casting mentioned before was manufactured by this metallic core casting method for trial, and the detailed investigation was carried out. As the result, the excellent internal quality was confirmed, accordingly at present, the production is made by this method. The form, dimensions and specification of the semi-spherical thick walled steel castings, the conventional casting plan, the metallic core casting plan, the design of metallic cores, molding and casting, and the examination of the castings made for trial are reported. (Kako, I.)

Manufacturing and Morphological Analysis of Composite Material of Polystyrene Nanospheres/Cadmium Metal Nanoparticles

Directory of Open Access Journals (Sweden)

Pratama Jujur Wibawa

2013-03-01

Full Text Available A very simple nanocomposite material has been in-situ manufactured from an aqueous polystyrene nanospheres dispersion and cadmium (Cd metal nanoparticles. The manufacturing was performed by using a high frequency of 40 kHz ultrasonic (US agitation for 45 minute at atmospheric pressure and at room temperature 20 oC. No chemical reducing agent and surfactant added in this manufacturing technique due to the US could reduce Cd2+ ions of cadmium nitrate tetrahydrate to Cd atomic metals nanoparticles whereas water molecules could act as a pseudo stabilizer for the manufactured material. A thin film was manufactured from aqueous colloidal nanocomposite material of Polystyrene nanospheres/Cd metal nanoparticles (PSNs/CdMNp fabricated on a hydrophilic silicon wafer. The thin film was then characterized by a JEOL-FESEM for its surface morphology characteristic and by ATR-FTIR spectrometry for its molecular change investigation. It could be clearly observed that surface morphology of the thin film material was not significantly changed under 633 nm wavelength continuous laser radiation exposure for 20 minute. In addition, its ATR-FTIR spectra of wave number peaks around 3400 cm-1 have been totally disappeared under the laser exposure whereas that at around 699 cm-1 and 668 cm-1 have not been significantly changed. The first phenomenon indicated that the hydrogen bond existed in PSNs/CdMNp material was collapsed by the laser exposure. The second phenomena indicated that the PSNs phenyl ring moiety was not totally destroyed under the laser exposure. It was suspected due to the existence of Cd nanoparticles covered throughout the spherical surface of PSNs/CdMNp material particles. Therefore a nice model of material structure of the mentioned PSNs/CdMNp nanocomposite material could be suggested in this research. It could be concluded that this research have been performed since the material structure model of the manufactured PSNs/CdMNp nanocomposite could be

Laser additive manufacturing bulk graphene-copper nanocomposites.

Science.gov (United States)

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J

2017-11-03

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Hard-on-hard lubrication in the artificial hip under dynamic loading conditions.

Directory of Open Access Journals (Sweden)

Robert Sonntag

Full Text Available The tribological performance of an artificial hip joint has a particularly strong influence on its success. The principle causes for failure are adverse short- and long-term reactions to wear debris and high frictional torque in the case of poor lubrication that may cause loosening of the implant. Therefore, using experimental and theoretical approaches models have been developed to evaluate lubrication under standardized conditions. A steady-state numerical model has been extended with dynamic experimental data for hard-on-hard bearings used in total hip replacements to verify the tribological relevance of the ISO 14242-1 gait cycle in comparison to experimental data from the Orthoload database and instrumented gait analysis for three additional loading conditions: normal walking, climbing stairs and descending stairs. Ceramic-on-ceramic bearing partners show superior lubrication potential compared to hard-on-hard bearings that work with at least one articulating metal component. Lubrication regimes during the investigated activities are shown to strongly depend on the kinematics and loading conditions. The outcome from the ISO gait is not fully confirmed by the normal walking data and more challenging conditions show evidence of inferior lubrication. These findings may help to explain the differences between the in vitro predictions using the ISO gait cycle and the clinical outcome of some hard-on-hard bearings, e.g., using metal-on-metal.

Thermodynamics and structure of liquid alkali metals from the charged-hard-sphere reference fluid

International Nuclear Information System (INIS)

Lai, S.K.; Akinlade, O.; Tosi, M.P.

1989-12-01

The evaluation of thermodynamic properties of liquid alkali metals is re-examined in the approach based on the Gibbs-Bogoliubov inequality and using the fluid of charged hard spheres in the mean spherical approximation as reference system, with a view to achieving consistency with the liquid structure factor. The perturbative variational calculation of the Helmholtz free energy is based on an ab initio and highly reliable nonlocal pseudopotential. Only limited improvement is found in the calculated thermodynamic functions, even when full advantage is taken of the two variational parameters inherent in this approach. The role of thermodynamic self-consistency between the equations of state of the reference fluid derived from the routes of the internal energy and of the virial theorem is then discussed, using previous results by Hoye and Stell. An approximate evaluation of the corresponding contribution to the free energy of liquid alkali metals yields appreciable improvements in both the thermodynamic functions and the liquid structure factor. It thus appears that an accurate treatment of thermodynamic self-consistency in the charged-hard-sphere system may help to resolve some of the difficulties that are commonly met in the evaluation of thermodynamic and structural properties of liquid metals. (author). 55 refs, 4 figs, 4 tabs

Phase stability, physical properties of rhenium diboride under high pressure and the effect of metallic bonding on its hardness

International Nuclear Information System (INIS)

Zhong, Ming-Min; Kuang, Xiao-Yu; Wang, Zhen-Hua; Shao, Peng; Ding, Li-Ping; Huang, Xiao-Fen

2013-01-01

Highlights: •The transition pressure P t between the ReB 2 –ReB 2 and MoB 2 –ReB 2 phases is firstly determinate. •The single-bonded B–B feather remains in ReB 2 compounds. •A semiempirical method to evaluate the hardness of crystals with partial metallic bond is presented. •The large hardness (39.1 GPa) of ReB 2 –ReB 2 indicate that it is a superhard material. •The zigzag interconnected B–Re and B–B covalent bonds underlie the ultraincompressibilities. -- Abstract: Using first-principles calculations, the elastic constants, thermodynamic property and structural phase transition of rhenium diboride under pressure are investigated by means of the pseudopotential plane-waves method, as well as the effect of metallic bond on its hardness. Eight candidate structures of known transition-metal compounds are chosen to probe for rhenium diboride ReB 2 . The calculated lattice parameters are consistent with the experimental and theoretical values. Based on the third order Birch–Murnaghan equation of states, the transition pressure P t between the ReB 2 –ReB 2 and MoB 2 –ReB 2 phases is firstly determinate. Elastic constants, shear modulus, Young’s modulus, Poisson’s ratio and Debye temperature are derived. The single-bonded B–B feather remains in ReB 2 compounds. Furthermore, according to Mulliken overlap population analysis, a semiempirical method to evaluate the hardness of multicomponent crystals with partial metallic bond is presented. Both strong covalency and a zigzag topology of interconnected bonds underlie the ultraincompressibilities. In addition, the superior performance and large hardness (39.1 GPa) of ReB 2 –ReB 2 indicate that it is a superhard material

Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review.

Science.gov (United States)

Wang, Xiaojian; Xu, Shanqing; Zhou, Shiwei; Xu, Wei; Leary, Martin; Choong, Peter; Qian, M; Brandt, Milan; Xie, Yi Min

2016-03-01

One of the critical issues in orthopaedic regenerative medicine is the design of bone scaffolds and implants that replicate the biomechanical properties of the host bones. Porous metals have found themselves to be suitable candidates for repairing or replacing the damaged bones since their stiffness and porosity can be adjusted on demands. Another advantage of porous metals lies in their open space for the in-growth of bone tissue, hence accelerating the osseointegration process. The fabrication of porous metals has been extensively explored over decades, however only limited controls over the internal architecture can be achieved by the conventional processes. Recent advances in additive manufacturing have provided unprecedented opportunities for producing complex structures to meet the increasing demands for implants with customized mechanical performance. At the same time, topology optimization techniques have been developed to enable the internal architecture of porous metals to be designed to achieve specified mechanical properties at will. Thus implants designed via the topology optimization approach and produced by additive manufacturing are of great interest. This paper reviews the state-of-the-art of topological design and manufacturing processes of various types of porous metals, in particular for titanium alloys, biodegradable metals and shape memory alloys. This review also identifies the limitations of current techniques and addresses the directions for future investigations. Copyright © 2016 Elsevier Ltd. All rights reserved.

Statistical experiments using the multiple regression research for prediction of proper hardness in areas of phosphorus cast-iron brake shoes manufacturing

Science.gov (United States)

Kiss, I.; Cioată, V. G.; Ratiu, S. A.; Rackov, M.; Penčić, M.

2018-01-01

Multivariate research is important in areas of cast-iron brake shoes manufacturing, because many variables interact with each other simultaneously. This article focuses on expressing the multiple linear regression model related to the hardness assurance by the chemical composition of the phosphorous cast irons destined to the brake shoes, having in view that the regression coefficients will illustrate the unrelated contributions of each independent variable towards predicting the dependent variable. In order to settle the multiple correlations between the hardness of the cast-iron brake shoes, and their chemical compositions several regression equations has been proposed. Is searched a mathematical solution which can determine the optimum chemical composition for the hardness desirable values. Starting from the above-mentioned affirmations two new statistical experiments are effectuated related to the values of Phosphorus [P], Manganese [Mn] and Silicon [Si]. Therefore, the regression equations, which describe the mathematical dependency between the above-mentioned elements and the hardness, are determined. As result, several correlation charts will be revealed.

Ultrafine Ceramic Grains Embedded in Metallic Glass Matrix: Achieving Superior Wear Resistance via Increase in Both Hardness and Toughness.

Science.gov (United States)

Yang, Lina; Wen, Mao; Dai, Xuan; Cheng, Gang; Zhang, Kan

2018-05-09

As structural materials, crystalline or metallic glass materials have attracted scientific and practical interests. However, some mechanisms involving critical size and shear bands have adverse effects on their mechanical properties. Here, we counter these two effects by introducing a special structure with ultrafine ceramic grains (with a diameter of ∼2.0 nm) embedded into a metallic glass matrix, wherein the grains are mainly composed of a Ta-W-N solid solution structure in nature, surrounded by a W-based amorphous matrix that contains Ta and N atoms. Such a structure is in situ formed during preparation, which combines the merits of both phases to achieve simultaneous increase in hardness and toughness relative to references (pure TaN and W) and thus superior wear resistance. Even more remarkable, a favorable variation of increased hardness but reduced elasticity modulus can be induced by this structure. Intrinsically, ultrafine ceramic grains (free of dislocations), embedded in the metallic glass matrix, could prevent shear band propagation within the glass matrix and further improve the hardness of the matrix material. In return, such glass matrix allows for stiffness neutralization and structural relaxation to reduce the elasticity modulus of ceramic grains. This study will offer a new guidance to fabricate ultrahigh-performance metal-based composites.

WHO water quality standards Vs Synergic effect(s) of fluoride, heavy metals and hardness in drinking water on kidney tissues

Science.gov (United States)

Wasana, Hewa M. S.; Perera, Gamage D. R. K.; Gunawardena, Panduka De S.; Fernando, Palika S.; Bandara, Jayasundera

2017-02-01

Despite WHO standards, waterborne diseases among the human being are rising alarmingly. It is known that the prolong exposure to contaminated water has major impact on public health. The effect of chemical contaminations in drinking water on human being is found to be chronic rather than acute and hence can be defined “consumption of contaminated drinking water could be a silent killer”. As the WHO recommended water quality standards are only for individual element and synergic effects of trace metals and anions have not been considered, investigation of synergic effects of trace metals and anions and their effect on human being is of prime important research. By an animal trial, we investigated the synergic effect(s) of heavy metals, aluminium, arsenic, fluoride and hardness in drinking water on kidney tissues of mice. Our investigation strongly suggests existing of a synergic effect especially among Cd, F and hardness of water which could lead to severe kidney damage in mice, even at WHO maximum recommended levels. Hence, the synergic effect(s) of trace metals, fluoride and hardness present in drinking water should be investigated meticulously when stipulating the water quality at WHO maximum recommended levels.

Effect of manufacturing process sequence on the corrosion resistance characteristics of coated metallic bipolar plates

Science.gov (United States)

Dur, Ender; Cora, Ömer Necati; Koç, Muammer

2014-01-01

Metallic bipolar plate (BPP) with high corrosion and low contact resistance, durability, strength, low cost, volume, and weight requirements is one of the critical parts of the PEMFC. This study is dedicated to understand the effect of the process sequence (manufacturing then coating vs. coating then manufacturing) on the corrosion resistance of coated metallic bipolar plates. To this goal, three different PVD coatings (titanium nitride (TiN), chromium nitride (CrN), zirconium nitride (ZrN)), with three thicknesses, (0.1, 0.5, 1 μm) were applied on BPPs made of 316L stainless steel alloy before and after two types of manufacturing (i.e., stamping or hydroforming). Corrosion test results indicated that ZrN coating exhibited the best corrosion protection while the performance of TiN coating was the lowest among the tested coatings and thicknesses. For most of the cases tested, in which coating was applied before manufacturing, occurrence of corrosion was found to be more profound than the case where coating was applied after manufacturing. Increasing the coating thickness was found to improve the corrosion resistance. It was also revealed that hydroformed BPPs performed slightly better than stamped BPPs in terms of the corrosion behavior.

Additive Manufacturing and Casting Technology Comparison: Mechanical Properties, Productivity and Cost Benchmark

Science.gov (United States)

Vevers, A.; Kromanis, A.; Gerins, E.; Ozolins, J.

2018-04-01

The casting technology is one of the oldest production technologies in the world but in the recent years metal additive manufacturing also known as metal 3D printing has been evolving with huge steps. Both technologies have capabilities to produce parts with internal holes and at first glance surface roughness is similar for both technologies, which means that for precise dimensions parts have to be machined in places where precise fit is necessary. Benchmark tests have been made to find out if parts which are produced with metal additive manufacturing can be used to replace parts which are produced with casting technology. Most of the comparative tests have been made with GJS-400-15 grade which is one of the most popular cast iron grades. To compare mechanical properties samples have been produced using additive manufacturing and tested for tensile strength, hardness, surface roughness and microstructure and then the results have been compared with the samples produced with casting technology. In addition, both technologies have been compared in terms of the production time and production costs to see if additive manufacturing is competitive with the casting technology. The original paper has been written in the Latvian language as part of the Master Thesis within the framework of the production technology study programme at Riga Technical University.

Variation behavior of residual stress distribution by manufacturing processes in welded pipes of austenitic stainless steel

International Nuclear Information System (INIS)

Ihara, Ryohei; Hashimoto, Tadafumi; Mochizuki, Masahito

2012-01-01

Stress corrosion cracking (SCC) has been observed near heat affected zone (HAZ) of primary loop recirculation pipes made of low-carbon austenitic stainless steel type 316L in the nuclear power plants. For the non-sensitization material, residual stress is the important factor of SCC, and it is generated by machining and welding. In the actual plants, welding is conducted after machining as manufacturing processes of welded pipes. It could be considered that residual stress generated by machining is varied by welding as a posterior process. This paper presents residual stress variation due to manufacturing processes of pipes using X-ray diffraction method. Residual stress distribution due to welding after machining had a local maximum stress in HAZ. Moreover, this value was higher than residual stress generated by welding or machining. Vickers hardness also had a local maximum hardness in HAZ. In order to clarify hardness variation, crystal orientation analysis with EBSD method was performed. Recovery and recrystallization were occurred by welding heat near the weld metal. These lead hardness decrease. The local maximum region showed no microstructure evolution. In this region, machined layer was remained. Therefore, the local maximum hardness was generated at machined layer. The local maximum stress was caused by the superposition effect of residual stress distributions due to machining and welding. Moreover, these local maximum residual stress and hardness are exceeded critical value of SCC initiation. In order to clarify the effect of residual stress on SCC initiation, evaluation including manufacturing processes is important. (author)

Effect of layered manufacturing techniques, alloy powders, and layer thickness on metal-ceramic bond strength.

Science.gov (United States)

Ekren, Orhun; Ozkomur, Ahmet; Ucar, Yurdanur

2018-03-01

Direct metal laser sintering (DMLS) and direct metal laser melting (DMLM) have become popular for fabricating the metal frameworks of metal-ceramic restorations. How the type of layered manufacturing device, layer thickness, and alloy powder may affect the bond strength of ceramic to metal substructure is unclear. The purpose of this in vitro study was to evaluate the bond strength of dental porcelain to metal frameworks fabricated using different layered manufacturing techniques (DMLS and DMLM), Co-Cr alloy powders, and layer thicknesses and to evaluate whether a correlation exists between the bond strength and the number of ceramic remnants on the metal surface. A total of 75 bar-shaped metal specimens (n=15) were fabricated using either DMLS or DMLM. The powder alloys used were Keramit NP-S and EOS-Cobalt-Chrome SP-2 with layer thicknesses of 20 μm and 30 μm. After ceramic application, the metal-ceramic bond strength was evaluated with a 3-point-bend test. Three-way ANOVA followed by the Tukey honest significance difference test were used for statistical analysis (α=.05). De-bonding surface microstructure was observed with scanning electron microscopy. Energy dispersive spectroscopy analysis was conducted to evaluate the correlation between ceramic remnants on the metal surface and bond strength values. The mean bond strength value of DMLS was significantly higher than that of DMLM. While no statistically significant difference was found between layer thicknesses, alloy powders closely affected bond strength. Statistical comparisons revealed that the highest bond strength could be achieved with DMLS-Cobalt-Chrome SP2-20μm, and the lowest bond strength was observed in DMLS-Keramit NP-S-20μm (P≤.05). No correlation was found between porcelain remnants on the metal surface and bond strength values. The layered manufacturing device and the alloy powders evaluated in the current study closely affected the bond strength of dental porcelain to a metal framework

Manufacturing process for the metal ceramic hybrid fuel cladding tube

International Nuclear Information System (INIS)

Jung, Yang Il; Kim, Sun Han; Park, Jeong Yong

2012-01-01

For application in LWRs with suppressed hydrogen release, a metal-ceramic hybrid cladding tube has been proposed. The cladding consists of an inner zirconium tube and outer SiC fiber matrix SiC ceramic composite. The inner zirconium allows the matrix to remain fully sealed even if the ceramic matrix cracks through. The outer SiC composite can increase the safety margin by taking the merits of the SiC itself. However, it is a challenging task to fabricate the metal-ceramic hybrid tube. Processes such as filament winding, matrix impregnation, and surface costing are additionally required for the existing Zr based fuel cladding tubes. In the current paper, the development of the manufacturing process will be introduced

Manufacturing process for the metal ceramic hybrid fuel cladding tube

Energy Technology Data Exchange (ETDEWEB)

Jung, Yang Il; Kim, Sun Han; Park, Jeong Yong [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

2012-10-15

For application in LWRs with suppressed hydrogen release, a metal-ceramic hybrid cladding tube has been proposed. The cladding consists of an inner zirconium tube and outer SiC fiber matrix SiC ceramic composite. The inner zirconium allows the matrix to remain fully sealed even if the ceramic matrix cracks through. The outer SiC composite can increase the safety margin by taking the merits of the SiC itself. However, it is a challenging task to fabricate the metal-ceramic hybrid tube. Processes such as filament winding, matrix impregnation, and surface costing are additionally required for the existing Zr based fuel cladding tubes. In the current paper, the development of the manufacturing process will be introduced.

Structure, elastic stiffness, and hardness of Os 1- xRu xB 2 solid solution transition-metal diborides

KAUST Repository

Kanoun, Mohammed; Hermet, Patrick; Goumri-Said, Souraya

2012-01-01

On the basis of recent experiments, the solid solution transition-metal diborides were proposed to be new ultra-incompressible hard materials. We investigate using density functional theory based methods the structural and mechanical properties, electronic structure, and hardness of Os 1-xRu xB 2 solid solutions. A difference in chemical bonding occurs between OsB 2 and RuB 2 diborides, leading to significantly different elastic properties: a large bulk, shear moduli, and hardness for Os-rich diborides and relatively small bulk, shear moduli, and hardness for Ru-rich diborides. The electronic structure and bonding characterization are also analyzed as a function of Ru-dopant concentration in the OsB 2 lattice. © 2012 American Chemical Society.

Structure, elastic stiffness, and hardness of Os 1- xRu xB 2 solid solution transition-metal diborides

KAUST Repository

Kanoun, Mohammed

2012-05-31

On the basis of recent experiments, the solid solution transition-metal diborides were proposed to be new ultra-incompressible hard materials. We investigate using density functional theory based methods the structural and mechanical properties, electronic structure, and hardness of Os 1-xRu xB 2 solid solutions. A difference in chemical bonding occurs between OsB 2 and RuB 2 diborides, leading to significantly different elastic properties: a large bulk, shear moduli, and hardness for Os-rich diborides and relatively small bulk, shear moduli, and hardness for Ru-rich diborides. The electronic structure and bonding characterization are also analyzed as a function of Ru-dopant concentration in the OsB 2 lattice. © 2012 American Chemical Society.

Titanium and zirconium metal powder spheroidization by thermal plasma processes

OpenAIRE

Bissett, H.; van der Walt, I.J.; Havenga, J.L.; Nel, J.T.

2015-01-01

New technologies used to manufacture high-quality components, such as direct laser sintering, require spherical powders of a narrow particle size distribution as this affects the packing density and sintering mechanism. The powder also has to be chemically pure as impurities such as H, O, C, N, and S causes brittleness, influence metal properties such as tensile strength, hardness, and ductility, and also increase surface tension during processing. Two new metal powder processes have been dev...

Microstructural and hardness investigations on a dissimilar metal weld between low alloy steel and Alloy 82 weld metal

International Nuclear Information System (INIS)

Chen, Z.R.; Lu, Y.H.; Ding, X.F.; Shoji, T.

2016-01-01

The investigation on microstructure and hardness at the fusion boundary (FB) region of a dissimilar metal weld (DMW) between low alloy steel (LAS) A508-III and Alloy 82 weld metal (WM) was carried out. The results indicated that there were two kinds of FBs, martensite FB and sharp FB, with obvious different microstructures, alternately distributed in the same FB. The martensite FB region had a gradual change of elemental concentration across FB, columnar WM grains with high length/width ratios, a thick martensite layer and a wide heat affected zone (HAZ) with large prior austenite grains. By comparison, the sharp FB region had a relatively sharp change of elemental concentration across the FB, WM grains with low length/width ratios and a narrow HAZ with smaller prior austenite grains. The martensite possessed a K-S orientation relationship with WM grains, while no orientation relationship was found between the HAZ grains and WM grains at the sharp FB. Compared with sharp FB there were much more Σ3 boundaries in the HAZ beside martensite FB. The hardness maximum of the martensite FB was much higher than that of the sharp FB, which was attributed to the martensite layer at the martensite FB. - Highlights: •Martensite and sharp FBs with different microstructures were found in the same FB. •There were high length/width-ratio WM grains and a wide HAZ beside martensite FB. •There were low length/width-ratio WM grains and a narrow HAZ beside sharp FB. •Compared with sharp FB, there were much more Σ3 boundaries in HAZ of martensite FB. •Hardness maximium of martensite FB was much higher than that of sharp FB.

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

Science.gov (United States)

Tylka, Jonathan; Cooper, Ken; Peralta, Stephen; Wilcutt, Terrence; Hughitt, Brian; Generazio, Edward

2016-01-01

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

PM - processing for manufacturing of metals with cellular structures

International Nuclear Information System (INIS)

Strobl, S.; Danninger, H.

2001-01-01

In this review the major Processes about manufacturing of metals with cellular structure are described - based on powder metallurgy, chemical deposition and some other methods (without melting techniques). It can be shown that during the last decade many interesting innovations led to new production methods to design cellular materials. Some of them are used nowadays in industry. Also characterization and properties become more important and have therefore been carried out carefully, because of their strong influence on the functions and applications of such materials. (author)

Manufacturing and Machining Challenges of Hybrid Aluminium Metal Matix Composites

Science.gov (United States)

Baburaja, Kammuluri; Sainadh Teja, S.; Karthik Sri, D.; Kuldeep, J.; Gowtham, V.

2017-08-01

Manufacturing which involves material removal processes or material addition processes or material transformation processes. One or all the processes to obtain the final desired properties for a material with desired shape which meets the required precision and accuracy values for the expected service life of a material in working conditions. Researchers found the utility of aluminium to be the second largest after steel. Aluminium and its metal matrix composite possess wide applications in various applications in aerospace industry, automobile industry, Constructions and even in kitchen utensils. Hybrid Al-MMCconsist of two different materials, and one will be from organic origin along with the base material. In this paper an attempt is made to bring out the importance of utilization of aluminium and the challenges concerned in manufacturing and machining of hybrid aluminium MMC.

Advanced optical modeling of TiN metal hard mask for scatterometric critical dimension metrology

Science.gov (United States)

Ebersbach, Peter; Urbanowicz, Adam M.; Likhachev, Dmitriy; Hartig, Carsten

2017-03-01

The majority of scatterometric production control models assume constant optical properties of the materials and only dimensional parameters are allowed to vary. However, this assumption, especially in case of thin-metal films, negatively impacts model precision and accuracy. In this work we focus on optical modeling of the TiN metal hardmask for scatterometry applications. Since the dielectric function of TiN exhibits thickness dependence, we had to take this fact into account. Moreover, presence of the highly absorbing films influences extracted thicknesses of dielectric layers underneath the metal films. The later phenomenon is often not reflected by goodness of fit. We show that accurate optical modeling of metal is essential to achieve desired scatterometric model quality for automatic process control in microelectronic production. Presented modeling methodology can be applied to other TiN applications such as diffusion barriers and metal gates as well as for other metals used in microelectronic manufacturing for all technology nodes.

Application Of Artificial Neural Networks In Modeling Of Manufactured Front Metallization Contact Resistance For Silicon Solar Cells

Directory of Open Access Journals (Sweden)

Musztyfaga-Staszuk M.

2015-09-01

Full Text Available This paper presents the application of artificial neural networks for prediction contact resistance of front metallization for silicon solar cells. The influence of the obtained front electrode features on electrical properties of solar cells was estimated. The front electrode of photovoltaic cells was deposited using screen printing (SP method and next to manufactured by two methods: convectional (1. co-fired in an infrared belt furnace and unconventional (2. Selective Laser Sintering. Resistance of front electrodes solar cells was investigated using Transmission Line Model (TLM. Artificial neural networks were obtained with the use of Statistica Neural Network by Statsoft. Created artificial neural networks makes possible the easy modelling of contact resistance of manufactured front metallization and allows the better selection of production parameters. The following technological recommendations for the screen printing connected with co-firing and selective laser sintering technology such as optimal paste composition, morphology of the silicon substrate, co-firing temperature and the power and scanning speed of the laser beam to manufacture the front electrode of silicon solar cells were experimentally selected in order to obtain uniformly melted structure well adhered to substrate, of a small front electrode substrate joint resistance value. The prediction possibility of contact resistance of manufactured front metallization is valuable for manufacturers and constructors. It allows preserving the customers’ quality requirements and bringing also measurable financial advantages.

Contributions of hard and soft blocks in the self-healing of metal-ligand-containing block copolymers

NARCIS (Netherlands)

Bose, Ranjita K.; Enke, Marcel; Grande, Antonio M.; Zechel, Stefan; Schacher, Felix H.; Hager, Martin D.; Garcia, Santiago J.; Schubert, Ulrich S.; van der Zwaag, Sybrand

2017-01-01

The main aim of this work is to study the respective contribution of the hard and soft blocks of a metal-ligand containing block copolymer to the self-healing behavior. To this aim, different block copolymers containing terpyridine were synthesized using reversible addition-fragmentation chain

Hardness of carbides, nitrides, and borides

International Nuclear Information System (INIS)

Schroeter, W.

1981-01-01

Intermetallic compounds of metals with non-metals such as C, N, and B show different hardness. Wagner's interaction parameter characterizes manner and extent of the interaction between the atoms of the substance dissolved and the additional elements in metallic mixed phases. An attempt has been made to correlate the hardness of carbides, nitrides, and borides (data taken from literature) with certain interaction parameters and associated thermodynamic quantities (ΔH, ΔG). For some metals of periods 4, 5, and 6 corresponding relations were found between microhardness, interaction parameters, heat of formation, and atomic number

Integrating Fiber Optic Strain Sensors into Metal Using Ultrasonic Additive Manufacturing

Science.gov (United States)

Hehr, Adam; Norfolk, Mark; Wenning, Justin; Sheridan, John; Leser, Paul; Leser, Patrick; Newman, John A.

2018-03-01

Ultrasonic additive manufacturing, a rather new three-dimensional (3D) printing technology, uses ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. This low temperature attribute of the process enables integration of temperature sensitive components, such as fiber optic strain sensors, directly into metal structures. This may be an enabling technology for Digital Twin applications, i.e., virtual model interaction and feedback with live load data. This study evaluates the consolidation quality, interface robustness, and load sensing limits of commercially available fiber optic strain sensors embedded into aluminum alloy 6061. Lastly, an outlook on the technology and its applications is described.

Contributions of hard and soft blocks in the self-healing of metal-ligand-containing block copolymers

NARCIS (Netherlands)

Bose, R.K.; Enke, Marcel; Grande, A.M.; Zechel, Stefan; Schacher, Felix H.; Hager, Martin D.; Garcia Espallargas, Santiago J.; Schubert, Ulrich S.; van der Zwaag, S.

2017-01-01

The main aim of this work is to study the respective contribution of the hard and soft blocks of a metal-ligand containing block copolymer to the self-healing behavior. To this aim, different block copolymers containing terpyridine were synthesized using reversible addition-fragmentation chain

Chemodynamics of metal ion complexation by charged nanoparticles: a dimensionless rationale for soft, core-shell and hard particle types.

Science.gov (United States)

Duval, Jérôme F L

2017-05-17

Soft nanoparticulate complexants are defined by a spatial confinement of reactive sites and electric charges inside their 3D body. In turn, their reactivity with metal ions differs significantly from that of simple molecular ligands. A revisited form of the Eigen mechanism recently elucidated the processes leading to metal/soft particle pair formation. Depending on e.g. particle size and metal ion nature, chemodynamics of nanoparticulate metal complexes is controlled by metal conductive diffusion to/from the particles, by intraparticulate complex formation/dissociation kinetics, or by both. In this study, a formalism is elaborated to achieve a comprehensive and systematic identification of the rate-limiting step governing the overall formation and dissociation of nanoparticulate metal complexes. The theory covers the different types of spherical particulate complexants, i.e. 3D soft/permeable and core-shell particles, and hard particles with reactive sites at the surface. The nature of the rate-limiting step is formulated by a dynamical criterion involving a power law function of the ratio between particle radius and an intraparticulate reaction layer thickness defined by the key electrostatic, diffusional and kinetic components of metal complex formation/dissociation. The analysis clarifies the intertwined contributions of particle properties (size, soft or hard type, charge, density or number of reactive sites) and aqueous metal ion dehydration kinetics in defining the chemodynamic behavior of nanoparticulate metal complexes. For that purpose, fully parameterized chemodynamic portraits involving the defining features of particulate ligand and metal ion as well as the physicochemical conditions in the local intraparticulate environment, are constructed and thoroughly discussed under conditions of practical interest.

Structure changes in steels and hard metal induced by nanosecond and femtosecond laser processing

Science.gov (United States)

Dumitru, Gabriel; Romano, Valerio; Weber, Heinz P.; Haefke, Henry; Gerbig, Yvonne; Sentis, Marc L.; Hermann, Joerg; Bruneau, Sebastien

2003-11-01

Investigations on the occurrence of structure and hardness changes (for two sorts of steel and for a hard metal substrate) in the immediate vicinity of laser induced craters are presented in this work. Experiments with femtosecond pulses were performed in air with a Ti:sapphire laser (800 nm, 100 fs) at mean fluences of 2, 5 and 10 J/cm2. Series of microcraters were induced with 100 to 5,000 laser pulses per hole. Experiments with similar fluences, but 10 to 40 pules per hole, were performed on the same materials using a Nd:YAG delivering 100 ns pulese. After laser irradiation, cuts were made through the processed samples and the changes occurred in the crystalline structure of the target materials were evidenced by metallographical analysis of the resulting cross-sections. Hardness measurements were performed in points situated in the immediate vicinity of the laser-induced pores. Affected zones in the material surrounding laser induced pores were always found in the ns-regime, however with different properties for various laser parameters. In the fs-regime, zones of modified materials were also found and in such zones a significant hardness increasing was evidenced; the limit of the low fluences regime, where no structure changes occurred, was found to be slightly above 2 J/cm2.

Dissolution rates and solubility of some metals in liquid gallium and aluminum

International Nuclear Information System (INIS)

Yatsenko, S P; Sabirzyanov, N A; Yatsenko, A S

2008-01-01

The effect of liquid gallium and aluminum on some hard metals leading to dissolution and formation of intermetallic compounds (IMC) under static conditions and rotation of a specimen is studied. The solubility parameters from the Clapeyron-Clausius equation were considered to estimate the stability of still not studied metals. The presented experimental data on solubility and corrosion in a wide temperature range allow to calculate a number of parameters useful in manufacturing and application of master-alloys

Characterization and properties of sintered WC–Co and WC–Ni–Fe hard metal alloys

International Nuclear Information System (INIS)

Chang, Shih-Hsien; Chen, Song-Ling

2014-01-01

Highlights: • WC–Ni–Fe alloy sintered at 1400 °C had the highest hardness (HRA 85.3 ± 0.5). • The optimal WC–Ni–Fe sintered alloy possessed the highest TRS value (2524.5 ± 1.0 MPa). • The fracture toughness of the sintered WC–Ni–Fe alloys is mainly provided by the Ni–Fe binders. • WC–Ni–Fe sintered alloy possessed the highest fracture toughness of K IC (15.1 MPa m 1/2 ). • The WC–Ni–Fe sintered alloy had the much better corrosion resistance in 0.15 M HCl solution. -- Abstract: The aim of this study is to explore two different tungsten carbide binders (Co and Ni–Fe) and then impose various sintering temperature treatments. Experimental results show that the optimal sintering temperatures for WC–Co and WC–Ni–Fe hard metal alloys are 1350 °C and 1400 °C for 1 h, respectively. Meanwhile, the WC–Co and WC–Ni–Fe alloys undergo a well liquid-phase sintering and, thus, exhibit excellent mechanical properties. In addition, the sintered WC–Co and WC–Ni–Fe alloys show that when the relative density reached 99.76% and 99.68%, the hardness was enhanced to HRA 84.4 ± 0.5 and 85.3 ± 0.5, and the TRS increased to 2471.2 ± 1.0 and 2524.5 ± 1.0 MPa, respectively. Moreover, the corrosion test results show that the WC–Ni–Fe alloy sintered at 1400 °C had the lowest corrosion current (I corr ) of 1.11 × 10 −5 A cm −2 and the highest polarization resistance (R p ) of 2464.61 Ω cm 2 in 0.15 M HCl solution. Simultaneously, the fracture toughness of K IC increased to 15.1 MPa m 1/2 . Compared with sintered WC–Co alloys, the sintered WC–Ni–Fe hard metal alloys possessed much better corrosion resistance and mechanical properties

Quasi-static strength and fractography analysis of two dental implants manufactured by direct metal laser sintering.

Science.gov (United States)

Gehrke, Sergio Alexandre; Pérez-Díaz, Leticia; Dedavid, Berenice Anina

2018-01-30

New manufacturing methods was developed to improve the tissues integration with the titanium alloy pieces. The present in vitro study was to assess the resistance and fracture mode after applied a quasi-static compressive force on the two dental implants manufactured by direct metal laser sintering. Twenty dental implants manufactured by direct metal laser sintering, using titanium alloy (Ti-6Al-4V) granules in two designs (n = 10 per group): Conventional dental implant (group Imp1) two-piece implant design, where the surgical implant and prosthetic abutment are two separate components and, the one-piece implant (group Imp2), where the surgical implant and prosthetic abutment are one integral piece. All samples were subjected to quasi-static loading at a 30° angle to the implant axis in a universal testing machine. The mean fracture strengths were 1269.2 ± 128.8 N for the group Imp1 and, 1259.5 ± 115.1 N for the group Imp2, without statistical differences (P = .8722). In both groups, the fracture surface does not present crack between the compact core and the superficial (less dense and porous) part of the implants. Based on the measured resistance data for the two implant models manufactured by direct metal laser sintering tested in the present study, we can suggest that they have adequate capacity to withstand the masticatory loads. © 2018 Wiley Periodicals, Inc.

3D Metal Printing - Additive Manufacturing Technologies for Frameworks of Implant-Borne Fixed Dental Prosthesis.

Science.gov (United States)

Revilla León, M; Klemm, I M; García-Arranz, J; Özcan, M

2017-09-01

An edentulous patient was rehabilitated with maxillary metal-ceramic and mandibular metal-resin implant-supported fixed dental prosthesis (FDP). Metal frameworks of the FDPs were fabricated using 3D additive manufacturing technologies utilizing selective laser melting (SLM) and electron beam melting (EBM) processes. Both SLM and EBM technologies were employed in combination with computer numerical control (CNC) post-machining at the implant interface. This report highlights the technical and clinical protocol for fabrication of FDPs using SLM and EBM additive technologies. Copyright© 2017 Dennis Barber Ltd.

Development of a recovery process of scraps resulting from the manufacture of metallic uranium fuels

International Nuclear Information System (INIS)

Camilo, Ruth L.; Kuada, Terezinha A.; Forbicini, Christina A.L.G.O.; Cohen, Victor H.; Araujo, Bertha F.; Lobao, Afonso S.T.

1996-01-01

The study of the dissolution of natural metallic uranium fuel samples with aluminium cladding is presented, in order to obtain optimized conditions for the system. The aluminium cladding was dissolved in an alkaline solution of Na OH/Na NO 3 and the metallic uranium with HNO 3 . A fumeless dissolution with total recovery of nitrous gases was achieved. The main purpose of this project was the recovery of uranium from scraps resulting from the manufacture of the metallic uranium fuel or other non specified fuels. (author)

Effects of Computer-Aided Manufacturing Technology on Precision of Clinical Metal-Free Restorations.

Science.gov (United States)

Lee, Ki-Hong; Yeo, In-Sung; Wu, Benjamin M; Yang, Jae-Ho; Han, Jung-Suk; Kim, Sung-Hun; Yi, Yang-Jin; Kwon, Taek-Ka

2015-01-01

The purpose of this study was to investigate the marginal fit of metal-free crowns made by three different computer-aided design/computer-aided manufacturing (CAD/CAM) systems. The maxillary left first premolar of a dentiform was prepared for all-ceramic crown restoration. Thirty all-ceramic premolar crowns were made, ten each manufactured by the Lava system, Cercon, and Cerec. Ten metal ceramic gold (MCG) crowns served as control. The marginal gap of each sample was measured under a stereoscopic microscope at 75x magnification after cementation. One-way ANOVA and the Duncan's post hoc test were used for data analysis at the significance level of 0.05. The mean (standard deviation) marginal gaps were 70.5 (34.4) μm for the MCG crowns, 87.2 (22.8) μm for Lava, 58.5 (17.6) μm for Cercon, and 72.3 (30.8) μm for Cerec. There were no significant differences in the marginal fit among the groups except that the Cercon crowns had significantly smaller marginal gaps than the Lava crowns (P < 0.001). Within the limitation of this study, all the metal-free restorations made by the digital CAD/CAM systems had clinically acceptable marginal accuracy.

Optimization of Sintering Time and Holding Time for 3D Printing of Fe-Based Metallic Glasses

Directory of Open Access Journals (Sweden)

Wenzheng Wu

2018-06-01

Full Text Available Fe-based metallic glasses are amorphous alloys with high strength, high hardness, and excellent corrosion resistance; however, the immaturity of processing methods has prevented their wide application in industrial production. Fe-based metallic glass parts were manufactured employing pneumatic injection additive manufacturing in this study. An evenly dispersed and stable Fe-based metallic glass powder slurry with a solids content of 50% was prepared firstly. Then the Fe-based metallic glass parts were printed. The printed parts were dried, debinded, and sintered for strengthening. The deformations of the printed parts and sintered parts relative to the original model were then analyzed by a 3D scanning reconstruction method. The slightly average bulging and sunken deformation of the printed parts and sintered parts confirmed the good printing accuracy of the pneumatic injection manufacture system. The effects of the sintering temperature and holding time on the properties of the sintered parts were studied. For a sintering temperature of 580 °C and holding time of 1 h, the surface quality of the sintered parts was better. The sintering of 3D-printed Fe-based metallic glass parts was preliminarily realized in this study, and the feasibility of preparing Fe-based metallic glass using pneumatic injection additive manufacture was verified.

Characterization of Ti and Co based biomaterials processed via laser based additive manufacturing

Science.gov (United States)

Sahasrabudhe, Himanshu

Titanium and Cobalt based metallic materials are currently the most ideal materials for load-bearing metallic bio medical applications. However, the long term tribological degradation of these materials still remains a problem that needs a solution. To improve the tribological performance of these two metallic systems, three different research approaches were adapted, stemming out four different research projects. First, the simplicity of laser gas nitriding was utilized with a modern LENS(TM) technology to form an in situ nitride rich later in titanium substrate material. This nitride rich composite coating improved the hardness by as much as fifteen times and reduced the wear rate by more than a magnitude. The leaching of metallic ions during wear was also reduced by four times. In the second research project, a mixture of titanium and silicon were processed on a titanium substrate in a nitrogen rich environment. The results of this reactive, in situ additive manufacturing process were Ti-Si-Nitride coatings that were harder than the titanium substrate by more than twenty times. These coatings also reduced the wear rate by more than two magnitudes. In the third research approach, composites of CoCrMo alloy and Calcium phosphate (CaP) bio ceramic were processed using LENS(TM) based additive manufacturing. These composites were effective in reducing the wear in the CoCrMo alloy by more than three times as well as reduce the leaching of cobalt and chromium ions during wear. The novel composite materials were found to develop a tribofilm during wear. In the final project, a combination of hard nitride coating and addition of CaP bioceramic was investigated by processing a mixture of Ti6Al4V alloy and CaP in a nitrogen rich environment using the LENS(TM) technology. The resultant Ti64-CaP-Nitride coatings significantly reduced the wear damage on the substrate. There was also a drastic reduction in the metal ions leached during wear. The results indicate that the three

Unique opportunities in powder injection molding of refractory and hard materials

International Nuclear Information System (INIS)

German, R.M.

2001-01-01

Powder injection molding (PIM) is a relatively new manufacturing process for the creation of complicated net-shapes outside the range usually possible via powder metallurgy technologies. This new process is now in production at more than 550 sites around the world. Although a small industry, PIM will soon pass $1 billion dollars (USA) in annual sales. This presentation overviews the PIM process, some of the new developments and some of the successes that have occurred with both refractory metals and hard metals. Example applications are seen in medical and dental devices, industrial components, wristwatches, jet engines, firearms, automotive components, and even hand tools. To help establish the novel growth opportunities, PIM is compared to other fabrication routes to better understand the design features arising with this new approach, providing a compelling case for substantial opportunities in the refractory and hard materials. Illustrations are provided of several components in production. New opportunities abound for the technology, since it eliminates the shape complexity barrier associated with die compaction and the cost of machining associated with complicated or dimensionally precise components. Further, a relative cost advantage exists for refractory and hard materials because PIM can use the same powders at the same prices as employed in alternative processes. Future successes will occur by early identification of candidate materials and designs. Early examples include tungsten heavy alloy components now reaching production rates of six million per month. (author)

Process combinations for the manufacturing of metal-plastic hybrid parts

International Nuclear Information System (INIS)

Drossel, W-G; Lies, C; Albert, A; Haase, R; Müller, R; Scholz, P

2016-01-01

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of “using the right material at the right place” is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts. (paper)

Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

OpenAIRE

Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A.; Guss, Gabe; Matthews, Manyalibo J.

2017-01-01

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas...

Mechanical and Fatigue Properties of Additively Manufactured Metallic Materials

Science.gov (United States)

Yadollahi, Aref

This study aims to investigate the mechanical and fatigue behavior of additively manufactured metallic materials. Several challenges associated with different metal additive manufacturing (AM) techniques (i.e. laser-powder bed fusion and direct laser deposition) have been addressed experimentally and numerically. Experiments have been carried out to study the effects of process inter-layer time interval--i.e. either building the samples one-at-a-time or multi-at-a-time (in-parallel)--on the microstructural features and mechanical properties of 316L stainless steel samples, fabricated via a direct laser deposition (DLD). Next, the effect of building orientation--i.e. the orientation in which AM parts are built--on microstructure, tensile, and fatigue behaviors of 17-4 PH stainless steel, fabricated via a laser-powder bed fusion (L-PBF) method was investigated. Afterwards, the effect of surface finishing--here, as-built versus machined--on uniaxial fatigue behavior and failure mechanisms of Inconel 718 fabricated via a laser-powder bed fusion technique was sought. The numerical studies, as part of this dissertation, aimed to model the mechanical behavior of AM materials, under monotonic and cyclic loading, based on the observations and findings from the experiments. Despite significant research efforts for optimizing process parameters, achieving a homogenous, defect-free AM product--immediately after fabrication--has not yet been fully demonstrated. Thus, one solution for ensuring the adoption of AM materials for application should center on predicting the variations in mechanical behavior of AM parts based on their resultant microstructure. In this regard, an internal state variable (ISV) plasticity-damage model was employed to quantify the damage evolution in DLD 316L SS, under tensile loading, using the microstructural features associated with the manufacturing process. Finally, fatigue behavior of AM parts has been modeled based on the crack-growth concept

Manufacture of highly loaded silica-supported cobalt Fischer–Tropsch catalysts from a metal organic framework

KAUST Repository

Sun, Xiaohui

2017-11-16

The development of synthetic protocols for the preparation of highly loaded metal nanoparticle-supported catalysts has received a great deal of attention over the last few decades. Independently controlling metal loading, nanoparticle size, distribution, and accessibility has proven challenging because of the clear interdependence between these crucial performance parameters. Here we present a stepwise methodology that, making use of a cobalt-containing metal organic framework as hard template (ZIF-67), allows addressing this long-standing challenge. Condensation of silica in the Co-metal organic framework pore space followed by pyrolysis and subsequent calcination of these composites renders highly loaded cobalt nanocomposites (~ 50 wt.% Co), with cobalt oxide reducibility in the order of 80% and a good particle dispersion, that exhibit high activity, C5 + selectivity and stability in Fischer-Tropsch synthesis.

Reuse of scrap of Al and steel SAE 1045 in metal composite as alternative of recycling route powder metallurgy

International Nuclear Information System (INIS)

Souza, V.E.S.; Masieiro, F.R.S.; Lourenco, J.M.; Felipe, R.C.T.S.

2009-01-01

Full text: The process of powder metallurgy in the production of parts through application of pressure on the selected ceramic or metal powders, which are subjected to a temperature of sintering for to occur consolidation of the components. The metal-mechanical industry is responsible for the generation of inputs from their manufacturing processes. This work aims to re-use of chips of Al and SAE 1045 steel by powder metallurgy of this is a viable and effective. This work is in the manufacture of a composite using Al 6060 metal matrix and steel 1045 as reinforcement (30%, 40%, 50%), under different compaction pressures (250MPa, 400MPa and 600MPa), analyzing the influence of compressibility in hardness of the compressed. The samples were sintered at a temperature of 500 ° C in an oven using resistive atmosphere of hydrogen for 45 minutes. After the procedures of the powder metallurgy technique were analyzed of the optical microscopy, x-ray diffraction, MEV and Rockwell hardness, which was found to be evaluated as not diffusibility between the steel and aluminum. (author)

Hard times; Schwere Zeiten

Energy Technology Data Exchange (ETDEWEB)

Grunwald, Markus

2012-10-02

The prices of silicon and solar wafers keep dropping. According to market research specialist IMS research, this is the result of weak traditional solar markets and global overcapacities. While many manufacturers are facing hard times, big producers of silicon are continuing to expand.

Advanced Manufacturing Technologies

Science.gov (United States)

Fikes, John

2016-01-01

Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

Effects of Computer-Aided Manufacturing Technology on Precision of Clinical Metal-Free Restorations

Directory of Open Access Journals (Sweden)

Ki-Hong Lee

2015-01-01

Full Text Available Purpose. The purpose of this study was to investigate the marginal fit of metal-free crowns made by three different computer-aided design/computer-aided manufacturing (CAD/CAM systems. Materials and Methods. The maxillary left first premolar of a dentiform was prepared for all-ceramic crown restoration. Thirty all-ceramic premolar crowns were made, ten each manufactured by the Lava system, Cercon, and Cerec. Ten metal ceramic gold (MCG crowns served as control. The marginal gap of each sample was measured under a stereoscopic microscope at 75x magnification after cementation. One-way ANOVA and the Duncan’s post hoc test were used for data analysis at the significance level of 0.05. Results. The mean (standard deviation marginal gaps were 70.5 (34.4 μm for the MCG crowns, 87.2 (22.8 μm for Lava, 58.5 (17.6 μm for Cercon, and 72.3 (30.8 μm for Cerec. There were no significant differences in the marginal fit among the groups except that the Cercon crowns had significantly smaller marginal gaps than the Lava crowns (P<0.001.  Conclusions. Within the limitation of this study, all the metal-free restorations made by the digital CAD/CAM systems had clinically acceptable marginal accuracy.

Evaluation of Metal Ion Concentration in Hard Tissues of Teeth in Residents of Central Poland

Directory of Open Access Journals (Sweden)

Piotr Wychowanski

2017-01-01

Full Text Available Objectives. The aim of the study was an assessment of the content of trace elements in enamel and dentin of teeth extracted in patients residing in urban and agricultural areas of Poland. Methods. The study included 30 generally healthy patients with retained third molars. 65 samples of enamel and dentin from individuals living in urban areas and 85 samples of enamel and dentin from individuals living in agricultural areas were prepared. The content of manganese, lead, cadmium, and chromium in the studied enamel and dentin samples from retained teeth was determined by Graphite Furnace Atomic Absorption Spectrometry. In the process of statistical hypothesis testing, the level of significance was assumed at α=0.05. Results. A comparative analysis of the data showed that enamel and dentin of inhabitants of industrialized areas contain significantly higher amounts of lead and cadmium than hard tissues of teeth in residents of agricultural areas and comparable amounts of manganese and chromium. Significance. It appears that hard tissues of retained teeth may constitute valuable material for assessment of long-term environmental exposure to metal ions. The study confirms that the risk of exposure to heavy metals depends on the place of residence and environmental pollution.

Structural characterization of biomedical Co–Cr–Mo components produced by direct metal laser sintering

International Nuclear Information System (INIS)

Barucca, G.; Santecchia, E.; Majni, G.; Girardin, E.; Bassoli, E.; Denti, L.; Gatto, A.; Iuliano, L.; Moskalewicz, T.; Mengucci, P.

2015-01-01

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co–Cr–Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111} γ planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields. - Highlights: • Samples of a Co–Cr–Mo biomedical alloy were produced by direct metal laser sintering. • Hardness values unexpectedly high were attributed to a peculiar microstructure. • Fine lamellae of the ε-phase alternated to the γ-phase were observed for the first time. • A nucleation and growth model for the observed microstructure is proposed

Effect of Cryogenic Treatment on Microstructure and Micro Hardness of Aluminium (LM25 - SiC Metal Matrix Composite

Directory of Open Access Journals (Sweden)

G Elango

2014-06-01

Full Text Available The basic aim of this paper is to increase awareness amongst the researchers and to draw their attention towards the present approach to deal with the cryogenic treatment for the nonferrous metals. Cryogenic treated nonferrous metals will exhibit longer wear and more durability. During metal making process, when solidification takes place, some molecules get caught in a random pattern. The molecules do move about at subzero and deep cryogenic treatment slowly. In this experimental study, the effect of cryogenic treatment on microstructure changes and the hardness properties varies for LM25 alloy and LM25-SiC metal matrix composite at -196°C. It is analyzed for different durations. The execution of cryogenic treatment on both alloy and MMCs changed the distribution of

Anomalous metallic state with strong charge fluctuations in BaxTi8O16 +δ revealed by hard x-ray photoemission spectroscopy

Science.gov (United States)

Dash, S.; Kajita, T.; Okawa, M.; Saitoh, T.; Ikenaga, E.; Saini, N. L.; Katsufuji, T.; Mizokawa, T.

2018-04-01

We have studied a charge-orbital driven metal-insulator transition (MIT) in hollandite-type BaxTi8O16 +δ by means of hard x-ray photoemission spectroscopy (HAXPES). The Ti 2 p HAXPES indicates strong Ti3 +/Ti4 + charge fluctuation in the metallic phase above the MIT temperature. The metallic phase is characterized by a power-law spectral function near the Fermi level which would be a signature of bad metal with non-Drude polaronic behavior. The power-law spectral shape is associated with the large Seebeck coefficient of the metallic phase in BaxTi8O16 +δ .

Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

Science.gov (United States)

Williams, Christopher Bryant

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of

Circular Economy: Questions for Responsible Minerals, Additive Manufacturing and Recycling of Metals

Directory of Open Access Journals (Sweden)

Damien Giurco

2014-05-01

Full Text Available The concept of the circular economy proposes new patterns of production, consumption and use, based on circular flows of resources. Under a scenario where there is a global shift towards the circular economy, this paper discusses the advent of two parallel and yet-to-be-connected trends for Australia, namely: (i responsible minerals supply chains and (ii additive manufacturing, also known as 3D production systems. Acknowledging the current context for waste management, the paper explores future interlinked questions which arise in the circular economy for responsible supply chains, additive manufacturing, and metals recycling. For example, where do mined and recycled resources fit in responsible supply chains as inputs to responsible production? What is required to ensure 3D production systems are resource efficient? How could more distributed models of production, enabled by additive manufacturing, change the geographical scale at which it is economic or desirable to close the loop? Examples are given to highlight the need for an integrated research agenda to address these questions and to foster Australian opportunities in the circular economy.

Modification of WC-Co Hard Metal by Ion Implantation with Ti+, AI+, N+, C+ and B+

International Nuclear Information System (INIS)

Rassoul, El.M.A.; Saleh, Z.A.; Waheed, A.F.; Abdel- Samad, S.M.; EI- Awadi, G.A.

2010-01-01

WC/Co hard metal was implanted by Ti + , AI + , N + , C + , and B + ions at a dose of 5x 10 17 ions/cm 2 at different energies ranging from 50 keV to 200 keV. The implanted layers were investigated by means of nano indentation, calotte measurements, SEM, X-ray diffraction XRD, tribometer and EDX. The maximum implanted zone was about 0.13 μm. The hardness of WC-Co was increased by a factor of 140% after its implantation by Ti, AI, and N and increased by a factor of 170 % after implantation by Ti + , AI + , C + , N + and B + ions as compared to the original value. Also friction coefficient of WC/Co was improved after ion implantation.

TESTS METALLIC BIOMATERIALS FOR COMPUTER-AIDED DESIGN AND MANUFACTURING OF FIXED PROSTHETIC RESTORATIONS

Directory of Open Access Journals (Sweden)

Anna M. RYNIEWICZ

2014-03-01

Full Text Available A direct metal laser sintering method (DMLS is a new technology used for getting structures by the CAD/CAM procedures. The aim of the elaboration was a question of structural identification and setting strength parameters of titanium (Ticp and its alloy (Ti6Al4V which are used to serve as base for those permanent prosthetic supplements which are later manufactured with the employment of CAD/CAM systems. The research work was performed on Ticp samples – those which were intended for manufacture of structures by decrement milling working, and Ti6Al4V samples that comes from laser increment sintering of powder. According to the results obtained, the following conclusion has been derived: when strength aspect is discussed, the DMLS method is a preferred one for manufacturing of load structures in dentistry and may be an alternate way for the CAD/CAM system used in decrement processing.

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

Science.gov (United States)

Hofmann, Douglas C.; Borgonia, John Paul C.; Dillon, Robert P.; Suh, Eric J.; Mulder, jerry L.; Gardner, Paul B.

2013-01-01

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an

Comparative Analysis of Properties and Microstructure of the Plastically Deformed Alloy Inconel®718, Manufactured by Plastic Working and Direct Metal Laser Sintering

Directory of Open Access Journals (Sweden)

Żaba K.

2016-03-01

Full Text Available Nickel superalloys as Inconel® are materials widely used in the aerospace industry among others for diffusers, combustion chamber, shells of gas generators and other. In most cases, manufacturing process of those parts are used metal strips, produced by conventional plastic processing techniques, and thus by hot or cold rolling. An alternative technology allowing for manufacturing components for jet engines is the technique of 3D printing (additive manufacturing, and most of all Direct Metal Laser Sintering, which is one of the latest achievement in field of additive technologies.

High-rate production of micro- and nanostructured surfaces: Injection molding and novel process for metal tooling manufacturing

Science.gov (United States)

De Jesus Vega, Marisely

Devices containing micro and nanostructured surfaces are developing and constantly finding new applications, especially for medical diagnostics, point-of-care applications, and microneedles. They are also employed in the functionalization of surfaces for superhydrophobicity, drag reduction, or reversible adhesion by mimicking bio-inspired surfaces. This research provides a thorough investigation on the effects of different polymeric materials and processing conditions on the replication of micro and nanostructured surfaces via injection molding. In addition, this dissertation also presents a novel approach for the production of durable microstructured metal tooling to be used for the production of surfaces with microchannels via injection molding. Materials such as thermoplastic vulcanizates are substituting regular thermoplastic materials and vulcanized elastomers in many applications due to their outstanding properties and ease of processability. These material properties broaden the scope of applications for microstructured surfaces. However, there is a need for understanding how these materials behave in microinjection molding since thermoplastic elastomers' behavior during injection molding have been shown to differ from that of the widely understood behavior of thermoplastics. Replication of microstructured surfaces using thermoplastic vulcanizates (TPV) was studied in the first part of this thesis. TPVs with different hardness's were molded using microinjection molding with various processing conditions and the replication and surface details of 20 microm pillars (aspect ratio of 1:1) were characterized. In the second part of this research liquid silicone rubber (LSR) was studied as a material for the production of micro and nanostructured surfaces. LSR is a silicone based material such as polydimethylsiloxane (PDMS), which is widely used for research and development of micro and nanostructured devices, and thus provides all the benefits of PDMS but can be

Influence of Scanning Speed on the Microhardness Property of Additive Manufactured Titanium Alloy

Directory of Open Access Journals (Sweden)

R. M. Mahamood

2016-12-01

Full Text Available Ti6Al4V is an important aerospace alloy, and it is challenging processing this material through traditional manufacturing processes. Laser metal deposition, an additive manufacturing process offers lots of advantages for processing aerospace materials, the ability to increase buy-to-fly ratio by at least 80% amongst other things. An improved property is achievable through laser metal deposition. The Ti6Al4V powder of particle size 150-200 μm was deposited using a 4.0 kW Rofin Sinar Nd: YAG laser on 72x72x5 mm Ti6Al4V substrate. The powder was delivered using argon gas as a shield. The scanning speed was varied between 0.01 and 0.12 m/sec. The microstructures of the deposited layers were studied by optical microscope and the microhardness was also measured using the Vickers hardness tester. The properties of the deposited tracks were compared to that of the substrate. The microhardness was found to increase with increase in scanning speed.

Production of fiberglass/metal composite material suitable for building habitat and manufacturing facilities

Science.gov (United States)

1987-01-01

The production of a fiberglass/metal composite material suitable for building habitats and manufacturing facilities was the project for Clemson. The concept and development of the knowledge necessary to produce glass fibers originated in the spring semester. During the summer, while at Johnson Space Center, fiberglass from a rock composition similar to ones found at the Apollo 16 site on the moon was successfully produced. The project this year was a continuation of last year's studies. We addressed the following problems which emerged as the work progressed: (1) Methods for coating the fibers with a metal were explored. We manufactured composites in two stages: Glass fibers without any coating on them; and fibers coated with metals as they were made. This proved to be a difficult process. Future activities include using a chemical vapor deposition process on fibers which have been made. (2) A glass furnace was developed which relies primarily on solar energy for melting the glass. The temperature of the melted glass is maintained by electrical means. The design is for 250 kg of glass per day. An electrical engineering student developed a scheme for controlling the melting and manufacturing process from the earth. This was done to minimize the human risk. Graphite refractories are relied on to contain the melt. (3) The glass composition chosen for the project is a relatively pure anorthite which is available in the highland regions of the lunar surface. A major problems with this material is that it melts at a comparatively high temperature. This problem will be solved by using graphite refractory materials for the furnace. The advantage of this glass composition is that it is very stable and does not tend to crystallize. (4) We have also refined the experimental furnace and fiber making machinery which we will be using at Johnson Space Center this summer. We believe that we will be able to draw and coat glass fibers in a vacuum for use in composites. We intend to

Manufacturing of aluminum composite material using stir casting process

International Nuclear Information System (INIS)

Jokhio, M.H.; Panhwar, M.I.; Unar, M.A.

2011-01-01

Manufacturing of aluminum alloy based casting composite materials via stir casting is one of the prominent and economical route for development and processing of metal matrix composites materials. Properties of these materials depend upon many processing parameters and selection of matrix and reinforcements. Literature reveals that most of the researchers are using 2, 6 and 7 xxx aluminum matrix reinforced with SiC particles for high strength properties whereas, insufficient information is available on reinforcement of 'AI/sub 2/O/sub 3/' particles in 7 xxx aluminum matrix. The 7 xxx series aluminum matrix usually contains Cu-Zn-Mg; Therefore, the present research was conducted to investigate the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix on mechanical properties of stir casting of aluminum composite materials reinforced with alpha 'AI/sub 2/O/sub 3/' particles using simple foundry melting alloying and casting route. The age hardening treatments were also applied to study the aging response of the aluminum matrix on strength, ductility and hardness. The experimental results indicate that aluminum matrix cast composite can be manufactured via conventional foundry method giving very good responses to the strength and ductility up to 10% 'AI/sub 2/O/sub 3/' particles reinforced in aluminum matrix. (author)

Manufacturing of Aluminum Composite Material Using Stir Casting Process

Directory of Open Access Journals (Sweden)

Muhammad Hayat Jokhio

2011-01-01

Full Text Available Manufacturing of aluminum alloy based casting composite materials via stir casting is one of the prominent and economical route for development and processing of metal matrix composites materials. Properties of these materials depend upon many processing parameters and selection of matrix and reinforcements. Literature reveals that most of the researchers are using 2, 6 and 7xxx aluminum matrix reinforced with SiC particles for high strength properties whereas, insufficient information is available on reinforcement of \\"Al2O3\\" particles in 7xxx aluminum matrix. The 7xxx series aluminum matrix usually contains Cu-Zn-Mg. Therefore, the present research was conducted to investigate the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix on mechanical properties of stir casting of aluminum composite materials reinforced with alpha \\"Al2O3\\" particles using simple foundry melting alloying and casting route. The age hardening treatments were also applied to study the aging response of the aluminum matrix on strength, ductility and hardness. The experimental results indicate that aluminum matrix cast composite can be manufactured via conventional foundry method giving very good responses to the strength and ductility up to 10% \\"Al2O3\\" particles reinforced in aluminum matrix.

Preliminary study on recycling of metallic waste from decommissioning of nuclear power plant for cask

International Nuclear Information System (INIS)

Ohe, Koichiro; Kato, Osamu; Saegusa, Toshiari

1999-01-01

Preliminary study was made on technology required to recycle of metallic waste from decommissioning for spent fuel storage cask and on quantity of the cask which can be produced by the metallic waste. The technical and institutional issues for the recycling were studied. The metallic waste from decommissioning may be technically used to a certain degree for manufacturing the casks. However, there were some technical issues to be solved. For example, the manufacturing factories should be established. The radioactive waste from the factories with radiation control should be handled and treated carefully. Quality of the cask should be properly controlled. The 'Clearance Levels' which allows to recycle decommissioning waste have been hardly enacted in Japan. Technical and economic evaluation on recycling of metallic waste from decommissioning for spent fuel storage cask should be conducted again after progress in recycling of radioactive waste of which radioactivity is below the 'Clearance Levels' in Japan. (author)

Manufacturing And High Temperature Oxidation Properties Of Electro-Sprayed Fe-24.5% Cr-5%Al Powder Porous Metal

Directory of Open Access Journals (Sweden)

Lee Kee-Ahn

2015-06-01

Full Text Available Fe-Cr-Al based Powder porous metals were manufactured using a new electro-spray process, and the microstructures and high-temperature oxidation properties were examined. The porous materials were obtained at different sintering temperatures (1350°C, 1400°C, 1450°C, and 1500°C and with different pore sizes (500 μm, 450 μm, and 200 μm. High-temperature oxidation experiments (TGA, Thermal Gravimetry Analysis were conducted for 24 hours at 1000°C in a 79% N2+ 21% O2, 100 mL/min. atmosphere. The Fe-Cr-Al powder porous metals manufactured through the electro-spray process showed more-excellent oxidation resistance as sintering temperature and pore size increased. In addition, the fact that the densities and surface areas of the abovementioned powder porous metals had the largest effects on the metal’s oxidation properties could be identified.

Innovations in Advanced Materials and Metals Manufacturing Project (IAM2)

Energy Technology Data Exchange (ETDEWEB)

Scott, Elizabeth [Columbia River Economic Development Council, Vancouver, WA (United States)

2017-01-06

This project, under the Jobs and Innovation Accelerator Challenge, Innovations in Advanced Materials and Metals Manufacturing Project, contracted with Cascade Energy to provide a shared energy project manager engineer to work with five different companies throughout the Portland metro grant region to implement ten energy efficiency projects and develop a case study to analyze the project model. As a part of the project, the energy project manager also looked into specific new technologies and methodologies that could change the way energy is consumed by manufacturers—from game-changing equipment and technology to monitor energy use to methodologies that change the way companies interact and use their machines to reduce energy consumption.

Treatment of Wastewater from Electroplating, Metal Finishing and Printed Circuit Board Manufacturing. Operation of Wastewater Treatment Plants Volume 4.

Science.gov (United States)

California State Univ., Sacramento. Dept. of Civil Engineering.

One of four manuals dealing with the operation of wastewater plants, this document was designed to address the treatment of wastewater from electroplating, metal finishing, and printed circuit board manufacturing. It emphasizes how to operate and maintain facilities which neutralize acidic and basic waters; treat waters containing metals; destroy…

Development of Standard Approach for Sickle Blade Manufacturing

OpenAIRE

Noordin, M. N. A; Hudzari, R. M; Azuan, H. N; Zainon, M. S; Mohamed, S. B; Wafi, S. A

2016-01-01

The sickle blade used in the motorised palm cutter known as “CANTAS” provides fast, easy and safe pruning and harvesting for those hard to reach applications. Jariz Technologies Company is experiencing problem in the consistency of sickle blade which was supplied by various blade manufacturers. Identifying the proper blade material with a certain hardness value would produce a consistent as well as long lasting sickle blade. A Standard Operating Procedure (SOP) in the manufacturing of the sic...

Manufacturing processes 2 grinding, honing, lapping

CERN Document Server

Klocke, Fritz

2009-01-01

Presents a view of the most common machining and non-machining manufacturing processes. This volume describes the characteristics of abrasive tools, their design and manufacturing, followed by the fundamentals of grinding fluids. It also discusses grinding of different materials (steel, cast iron, hard and brittle materials, nickel and titanium).

Manufacturing of superconductive silver/ceramic composites

DEFF Research Database (Denmark)

Seifi, Behrouz; Bech, Jakob Ilsted; Eriksen, Morten

2000-01-01

Manufacturing of superconducting metal/ceramic composites is a rather new discipline within materials forming processes. High Temperature SuperConductors, HTSC, are manufactured applying the Oxide-Powder-In-Tube process, OPIT. A ceramic powder containing lead, calcium, bismuth, strontium, and cop......Manufacturing of superconducting metal/ceramic composites is a rather new discipline within materials forming processes. High Temperature SuperConductors, HTSC, are manufactured applying the Oxide-Powder-In-Tube process, OPIT. A ceramic powder containing lead, calcium, bismuth, strontium...

Structural characterization of biomedical Co–Cr–Mo components produced by direct metal laser sintering

Energy Technology Data Exchange (ETDEWEB)

Barucca, G., E-mail: g.barucca@univpm.it [SIMAU, Università Politecnica delle Marche, via Brecce Bianche, 60131 Ancona (Italy); Santecchia, E.; Majni, G. [SIMAU, Università Politecnica delle Marche, via Brecce Bianche, 60131 Ancona (Italy); Girardin, E. [DISCO, Università Politecnica delle Marche, via Brecce Bianche, 60131 Ancona (Italy); Bassoli, E.; Denti, L.; Gatto, A. [DIMeC, University of Modena and Reggio Emilia, via Vignolese 905/B, Modena 41125 (Italy); Iuliano, L. [DISPEA, Politecnico di Torino, C.so Duca degli Abruzzi 24, 10129 Torino (Italy); Moskalewicz, T. [Faculty of Metals Engineering and Industrial Computer Science, AGH University of Science and Technology, Al. Mickiewicza 30, 30-059 Kraków (Poland); Mengucci, P. [SIMAU, Università Politecnica delle Marche, via Brecce Bianche, 60131 Ancona (Italy)

2015-03-01

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co–Cr–Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111}{sub γ} planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields. - Highlights: • Samples of a Co–Cr–Mo biomedical alloy were produced by direct metal laser sintering. • Hardness values unexpectedly high were attributed to a peculiar microstructure. • Fine lamellae of the ε-phase alternated to the γ-phase were observed for the first time. • A nucleation and growth model for the observed microstructure is proposed.

Microstructure and hardness studies of Inconel 718 manufactured by selective laser melting before and after solution heat treatment

International Nuclear Information System (INIS)

Tucho, Wakshum M.; Cuvillier, Priscille; Sjolyst-Kverneland, Atle; Hansen, Vidar

2017-01-01

The microstructure of Additive Manufactured (AM) Inconel 718 in general and Selective Laser Melting (SLM), in particular is different from the material produced by conventional methods due to the rapid solidification process associated with the former. As a result, the widely adapted standard solution heat treatment temperature (<1100 °C) for conventional material is found to be not high enough for materials fabricated with SLM method in order to dissolve Laves and other microsegregated phases for releasing the ageing constituents (Nb, Ti, Al) sufficiently into the alloy matrix. In this study, sample of Inconel 718 fabricated with SLM method were solution heat-treated to 1100 °C or 1250 °C at different hold times to investigate the dissolution of macro- and micro-segregated precipitates. Investigations of microstructure and segregation in as-printed and solution heat-treated states have been studied using Transmission Electron Microscopy (TEM), Scanning Electron Microscopy (SEM) and Optical Microscopy (OM). Measurement of material hardness was performed with Vickers hardness tests. The microstructure of the as-printed parts exhibit non-columnar grains, but contain well-shaped columnar/cellular sub-grains. The intergranular boundaries are decorated with high density of dislocations and segregated particles. Tremendous stress relief and grain coarsening were observed with solution heat treatment. In particular, at 1250 °C annealing, the sub-grains, including precipitates and dislocation networks along the sub-grain boundaries, were entirely dissolved. However, the 1100/1250 °C solution heat treatment scheme could not dissolve microsegregated precipitates and carbides completely. Details of the analysis on microstructure, dissolution of precipitates and hardness are presented.

Microstructure and hardness studies of Inconel 718 manufactured by selective laser melting before and after solution heat treatment

Energy Technology Data Exchange (ETDEWEB)

Tucho, Wakshum M., E-mail: wakshum.m.tucho@uis.no [Department of Mechanical and Structural Engineering and Materials Science, University of Stavanger, N-4036 Stavanger (Norway); Cuvillier, Priscille [Department of Mechanical and Structural Engineering and Materials Science, University of Stavanger, N-4036 Stavanger (Norway); Sjolyst-Kverneland, Atle [Roxar/Emerson Process Management, POB 112, 4065 Stavanger (Norway); Hansen, Vidar [Department of Mechanical and Structural Engineering and Materials Science, University of Stavanger, N-4036 Stavanger (Norway)

2017-03-24

The microstructure of Additive Manufactured (AM) Inconel 718 in general and Selective Laser Melting (SLM), in particular is different from the material produced by conventional methods due to the rapid solidification process associated with the former. As a result, the widely adapted standard solution heat treatment temperature (<1100 °C) for conventional material is found to be not high enough for materials fabricated with SLM method in order to dissolve Laves and other microsegregated phases for releasing the ageing constituents (Nb, Ti, Al) sufficiently into the alloy matrix. In this study, sample of Inconel 718 fabricated with SLM method were solution heat-treated to 1100 °C or 1250 °C at different hold times to investigate the dissolution of macro- and micro-segregated precipitates. Investigations of microstructure and segregation in as-printed and solution heat-treated states have been studied using Transmission Electron Microscopy (TEM), Scanning Electron Microscopy (SEM) and Optical Microscopy (OM). Measurement of material hardness was performed with Vickers hardness tests. The microstructure of the as-printed parts exhibit non-columnar grains, but contain well-shaped columnar/cellular sub-grains. The intergranular boundaries are decorated with high density of dislocations and segregated particles. Tremendous stress relief and grain coarsening were observed with solution heat treatment. In particular, at 1250 °C annealing, the sub-grains, including precipitates and dislocation networks along the sub-grain boundaries, were entirely dissolved. However, the 1100/1250 °C solution heat treatment scheme could not dissolve microsegregated precipitates and carbides completely. Details of the analysis on microstructure, dissolution of precipitates and hardness are presented.

Depositing laser-generated nanoparticles on powders for additive manufacturing of oxide dispersed strengthened alloy parts via laser metal deposition

Science.gov (United States)

Streubel, René; Wilms, Markus B.; Doñate-Buendía, Carlos; Weisheit, Andreas; Barcikowski, Stephan; Henrich Schleifenbaum, Johannes; Gökce, Bilal

2018-04-01

We present a novel route for the adsorption of pulsed laser-dispersed nanoparticles onto metal powders in aqueous solution without using any binders or surfactants. By electrostatic interaction, we deposit Y2O3 nanoparticles onto iron-chromium based powders and obtain a high dispersion of nano-sized particles on the metallic powders. Within the additively manufactured component, we show that the particle spacing of the oxide inclusion can be adjusted by the initial mass fraction of the adsorbed Y2O3 particles on the micropowder. Thus, our procedure constitutes a robust route for additive manufacturing of oxide dispersion-strengthened alloys via oxide nanoparticles supported on steel micropowders.

4. Seminar on efficient metal forming and machining: papers

International Nuclear Information System (INIS)

1982-01-01

The 4th seminar on efficient metal forming and machining was held at the CSIR conference centre in Pretoria on 16 November 1982. This conference basically discussed the forming, fabrication and machining of metals which included the different methods used as well as new developments on tools manufacturing and their applications. The topics that were discussed cover subjects such as the creep feed grinding, thermal properties of coating materials and their effect on the efficiency of coated cutting tools, economic rough and finish milling, the design and application of high speed steel cutting tools, aluminium extrusion, the manufacturing and finishing of extrusion dies, broaching techniques, cold forming in the fastener industry, finishing methods for spiral, bevel and hypoid gears, laser cutting, press tool design, and productivity in the forging industry. Another topic that were discussed, is the current status of diamond and cubic boron nitride composites, their synthesis and roll in the production of a new range of ultra hard ceramic-type materials

Highly hard yet toughened bcc-W coating by doping unexpectedly low B content

KAUST Repository

Yang, Lina

2017-08-18

Either hardness or toughness has been the core interest in scientific exploration and technological pursuit for a long time. However, it is still a big challenge to enhance the hardness and toughness at the same time, since the improvement of one side is always at the expense of the other one. Here, we have succeeded in dealing with this pair of conflict based on tungsten (W) coating by doping boron (B) via magnetron co-sputtering. The results reveal that the introduction of low concentrations of B (6.3 at. %), in the doping regime, leads to the formation of W(B) supersaturated solid solution with refined grains. Meanwhile, the doping-induced higher compressive stress, higher H/E* and denser microstructure result in a surprising combination of improved hardness (2 × larger than pure W) and superior toughness (higher crack formation threshold compared to pure W). We believe this is an innovative sight to design new generation of transition-metal-based multifunctional coatings. Besides, our results are applicable for industrial application because it can be realized by simple manufacturing approaches, e.g. magnetron sputtering technology.

Performance of Metal Cutting on Endmills Manufactured by Cooling-Air and Minimum Quantity Lubrication Grinding

Science.gov (United States)

Inoue, Shigeru; Aoyama, Tojiro

Grinding fluids have been commonly used during the grinding of tools for their cooling and lubricating effect since the hard, robust materials used for cutting tools are difficult to grind. Grinding fluids help prevent a drop in hardness due to burning of the cutting edge and keep chipping to an absolute minimum. However, there is a heightened awareness of the need to improve the work environment and protect the global environment. Thus, the present study is aimed at applying dry grinding, cooling-air grinding, cooling-air grinding with minimum quantity lubrication (MQL), and oil-based fluid grinding to manufacturing actual endmills (HSS-Co). Cutting tests were performed by a vertical machining center. The results indicated that the lowest surface inclination values and longest tool life were obtained by cooling-air grinding with MQL. Thus, cooling-air grinding with MQL has been demonstrated to be at least as effective as oil-based fluid grinding.

How to estimate hardness of crystals on a pocket calculator

International Nuclear Information System (INIS)

Simunek, Antonin

2007-01-01

A generalization of the semiempirical microscopic model of hardness is presented and applied to currently studied borides, carbides, and nitrides of heavy transition metals. The hardness of OsB, OsC, OsN, PtN, RuC, RuB 2 , ReB 2 , OsB 2 , IrN 2 , PtN 2 , and OsN 2 crystals in various structural phases is predicted. It is found that none of the transition metal crystals is superhard, i.e., with hardness greater than 40 GPa. The presented method provides materials researchers with a practical tool in the search for new hard materials

Femtosecond laser additive manufacturing of YSZ

Energy Technology Data Exchange (ETDEWEB)

Liu, Jian; Bai, Shuang [PolarOnyx, Inc., San Jose, CA (United States)

2017-04-15

Laser additive manufacturing (LAM) of Yttria-Stabilized Zirconia (YSZ) is investigated using femtosecond (fs) fiber lasers. Various processing conditions are studied, which leads to desired characteristics in terms of morphology, porosity, hardness, microstructural and mechanical properties of the processed components. High-density (>99%) YSZ part with refined grain and increased hardness was obtained. Microstructure features of fabricated specimens were studied with SEM, EDX, the measured micro hardness is achieved as high as 18.84 GPa. (orig.)

Economic Assessment for Recycling Critical Metals From Hard Disk Drives Using a Comprehensive Recovery Process

Science.gov (United States)

Nguyen, Ruby Thuy; Diaz, Luis A.; Imholte, D. Devin; Lister, Tedd E.

2017-09-01

Since the 2011 price spike of rare earth elements (REEs), research on permanent magnet recycling has blossomed globally in an attempt to reduce future REE criticality. Hard disk drives (HDDs) have emerged as one feasible feedstock for recovering valuable REEs such as praseodymium, neodymium, and dysprosium. Nevertheless, current processes for recycling electronic waste only focus on certain metals as a result of feedstock and metal price uncertainties. In addition, there is a perception that recycling REEs is unprofitable. To shed some light on the economic viability of REE recycling from U.S. HDDs, this article combines techno-economic information of an electro-hydrometallurgical process with end-of-life HDD availability in a simulation model. The results showed that adding REE recovery to an HDD base and precious metal recovery process was profitable given current prices. Recovered REEs from U.S. HDDs could meet up to 5.2% rest-of-world (excluding China) neodymium magnet demand. Feedstock, aluminum, and gold prices are key factors to recycling profitability. REEs contributed 13% to the co-recycling profit.

Radiation hardness of β-Ga2O3 metal-oxide-semiconductor field-effect transistors against gamma-ray irradiation

Science.gov (United States)

Wong, Man Hoi; Takeyama, Akinori; Makino, Takahiro; Ohshima, Takeshi; Sasaki, Kohei; Kuramata, Akito; Yamakoshi, Shigenobu; Higashiwaki, Masataka

2018-01-01

The effects of ionizing radiation on β-Ga2O3 metal-oxide-semiconductor field-effect transistors (MOSFETs) were investigated. A gamma-ray tolerance as high as 1.6 MGy(SiO2) was demonstrated for the bulk Ga2O3 channel by virtue of weak radiation effects on the MOSFETs' output current and threshold voltage. The MOSFETs remained functional with insignificant hysteresis in their transfer characteristics after exposure to the maximum cumulative dose. Despite the intrinsic radiation hardness of Ga2O3, radiation-induced gate leakage and drain current dispersion ascribed respectively to dielectric damage and interface charge trapping were found to limit the overall radiation hardness of these devices.

Radiation hardness of undoped BGO crystals

International Nuclear Information System (INIS)

Sahu, S.K.; Peng, K.C.; Huang, H.C.; Wang, C.H.; Chang, Y.H.; Hou, W.S.; Ueno, K.; Chou, F.I.; Wei, Y.Y.

1997-01-01

We measured the radiation hardness of undoped BGO crystals from two different manufacturers. Such crystals are proposed to be used in a small-angle calorimeter of the BELLE detector of the KEK B-factory. Transparency and scintillation light output of the crystals were monitored to see the effect of radiation damage. The crystals show considerable radiation hardness up to 10.2 Mrad equivalent dose, which is much higher than the maximum expected dosage of 500 krad per year of running at BELLE. (orig.)

Microstructure and micro-hardness analyses of titanium alloy Ti-6Al-4V parts manufactured by selective laser melting

Directory of Open Access Journals (Sweden)

Lancea Camil

2017-01-01

Full Text Available Selective Laser Melting (SLM is one of the powder based additive manufacturing technologies and it is, as well, the most rapidly growing technique in Rapid Prototyping. In this paper is presented a microstructure analysis using Scanning Electron Microscope (LEO 1525 SEM, of Ti6Al4V parts exposed into a corrosion environment. The corrosion environment was generated using a salt chamber with 5% and 10% NaCl concentration and an ACS-Sunrise climatic chamber. The parts were also subjected to tests in order to determine their micro-hardness, followed by a statistical processing of the obtained data. The parts, having a lattice structure, were built on a Selective Laser Melting machine.

Use of the gamma-ray absorption technique as a quality control procedure in the manufacture of powder metal shaped charge liners

CSIR Research Space (South Africa)

Lawrie, JJ

2010-09-01

Full Text Available The use of the gamma-ray absorption technique as a tool in evaluating the quality of manufactured powder metal liners was investigated. With powder metal liners, it is not only of interest to know whether the liner conforms geometrically...

Experimental study on internal cooling system in hard turning of HCWCI using CBN tools

Science.gov (United States)

Ravi, A. M.; Murigendrappa, S. M.

2018-04-01

In recent times, hard turning became most emerging technique in manufacturing processes, especially to cut high hard materials like high chrome white cast iron (HCWCI). Use of Cubic boron nitride (CBN), pCBN and Carbide tools are most appropriate to shear the metals but are uneconomical. Since hard turning carried out in dry condition, lowering the tool wear by minimizing tool temperature is the only solution. Study reveals, no effective cooling systems are available so for in order to enhance the tool life of the cutting tools and to improve machinability characteristics. The detrimental effect of cutting parameters on cutting temperature is generally controlled by proper selections. The objective of this paper is to develop a new cooling system to control tool tip temperature, thereby minimizing the cutting forces and the tool wear rates. The materials chosen for this work was HCWCI and cutting tools are CBN inserts. Intricate cavities were made on the periphery of the tool holder for easy flow of cold water. Taguchi techniques were adopted to carry out the experimentations. The experimental results confirm considerable reduction in the cutting forces and tool wear rates.

Manufacturing of metallic porous structures to be used in capillary pumping systems

Directory of Open Access Journals (Sweden)

Eduardo Gonçalves Reimbrecht

2003-12-01

Full Text Available Sintered metallic porous structures have an application as capillary structures in two-phase heat transfer loops. In this work the manufacturing procedure of tubular porous structures for capillary pump application is discussed. The application of porous structures on capillary pumping systems requires porosity higher than 40% and pore size diameter lower than 20 µm. Carbonyl nickel powder with particle diameter between 3 and 7 µm and stainless steel AISI316L powder with particle diameter between 1 and 22 µm were used as raw material. Sintering under hydrogen atmosphere was performed both in a resistive furnace and in a plasma reactor. Temperature and time were the modified parameters to obtain suitable porosity and roundness on the samples. The porosity was measured using the Arquimedes Principle (MPIF-42, the roundness was evaluated using a simplified measurement technique of the sample diameter and the pore size distribution was determined by image analysis techniques. Images obtained by Scanning Electronic Microscopy were employed on the image analysis. The sintering parameters selected to manufacture nickel samples were 700 °C and 30 min resulting in a porosity of about 44%. The sintering parameters selected to manufacture stainless steel samples were 1000 °C and 30 min resulting in a porosity of about 40%.

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

Science.gov (United States)

Hehr, Adam; Wenning, Justin; Terrani, Kurt; Babu, Sudarsanam Suresh; Norfolk, Mark

2017-03-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact with the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. It is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.

Correction of facial and mandibular asymmetry using a computer aided design/computer aided manufacturing prefabricated titanium implant.

Science.gov (United States)

Watson, Jason; Hatamleh, Muhanad; Alwahadni, Ahed; Srinivasan, Dilip

2014-05-01

Patients with significant craniofacial asymmetry may have functional problems associated with their occlusion and aesthetic concerns related to the imbalance in soft and hard tissue profiles. This report details a case of facial asymmetry secondary to left mandible angle deficiency due to undergoing previous radiotherapy. We describe the correction of the bony deformity using computer aided design/computer aided manufacturing custom-made titanium onlay using novel direct metal laser sintering. The direct metal laser sintering onlay proved a very accurate operative fit and showed a good aesthetic correction of the bony defect with no reported complications postoperatively. It is a useful low-morbidity technique, and there is no resorption or associated donor-site complications.

Evaluation of hard fossil fuel

International Nuclear Information System (INIS)

Zivkovic, S.; Nuic, J.

1999-01-01

Because of its inexhaustible supplies hard fossil fuel will represent the pillar of the power systems of the 21st century. Only high-calorie fossil fuels have the market value and participate in the world trade. Low-calorie fossil fuels ((brown coal and lignite) are fuels spent on the spot and their value is indirectly expressed through manufactured kWh. For the purpose of determining the real value of a tonne of low-calorie coal, the criteria that help in establishing the value of a tonne of hard coal have to be corrected and thus evaluated and assessed at the market. (author)

ASSESSMENT OF SURFACE FINISH AND DIMENSIONAL ACCURACY OF TOOLS MANUFACTURED BY METAL CASTING IN RAPID PROTOTYPING SAND MOULDS

OpenAIRE

Nyembwe, K.; De Beer, D. J.; Van der Walt, J. G.; Bhero, S.

2012-01-01

In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP) sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final qu...

A method for manufacturing kernels of metallic oxides and the thus obtained kernels

International Nuclear Information System (INIS)

Lelievre Bernard; Feugier, Andre.

1973-01-01

A method is described for manufacturing fissile or fertile metal oxide kernels, consisting in adding at least a chemical compound capable of releasing ammonia to an aqueous solution of actinide nitrates dispersing the thus obtained solution dropwise in a hot organic phase so as to gelify the drops and transform them into solid particles, washing drying and treating said particles so as to transform them into oxide kernels. Such a method is characterized in that the organic phase used in the gel-forming reactions comprises a mixture of two organic liquids, one of which acts as a solvent, whereas the other is a product capable of extracting the metal-salt anions from the drops while the gel forming reaction is taking place. This can be applied to the so-called high temperature nuclear reactors [fr

Cathode-sputtered Ti-Zr-N-C-O base hard coatings and stability of said coatings on hard metals and working steels. Kathodenzerstaeubte Hartstoffschichten auf Basis Ti-Zr-N-C-O und deren Stabilitaet auf Hartmetall und Gebrauchsstaehlen

Energy Technology Data Exchange (ETDEWEB)

Boehmer, M.

1986-02-26

This paper deals with the examination of the metallurgical and thermal stability of the resistant material layers of titanium in connection with the substrate material influence. As substrate material were chosen: hard metal (81% WC, 12% TiC+TaC, 7% Co), high speed steel (DIN 1.3343), austenitic nickel chromium steel (X5 CrNi 18 9) and unalloyed tool steel (DIN 1.1545). The hard materials of titanium were deposited by means of cathode evaporation.

Self propagating high temperature synthesis of mixed carbide and boride powder systems for cutting tools manufacturing

International Nuclear Information System (INIS)

Vallauri, D.; Cola, P.L. de; Piscone, F.; Amato, I.

2001-01-01

TiC-TiB 2 composites have been produced via SHS technique starting from low cost raw materials like TiO 2 , B 4 C, Mg. The influence of the diluent phase (Mg, TiC) content on combustion temperature has been investigated. The use of magnesium as the reductant phase allowed acid leaching of the undesired oxide product (MgO), leaving pure hard materials with fine particle size suitable to be employed in cutting tools manufacturing through cold pressing and sintering route. The densification has shown to be strongly dependent on the wetting additions. The influence of the metal binder and wetting additions on the sintering process has been investigated. A characterization of the obtained materials was performed by the point of view of cutting tools life (hardness, toughness, strength). (author)

A crossover from high stiffness to high hardness. The case of osmium and its borides

International Nuclear Information System (INIS)

Bian, Yongming; Li, Anhu; Liu, Xiaomei; Shanghai Univ. of Engineering Science; Liang, Yongcheng

2016-01-01

Transition-metal light-element compounds are currently raising great expectations for hard and superhard materials. Using the widely attracting osmium (Os) and its borides (OsB, Os_2B_3 and OsB_2) as prototypes, we demonstrate by first-principles calculations that heavy transition metals, which possess high stiffness but low hardness, can be converted into highly hard materials by incorporating of light elements to form compounds. Such a crossover is a manifestation that the underlying sources of high stiffness and high hardness are fundamentally different. The stiffness is related to elastic deformation that is closely associated with valence electron density, whereas the hardness depends strongly on plastic deformation that is determined by bonding nature. Therefore, the incorporation of light atoms into transition metal should be a valid pathway of designing hard and superhard materials. This strategy is in principle also applicable to other transition-metal borides, carbides, and nitrides.

Multiple Study of Case Involving Implementation of Lean Manufacturing

Directory of Open Access Journals (Sweden)

Delvio Venanzi

2018-03-01

Full Text Available This article aims to show some factors that can cause companies to succeed or fail in their attempts to use lean manufacturing, by performing a multiple case study which presents two successful cases and three conditions of failure, in a survey of five large companies, all belonging to the metal-mechanical sector, located in Campinas and Sorocaba, both in the state of São Paulo, Brazil. The data were collected using exploratory research between the periods of January 2013 and February 2015. The results show that successful cases of lean manufacturing implementation are the result of a more organized work environment, standardization of production and service areas, employee satisfaction, productivity results and quality of the final product. Unsuccessful deployments result from poor execution and faulty planning, that has no benefit and ultimately decrease the morale of its employees, creating more distrust and frustration directly influencing the results and productivity. In other words, lean manufacturing implementation requires hard and continuous work and these procedures should be aligned with the mission and goals of companies and mainly focus on the maintenance result by using tools to monitor and track the process systematically and also making investments to eliminate waste.

Use of reliability engineering in development and manufacturing of metal parts

International Nuclear Information System (INIS)

Khan, A.; Iqbal, M.A.; Asif, M.

2005-01-01

The reliability engineering predicts modes of failures and weak links before the system is built instead of failure case study. The reliability engineering analysis will help in the manufacturing economy, assembly accuracy and qualification by testing, leading to production of metal parts in an aerospace industry. This methodology will also minimize the performance constraints in any requirement for the application of metal components in aerospace systems. The reliability engineering predicts the life of the parts under loading conditions whether dynamic or static. Reliability predictions can help engineers in making decisions about design of components, materials selection and qualification under applied stress levels. Two methods of reliability prediction i.e. Part Stress Analysis and Part Count have been used in this study. In this paper we will discuss how these two methods can be used to measure reliability of a system during development phases, which includes the measuring effect of environmental and operational variables. The equations are used to measure the reliability of each type of component, as well as, integration for measuring system applied for the reliability analysis. (author)

Apoptosis induction in human lymphocytes after in vitro exposure to cobalt/hard metal compounds

International Nuclear Information System (INIS)

Boeck, M. de; Decordier, I.; Lombaert, N.; Cundari, E.; Kirsch-Volders, M.; Lison, D.

2001-01-01

Full text: An increased risk of lung cancer is associated with occupational exposure to mixtures of cobalt metal (Co) and tungsten carbide (WC) particles, but apparently not when exposure is to cobalt alone. The mechanism for this increased cancer risk is not fully understood. The evaluation of the in vitro genotoxic effects in lymphocytes exposed to varying cobalt species demonstrated that the WC-Co hard metal mixture is more genotoxic (DNA damage, chromosome/genome mutations) than metallic Co alone. WC alone was not genotoxic. Thus, WC-Co represents a specific (geno)toxic entity. In order to assess the survival of human lymphocytes after in vitro exposure to metallic Co, CoCl 2 , WC and the WC-Co mixture, two apoptosis/necrosis detection methods were applied (annexin V staining and flow cytometry). Annexin-V staining of early apoptotic cells demonstrated a dose- and time dependent induction of apoptosis by metallic Co, CoCl 2 , WC and the WC-Co mixture. The time course of the process varied according to the metal species tested. Metallic Co and CoCl 2 caused a gradually increasing frequency of apoptotic cells with time (up to 24 h). WC-induced apoptosis displayed a typical 6 hour peak, which was not the case for the WC-Co mixture or for Co. Apoptosis induction by the WC-Co mixture was intermediate between that induced by Co and WC separately. Analysis of propidium iodide stained cells by flow cytometry was performed as a later marker for apoptosis induction. Preliminary data indicate similar tendencies of apoptosis induction as those detected by annexin-V. Identification of the apoptotic pathway triggered by the metal compounds was studied by inhibition of the ceramide-apoptosis pathway by fumonisin causing reduction of apoptosis induction for all compounds, but strongest after 6 hour exposure to WC. The use of specific caspase inhibitors will allow to further elucidate the different pathways involved. The current data demonstrating in vitro the apoptosis

Apoptosis induction in human lymphocytes after in vitro exposure to cobalt/hard metal compounds

Energy Technology Data Exchange (ETDEWEB)

Boeck, M de; Decordier, I; Lombaert, N; Cundari, E; Kirsch-Volders, M [Vrije Universiteit Brussel, Laboratorium voor Cellulaire Genetica, Brussel (Belgium); Lison, D [Universite catholique de Louvain, Unite de Toxicologie industrielle et Medecine du Travail, Bruxelles (Belgium)

2001-07-01

Full text: An increased risk of lung cancer is associated with occupational exposure to mixtures of cobalt metal (Co) and tungsten carbide (WC) particles, but apparently not when exposure is to cobalt alone. The mechanism for this increased cancer risk is not fully understood. The evaluation of the in vitro genotoxic effects in lymphocytes exposed to varying cobalt species demonstrated that the WC-Co hard metal mixture is more genotoxic (DNA damage, chromosome/genome mutations) than metallic Co alone. WC alone was not genotoxic. Thus, WC-Co represents a specific (geno)toxic entity. In order to assess the survival of human lymphocytes after in vitro exposure to metallic Co, CoCl{sub 2}, WC and the WC-Co mixture, two apoptosis/necrosis detection methods were applied (annexin V staining and flow cytometry). Annexin-V staining of early apoptotic cells demonstrated a dose- and time dependent induction of apoptosis by metallic Co, CoCl{sub 2}, WC and the WC-Co mixture. The time course of the process varied according to the metal species tested. Metallic Co and CoCl{sub 2} caused a gradually increasing frequency of apoptotic cells with time (up to 24 h). WC-induced apoptosis displayed a typical 6 hour peak, which was not the case for the WC-Co mixture or for Co. Apoptosis induction by the WC-Co mixture was intermediate between that induced by Co and WC separately. Analysis of propidium iodide stained cells by flow cytometry was performed as a later marker for apoptosis induction. Preliminary data indicate similar tendencies of apoptosis induction as those detected by annexin-V. Identification of the apoptotic pathway triggered by the metal compounds was studied by inhibition of the ceramide-apoptosis pathway by fumonisin causing reduction of apoptosis induction for all compounds, but strongest after 6 hour exposure to WC. The use of specific caspase inhibitors will allow to further elucidate the different pathways involved. The current data demonstrating in vitro the

Microchannel neural interface manufacture by stacking silicone and metal foil laminae

Science.gov (United States)

Lancashire, Henry T.; Vanhoestenberghe, Anne; Pendegrass, Catherine J.; Ajam, Yazan Al; Magee, Elliot; Donaldson, Nick; Blunn, Gordon W.

2016-06-01

Objective. Microchannel neural interfaces (MNIs) overcome problems with recording from peripheral nerves by amplifying signals independent of node of Ranvier position. Selective recording and stimulation using an MNI requires good insulation between microchannels and a high electrode density. We propose that stacking microchannel laminae will improve selectivity over single layer MNI designs due to the increase in electrode number and an improvement in microchannel sealing. Approach. This paper describes a manufacturing method for creating MNIs which overcomes limitations on electrode connectivity and microchannel sealing. Laser cut silicone—metal foil laminae were stacked using plasma bonding to create an array of microchannels containing tripolar electrodes. Electrodes were DC etched and electrode impedance and cyclic voltammetry were tested. Main results. MNIs with 100 μm and 200 μm diameter microchannels were manufactured. High electrode density MNIs are achievable with electrodes present in every microchannel. Electrode impedances of 27.2 ± 19.8 kΩ at 1 kHz were achieved. Following two months of implantation in Lewis rat sciatic nerve, micro-fascicles were observed regenerating through the MNI microchannels. Significance. Selective MNIs with the peripheral nervous system may allow upper limb amputees to control prostheses intuitively.

Quantitative Analysis of Electroplated Nickel Coating on Hard Metal

Directory of Open Access Journals (Sweden)

Hassan A. Wahab

2013-01-01

Full Text Available Electroplated nickel coating on cemented carbide is a potential pretreatment technique for providing an interlayer prior to diamond deposition on the hard metal substrate. The electroplated nickel coating is expected to be of high quality, for example, indicated by having adequate thickness and uniformity. Electroplating parameters should be set accordingly for this purpose. In this study, the gap distances between the electrodes and duration of electroplating process are the investigated variables. Their effect on the coating thickness and uniformity was analyzed and quantified using design of experiment. The nickel deposition was carried out by electroplating in a standard Watt’s solution keeping other plating parameters (current: 0.1 Amp, electric potential: 1.0 V, and pH: 3.5 constant. The gap distance between anode and cathode varied at 5, 10, and 15 mm, while the plating time was 10, 20, and 30 minutes. Coating thickness was found to be proportional to the plating time and inversely proportional to the electrode gap distance, while the uniformity tends to improve at a large electrode gap. Empirical models of both coating thickness and uniformity were developed within the ranges of the gap distance and plating time settings, and an optimized solution was determined using these models.

A crossover from high stiffness to high hardness. The case of osmium and its borides

Energy Technology Data Exchange (ETDEWEB)

Bian, Yongming; Li, Anhu [Tongji Univ., Shanghai (China). School of Mechanical Engineering; Liu, Xiaomei [Tongji Univ., Shanghai (China). School of Mechanical Engineering; Shanghai Univ. of Engineering Science (China). College of Mechanical Engineering; Liang, Yongcheng [Shanghai Ocean Univ. (China). College of Engineering Science and Technology

2016-07-01

Transition-metal light-element compounds are currently raising great expectations for hard and superhard materials. Using the widely attracting osmium (Os) and its borides (OsB, Os{sub 2}B{sub 3} and OsB{sub 2}) as prototypes, we demonstrate by first-principles calculations that heavy transition metals, which possess high stiffness but low hardness, can be converted into highly hard materials by incorporating of light elements to form compounds. Such a crossover is a manifestation that the underlying sources of high stiffness and high hardness are fundamentally different. The stiffness is related to elastic deformation that is closely associated with valence electron density, whereas the hardness depends strongly on plastic deformation that is determined by bonding nature. Therefore, the incorporation of light atoms into transition metal should be a valid pathway of designing hard and superhard materials. This strategy is in principle also applicable to other transition-metal borides, carbides, and nitrides.

Surface flow in severe plastic deformation of metals by sliding

International Nuclear Information System (INIS)

Mahato, A; Yeung, H; Chandrasekar, S; Guo, Y

2014-01-01

An in situ study of flow in severe plastic deformation (SPD) of surfaces by sliding is described. The model system – a hard wedge sliding against a metal surface – is representative of surface conditioning processes typical of manufacturing, and sliding wear. By combining high speed imaging and image analysis, important characteristics of unconstrained plastic flow inherent to this system are highlighted. These characteristics include development of large plastic strains on the surface and in the subsurface by laminar type flow, unusual fluid-like flow with vortex formation and surface folding, and defect and particle generation. Preferred conditions, as well as undesirable regimes, for surface SPD are demarcated. Implications for surface conditioning in manufacturing, modeling of surface deformation and wear are discussed

Structural characterization of biomedical Co-Cr-Mo components produced by direct metal laser sintering.

Science.gov (United States)

Barucca, G; Santecchia, E; Majni, G; Girardin, E; Bassoli, E; Denti, L; Gatto, A; Iuliano, L; Moskalewicz, T; Mengucci, P

2015-03-01

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co-Cr-Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111}γ planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields. Copyright © 2014 Elsevier B.V. All rights reserved.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

Science.gov (United States)

Yang, Nancy; Yee, J.; Zheng, B.; Gaiser, K.; Reynolds, T.; Clemon, L.; Lu, W. Y.; Schoenung, J. M.; Lavernia, E. J.

2017-04-01

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. The study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. The study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. The current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

International Nuclear Information System (INIS)

Roehling, Tien T.; Wu, Sheldon S.Q.; Khairallah, Saad A.; Roehling, John D.; Soezeri, S. Stefan; Crumb, Michael F.; Matthews, Manyalibo J.

2017-01-01

Additively manufactured (AM) metals are often highly textured, containing large columnar grains that initiate epitaxially under steep temperature gradients and rapid solidification conditions. These unique microstructures partially account for the massive property disparity existing between AM and conventionally processed alloys. Although equiaxed grains are desirable for isotropic mechanical behavior, the columnar-to-equiaxed transition remains difficult to predict for conventional solidification processes, and much more so for AM. In this study, the effects of laser intensity profile ellipticity on melt track macrostructures and microstructures were studied in 316L stainless steel. Experimental results were supported by temperature gradients and melt velocities simulated using the ALE3D multi-physics code. As a general trend, columnar grains preferentially formed with increasing laser power and scan speed for all beam profiles. However, when conduction mode laser heating occurs, scan parameters that result in coarse columnar microstructures using Gaussian profiles produce equiaxed or mixed equiaxed-columnar microstructures using elliptical profiles. By modulating spatial laser intensity profiles on the fly, site-specific microstructures and properties can be directly engineered into additively manufactured parts.

Bond-orientational analysis of hard-disk and hard-sphere structures.

Science.gov (United States)

Senthil Kumar, V; Kumaran, V

2006-05-28

We report the bond-orientational analysis results for the thermodynamic, random, and homogeneously sheared inelastic structures of hard-disks and hard-spheres. The thermodynamic structures show a sharp rise in the order across the freezing transition. The random structures show the absence of crystallization. The homogeneously sheared structures get ordered at a packing fraction higher than the thermodynamic freezing packing fraction, due to the suppression of crystal nucleation. On shear ordering, strings of close-packed hard-disks in two dimensions and close-packed layers of hard-spheres in three dimensions, oriented along the velocity direction, slide past each other. Such a flow creates a considerable amount of fourfold order in two dimensions and body-centered-tetragonal (bct) structure in three dimensions. These transitions are the flow analogs of the martensitic transformations occurring in metals due to the stresses induced by a rapid quench. In hard-disk structures, using the bond-orientational analysis we show the presence of fourfold order. In sheared inelastic hard-sphere structures, even though the global bond-orientational analysis shows that the system is highly ordered, a third-order rotational invariant analysis shows that only about 40% of the spheres have face-centered-cubic (fcc) order, even in the dense and near-elastic limits, clearly indicating the coexistence of multiple crystalline orders. When layers of close-packed spheres slide past each other, in addition to the bct structure, the hexagonal-close-packed (hcp) structure is formed due to the random stacking faults. Using the Honeycutt-Andersen pair analysis and an analysis based on the 14-faceted polyhedra having six quadrilateral and eight hexagonal faces, we show the presence of bct and hcp signatures in shear ordered inelastic hard-spheres. Thus, our analysis shows that the dense sheared inelastic hard-spheres have a mixture of fcc, bct, and hcp structures.

Laser, tungsten inert gas, and metal active gas welding of DP780 steel: Comparison of hardness, tensile properties and fatigue resistance

International Nuclear Information System (INIS)

Lee, Jeong Hun; Park, Sung Hyuk; Kwon, Hyuk Sun; Kim, Gyo Sung; Lee, Chong Soo

2014-01-01

Highlights: • We report the mechanical properties of DP780 steel welded by three methods. • The size of the welded zone increases with heat input (MAG > TIG > laser). • The hardness of the welded zone increases with cooling rate (laser > TIG > MAG). • Tensile and fatigue properties are strongly dependent on welding method. • Crack initiation sites depend on the microstructural features of the welded zone. - Abstract: The microstructural characteristics, tensile properties and low-cycle fatigue properties of a dual-phase steel (DP780) were investigated following its joining by three methods: laser welding, tungsten inert gas (TIG) welding, and metal active gas (MAG) welding. Through this, it was found that the size of the welded zone increases with greater heat input (MAG > TIG > laser), whereas the hardness of the weld metal (WM) and heat-affected zone (HAZ) increases with cooling rate (laser > TIG > MAG). Consequently, laser- and TIG-welded steels exhibit higher yield strength than the base metal due to a substantially harder WM. In contrast, the strength of MAG-welded steel is reduced by a broad and soft WM and HAZ. The fatigue life of laser-and TIG-welded steel was similar, with both being greater than that of MAG-welded steel; however, the fatigue resistance of all welds was inferior to that of the non-welded base metal. Finally, crack initiation sites were found to differ depending on the microstructural characteristics of the welded zone, as well as the tensile and cyclic loading

Additive Manufacturing and Characterization of Polylactic Acid (PLA) Composites Containing Metal Reinforcements

Science.gov (United States)

Kuentz, Lily; Salem, Anton; Singh, M.; Halbig, M. C.; Salem, J. A.

2016-01-01

Additive manufacturing of polymeric systems using 3D printing has become quite popular recently due to rapid growth and availability of low cost and open source 3D printers. Two widely used 3D printing filaments are based on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) systems. PLA is much more environmentally friendly in comparison to ABS since it is made from renewable resources such as corn, sugarcane, and other starches as precursors. Recently, polylactic acid-based metal powder containing composite filaments have emerged which could be utilized for multifunctional applications. The composite filaments have higher density than pure PLA, and the majority of the materials volume is made up of polylactic acid. In order to utilize functionalities of composite filaments, printing behavior and properties of 3-D printed composites need to be characterized and compared with the pure PLA materials. In this study, pure PLA and composite specimens with different metallic reinforcements (Copper, Bronze, Tungsten, Iron, etc) were 3D printed at various layer heights and resulting microstructures and properties were characterized. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) behavior of filaments with different reinforcements were studied. The microscopy results show an increase in porosity between 3-D printed regular PLA and the metal composite PLA samples, which could produce weaker mechanical properties in the metal composite materials. Tensile strength and fracture toughness behavior of specimens as a function of print layer height will be presented.

Survey of US Department of Defense Manufacturing Technology Program activities applicable to civilian manufacturing industries. Final report

Energy Technology Data Exchange (ETDEWEB)

Azimi, S.A.; Conrad, J.L.; Reed, J.E.

1985-03-01

Intent of the survey was to identify and characterize activities potentially applicable to improving energy efficiency and overall productivity in the civilian manufacturing industries. The civilian industries emphasized were the general manufacturing industries (including fabricated metals, glass, machinery, paper, plastic, textile, and transportation equipment manufacturing) and the primary metals industries (including primary aluminum, copper, steel, and zinc production). The principal steps in the survey were to: develop overview taxonomies of the general manufacturing and primary metals industries as well as specific industry taxonomies; identify needs and opportunities for improving process energy efficiency and productivity in the industries included; identify federal programs, capabilities, and special technical expertise that might be relevant to industry's needs and opportunities; contact federal laboratories/facilities, through visits and other forms of inquiry; prepare formatted profiles (descriptions) potentially applicable work efforts; review findings with industry; and compile and evaluate industry responses.

Contact-Free Support Structures for Part Overhangs in Powder-Bed Metal Additive Manufacturing

Directory of Open Access Journals (Sweden)

Kenneth Cooper

2017-12-01

Full Text Available This study investigates the feasibility of a novel concept, contact-free support structures, for part overhangs in powder-bed metal additive manufacturing. The intent is to develop alternative support designs that require no or little post-processing, and yet, maintain effectiveness in minimizing overhang distortions. The idea is to build, simultaneously during part fabrications, a heat sink (called “heat support”, underneath an overhang to alter adverse thermal behaviors. Thermomechanical modeling and simulations using finite element analysis were applied to numerically research the heat support effect on overhang distortions. Experimentally, a powder-bed electron beam additive manufacturing system was utilized to fabricate heat support designs and examine their functions. The results prove the concept and demonstrate the effectiveness of contact-free heat supports. Moreover, the method was tested with different heat support parameters and applied to various overhang geometries. It is concluded that the heat support proposed has the potential to be implemented in industrial applications.

Novel manufacturing process of nanoparticle/Al composite filler metals of tungsten inert gas welding by accumulative roll bonding

Energy Technology Data Exchange (ETDEWEB)

Fattahi, M., E-mail: fattahi.put@gmail.com [Technical Inspection Engineering Department, Petroleum University of Technology, Abadan (Iran, Islamic Republic of); Noei Aghaei, V. [Aerospace Engineering Department, Sharif University of Technology, Tehran (Iran, Islamic Republic of); Dabiri, A.R. [Technical Inspection Engineering Department, Petroleum University of Technology, Abadan (Iran, Islamic Republic of); Amirkhanlou, S. [Young Researchers and Elite Club, Najafabad Branch, Islamic Azad University, Najafabad (Iran, Islamic Republic of); Akhavan, S.; Fattahi, Y. [Materials Engineering Department, Isfahan University of Technology, Isfahan (Iran, Islamic Republic of)

2015-11-11

In the present work, accumulative roll bonding (ARB) was used as an effective method for manufacturing nanoparticle/Al composite filler metals of tungsten inert gas (TIG) welding. After welding, the distribution of ceramic nanoparticles and mechanical properties of welds were investigated. By applying ARB, ceramic nanoparticles were uniformly dispersed in the composite filler metals. Consequently, the welds produced by these filler metals had a uniform dispersion of ceramic nanoparticles in their compositions. The test results showed that the yield strength of welds was greatly increased when using the nanoparticle/Al composite filler metals. The improvement in the yield strength was attributed to the coefficient of thermal expansion mismatch and Orowan strengthening mechanisms. Therefore, according to the results presented in this paper, it can be concluded that the nanoparticle/Al composite filler metals can serve as a novel filler metal for TIG welding of aluminum and its alloys.

Laser additive manufacturing of high-performance materials

CERN Document Server

Gu, Dongdong

2015-01-01

This book entitled “Laser Additive Manufacturing of High-Performance Materials” covers the specific aspects of laser additive manufacturing of high-performance new materials components based on an unconventional materials incremental manufacturing philosophy, in terms of materials design and preparation, process control and optimization, and theories of physical and chemical metallurgy. This book describes the capabilities and characteristics of the development of new metallic materials components by laser additive manufacturing process, including nanostructured materials, in situ composite materials, particle reinforced metal matrix composites, etc. The topics presented in this book, similar as laser additive manufacturing technology itself, show a significant interdisciplinary feature, integrating laser technology, materials science, metallurgical engineering, and mechanical engineering. This is a book for researchers, students, practicing engineers, and manufacturing industry professionals interested i...

Power electronic modules design and manufacture

CERN Document Server

Sheng, William W

2004-01-01

IntroductionSelection ProcedureMaterialsInsulating Substrate and MetallizationBase PlateBonding MaterialPower Interconnection and TerminalEncapsulantPlastic Case and Cover Manufacturing of Power IGBT ModulesManufacturing Process Process Control/Long-Term ReliabilityManufacturing FacilitiesManufacturing Flow Charts DesignThermal ManagementCircuit PartitioningDesign Guidelines and ConsiderationsThermal Results of Different Samples

Mechanical properties of open-cell metallic biomaterials manufactured using additive manufacturing

International Nuclear Information System (INIS)

Campoli, G.; Borleffs, M.S.; Amin Yavari, S.; Wauthle, R.; Weinans, H.; Zadpoor, A.A.

2013-01-01

Highlights: ► Finite element (FE) models were used to predict the mechanical properties of porous biomaterials. ► Porous materials were produced using additive manufacturing techniques. ► Manufacturing irregularities need to be implemented in FE models. ► FE models are more accurate than analytical models in predicting mechanical properties. - Abstract: An important practical problem in application of open-cell porous biomaterials is the prediction of the mechanical properties of the material given its micro-architecture and the properties of its matrix material. Although analytical methods can be used for this purpose, these models are often based on several simplifying assumptions with respect to the complex architecture and cannot provide accurate prediction results. The aim of the current study is to present finite element (FE) models that can predict the mechanical properties of porous titanium produced using selective laser melting or selective electron beam melting. The irregularities caused by the manufacturing process including structural variations of the architecture are implemented in the FE models using statistical models. The predictions of FE models are compared with those of analytical models and are tested against experimental data. It is shown that, as opposed to analytical models, the predictions of FE models are in agreement with experimental observations. It is concluded that manufacturing irregularities significantly affect the mechanical properties of porous biomaterials

Manufacture and inspection of metal containers for the storage of waste contaminated with caesium-137

International Nuclear Information System (INIS)

Brito, M.J.D.; Moreira, M.S.

1998-01-01

Several stages are described of the design and manufacture of a prototype unit and 15 metal cylindrical containers for the storage of contaminated waste generated by the radiological accident of Goiania in 1987. The tasks involved technicians from the Nuclear Technology Development Centre (CDTN) of Belo Horizonte and the co-authors, who conducted inspections in the period between 10 March 1993 and 18 May 1993 at the foundry in Goiania. (author)

Development of in-Situ Al-Si/CuAl₂ Metal Matrix Composites: Microstructure, Hardness, and Wear Behavior.

Science.gov (United States)

Tash, Mahmoud M; Mahmoud, Essam R I

2016-06-02

In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15%) into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD) pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl₂, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl₂ at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature.

Effect of Solution Treatment Process on Hardness of Alumina Reinforced Al-9Zn Composite Produced by Squeeze Casting

Directory of Open Access Journals (Sweden)

Dwi Rahmalina

2014-10-01

Full Text Available Characteristics of aluminium matrix composites reinforced by alumina have been developed to improve mechanical properties. One of the determining factors in the development of this material is parameter of solution treatment process. This study discusses the performance of the composite matrix of Al-9Zn-6Mg-3Si reinforced by alumina powder of 5 % volume fraction. Composite are manufactured by squeeze casting process with the pressure of 20 Ton in the metal mould. To improve mechanical properties, the precipitation hardening process is conducted through variation of temperature of solution treatment of 450, 475 and 500 °C and holding time of solution treatment of 30, 60 and 90 minutes. Materials are characterized by hardness testing and microstructure observation. The results showed that the optimum condition of hardness was produced by solution treatment temperature of 500 °C and 90 minutes holding time of 86 HRB.

Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts.

Science.gov (United States)

Alfieri, Vittorio; Argenio, Paolo; Caiazzo, Fabrizia; Sergi, Vincenzo

2016-12-31

Optimization of processing parameters and exposure strategies is usually performed in additive manufacturing to set up the process; nevertheless, standards for roughness may not be evenly matched on a single complex part, since surface features depend on the building direction of the part. This paper aims to evaluate post processing treating via laser surface modification by means of scanning optics and beam wobbling to process metal parts resulting from selective laser melting of stainless steel in order to improve surface topography. The results are discussed in terms of roughness, geometry of the fusion zone in the cross-section, microstructural modification, and microhardness so as to assess the effects of laser post processing. The benefits of beam wobbling over linear scanning processing are shown, as heat effects in the base metal are proven to be lower.

Microbiological quality of soft, semi-hard and hard cheeses during the shelf-life

Directory of Open Access Journals (Sweden)

Josip Vrdoljak

2016-03-01

Full Text Available Cheeses as ready-to-eat food should be considered as a potential source of foodborne pathogens, primarily Listeria monocytogenes. The aim of present study was to determine the microbiological quality of soft, semi-hard and hard cheeses during the shelf-life, with particular reference to L. monocytogenes. Five types of cheeses were sampled at different timepoints during the cold storage and analyzed for presence of Salmonella and L. monocytogenes, as well as lactic acid bacteria, Escherichia coli, coagulase-positive staphylococci, yeasts, molds, sulfite-reducing clostridia and L. monocytogenes counts. Water activity, pH and NaCl content were monitored in order to evaluate the possibility of L. monocytogenes growth. Challenge test for L. monocytogenes was performed in soft whey cheese, to determine the growth potential of pathogen during the shelf-life of product. All analyzed cheeses were compliant with microbiological criteria during the shelf-life. In soft cheeses, lactic acid bacteria increased in the course of the shelf-life period (1.2-2.6 log increase, while in semi-hard and hard cheeses it decreased (1.6 and 5.2 log decrease, respectively. Soft cheeses support the growth of L. monocytogenes according to determined pH values (5.8-6.5, water activity (0.99-0.94, and NaCl content (0.3-1.2%. Challenge test showed that L. monocytogenes growth potential in selected soft cheese was 0.43 log10 cfu/g during 8 days at 4°C. Water activity in semi-hard and hard cheeses was a limiting factor for Listeria growth during the shelf-life. Soft, semi-hard and hard cheeses were microbiologically stable during their defined shelf-life. Good manufacturing and hygienic practices must be strictly followed in the production of soft cheeses as Listeria-supporting food and be focused on preventing (recontamination.

Progress of alternative sintering approaches of inkjet-printed metal inks and their application for manufacturing of flexible electronic devices

NARCIS (Netherlands)

Wünscher, S.; Abbel, R.; Perelaer, J.; Schubert, U.S.

2014-01-01

Well-defined high resolution structures with excellent electrical conductivities are key components of almost every electronic device. Producing these by printing metal based conductive inks on polymer foils represents an important step forward towards the manufacturing of plastic electronic

Further studies on gold alloys used in fabrication of porcelain-fused-to-metal restorations.

Science.gov (United States)

Civjan, S; Huget, E F; Dvivedi, N; Cosner, H J

1975-03-01

Composition, microstructure, castability, mechanical properties, and heat treatment characteristics of two gold-palladium-silver-based alloys were studied. The materials exhibited compositional as well as microstructural differences. Clinically acceptable castings could not be obtained when manufacturers' recommended casting temperatures were used. Ultimate tensile strength, yield strength, modulus of elasticity, and Brinell hardness values for the alloys were comparable. The elastic limit of Cameo, however, was significantly higher than that of vivo-star. Maximum rehardening of annealed castings occurred on reheat treatment at temperatures between 1,200 and 1,300 F. As-cast specimens, however, were not heat hardenable. The sequence of heat treatments used in the application of porcelain reduced slightly the hardness of both alloys. Hardness of the metal substructures was not increased by return of porcelain-coated specimens to a 1,250 F oven for final heat treatment.

Fully Disposable Manufacturing Concepts for Clinical and Commercial Manufacturing and Ballroom Concepts.

Science.gov (United States)

Boedeker, Berthold; Goldstein, Adam; Mahajan, Ekta

2017-11-04

The availability and use of pre-sterilized disposables has greatly changed the methods used in biopharmaceuticals development and production, particularly from mammalian cell culture. Nowadays, almost all process steps from cell expansion, fermentation, cell removal, and purification to formulation and storage of drug substances can be carried out in disposables, although there are still limitations with single-use technologies, particularly in the areas of pretesting and quality control of disposables, bag and connections standardization and qualification, extractables and leachables (E/L) validation, and dependency on individual vendors. The current status of single-use technologies is summarized for all process unit operations using a standard mAb process as an example. In addition, current pros and cons of using disposables are addressed in a comparative way, including quality control and E/L validation.The continuing progress in developing single-use technologies has an important impact on manufacturing facilities, resulting in much faster, less expensive and simpler plant design, start-up, and operation, because cell culture process steps are no longer performed in hard-piped unit operations. This leads to simpler operations in a lab-like environment. Overall it enriches the current landscape of available facilities from standard hard-piped to hard-piped/disposables hybrid to completely single-use-based production plants using the current segregation and containment concept. At the top, disposables in combination with completely and functionally closed systems facilitate a new, revolutionary design of ballroom facilities without or with much less segregation, which enables us to perform good manufacturing practice manufacturing of different products simultaneously in unclassified but controlled areas.Finally, single-use processing in lab-like shell facilities is a big enabler of transferring and establishing production in emergent countries, and this is

Trial manufacture of rotary friction tester and frictional force measurement of metals

CERN Document Server

Abe, T; Kanari, M; Tanzawa, S

2002-01-01

In the plasma confinement type fusion reactor, in-vessel structures such as a blanket module slide at the joints each other when plasma disruption occurs, and then frictional heat is generated there. Therefore, for the selection of material and the use as the design data, it is important to understand the frictional characteristics of metals and ceramic films in the vacuum. In the present study, we have manufactured a prototype of rotary friction tester and examined the performances of the tester. The frictional characteristics of metals in the room air was measured using the friction tester, and the results obtained are as follows. A drifting friction force for a constant time and a friction force during the idling were 98 mN and 225 mN, respectively. These values were sufficiently small as compared to pressing load (9.8 - 57.8 N) used in the friction test. In a friction force measurement of stainless steel, dynamic friction force obeyed Amontons' law which indicated that dynamic friction force is not depend...

Additively manufactured metallic porous biomaterials based on minimal surfaces : A unique combination of topological, mechanical, and mass transport properties

NARCIS (Netherlands)

Bobbert, F S L; Lietaert, K; Eftekhari, A A; Pouran, B; Ahmadi, S M; Weinans, H; Zadpoor, A A

2017-01-01

Porous biomaterials that simultaneously mimic the topological, mechanical, and mass transport properties of bone are in great demand but are rarely found in the literature. In this study, we rationally designed and additively manufactured (AM) porous metallic biomaterials based on four different

Production of hard metal by HPHT using NB as a new binder

International Nuclear Information System (INIS)

Oliveira, M.P.; Barros, R.A.; Pecanha Junior, L.A.F.; Guimaraes, R.S.; Filgueira, M.

2016-01-01

Full text: Due to the growing metalworking sector, development of new materials for use as cutting tools is necessary, seeking the reduction of energy consumption, as well as the machining time. In this sense, carbide inserts are widely used as tools. Usually, these inserts are manufactured with the use of cobalt as a binder. However, this material is scarce in the market and its cost is very high, and has high toxicity. This paper aims to produce carbide inserts by sintering at high pressure and high temperature (HP-HT), using innovative alloying elements, more easily accessible and at a low cost, such as Nb and Ni. The inserts were produced as follows: powders were sintered under 7,7GPa pressure and temperatures between 1550 deg C and 1850 deg C. Excellent results of densification, hardness and fracture toughness of the inserts was achieved. The phases formed in the sintering were analyzed by XRD. Microstructure was studied by scanning electron microscopy (SEM) and laser microscopy (CONFOCAL). Machining tests were carried out according to the ISO-3685 standard, indicating improved performance for the produced inserts. (author)

Production of hard metal by HPHT using NB as a new binder

Energy Technology Data Exchange (ETDEWEB)

Oliveira, M.P.; Barros, R.A.; Pecanha Junior, L.A.F.; Guimaraes, R.S.; Filgueira, M. [Universidade Estadual do Norte Fluminense (UENF), Niteroi, RJ (Brazil)

2016-07-01

Full text: Due to the growing metalworking sector, development of new materials for use as cutting tools is necessary, seeking the reduction of energy consumption, as well as the machining time. In this sense, carbide inserts are widely used as tools. Usually, these inserts are manufactured with the use of cobalt as a binder. However, this material is scarce in the market and its cost is very high, and has high toxicity. This paper aims to produce carbide inserts by sintering at high pressure and high temperature (HP-HT), using innovative alloying elements, more easily accessible and at a low cost, such as Nb and Ni. The inserts were produced as follows: powders were sintered under 7,7GPa pressure and temperatures between 1550 deg C and 1850 deg C. Excellent results of densification, hardness and fracture toughness of the inserts was achieved. The phases formed in the sintering were analyzed by XRD. Microstructure was studied by scanning electron microscopy (SEM) and laser microscopy (CONFOCAL). Machining tests were carried out according to the ISO-3685 standard, indicating improved performance for the produced inserts. (author)

Local microstructures, Hardness and mechanical properties of a stainless steel pipe-welded joint

International Nuclear Information System (INIS)

Zhao Yongxiang; Gao Qing; Cai Lixun

2000-01-01

An experimental investigation is carefully performed into the local microstructures, hardness values and monotonic mechanical properties of the three zones (the base metal, heat affecting zone and weld metal) of 1Cr18Ni9Ti stainless steel pipe-welded joint. The local microstructures are observed by a metallurgical test and a surface replica technology, the local hardness values are measures by a random Vickers hardness test, and the local mechanical properties are characterized by the Ramberg-Osgood and modified Ramberg-Osgood stress-stain relations. The investigation reveals that there are significant differences of the three zones in the local microstructures, hardness values and monotonic mechanical properties, especially of the three zones in the local microstructure, hardness values and monotonic mechanical properties, especially of the weld metal. The weld metal exhibits the largest heterogeneity of local microstructures and monotonic mechanical properties, and the largest scatter of local hardness values. It is necessary to consider these difference and introduce the reliability method to model the scatter in the pipe analysis. In addition, it is verified that a columnar grain structure, which is made up of matrix-rich δ ferrite bands, can characterize the weld metal and the distance between the neighboring rich δ ferrite bands is an appropriate measurement of the columnar grain structure. This measurement is in accordance with the transition point between the microstructural short crack and physical small crack stages, which are generally used for characterizing the short fatigue crack behavior of materials. This indicates that the microstructure controls the fatigue damage character of the present material

Correlation between the sub-structure parameters and the manufacturing technologies of metal threads in historical textiles using X-ray line profile analysis

Energy Technology Data Exchange (ETDEWEB)

Csiszar, Gabor; Ungar, Tamas [Eoetvoes University Budapest, Department of Materials Physics, Budapest (Hungary); Jaro, Marta [Hungarian National Museum, Budapest (Hungary)

2013-06-15

Micro-structure can talk when documentation is missing. In ancient Roman or medieval periods, kings, queens, or just rich people decorated their clothes or even their horse covers richly with miniature jewels or metal threads. The origin or the fabrication techniques of these ancient threads is often unknown. Thirteen thread samples made of gold or gilt silver manufactured during the last sixteen hundred years are investigated for the micro-structure in terms of dislocation density, crystallite size, and planar defects. In a few cases, these features are compared with sub-structure of similar metallic threads prepared in modern, twentieth century workshops. The sub-structure is determined by X-ray line profile analysis, using high resolution diffractograms with negligible instrumental broadening. On the basis of the sub-structure parameters, we attempt to assess the metal-threads manufacturing procedures on samples stemming from the fourth century A.D. until now. (orig.)

Short-term acute hypercapnia affects cellular responses to trace metals in the hard clams Mercenaria mercenaria.

Science.gov (United States)

Ivanina, Anna V; Beniash, Elia; Etzkorn, Markus; Meyers, Tiffany B; Ringwood, Amy H; Sokolova, Inna M

2013-09-15

Estuarine and coastal habitats experience large fluctuations of environmental factors such as temperature, salinity, partial pressure of CO2 ( [Formula: see text] ) and pH; they also serve as the natural sinks for trace metals. Benthic filter-feeding organisms such as bivalves are exposed to the elevated concentrations of metals in estuarine water and sediments that can strongly affect their physiology. The effects of metals on estuarine organisms may be exacerbated by other environmental factors. Thus, a decrease in pH caused by high [Formula: see text] (hypercapnia) can modulate the effects of trace metals by affecting metal bioavailability, accumulation or binding. To better understand the cellular mechanisms of interactions between [Formula: see text] and trace metals in marine bivalves, we exposed isolated mantle cells of the hard clams (Mercenaria mercenaria) to different levels of [Formula: see text] (0.05, 1.52 and 3.01 kPa) and two major trace metal pollutants - cadmium (Cd) and copper (Cu). Elevated [Formula: see text] resulted in a decrease in intracellular pH (pHi) of the isolated mantle cells from 7.8 to 7.4. Elevated [Formula: see text] significantly but differently affected the trace metal accumulation by the cells. Cd uptake was suppressed at elevated [Formula: see text] levels while Cu accumulation has greatly accelerated under hypercapnic conditions. Interestingly, at higher extracellular Cd levels, labile intracellular Cd(2+) concentration remained the same, while intracellular levels of free Zn(2+) increased suggesting that Cd(2+) substitutes bound Zn(2+) in these cells. In contrast, Cu exposure did not affect intracellular Zn(2+) but led to a profound increase in the intracellular levels of labile Cu(2+) and Fe(2+). An increase in the extracellular concentrations of Cd and Cu led to the elevated production of reactive oxygen species under the normocapnic conditions (0.05 kPa [Formula: see text] ); surprisingly, this effect was mitigated in

Optimization of heat treatment parameters for additive manufacturing and gravity casting AlSi10Mg alloy

Science.gov (United States)

Girelli, L.; Tocci, M.; Montesano, L.; Gelfi, M.; Pola, A.

2017-11-01

Additive manufacturing of metals is a production process developed in the last few years to realize net shape components with complex geometry and high performance. AlSi10Mg is one of the most widely used aluminium alloys, both in this field and in conventional foundry processes, for its significant mechanical properties combined with good corrosion resistance. In this paper the effect of heat treatment on AlSi10Mg alloy was investigated. Solution and ageing treatments were carried out with different temperatures and times on samples obtained by direct metal laser sintering and gravity casting in order to compare their performance. Microstructural analyses and hardness tests were performed to investigate the effectiveness of the heat treatment. The results were correlated to the sample microstructure and porosity, analysed by means of optical microscopy and density measurements. It was found that, in the additive manufactured samples, the heat treatment can reduce significantly the performance of the alloy also because of the increase of porosity due to entrapped gas during the deposition technique and that the higher the solution temperature the higher the increase of such defects. A so remarkable effect was not found in the conventional cast alloy.

The effect of three whitening oral rinses on enamel micro-hardness.

Science.gov (United States)

Potgieter, E; Osman, Y; Grobler, S R

2014-05-01

The purpose of this study was to determine the effect on human enamel micro-hardness of three over-the-counter whitening oral rinses available in South Africa. Enamel fragments were gathered into three groups of 15 each. One group was exposed to Colgate Plax Whitening Blancheur, the second group to White Glo 2 in 1 and the third to Plus White, in each case for periods recommended by the respective manufacturers. Surface micro-hardness of all groups was measured before and after a 14 day treatment period. pH levels of the oral rinses were also determined with a combination pH electrode. Pre- and post- treatment data were analysed by the Wilcoxon Signed Rank Sum Test. According to the micro-hardness values no significant (p > 0.05) enamel damage was found as a result of treatment. However, it was observed that Colgate Pax and White Glo decreased the enamel hardness, an early sign of enamel damage, while Plus White showed a small increase in hardness. The three whitening oral rinses on the South African market do not damage the tooth enamel significantly when used as recommended by the manufacturers. However, extending the contact period and increasing the frequency of application might lead to damage of enamel.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives.

Science.gov (United States)

Gonzalez-Gutierrez, Joamin; Cano, Santiago; Schuschnigg, Stephan; Kukla, Christian; Sapkota, Janak; Holzer, Clemens

2018-05-18

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

Science.gov (United States)

Cano, Santiago

2018-01-01

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented. PMID:29783705

Microstructure, hardness, corrosion resistance and porcelain shear bond strength comparison between cast and hot pressed CoCrMo alloy for metal-ceramic dental restorations.

Science.gov (United States)

Henriques, B; Soares, D; Silva, F S

2012-08-01

The purpose of this study was to compare the microstructure, hardness, corrosion resistance and metal-porcelain bond strength of a CoCrMo dental alloy obtained by two routes, cast and hot pressing. CoCrMo alloy substrates were obtained by casting and hot pressing. Substrates' microstructure was examined by the means of Optical Microscopy (OM) and by Scanning Electron Microscope (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). Hardness tests were performed in a microhardness indenter. The electrochemical behavior of substrates was investigated through potentiodynamic tests in a saline solution (8g NaCl/L). Substrates were bonded to dental porcelain and metal-porcelain bond strength was assessed by the means of a shear test performed in a universal test machine (crosshead speed: 0.5 mm/min) until fracture. Fractured surfaces as well as undestroyed interface specimens were examined with Stereomicroscopy and SEM-EDS. Data was analyzed with Shapiro-Wilk test to test the assumption of normality. The t-test (pmicrostructures whereas hot pressed specimens exhibited a typical globular microstructure with a second phase spread through the matrix. The hardness registered for hot pressed substrates was greater than that of cast specimens, 438±24HV/1 and 324±8HV/1, respectively. Hot pressed substrates showed better corrosion properties than cast ones, i.e. higher OCP; higher corrosion potential (E(corr)) and lower current densities (i(corr)). No significant difference was found (p<0.05) in metal-ceramic bond strength between cast (116.5±6.9 MPa) and hot pressed (114.2±11.9 MPa) substrates. The failure type analysis revealed an adhesive failure for all specimens. Hot pressed products arise as an alternative to cast products in dental prosthetics, as they impart enhanced mechanical and electrochemical properties to prostheses without compromising the metal-ceramic bond strength. Copyright © 2012 Elsevier Ltd. All rights reserved.

A Personal Desktop Liquid-Metal Printer as a Pervasive Electronics Manufacturing Tool for Society in the Near Future

Directory of Open Access Journals (Sweden)

Jun Yang

2015-12-01

Full Text Available It has long been a dream in the electronics industry to be able to write out electronics directly, as simply as printing a picture onto paper with an office printer. The first-ever prototype of a liquid-metal printer has been invented and demonstrated by our lab, bringing this goal a key step closer. As part of a continuous endeavor, this work is dedicated to significantly extending such technology to the consumer level by making a very practical desktop liquid-metal printer for society in the near future. Through the industrial design and technical optimization of a series of key technical issues such as working reliability, printing resolution, automatic control, human-machine interface design, software, hardware, and integration between software and hardware, a high-quality personal desktop liquid-metal printer that is ready for mass production in industry was fabricated. Its basic features and important technical mechanisms are explained in this paper, along with demonstrations of several possible consumer end-uses for making functional devices such as light-emitting diode (LED displays. This liquid-metal printer is an automatic, easy-to-use, and low-cost personal electronics manufacturing tool with many possible applications. This paper discusses important roles that the new machine may play for a group of emerging needs. The prospective future of this cutting-edge technology is outlined, along with a comparative interpretation of several historical printing methods. This desktop liquid-metal printer is expected to become a basic electronics manufacturing tool for a wide variety of emerging practices in the academic realm, in industry, and in education as well as for individual end-users in the near future.

Effect of magneto rheological damper on tool vibration during hard turning

Science.gov (United States)

Paul, P. Sam; Varadarajan, A. S.

2012-12-01

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

Distributions, sources and pollution status of 17 trace metal/metalloids in the street dust of a heavily industrialized city of central China

International Nuclear Information System (INIS)

Li, Zhonggen; Feng, Xinbin; Li, Guanghui; Bi, Xiangyang; Zhu, Jianming; Qin, Haibo; Dai, Zhihui; Liu, Jinling; Li, Qiuhua; Sun, Guangyi

2013-01-01

A series of representative street dust samples were collected from a heavily industrialized city, Zhuzhou, in central China, with the aim to investigate the spatial distribution and pollution status of 17 trace metal/metalloid elements. Concentrations of twelve elements (Pb, Zn, Cu, Cd, Hg, As, Sb, In, Bi, Tl, Ag and Ga) were distinctly amplified by atmospheric deposition resulting from a large scale Pb/Zn smelter located in the northwest fringe of the city, and followed a declining trend towards the city center. Three metals (W, Mo and Co) were enriched in samples very close to a hard alloy manufacturing plant, while Ni and Cr appeared to derive predominantly from natural sources. Other industries and traffic had neglectable effects on the accumulation of observed elements. Cd, In, Zn, Ag and Pb were the five metal/metalloids with highest pollution levels and the northwestern part of city is especially affected by heavy metal pollution. -- Highlights: •Large-scale Pb/Zn smelters contributed to elevated trace elements in the street dust. •The hard alloy processing caused the enrichment of a few elements. •Cd, In, Zn, Ag and Pb were the most polluted elements. •Northwestern Zhuzhou suffered severe contamination for a range of trace elements. -- Pb/Zn smelting and hard alloy processing operations have caused seriously contamination of trace metal/metalloids in the street dust

Experimental Investigation of White Layer formation in Hard Turning

Science.gov (United States)

Umbrello, D.; Rotella, G.; Crea, F.

2011-05-01

Hard turning with super hard cutting tools, like PCBN or Ceramics inserts, represents an interesting advance in the manufacturing industry, regarding the finishing of hardened steels. This innovative machining technique is considered an attractive alternative to traditional finish grinding operations because of the high flexibility, the ability to achieve higher metal removal rates, the possibility to operate without the use of coolants, and the capability to achieve comparable workpiece quality. However, the surface integrity effects of hard machining need to be taken into account due to their influence on the life of machined components. In particular, the formation of a usually undesirable white layer at the surface needs further investigation. Three different mechanisms have been proposed as main responsible of the white layer genesis: (i) microstructural phase transformation due to a rapid heating and quenching, (ii) severe plastic deformation resulting in a homogenous structure and/or a very fine grain size microstructure; (iii) surface reaction with the environment. In this research, an experimental campaign was carried out and several experimental techniques were used in order to analyzed the machined surface and to understand which of the above mentioned theories is the main cause of the white layer formation when AISI 52100 hardened steel is machined by PCBN inserts. In particular, the topography characterization has obtained by means of optical and scanning electron microscope (SEM) while microstructural phase composition and chemical characterization have been respectively detected using X-ray Diffraction (XRD) and Energy-dispersive X-ray spectroscopy (EDS) techniques. The results prove that the white layer is the result of microstructural alteration, i.e. the generation of a martensitic structure.

3D FE simulation of semi-finishing machining of Ti6Al4V additively manufactured by direct metal laser sintering

Science.gov (United States)

Imbrogno, Stano; Rinaldi, Sergio; Raso, Antonio; Bordin, Alberto; Bruschi, Stefania; Umbrello, Domenico

2018-05-01

The Additive Manufacturing techniques are gaining more and more interest in various industrial fields due to the possibility of drastically reduce the material waste during the production processes, revolutionizing the standard scheme and strategies of the manufacturing processes. However, the metal parts shape produced, frequently do not satisfy the tolerances as well as the surface quality requirements. During the design phase, the finite element simulation results a fundamental tool to help the engineers in the correct decision of the most suitable process parameters, especially in manufacturing processes, in order to produce products of high quality. The aim of this work is to develop a 3D finite element model of semi-finishing turning operation of Ti6Al4V, produced via Direct Metal Laser Sintering (DMLS). A customized user sub-routine was built-up in order to model the mechanical behavior of the material under machining operations to predict the main fundamental variables as cutting forces and temperature. Moreover, the machining induced alterations are also studied by the finite element model developed.

Measurement of electromagnetic properties of powder and solid metal materials for additive manufacturing

Science.gov (United States)

Todorov, Evgueni Iordanov

2017-04-01

The lack of validated nondestructive evaluation (NDE) techniques for examination during and after additive manufacturing (AM) component fabrication is one of the obstacles in the way of broadening use of AM for critical applications. Knowledge of electromagnetic properties of powder (e.g. feedstock) and solid AM metal components is necessary to evaluate and deploy electromagnetic NDE modalities for examination of AM components. The objective of this research study was to develop and implement techniques for measurement of powder and solid metal electromagnetic properties. Three materials were selected - Inconel 625, duplex stainless steel 2205, and carbon steel 4140. The powder properties were measured with alternate current (AC) model based eddy current technique and direct current (DC) resistivity measurements. The solid metal properties were measured with DC resistivity measurements, DC magnetic techniques, and AC model based eddy current technique. Initial magnetic permeability and electrical conductivity were acquired for both powder and solid metal. Additional magnetic properties such as maximum permeability, coercivity, retentivity, and others were acquired for 2205 and 4140. Two groups of specimens were tested along the build length and width respectively to investigate for possible anisotropy. There was no significant difference or anisotropy when comparing measurements acquired along build length to those along the width. A trend in AC measurements might be associated with build geometry. Powder electrical conductivity was very low and difficult to estimate reliably with techniques used in the study. The agreement between various techniques was very good where adequate comparison was possible.

Flow characteristics of metallic powder grains for additive manufacturing

Directory of Open Access Journals (Sweden)

Peters Bernhard

2017-01-01

Full Text Available Directed energy deposition technologies for additive manufacturing such as laser selective melting (SLM or electron beam melting (EBM is a fast growing technique mainly due to its flexibility in product design. However, the process is a complex interaction of multi-physics on multiple length scales that are still not entirely understood. A particular challenging task are the flow characteristics of metallic powder ejected as jets from a nozzle and shielded by an inert turbulent gas flow. Therefore, the objective is to describe numerically the complex interaction between turbulent flow and powder grains. In order to include both several physical processes and length scales an Euler-Lagrange technology is applied. Within this framework powder is treated by the Discrete-Element-Method, while gas flow is described by Euler approaches as found in classical Computational Fluid Dynamics (CFD. The described method succeeded in delivering more accuracy and consistency than a standard approach based on the volume averaging technique and therefore, is suited for the solution of problems within an engineering framework.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

Science.gov (United States)

Sidambe, Alfred T.

2014-01-01

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy. PMID:28788296

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

Directory of Open Access Journals (Sweden)

Alfred T. Sidambe

2014-12-01

Full Text Available Titanium (Ti and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

Biocompatibility of Advanced Manufactured Titanium Implants-A Review.

Science.gov (United States)

Sidambe, Alfred T

2014-12-19

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

High Re-Operation Rates Using Conserve Metal-On-Metal Total Hip Articulations

DEFF Research Database (Denmark)

Mogensen, S L; Jakobsen, Thomas; Christoffersen, Hardy

2016-01-01

INTRODUCTION: Metal-on-metal hip articulations have been intensely debated after reports of adverse reactions and high failure rates. The aim of this study was to retrospectively evaluate the implant of a metal-on.metal total hip articulation (MOM THA) from a single manufacture in a two-center st......INTRODUCTION: Metal-on-metal hip articulations have been intensely debated after reports of adverse reactions and high failure rates. The aim of this study was to retrospectively evaluate the implant of a metal-on.metal total hip articulation (MOM THA) from a single manufacture in a two...

Integration of Heat Treatment with Shot Peening of 17-4 Stainless Steel Fabricated by Direct Metal Laser Sintering

Science.gov (United States)

AlMangour, Bandar; Yang, Jenn-Ming

2017-11-01

Direct metal laser sintering (DMLS) is a promising powder-based additive manufacturing process for fabrication of near-net-shape parts. However, the typically poor fatigue performance of DMLS parts must be addressed for use in demanding industrial applications. Post-treatment can be applied to enhance the performance of such components. Earlier attempts at inducing grain refinement through severe plastic deformation of part surfaces using shot peening improved the physical and mechanical properties of metals without chemical alteration. However, heat treatment can modify the surface-hardening effects attained by shot peening. Hence, we examined the feasibility of applying shot peening combined with heat treatment to improve the performance of DMLS-fabricated 17-4 stainless steel parts through microstructural evolution studies and hardness measurements. Compared to a specimen treated only by shot peening, the sample exposed to additional heat treatment showed increased hardness due to aging of the dominant phase.

Electronic transport properties of 4f shell elements of liquid metal using hard sphere Yukawa system

Science.gov (United States)

Patel, H. P.; Sonvane, Y. A.; Thakor, P. B.

2018-04-01

The electronic transport properties are analyzed for 4f shell elements of liquid metals. To examine the electronic transport properties like electrical resistivity (ρ), thermal conductivity (σ) and thermo electrical power (Q), we used our own parameter free model potential with the Hard Sphere Yukawa (HSY) reference system. The screening effect on aforesaid properties has been examined by using different screening functions like Hartree (H), Taylor (T) and Sarkar (S). The correlations of our resultsand other data with available experimental values are intensely promising. Also, we conclude that our newly constructed parameter free model potential is capable of explaining the above mentioned electronic transport properties.

The influence of material hardness on liquid droplet impingement erosion

International Nuclear Information System (INIS)

Fujisawa, Nobuyuki; Yamagata, Takayuki; Takano, Shotaro; Saito, Kengo; Morita, Ryo; Fujiwara, Kazutoshi; Inada, Fumio

2015-01-01

Highlights: • Liquid droplet impingement erosion is studied for various metal materials. • Average power dependency on droplet velocity is found as 7. • Power dependency on Vickers hardness is found as −4.5. • An empirical formula is constructed for erosion rates of metal materials. • Predicted erosion rate is well correlated with experiment within a factor of 1.5. - Abstract: This paper describes the experimental study on the liquid droplet impingement erosion of metal materials to understand the influence of material hardness on the erosion rate. The experiment is carried out using a water spray jet apparatus with a condition of relatively thin liquid film thickness. The metal materials tested are pure aluminum, aluminum alloy, brass, mild steel, carbon steel and stainless steel. The liquid droplets considered are 30 ± 5 μm in volume average diameter of water, which is the same order of droplet diameter in the actual pipeline in nuclear/fossil power plants. In order to understand the influence of material hardness on the liquid droplet impingement erosion, the scanning electron microscope (SEM) observation on the eroded surface and the measurement of erosion rate are carried out in the terminal stage of erosion. The experimental results indicate that the erosion rates are expressed by the droplet velocity, volume flux, Vickers hardness and the liquid film thickness, which are fundamentals of the liquid droplet impingement erosion. The empirical formula shows that the power index for droplet velocity dependency is found to be 7 with a scattering from 5 to 9 depending on the materials, while the power index for Vickers hardness dependency is found as −4.5

The influence of material hardness on liquid droplet impingement erosion

Energy Technology Data Exchange (ETDEWEB)

Fujisawa, Nobuyuki, E-mail: fujisawa@eng.niigata-u.ac.jp [Visualization Research Center, Niigata University, 8050, Ikarashi 2-Nocho, Nishi-ku, Niigata 950-2181 (Japan); Yamagata, Takayuki, E-mail: yamagata@eng.niigata-u.ac.jp [Visualization Research Center, Niigata University, 8050, Ikarashi 2-Nocho, Nishi-ku, Niigata 950-2181 (Japan); Takano, Shotaro; Saito, Kengo [Graduate School of Science and Technology, Niigata University, 8050, Ikarashi 2-Nocho, Nishi-ku, Niigata 950-2181 (Japan); Morita, Ryo; Fujiwara, Kazutoshi; Inada, Fumio [Central Research Institute of Electric Power Industry, 2-11-1, Iwatokita, Komae, Tokyo 201-8511 (Japan)

2015-07-15

Highlights: • Liquid droplet impingement erosion is studied for various metal materials. • Average power dependency on droplet velocity is found as 7. • Power dependency on Vickers hardness is found as −4.5. • An empirical formula is constructed for erosion rates of metal materials. • Predicted erosion rate is well correlated with experiment within a factor of 1.5. - Abstract: This paper describes the experimental study on the liquid droplet impingement erosion of metal materials to understand the influence of material hardness on the erosion rate. The experiment is carried out using a water spray jet apparatus with a condition of relatively thin liquid film thickness. The metal materials tested are pure aluminum, aluminum alloy, brass, mild steel, carbon steel and stainless steel. The liquid droplets considered are 30 ± 5 μm in volume average diameter of water, which is the same order of droplet diameter in the actual pipeline in nuclear/fossil power plants. In order to understand the influence of material hardness on the liquid droplet impingement erosion, the scanning electron microscope (SEM) observation on the eroded surface and the measurement of erosion rate are carried out in the terminal stage of erosion. The experimental results indicate that the erosion rates are expressed by the droplet velocity, volume flux, Vickers hardness and the liquid film thickness, which are fundamentals of the liquid droplet impingement erosion. The empirical formula shows that the power index for droplet velocity dependency is found to be 7 with a scattering from 5 to 9 depending on the materials, while the power index for Vickers hardness dependency is found as −4.5.

Manufacturing techniques for titanium aluminide based alloys and metal matrix composites

Science.gov (United States)

Kothari, Kunal B.

Dual phase titanium aluminides composed vastly of gamma phase (TiAl) with moderate amount of alpha2 phase (Ti3Al) have been considered for several high temperature aerospace and automobile applications. High specific strength coupled with good high temperature performance in the areas of creep and oxidation resistance makes titanium aluminides "materials of choice" for next generation propulsion systems. Titanium alumnides are primarily being considered as potential replacements for Ni-based superalloys in gas turbine engine components with aim of developing more efficient and leaner engines exhibiting high thrust-to-weight ratio. Thermo-mechanical treatments have shown to enhance the mechanical performance of titanium aluminides. Additionally, small additions of interstitial elements have shown further and significant improvement in the mechanical performance of titanium alumnide alloys. However, titanium aluminides lack considerably in room temperature ductility and as a result manufacturing processes of these aluminides have greatly suffered. Traditional ingot metallurgy and investment casting based methods to produce titanium aluminide parts in addition to being expensive, have also been unsuccessful in producing titanium aluminides with the desired mechanical properties. Hence, the manufacturing costs associated with these methods have completely outweighed the benefits offered by titanium aluminides. Over the last two decades, several powder metallurgy based manufacturing techniques have been studied to produce titanium aluminide parts. These techniques have been successful in producing titanium aluminide parts with a homogeneous and refined microstructure. These powder metallurgy techniques also hold the potential of significant cost reduction depending on the wide market acceptance of titanium aluminides. In the present study, a powder metallurgy based rapid consolidation technique has been used to produce near-net shape parts of titanium aluminides. Micron

Additively manufactured porous tantalum implants

NARCIS (Netherlands)

Wauthle, Ruben; Van Der Stok, Johan; Yavari, Saber Amin; Van Humbeeck, Jan; Kruth, Jean Pierre; Zadpoor, Amir Abbas; Weinans, Harrie; Mulier, Michiel; Schrooten, Jan

2015-01-01

The medical device industry's interest in open porous, metallic biomaterials has increased in response to additive manufacturing techniques enabling the production of complex shapes that cannot be produced with conventional techniques. Tantalum is an important metal for medical devices because of

Cerium doped heavy metal fluoride glasses, a possible alternative for electromagnetic calorimetry

Energy Technology Data Exchange (ETDEWEB)

Auffray, E. [CERN, Geneva (Switzerland); Bouttet, D. [LPCM Lyon, CNRS and Universite Claude Bernard, Villeurbanne (France); Dafinei, I. [CERN, Geneva (Switzerland); Fay, J. [IPN Lyon, IN2P3-CNRS and Universite Claude Bernard, Villeurbanne (France); Lecoq, P. [CERN, Geneva (Switzerland); Mares, J.A. [Institute of Physics, Praha (Czech Republic); Martini, M. [University of Milan, Department of Physics, Milan (Italy); Maze, G. [Le Verre Fluore, F - 35770 Vern/Seiche, Bretagne (France); Meinardi, F. [University of Milan, Department of Physics, Milan (Italy); Moine, B. [LPCM Lyon, CNRS and Universite Claude Bernard, Villeurbanne (France); Nikl, M. [Institute of Physics, Praha (Czech Republic); Pedrini, C. [LPCM Lyon, CNRS and Universite Claude Bernard, Villeurbanne (France); Poulain, M. [Le Verre Fluore, F - 35770 Vern/Seiche, Bretagne (France); Schneegans, M. [LAPP, IN2P3-CNRS, Annecy-le-Vieux (France); Tavernier, S. [VUB, Vrije Universiteit Brussels, Brussels (Belgium); Vedda, A. [University of Milan, Department of Physics, Milan (Italy)

1996-10-11

The article is an overview of the research activity made in the framework of the Crystal Clear Collaboration aimed at obtaining scintillating glasses able to fit the constraints imposed for the active medium of the central Electromagnetic Calorimeter at CMS. The manufacturing of heavy metal fluoride glasses doped with Ce{sup 3+} is discussed. The luminescence and scintillation characteristics as well as the radiation hardness properties are extensively studied in the case of Ce doped fluorohafnate, found to be the most convenient glass scintillator for high energy physics applications. (orig.).

Cerium doped heavy metal fluoride glasses, a possible alternative for electromagnetic calorimetry

International Nuclear Information System (INIS)

Auffray, E.; Bouttet, D.; Dafinei, I.; Fay, J.; Lecoq, P.; Mares, J.A.; Martini, M.; Maze, G.; Meinardi, F.; Moine, B.; Nikl, M.; Pedrini, C.; Poulain, M.; Schneegans, M.; Tavernier, S.; Vedda, A.

1996-01-01

The article is an overview of the research activity made in the framework of the Crystal Clear Collaboration aimed at obtaining scintillating glasses able to fit the constraints imposed for the active medium of the central Electromagnetic Calorimeter at CMS. The manufacturing of heavy metal fluoride glasses doped with Ce 3+ is discussed. The luminescence and scintillation characteristics as well as the radiation hardness properties are extensively studied in the case of Ce doped fluorohafnate, found to be the most convenient glass scintillator for high energy physics applications. (orig.)

Additive manufacture with IN625 superalloy using laser and plasma transferred arc

International Nuclear Information System (INIS)

Cardozo, Eloisa Pereira; D'Oliveira, Ana Sofia C.M.; Ganguly, Supryio; Pardal, Goncalo Rodrigues

2016-01-01

Full text: Additive manufacturing of mechanical components processed with metallic alloys is a growing market due to its full potential over the traditional manufacturing. Material efficiency is a key factor towards the selection of AM procedures, particularly for parts fabricated with high cost alloys such as Ni based alloys. Inspite the advantages of this innovative technique many challenges have to be met before its wide acceptance by industries from different sectors. This study contributes to the current knowledge progress regarding the analysis of AM parts processed by laser and Plasma transferred arc (PTA). IN625 Ni based alloy, layer by- layer parts were processed and analyzed in the as processed condition and after homogenization heat treatment. Characterization was carried out by confocal and scanning electron microscopy, X-ray diffraction and microhardness profile. Results revealed similar hardness although laser AM specimens exhibited a finer structure. Data acquire after the homogenization heat treatment suggests the as processed PTA samples to have a more stable microstructure. Discussion highlights the potential of each technique and their competitiveness. (author)

Additive manufacture with IN625 superalloy using laser and plasma transferred arc

Energy Technology Data Exchange (ETDEWEB)

Cardozo, Eloisa Pereira; D' Oliveira, Ana Sofia C.M., E-mail: elocrdz@gmail.com [Universidade Federal do Parana (UFPR), PR (Brazil); Ganguly, Supryio; Pardal, Goncalo Rodrigues [Cranfield University, Bedford (United Kingdom)

2016-07-01

Full text: Additive manufacturing of mechanical components processed with metallic alloys is a growing market due to its full potential over the traditional manufacturing. Material efficiency is a key factor towards the selection of AM procedures, particularly for parts fabricated with high cost alloys such as Ni based alloys. Inspite the advantages of this innovative technique many challenges have to be met before its wide acceptance by industries from different sectors. This study contributes to the current knowledge progress regarding the analysis of AM parts processed by laser and Plasma transferred arc (PTA). IN625 Ni based alloy, layer by- layer parts were processed and analyzed in the as processed condition and after homogenization heat treatment. Characterization was carried out by confocal and scanning electron microscopy, X-ray diffraction and microhardness profile. Results revealed similar hardness although laser AM specimens exhibited a finer structure. Data acquire after the homogenization heat treatment suggests the as processed PTA samples to have a more stable microstructure. Discussion highlights the potential of each technique and their competitiveness. (author)

Pressure-induced structural transition and thermodynamic properties of RhN2 and the effect of metallic bonding on its hardness

International Nuclear Information System (INIS)

Liu Jun; Kuang Xiao-Yu; Wang Zhen-Hua; Huang Xiao-Fen

2012-01-01

The elastic constant, structural phase transition, and effect of metallic bonding on the hardness of RhN 2 under high pressure are investigated through the first-principles calculation by means of the pseudopotential plane-wave method. Three structures are chosen to investigate for RhN 2 , namely, simple hexagonal P6/mmm (denoted as SH), orthorhombic Pnnm (marcasite), and simple tetragonal P4/mbm (denoted as ST). Our calculations show that the SH phase is energetically more stable than the other two phases at zero pressure. On the basis of the third-order Birch—Murnaghan equation of states, we find that the phase transition pressures from an SH to a marcasite structure and from a marcasite to an ST structure are 1.09 GPa and 354.57 GPa, respectively. Elastic constants, formation enthalpies, shear modulus, Young's modulus, and Debye temperature of RhN 2 are derived. The calculated values are, generally speaking, in good agreement with the previous theoretical results. Meanwhile, it is found that the pressure has an important influence on physical properties. Moreover, the effect of metallic bonding on the hardness of RhN 2 is investigated. This is a quantitative investigation on the structural properties of RhN 2 , and it still awaits experimental confirmation. (condensed matter: structural, mechanical, and thermal properties)

Evaluation of the impact energy of the samples produced by the additive manufacturing technology

Directory of Open Access Journals (Sweden)

J. Dobránsky

2016-07-01

Full Text Available The article covered the evaluation of the impact energy, notch toughness and morphology of the fracture surfaces of the specimens manufactured by the Direct Metal Laser Sintering Technology. Specimens without heat treatment with no notch were not broken through in course of testing, therefore there was no fracture surface present. The heat treatment resulted in the increase in hardness values. The values of impact energy after the heat treatment was approximately 60 % lower. Ductile intergranular fracture with more or less segmented dimple morphology appeared in every specimen. At places where the internal plastic bond was resisting the test, cracks remaining after particles broke away from the surface can be seen as craters.

The effect of heat treatment on structure and properties of hard metals on a tungsten carbide basis with iron-nickel-binders

International Nuclear Information System (INIS)

Chaporova, I.N.; Kudryavtseva, V.I.; Sapronova, Z.N.; Sychkova, L.V.

1980-06-01

In the present paper the effect of storage and quenching on structure and properties of WC(Fe,Ni)-hardmetals was investigated. Starting materials were powders of tungsten carbide, iron and nickel, commonly used for the hard metal production. WC(Fe,Ni)-specimens (Fe: Ni = 80:20, 85:15) with 8, 11, 80, 85, 89 and 92 percent by weight were produced for the investigation. (orig.) [de

Surface modification of additive manufactured metal products by an intense electron beam

Science.gov (United States)

Teresov, A. D.; Koval, N. N.; Ivanov, Yu F.; Petrikova, E. A.; Krysina, O. V.

2017-11-01

On the example of VT6 titanium alloy it is shown that successive surface modification of additive manufactured metal specimens in vacuum at an argon pressure of 3.5·10-2 by ten pulses with 200 μs, 45 J/cm2 and then by three pulses with 50 μm, 20 J/cm2 provides a considerable decrease in their porosity and surface roughness (20 times for Ra) while their surface microhardness, friction coefficient, and wear level remain almost unchanged. After electron beam irradiation, the ultimate tensile strength of the material increases 1.33 times, and its tensile strain 1.18 times. For specimens obtained by conventional metallurgy and irradiated in the same modes, no such effects are observed.

Analyses of heavy metals in mineral trioxide aggregate and Portland cement.

Science.gov (United States)

Schembri, Matthew; Peplow, George; Camilleri, Josette

2010-07-01

Portland cement is used in the construction industry as a binder in concrete. It is manufactured from chalk, limestone, and clay, which are clinkered at very high temperatures and ground with gypsum to form Portland cement. The raw materials and the manufacturing process can result in the inclusion of heavy metals in Portland cement. Portland cement with a four to one addition of bismuth oxide is marketed as mineral trioxide aggregate (MTA), which is used mainly as a dental material. Heavy metal inclusion can be of concern because MTA is in contact with hard and soft tissues. Measurements of arsenic, lead, and chromium in hydrated gray and white Portland cement, ProRoot MTA, and MTA Angelus were conducted with graphite furnace atomic absorption spectrophotometry after acid digestion on the hydrated material. The leaching of the metal ions from the solid material in water and simulated body fluid (SBF) was also determined. All cement types showed high relative values of leached chromium compared with arsenic and lead in both the total metal content and leached species. The gray Portland cement showed the highest total amount of metal. The white Portland and both MTAs had lower values for all the leached metal ions. Both MTAs released more arsenic than the amount specified in ISO 9917-1 (2007). Portland cements and MTAs showed evidence of heavy metals in the acid-soluble form as well as leaching in deionized water and SBF. MTA contained levels of arsenic higher than the safe limit specified by the ISO 9917-1 (2007). Copyright 2010 American Association of Endodontists. Published by Elsevier Inc. All rights reserved.

Development of procedures for the acquisition of metal Additive Manufacturing (AM) parts for use in the CSIR's wind tunnel models

CSIR Research Space (South Africa)

Johnston, C

2015-11-04

Full Text Available The first Additive Manufacturing (AM) non-load-bearing, client furnished part was used in the CSIR’s wind tunnels in 2007. The advent of metal-grown materials, and the acquisition of machines to grow them in South Africa, has made it feasible...

Surface coatings of mixed hard alloy powder metals sintered-on in vacuo

International Nuclear Information System (INIS)

Knotek, O.; Reimann, H.

1980-01-01

No technological difficulties are to be encountered in the processing of pseudo hard alloys in the form of powder compounds of conventional nickel base hard alloys with carbides. There is a great alloy influence on the resulting structures of the surface layers. Under some processing conditions the tungsten carbide is completely dissolved from molten matrix alloy. Hard phases on chromium carbide basis resulted upon cooling. Induced chromium carbide Cr 3 C 2 retains its structure while absorbing large amounts of iron into its grid. It can be concluded that not only alloying properties, but also eminently structural criterions are decisive for the stability of the applied supplementary hard phases. (orig.) [de

Utilisation of fly ash for the management of heavy metal containing primary chemical sludge generated in a leather manufacturing industry

Energy Technology Data Exchange (ETDEWEB)

Sekaran, G.; Rao, B.P.; Ghanamani, A.; Rajamani, S. [Central Leather Research Institute, Chennai (India). Dept. of Environmental Technology

2003-07-01

The present study aims at disposal of primary chemical sludge generated in the tanning industry by solidification and stabilization process using flyash generated from thermal power plant along with binders and also on evaluating the leachability of heavy metal from the solidified product. The primary chemical sludge containing heavy metals iron and chromium were obtained from a garment leather manufacturing company at Chennai in India. The sludge was dried in open environment and it was powdered to fine size in a grinder. Binding increases stabilization of heavy metal in calcined sludge with refractory binders such as clay, fly ash, lime and ordinary Portland cement. Fly ash can be considered as the additional binder for producing stronger bricks, with high metal fixation efficiency, and minimum rate of removal of heavy metal and minimum diffusion co-efficient. 15 refs., 5 figs., 5 tabs.

Correlation between Fe–V–C alloys surface hardness and plasma temperature via LIBS technique

Energy Technology Data Exchange (ETDEWEB)

Messaoud Aberkane, S., E-mail: smessaoud@cdta.dz [Centre de Développement des Technologies Avancées, Baba Hassen, Alger (Algeria); Bendib, A. [Université des Sciences et de Technologie Houari Boumediene, Bab-Ezzouar, Alger (Algeria); Yahiaoui, K.; Boudjemai, S.; Abdelli-Messaci, S.; Kerdja, T. [Centre de Développement des Technologies Avancées, Baba Hassen, Alger (Algeria); Amara, S.E. [Université des Sciences et de Technologie Houari Boumediene, Bab-Ezzouar, Alger (Algeria); Harith, M.A. [National Institute of Laser Enhanced Science, Cairo University (Egypt)

2014-05-01

Highlights: • New application of LIBS in industry. • Hardness of metallic alloys estimation using LIBS calibration curves. • Linear correlation between the plasma temperature and the hardness of metallic alloys. • The shock wave is fast when the material is hard. - Abstract: Surface hardness is a very important characteristic of metals. Its monitoring plays a key role in industry. In the present paper, using laser induced breakdown spectroscopy (LIBS), Fe–V{sub 18%}–C{sub 1%} alloys with different heat treatments have been used for making the correlation between surface hardness and laser-induced plasma temperatures. All investigated samples were characterized by the same ferrite phase with different Vickers surface hardnesses. The differences in hardness values were attributed to the crystallite size changes. A linear relationship has been obtained between the Vickers surface hardness and the laser induced plasma temperature. For comparison the relation between surface hardness and the ratio of the vanadium ionic to atomic spectral lines intensities (VII/VI) provided good linear results too. However, adopting the proposed approach of using the plasma temperature, instead, is more reliable in view of the difficulties that could be encountered in choosing the proper ionic and atomic spectral lines. To validate this approach we have investigated the shock wave speed induced by laser interaction with the used samples. It was found that harder is the material faster is the shock wave. The determination of the surface hardness via measuring T{sub e} shows the feasibility of using LIBS as an easy and reliable method for in situ industrial application for production control.

Determination of pollutants in foundry during the manufacture of metal constructions for high buildings

Science.gov (United States)

Ivanova, Irina; Sushko, Elena; Lyshnikova, Anna; Prykina, Larisa

2018-03-01

Current developments are devoted to the environmental safety of the foundry. There is a significant amount of pollutants, according to dust, which is released in the working area, during the manufacture of metal structures for high buildings. From the point of dust extraction, the most unfavorable areas are shot blasting, sand-blasting chambers and knockout grills. The weight fraction of dust composition with diameters up to 20 μm reaches 43,8% by mass, according to experimental analysis. This kind of dust is the most dangerous to employees and also it creates problems for dust-cleaning in the air.

Development of in-Situ Al-Si/CuAl2 Metal Matrix Composites: Microstructure, Hardness, and Wear Behavior

Directory of Open Access Journals (Sweden)

Mahmoud M. Tash

2016-06-01

Full Text Available In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15% into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl2, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl2 at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature.

Solid-State Additive Manufacturing for Heat Exchangers

Science.gov (United States)

Norfolk, Mark; Johnson, Hilary

2015-03-01

Energy densities in devices are increasing across many industries including power generation, high power electronics, manufacturing, and automotive. Increasingly, there is a need for very high efficiency thermal management devices that can pull heat out of a small area at higher and higher rates. Metal additive manufacturing (AM) technologies have the promise of creating parts with complex internal geometries required for integral thermal management. However, this goal has not been met due to constraints in fusion-based metal 3D printers. This work presents a new strategy for metal AM of heat exchangers using an ultrasonic sheet lamination approach.

Hot stamping advanced manufacturing technology of lightweight car body

CERN Document Server

Hu, Ping; He, Bin

2017-01-01

This book summarizes the advanced manufacturing technology of original innovations in hot stamping of lightweight car body. A detailed description of the technical system and basic knowledge of sheet metal forming is given, which helps readers quickly understand the relevant knowledge in the field. Emphasis has been placed on the independently developed hot stamping process and equipment, which help describe the theoretical and experimental research on key problems involving stress field, thermal field and phase transformation field in hot stamping process. Also, a description of the formability at elevated temperature and the numerical simulation algorithms for high strength steel hot stamping is given in combination with the experiments. Finally, the book presents some application cases of hot stamping technology such as the lightweight car body design using hot stamping components and gradient hardness components, and the cooling design of the stamping tool. This book is intended for researchers, engineers...

Determination of natural and artificial radionuclides and some trace metals in manufactured food of Syrian infant and their intake rates

International Nuclear Information System (INIS)

Al-Masri, M. S.; Nashawati, A.; Amin, Y.; Ibrahim, S.

2001-06-01

Natural and artificial radionuclides and some trace metals in some manufactured food of Syrian infant and their intake rates have been determined. Seventeen manufactured food and eleven types of canned milked, were collected from the local market, and chemically and radioactivity analyzed; radium-226, radium-228, potassium-40, lead-210, polonium-210 and trace metals (Pb, Cd, Cu, Zn) being determined. Results have shown that 210 Po concentration varied between 0.38 and 2.89 Bq/Kg in canned milk while the highest concentration in infant food was found to be 1.69 Bq/Kg; other radionuclides concentration being below the limit of detection. Total uranium concentration varied between 2.2 and 10.5 μg/Kg in milk samples and 0.78-6.0 μg/Kg in food stuff samples. In addition, concentration of Pb and Cd in all samples were found to be very low and lower than the lower of limit of detection of the analytical method. (author)

Short-term acute hypercapnia affects cellular responses to trace metals in the hard clams Mercenaria mercenaria

International Nuclear Information System (INIS)

Ivanina, Anna V.; Beniash, Elia; Etzkorn, Markus; Meyers, Tiffany B.; Ringwood, Amy H.; Sokolova, Inna M.

2013-01-01

Highlights: •P CO 2 alters accumulation of Cd and Cu in clam cells. •Accumulation of Cd induces release of free Zn 2+ . •Accumulation of Cu induces an increase in free Cu 2+ and Fe 2+ . •Metal-induced oxidative stress is alleviated at high P CO 2 . •Toxicity of Cu in likely enhanced while that of Cd alleviated by high P CO 2 . -- Abstract: Estuarine and coastal habitats experience large fluctuations of environmental factors such as temperature, salinity, partial pressure of CO 2 (P CO 2 ) and pH; they also serve as the natural sinks for trace metals. Benthic filter-feeding organisms such as bivalves are exposed to the elevated concentrations of metals in estuarine water and sediments that can strongly affect their physiology. The effects of metals on estuarine organisms may be exacerbated by other environmental factors. Thus, a decrease in pH caused by high P CO 2 (hypercapnia) can modulate the effects of trace metals by affecting metal bioavailability, accumulation or binding. To better understand the cellular mechanisms of interactions between P CO 2 and trace metals in marine bivalves, we exposed isolated mantle cells of the hard clams (Mercenaria mercenaria) to different levels of P CO 2 (0.05, 1.52 and 3.01 kPa) and two major trace metal pollutants – cadmium (Cd) and copper (Cu). Elevated P CO 2 resulted in a decrease in intracellular pH (pH i ) of the isolated mantle cells from 7.8 to 7.4. Elevated P CO 2 significantly but differently affected the trace metal accumulation by the cells. Cd uptake was suppressed at elevated P CO 2 levels while Cu accumulation has greatly accelerated under hypercapnic conditions. Interestingly, at higher extracellular Cd levels, labile intracellular Cd 2+ concentration remained the same, while intracellular levels of free Zn 2+ increased suggesting that Cd 2+ substitutes bound Zn 2+ in these cells. In contrast, Cu exposure did not affect intracellular Zn 2+ but led to a profound increase in the intracellular levels

Toughness of submerged arc weld metals of controlled rolled NB bearing steel

International Nuclear Information System (INIS)

Yamaguchi, T.; Shiga, A.; Kamada, A.; Tsuboi, J.

1982-01-01

The toughness and the hardness of reheated weld metals depend on the maximum reheating temperature. When the maximum reheating temperature is 500 to 700 0 C, the hardness of single pass weld metal increases and the toughness decreases because of fine Nb- and V-carbonitride precipitation. When the maximum reheating temperature is over 800 0 C, the hardness and the toughness remain almost unchanged. The stress relieving treatment of single pass weld metal at 600 0 C for 1 up to about 100 hours causes the increase in hardness and then decreases the hardness gradually. It needs over 500 hours to obtain the same hardness value as that of as-welded metal. The addition of Ti to weld metal is very effective to improve the toughness, however excess Ti increases the hardness of stress relieved weld metal by precipitating as fine Ti-carbonitride. Therefore Ti addition should be restricted within the lowest limit required to improve as-welded metal toughness. The optimum Ti content is about 0.020% in the case of weld metal of which oxygen content is 350 ppM or so. In multipass welding, the hardness of weld metal affected by subsequent weld heat cycle varies from pass to pass, because Nb and V content change with the passes as the result of the change in dilution from base metal. The most hardened zone is observed in the reheated first pass weld metal, in which Nb and V content are the highest. Good weld metal toughness would be obtained by lowering dilution from base metal and taking advantage of grain refinement by subsequent passes

Sweeping total reflection X-ray fluorescence optimisation to monitor the metallic contamination into IC manufacturing

International Nuclear Information System (INIS)

Borde, Yannick; Danel, Adrien; Roche, Agnes; Veillerot, Marc

2008-01-01

Among the methods available on the market today to control as metallic contamination in integrated circuit manufacturing, Sweeping Total reflection X-ray Fluorescence mode appears a very good method, providing fast and entire wafer mapping. With the goal of a pertinent use of Sweeping Total reflection X-ray Fluorescence in advanced Integrated Circuit manufacturing this work discusses how acceptable levels of contamination specified by the production (low levels to be detected) can be taken into account. The relation between measurement results (surface coverage, throughput, low limit of detection, limit of quantification, quantification of localized contamination) and Sweeping Total reflection X-ray Fluorescence parameters (number of measurement points and integration time per point) is presented in details. In particular, a model is proposed to explain the mismatch between actual surface contamination in a localized spot on wafer and Total reflection X-ray Fluorescence reading. Both calibration and geometric issues have been taken into account

A hard x-ray prototype production exposure station at NSLS

International Nuclear Information System (INIS)

Johnson, E.D.; Milne, J.C.

1997-07-01

Exposures conducted at the NSLS R and D beamline (X-27B) for High Aspect Ratio Precision Manufacture have proven sufficiently successful that the authors are constructing a dedicated hard x-ray exposure beamline. The new beamline (X-14B) provides an exposure field ∼ 120 mm wide, three times larger than that of X-27B. The scanner is based on the hydraulic system from the X-27B program. It is optimized for planar exposures and takes advantage of the full 525 mm stroke available. Exposures of multiple substrates and masks will be possible, with the fixturing supporting mounting of substrate holders from other groups (ALS, APS, CAMD, and UW). The function of this beamline is to establish a hard x-ray exposure station where manufacturing scale protocols can be developed and ultimately exploited for production runs

Glyphosate, Hard Water and Nephrotoxic Metals: Are They the Culprits Behind the Epidemic of Chronic Kidney Disease of Unknown Etiology in Sri Lanka?

Science.gov (United States)

Jayasumana, Channa; Gunatilake, Sarath; Senanayake, Priyantha

2014-01-01

The current chronic kidney disease epidemic, the major health issue in the rice paddy farming areas in Sri Lanka has been the subject of many scientific and political debates over the last decade. Although there is no agreement among scientists about the etiology of the disease, a majority of them has concluded that this is a toxic nephropathy. None of the hypotheses put forward so far could explain coherently the totality of clinical, biochemical, histopathological findings, and the unique geographical distribution of the disease and its appearance in the mid-1990s. A strong association between the consumption of hard water and the occurrence of this special kidney disease has been observed, but the relationship has not been explained consistently. Here, we have hypothesized the association of using glyphosate, the most widely used herbicide in the disease endemic area and its unique metal chelating properties. The possible role played by glyphosate-metal complexes in this epidemic has not been given any serious consideration by investigators for the last two decades. Furthermore, it may explain similar kidney disease epidemics observed in Andra Pradesh (India) and Central America. Although glyphosate alone does not cause an epidemic of chronic kidney disease, it seems to have acquired the ability to destroy the renal tissues of thousands of farmers when it forms complexes with a localized geo environmental factor (hardness) and nephrotoxic metals. PMID:24562182

Microindentation hardness evaluation of iridium alloy clad vent set cups

International Nuclear Information System (INIS)

Ulrich, G.B.; DeRoos, L.F.; Stinnette, S.E.

1993-01-01

An iridium alloy, DOP-26, is used as cladding for 238 PuO 2 fuel in radioisotope heat sources for space power systems. Presently, DOP-26 iridium alloy clad vent sets (CVS) are being manufactured at the Oak Ridge Y-12 Plant for potential use in the National Aeronautics and Space Administration's Cassini mission to Saturn. Wrought/ground/stress relieved blanks are warm formed into CVS cups. These cups are then annealed to recrystallize the material for subsequent fabrication/assembly operations as well as for final use. One of the cup manufacturing certification requirements is to test for Vickers microindentation hardness. New microindentation hardness specification limits, 210 to 310 HV, have been established for a test load of 1000 grams-force (gf). The original specification limits, 250 to 350 HV, were for 200 gf testing. The primary reason for switching to a higher test load was to reduce variability in the test data. The DOP-26 alloy exhibits microindentation hardness load dependence, therefore, new limits were needed for 1000 gf testing. The new limits were established by testing material from 15 CVS cups using 200 gf and 1000 gf loads and then statistically analyzing the data. Additional work using a Knoop indenter and a 10 gf load indicated that the DOP-26 alloy grain boundaries have higher hardnesses than the grain interiors

Microindentation hardness evaluation of iridium alloy clad vent set cups

International Nuclear Information System (INIS)

Ulrich, G.B.; DeRoos, L.F.; Stinnette, S.E.

1992-01-01

An iridium alloy, DOP-26, is used as cladding for 238 PuO 2 fuel in radioisotope heat sources for space power systems. Presently, DOP-26 iridium alloy clad vent sets (CVS) are being manufactured at the Oak Ridge Y-12 Plant for potential use in the National Aeronautics and Space Administration's Cassini mission to Saturn. Wrought/ground/stress relieved blanks are warm formed into CVS cups. These cups are then annealed to recrystallize the material for subsequent fabrication/assembly operations as well as for final use. One of the cup manufacturing certification requirements is to test for Vickers microindentation hardness. New microindentation hardness specification limits, 210 to 310 HV, have been established for a test load of 1000 grams-force (gf). The original specification limits, 250 to 350 HV, were for 200 gf testing. The primary reason for switching to a higher test load was to reduce variability in the test data. The DOP-26 alloy exhibits microindentation hardness load dependence, therefore, new limits were needed for 1000 gf testing. The new limits were established by testing material from 15 CVS cups using 200 gf and 1000 gf loads and then statistically analyzing the data. Additional work using a Knoop indenter and a 10 gf load indicated that the DOP-26 alloy grain boundaries have higher hardnesses than the grain interiors

Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings

Directory of Open Access Journals (Sweden)

S. Vignesh

2017-04-01

Full Text Available Flow based Erosion – corrosion problems are very common in fluid handling equipments such as propellers, impellers, pumps in warships, submarine. Though there are many coating materials available to combat erosion–corrosion damage in the above components, iron based amorphous coatings are considered to be more effective to combat erosion–corrosion problems. High velocity oxy-fuel (HVOF spray process is considered to be a better process to coat the iron based amorphous powders. In this investigation, iron based amorphous metallic coating was developed on 316 stainless steel substrate using HVOF spray technique. Empirical relationships were developed to predict the porosity and micro hardness of iron based amorphous coating incorporating HVOF spray parameters such as oxygen flow rate, fuel flow rate, powder feed rate, carrier gas flow rate, and spray distance. Response surface methodology (RSM was used to identify the optimal HVOF spray parameters to attain coating with minimum porosity and maximum hardness.

Single-use disposable technologies for biopharmaceutical manufacturing.

Science.gov (United States)

Shukla, Abhinav A; Gottschalk, Uwe

2013-03-01

The manufacture of protein biopharmaceuticals is conducted under current good manufacturing practice (cGMP) and involves multiple unit operations for upstream production and downstream purification. Until recently, production facilities relied on the use of relatively inflexible, hard-piped equipment including large stainless steel bioreactors and tanks to hold product intermediates and buffers. However, there is an increasing trend towards the adoption of single-use technologies across the manufacturing process. Technical advances have now made an end-to-end single-use manufacturing facility possible, but several aspects of single-use technology require further improvement and are continually evolving. This article provides a perspective on the current state-of-the-art in single-use technologies and highlights trends that will improve performance and increase the market penetration of disposable manufacturing in the future. Copyright © 2012 Elsevier Ltd. All rights reserved.

Surface modification of the hard metal tungsten carbide-cobalt by boron ion implantation

International Nuclear Information System (INIS)

Mrotchek, I.

2007-01-01

In the present thesis ion beam implantation of boron is studied as method for the increasement of the hardness and for the improvement of the operational characteristics of cutting tools on the tungsten carbide-cobalt base. For the boron implantation with 40 keV energy and ∼5.10 17 ions/cm 2 fluence following topics were shown: The incoerporation of boron leads to a deformation and remaining strain of the WC lattice, which possesses different stregth in the different directions of the elementary cell. The maximum of the deformation is reached at an implantation temperature of 450 C. The segregation of the new phases CoWB and Co 3 W was detected at 900 C implantation temperature. At lower temperatures now new phases were found. The tribological characteristics of WC-Co are improved. Hereby the maxiaml effect was measured for implantation temperatures from 450 C to 700 C: Improvement of the microhardness by the factor 2..2.5, improvement of the wear resistance by the factor 4. The tribological effects extend to larger depths than the penetration depth of the boron implantation profile. The detected property improvements of the hard metal H3 show the possibility of a practical application of boron ion implantation in industry. The effects essential for a wer decreasement are a hardening of the carbide phase by deformation of the lattice, a hardening of the cobalt binding material and the phase boundaries because of the formation of a solid solution of the implanted boron atoms in Co and by this a blocking of the dislocation movement and the rupture spreading under load

A Forging Hardness Dispersion Effect on the Energy Consumption of Machining

Directory of Open Access Journals (Sweden)

L. D. Mal'kova

2015-01-01

Full Text Available The aim of the work is to evaluate a hardness dispersion of forgings to be further machined, and analyse the impact of this dispersion on the resulting power consumption when cutting.The paper studies the hardness values of three kinds of parts for automotive manufacturing. Sample of each part was n = 100 pieces. Analysis of measurements showed that 46% - 93% of parts meet requirements for a range defined by the work-piece working drawing. It was found that hardness of one batch of forgings is under dispersion, which distribution is governed by the normal law.The work provides calculations for machining the external cylindrical surfaces of the considered parts. In the context of calculating are adopted parameters of the enterprise-processing rate. It is found that power consumption of machining because of the dispersion values of the work-piece hardness is a function of the random BH variable and it itself is a random variable. Two types of samples are considered, namely: the full sample and that of the values that meet requirements for hardness. The coefficient of variation for samples that meet the technical requirements for hardness is lower than for the full samples, so their average value is more reliable characteristic of a set. It was also found that to ensure a reliable prediction of power consumption in designing the manufacturing processes it is necessary to reduce a tolerance range of workpiece hardness to the limit.The work gives a comparative evaluation of electric power consumption per unit cylindrical surface of the parts under consideration. A relative change in the electric power consumed at the minimum and maximum levels of the hardness value was introduced as an evaluation criterion. It is found that with changing hardness of machined work-pieces within the tolerance, the change in power consumption in machining the unit surface reaches 16% while in the case its being out of the specified range it does 47%.

Demonstration test on manufacturing 200 l drum inner shielding material for recycling of reactor operating metal scrap

International Nuclear Information System (INIS)

Umemura, A.; Kimura, K.; Ueno, H.

1993-01-01

Low-level reactor wastes should be safely recycled considering those resource values, the reduction of waste disposal volume and environmental effects. The reasonable recycling system of reactor operating metal scrap has been studied and it was concluded that the 200 liter drum inner shielding material is a very promising product for recycling within the nuclear industry. The drum inner shielding material does not require high quality and so it is expected to be easily manufactured by melting and casting from roughly sorted scrap metals. This means that the economical scrap metal recycling system can be achieved by introducing it. Furthermore its use will ensure safety because of being contained in a drum. In order to realize this recycling system with the drum inner shielding material, the demonstration test program is being conducted. The construction of the test facility, which consists of a melting and refining furnace, a casting apparatus, a machining apparatus etc., was finishing in September, 1992

Etch Defect Characterization and Reduction in Hard-Mask-Based Al Interconnect Etching

International Nuclear Information System (INIS)

Lee, H.J.; Hung, C.L.; Leng, C.H.; Lian, N.T.; Young, L.W.

2009-01-01

This paper identifies the defect adders, for example, post hard-mask etch residue, post metal etch residue, and blocked etch metal island and investigates the removal characteristics of these defects within the oxide-masked Al etching process sequence. Post hard-mask etch residue containing C atom is related to the hardening of photoresist after the conventional post-RIE ashing at 275 degree C. An in situ O 2 -based plasma ashing on RIE etcher was developed to prevent the photoresist hardening from the high-ashing temperature; followed wet stripping could successfully eliminate such hardened polymeric residue. Post metal etch residue was caused from the attack of the Al sidewall by Cl atoms, and too much CHF 3 addition in the Al main etch step passivated the surface of Al resulting in poor capability to remove the Al-containing residue. The lower addition of CHF 3 in the Al main etch step would benefit from the residue removal. One possibility of blocked etch metal island creating was due to the micro masking formed on the opening of Ti N during the hard-mask patterning. We report that an additional Ti N surface pretreatment with the Ar/CHF 3 /N 2 plasmas could reduce the impact of the micro masking residues on blocked metal etch.

High Purity Tungsten Spherical Particle Preparation From WC-Co Spent Hard Scrap

Directory of Open Access Journals (Sweden)

Han Chulwoong

2015-06-01

Full Text Available Tungsten carbide-cobalt hard metal scrap was recycled to obtain high purity spherical tungsten powder by a combined hydrometallurgy and physical metallurgy pathway. Selective leaching of tungsten element from hard metal scrap occurs at solid / liquid interface and therefore enlargement of effective surface area is advantageous. Linear oxidation behavior of Tungsten carbide-cobalt and the oxidized scrap is friable to be pulverized by milling process. In this regard, isothermally oxidized Tungsten carbide-cobalt hard metal scrap was mechanically broken into particles and then tungsten trioxide particle was recovered by hydrometallurgical method. Recovered tungsten trioxide was reduced to tungsten particle in a hydrogen environment. After that, tungsten particle was melted and solidified to make a spherical one by RF (Ratio Frequency thermal plasma process. Well spherical tungsten micro-particle was successfully obtained from spent scrap. In addition to the morphological change, thermal plasma process showed an advantage for the purification of feedstock particle.

Material investigation for manufacturing of reference step gauges for CT scanning verification

DEFF Research Database (Denmark)

Cantatore, Angela; Angel, Jais Andreas Breusch; De Chiffre, Leonardo

2012-01-01

This work deals with the study of stability and material investigation for manufacturing of step gauges for CT scanning verification. Four replica step gauges were fabricated using a bisacryl material for dental applications and the stability over five months was monitored using a tactile CMM....... The material was unstable, probably due to a modification of the chemical composition which lowered the hardness. New step gauges were manufactured through milling. Polyetheretherketone (PEEK) and Polyp-phenylenesulphide (PPS with 40% glass) fulfil the requirements regarding hardness and mechanical properties...... and two series of five step gauges (one series for each material) were manufactured by milling. Results show a significant improvement in terms of form stability and surface geometry quality of the new step gauges with respect to the replica step gauges in Luxabite, as reported below....

Manufacturing consumption of energy 1994

Energy Technology Data Exchange (ETDEWEB)

NONE

1997-12-01

This report provides estimates on energy consumption in the manufacturing sector of the U.S. economy based on data from the Manufacturing Energy Consumption Survey. The sample used in this report represented about 250,000 of the largest manufacturing establishments which account for approximately 98 percent of U.S. economic output from manufacturing, and an expected similar proportion of manufacturing energy use. The amount of energy use was collected for all operations of each establishment surveyed. Highlights of the report include profiles for the four major energy-consuming industries (petroleum refining, chemical, paper, and primary metal industries), and an analysis of the effects of changes in the natural gas and electricity markets on the manufacturing sector. Seven appendices are included to provide detailed background information. 10 figs., 51 tabs.

CMOS optimization for radiation hardness

International Nuclear Information System (INIS)

Derbenwick, G.F.; Fossum, J.G.

1975-01-01

Several approaches to the attainment of radiation-hardened MOS circuits have been investigated in the last few years. These have included implanting the SiO 2 gate insulator with aluminum, using chrome-aluminum layered gate metallization, using Al 2 O 3 as the gate insulator, and optimizing the MOS fabrication process. Earlier process optimization studies were restricted primarily to p-channel devices operating with negative gate biases. Since knowledge of the hardness dependence upon processing and design parameters is essential in producing hardened integrated circuits, a comprehensive investigation of the effects of both process and design optimization on radiation-hardened CMOS integrated circuits was undertaken. The goals are to define and establish a radiation-hardened processing sequence for CMOS integrated circuits and to formulate quantitative relationships between process and design parameters and the radiation hardness. Using these equations, the basic CMOS design can then be optimized for radiation hardness and some understanding of the basic physics responsible for the radiation damage can be gained. Results are presented

Photon Doppler Velocimeter to Measure Entrained Additive Manufactured Bulk Metal Powders in Hot Subsonic and Supersonic Oxygen Gas

Science.gov (United States)

Tylka, Jonathan

2016-01-01

Parts produced by additive manufacturing, particularly selective laser melting (SLM), have been shown to silt metal particulate even after undergoing stringent precision aerospace cleaning processes (Lowrey 2016). As printed parts are used in oxygen systems with increased pressures, temperatures, and gas velocity, the risk of ignition by particle impact, the most common direct ignition source of metals in oxygen, substantially increases. The White Sands Test Facility (WSTF), in collaboration with Marshall Space Flight Center (MSFC), desires to test the ignitability of SLM metals by particle impact in heated oxygen. The existing test systems rely on gas velocity calculations to infer particle velocity in both subsonic and supersonic particle impact systems. Until now, it was not possible to directly measure particle velocity. To increase the fidelity of planned SLM ignition studies, it is necessary to validate that the Photon Doppler Velocimetry(PDV) test system can accurately measure particle velocity.

Defect Characterization for Material Assurance in Metal Additive Manufacturing (FY15-0664)

Energy Technology Data Exchange (ETDEWEB)

Salzbrenner, Bradley; Boyce, Brad; Jared, Bradley Howell; Rodelas, Jeffrey; Laing, John Robert

2016-02-01

No industry-wide standards yet exist for minimum properties in additively manufactured (AM) metals. While AM alloys such as 17-4 precipitation hardened stainless steel have been shown to have average properties that can be comparable to wrought or cast product, they suffer from inconsistent performance. Variability in the feedstock powder, feature sizes, thermal history, and laser performance can lead to unpredictable surface finish, chemistry, phase content, and defects. To address this issue, rapid, efficient, high-throughput mechanical testing and data analysis was developed, providing profound statistical insight into the stochastic variability in properties. With this new approach, 1000’s of comprehensive tensile tests can be performed for the cost of 10’s of conventional tests. This new high-throughput approach provides a material qualification pathway that is commensurate with the quick turn-around benefit of AM.

Study on the sintered characteristics and properties of nanostructured WC–15 wt% (Fe–Ni–Co) and WC–15 wt% Co hard metal alloys

Energy Technology Data Exchange (ETDEWEB)

Chang, Shih-Hsien, E-mail: changsh@ntut.edu.tw [Department of Materials and Mineral Resources Engineering, National Taipei University of Technology, Taipei 10608, Taiwan (China); Chang, Ming-Hung [Department of Materials and Mineral Resources Engineering, National Taipei University of Technology, Taipei 10608, Taiwan (China); Huang, Kuo-Tsung [Department of Auto-Mechanics, National Kangshan Agricultural Industrial Senior High School, Kaohsiung 82049, Taiwan (China)

2015-11-15

In this work, four different vacuum sintering temperatures (1250 °C, 1300 °C, 1350 °C and 1400 °C) were studied to determine the optimal process parameters of nano WC–15 wt% (Fe–Ni–Co) and WC–15 wt% Co sintered hard metal alloys. Experimental results showed that the optimal sintering temperatures for nano WC–(Fe–Ni–Co) and WC–Co alloys were 1300 °C and 1350 °C for 1 h, respectively. The sintered nano WC–(Fe–Ni–Co) and WC–Co hard metal alloys showed a good contiguity of 0.44 and 0.42; hardness was enhanced to HRA 90.83 and 90.92; the transverse rupture strength (TRS) increased to 2567.97 and 2860.08 MPa; and K{sub IC} was 16.23 and 12.33 MPa√m, respectively. Although the nano WC–(Fe–Ni–Co) alloys possessed a slightly lower TRS value, they exhibited superior fracture toughness (K{sub IC}) and hardness similar to that of the nano WC–Co material. Significantly, nano WC–(Fe–Ni–Co) alloys could be sintered at a lower temperature and still retained their excellent mechanical properties. - Graphical abstract: The following figure shows the fracture morphology of the WC–(Fe–Ni–Co) and WC–Co specimens by means of high-magnification SEM after the K{sub IC} tests. Fig. a shows that numerous binder phases (Fe–Ni–Co) existed in the crack areas, which resisted the penetration and extension of the cracks. Due to the bridging effect of the binder phase, the stress concentration of the crack tip will be resolved through plastic deformation; thus, the cracks did not continue to extend. Once the deformation reaches a critical value, the crack propagation occurs. Meanwhile, the binder phase can link together the two crack faces through the bridging process. Although parts of the cracked areas also showed the bridging effect in the WC–Co specimens, as shown by the arrows (Fig. b), the crack propagation path was not obviously affected. This result corresponds to the tortuosity phenomenon. Consequently, the bridging process

Incremental electrohydraulic forming - A new approach for the manufacture of structured multifunctional sheet metal blanks

Science.gov (United States)

Djakow, Eugen; Springer, Robert; Homberg, Werner; Piper, Mark; Tran, Julian; Zibart, Alexander; Kenig, Eugeny

2017-10-01

Electrohydraulic Forming (EHF) processes permit the production of complex, sharp-edged geometries even when high-strength materials are used. Unfortunately, the forming zone is often limited as compared to other sheet metal forming processes. The use of a special industrial-robot-based tool setup and an incremental process strategy could provide a promising solution for this problem. This paper describes such an innovative approach using an electrohydraulic incremental forming machine, which can be employed to manufacture the large multifunctional and complex part geometries in steel, aluminium, magnesium and reinforced plastic that are employed in lightweight constructions or heating elements.

Metal fuel manufacturing and irradiation performance

International Nuclear Information System (INIS)

Pedersen, D.R.; Walters, L.C.

1992-01-01

The advances in metal fuel by the Integral Fast Reactor Program at Argonne National Laboratory are the subject of this paper. The Integral Fast Reactor (IFR) is an advanced liquid-metal-cooled reactor concept being developed at Argonne National Laboratory. The advances stressed in the paper include fuel irradiation performance, and improved passive safety. The goals and the safety philosophy of the Integral Fast Reactor Program are stressed

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

International Nuclear Information System (INIS)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-01-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

Science.gov (United States)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-03-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

Energy Technology Data Exchange (ETDEWEB)

Thivillon, L.; Bertrand, Ph.; Laget, B. [Ecole Nationale d' Ingenieurs de Saint-Etienne (ENISE), DIPI Laboratory, 58 rue Jean Parot, 42023 Saint-Etienne cedex 2 (France); Smurov, I. [Ecole Nationale d' Ingenieurs de Saint-Etienne (ENISE), DIPI Laboratory, 58 rue Jean Parot, 42023 Saint-Etienne cedex 2 (France)], E-mail: smurov@enise.fr

2009-03-31

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

Metallic powder-bed based 3D printing of cellular scaffolds for orthopaedic implants: A state-of-the-art review on manufacturing, topological design, mechanical properties and biocompatibility.

Science.gov (United States)

Tan, X P; Tan, Y J; Chow, C S L; Tor, S B; Yeong, W Y

2017-07-01

Metallic cellular scaffold is one of the best choices for orthopaedic implants as a replacement of human body parts, which could improve life quality and increase longevity for the people needed. Unlike conventional methods of making cellular scaffolds, three-dimensional (3D) printing or additive manufacturing opens up new possibilities to fabricate those customisable intricate designs with highly interconnected pores. In the past decade, metallic powder-bed based 3D printing methods emerged and the techniques are becoming increasingly mature recently, where selective laser melting (SLM) and selective electron beam melting (SEBM) are the two representatives. Due to the advantages of good dimensional accuracy, high build resolution, clean build environment, saving materials, high customisability, etc., SLM and SEBM show huge potential in direct customisable manufacturing of metallic cellular scaffolds for orthopaedic implants. Ti-6Al-4V to date is still considered to be the optimal materials for producing orthopaedic implants due to its best combination of biocompatibility, corrosion resistance and mechanical properties. This paper presents a state-of-the-art overview mainly on manufacturing, topological design, mechanical properties and biocompatibility of cellular Ti-6Al-4V scaffolds via SLM and SEBM methods. Current manufacturing limitations, topological shortcomings, uncertainty of biocompatible test were sufficiently discussed herein. Future perspectives and recommendations were given at the end. Copyright © 2017 Elsevier B.V. All rights reserved.

Analysis, manufacture and characterization of Ni/Cu functionally graded structures

International Nuclear Information System (INIS)

Rubio, Wilfredo Montealegre; Paulino, Glaucio H.; Silva, Emilio Carlos Nelli

2012-01-01

Highlights: ► Functionally graded structures (FGSs) of nickel and copper can be manufactured. ► The hardness curve of FGS can be used for approximating the gradation function of elastic properties. ► The graded finite element approaches with great accuracy the FGS resonance frequencies obtained experimentally. -- Abstract: In this work, an experimental and numerical analysis and characterization of functionally graded structures (FGSs) is developed. Nickel (Ni) and copper (Cu) materials are used as basic materials in the numerical modeling and experimental characterization. For modeling, a MATLAB finite element code is developed, which allows simulation of harmonic and modal analysis considering the graded finite element formulation. For experimental characterization, Ni–Cu FGSs are manufactured by using spark plasma sintering technique. Hardness and Young’s modulus are found by using microindentation and ultrasonic measurements, respectively. The effective gradation of Ni/Cu FGS is addressed by means of optical microscopy, energy dispersive spectrometry, scanning electron microscopy and hardness testing. For the purpose of comparing modeling and experimental results, the hardness curve, along the gradation direction, is used for identifying the gradation profile; accordingly, the experimental hardness curve is used for approximating the Young’s modulus variation and the graded finite element modeling is used for verification. For the first two resonance frequency values, a difference smaller than 1% between simulated and experimental results is obtained.

Influencia de la tecnología de fabricación de las cuchillas de metal en el estado de las tensiones residuales // Influence of the metal cutters manufacturing technology in the state of the residual tensions

Directory of Open Access Journals (Sweden)

M. Rivas Santana

1998-01-01

Full Text Available En este trabajo se realiza un análisis cualitativo (y en algunos casos cuantitativos de las tensiones residuales, de primero ysegundo género, que surgen durante el proceso de soldadura y afilado de las cuchillas de metal duro.______________________________________________________________________AbstractIn this work is accomplished a qualitative analysis (in some instances quantitative of the residual tensions, of first and secondgender, that emerge during the welding process and sharpened of the hard metal cutters.

OsB 2 and RuB 2, ultra-incompressible, hard materials: First-principles electronic structure calculations

Science.gov (United States)

Chiodo, S.; Gotsis, H. J.; Russo, N.; Sicilia, E.

2006-07-01

Recently it has been reported that osmium diboride has an unusually large bulk modulus combined with high hardness, and consequently is a most interesting candidate as an ultra-incompressible and hard material. The electronic and structural properties of the transition metal diborides OsB 2 and RuB 2 have been calculated within the local density approximation (LDA). It is shown that the high hardness is the result of covalent bonding between transition metal d states and boron p states in the orthorhombic structure.

A production throughput forecasting system in an automated hard disk drive test operation using GRNN

Energy Technology Data Exchange (ETDEWEB)

Samattapapong, N.; Afzulpurkar, N.

2016-07-01

The goal of this paper is to develop a pragmatic system of a production throughput forecasting system for an automated test operation in a hard drive manufacturing plant. The accurate forecasting result is necessary for the management team to response to any changes in the production processes and the resources allocations. In this study, we design a production throughput forecasting system in an automated test operation in hard drive manufacturing plant. In the proposed system, consists of three main stages. In the first stage, a mutual information method was adopted for selecting the relevant inputs into the forecasting model. In the second stage, a generalized regression neural network (GRNN) was implemented in the forecasting model development phase. Finally, forecasting accuracy was improved by searching the optimal smoothing parameter which selected from comparisons result among three optimization algorithms: particle swarm optimization (PSO), unrestricted search optimization (USO) and interval halving optimization (IHO). The experimental result shows that (1) the developed production throughput forecasting system using GRNN is able to provide forecasted results close to actual values, and to projected the future trends of production throughput in an automated hard disk drive test operation; (2) An IHO algorithm performed as superiority appropriate optimization method than the other two algorithms. (3) Compared with current forecasting system in manufacturing, the results show that the proposed system’s performance is superior to the current system in prediction accuracy and suitable for real-world application. The production throughput volume is a key performance index of hard disk drive manufacturing systems that need to be forecast. Because of the production throughput forecasting result is useful information for management team to respond to any changing in production processes and resources allocation. However, a practically forecasting system for

Effect of Temperature on the Toughness of Locally Manufactured Low Alloy Steel SUP9 Used for Manufacturing Leaf Springs

Directory of Open Access Journals (Sweden)

Muhammad Ishaque Abro

2011-10-01

Full Text Available The effect of heat treatment on locally manufactured low alloy steel grade SUP9 most frequently used in making leaf springs for automobiles was studied. While for determination of toughness and hardness Charpy impact testing machine and Rockwell hardness tester were used. The cryogenic test temperatures were achieved by soaking the samples in liquid nitrogen and temperature was measured using digital thermometer capable of reading the temperature from -40-200oC. Hardening, tempering and austempering treatments were conducted using muffle furnace and salt bath furnace. After heat treatment samples were quenched in oil. The results of present work confirmed that toughness and hardness are inversely related with each other and are highly dependent on the type of heat treatment employed. Highest toughness was measured after austempering at 450oC. Effect of test temperature revealed that toughness of the samples increased significantly with decreasing temperature. DBTT (Ductile to Brittle Transition Temperature of the austempered samples was observed at -10oC, whereas, that of tempered samples could not be determined. Based on the test results authors wish to recommend the 600oC tempering temperature in place of 450oC where normally tempering is practiced in Alwin industry Karachi during manufacturing of leaf spring.

Linear electron accelerator body and method of its manufacture

International Nuclear Information System (INIS)

Landa, V.; Maresova, V.; Lucek, J.; Prusa, F.

1988-01-01

The accelerator body consists of a hollow casing made of a high electric conductivity metal. The inside is partitioned with a system of resonators. The resonator body is made of one piece of the same metal as the casing or a related one (e.g., copper -coper, silver-copper, copper-copper alloy). The accelerator body is manufactured using the cathodic process on the periphery of a system of metal partitions and negative models of resonator cavities fitted to a metal pin. The pin is then removed from the system and the soluble models of the cavities are dissolved in a solvent. The advantage of the design and the method of manufacture is that the result is a compact, perfectly tight body with a perfectly lustre surface. The casing wall can be very thin, which improves accelerator performance. The claimed method can also be used in manufacturing miniature accelerators. (E.J.). 1 fig

Building memristive and radiation hardness TiO{sub 2}-based junctions

Energy Technology Data Exchange (ETDEWEB)

Ghenzi, N., E-mail: n.ghenzi@gmail.com [Gerencia de Investigación y Aplicaciones, Comisión Nacional de Energía Atómica (Argentina); Rubi, D. [Gerencia de Investigación y Aplicaciones, Comisión Nacional de Energía Atómica (Argentina); ECyT, UNSAM, Martín de Irigoyen 3100, 1650 San Martín, Bs As (Argentina); Consejo Nacional de Investigaciones Científicas y Técnicas (CONICET) (Argentina); Mangano, E.; Gimenez, G. [Instituto Nacional de Tecnología Industrial (INTI) (Argentina); Lell, J. [Gerencia de Investigación y Aplicaciones, Comisión Nacional de Energía Atómica (Argentina); Zelcer, A. [Gerencia Química, Comisión Nacional de Energía Atómica (Argentina); ECyT, UNSAM, Martín de Irigoyen 3100, 1650 San Martín, Bs As (Argentina); Stoliar, P. [ECyT, UNSAM, Martín de Irigoyen 3100, 1650 San Martín, Bs As (Argentina); IMN, Université de Nantes, CNRS, 2 rue de la Houssinière, BP 32229, 44322 Nantes (France); and others

2014-01-01

We study micro-scale TiO{sub 2} junctions that are suitable to be used as resistive random-access memory nonvolatile devices with radiation hardness memristive properties. The fabrication and structural and electrical characterization of the junctions are presented. We obtained a retentivity of 10{sup 5} s, an endurance of 10{sup 4} cycles and reliable switching with short electrical pulses (time-width below 10 ns). Additionally, the devices were exposed to 25 MeV oxygen ions. Then, we performed electrical measurements comparing pristine and irradiated devices in order to check the feasibility of using these junctions as memory elements with memristive and radiation hardness properties. - Highlights: • We fabricated radiation hardness memristive metal insulator metal junctions. • We characterized the structural properties of the devices. • We showed the feasibility of the junctions as a non-volatile memory.

Work Hard / Play Hard

OpenAIRE

Burrows, J.; Johnson, V.; Henckel, D.

2016-01-01

Work Hard / Play Hard was a participatory performance/workshop or CPD experience hosted by interdisciplinary arts atelier WeAreCodeX, in association with AntiUniversity.org. As a socially/economically engaged arts practice, Work Hard / Play Hard challenged employees/players to get playful, or go to work. 'The game changes you, you never change the game'. Employee PLAYER A 'The faster the better.' Employer PLAYER B

Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs.

Science.gov (United States)

Sing, Swee Leong; An, Jia; Yeong, Wai Yee; Wiria, Florencia Edith

2016-03-01

Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two AM processes suitable for metallic orthopaedic implant applications, namely selective laser melting (SLM) and electron beam melting (EBM) are presented. Several critical design factors such as the need for data acquisition for patient-specific design, design dependent porosity for osteo-inductive implants, surface topology of the implants and design for reduction of stress-shielding in implants are discussed. Additive manufactured biomaterials such as 316L stainless steel, titanium-6aluminium-4vanadium (Ti6Al4V) and cobalt-chromium (CoCr) are highlighted. Limitations and future potential of such technologies are also explored. © 2015 Orthopaedic Research Society. Published by Wiley Periodicals, Inc.

Manufacture of titanium and zirconium hydrides

International Nuclear Information System (INIS)

Mares, F.; Hanslik, T.

1973-01-01

A method is described of manufacturing titanium and zirconium hydrides by hydrogenation of said metals characterized by the reaction temperature ranging between 250 to 500 degC, hydrogen pressure of 20 to 300 atm and possibly by the presence of a hydride of the respective metal. (V.V.)

Parametric study of development of Inconel-steel functionally graded materials by laser direct metal deposition

International Nuclear Information System (INIS)

Shah, Kamran; Haq, Izhar ul; Khan, Ashfaq; Shah, Shaukat Ali; Khan, Mushtaq; Pinkerton, Andrew J

2014-01-01

Highlights: • Functionally graded steel and nickel super-alloy structures have been developed. • Mechanical properties of FGMs can be controlled by process input parameters. • SDAS is strongly dependent on the laser power and powder mass flow rate. • Carbides provide a mechanism to control the hardness and wear resistance of FGM. • Tensile strength of FGM is dependent on the laser power and powder mass flow rate. - Abstract: Laser direct metal deposition (LDMD) has developed from a prototyping to a single and multiple metals manufacturing technique. It offers an opportunity to produce graded components, with differing elemental composition, phase and microstructure at different locations. In this work, continuously graded Stainless Steel 316L and Inconel 718 thin wall structures made by direct laser metal deposition process have been explored. The paper considers the effects of process parameters including laser power levels and powder mass flow rates of SS316L and Inconel 718 during the deposition of the Steel–Ni graded structures. Microstructure characterisation and phase identification are performed by optical microscopy and X-ray diffraction techniques. Mechanical testing, using methods such as hardness, wear resistance and tensile testing have been carried out on the structures. XRD results show the presence of the NbC and Fe 2 Nb phases formed during the deposition. The effect of experimental parameters on the microstructure and physical properties are determined and discussed. Work shows that mechanical properties can be controlled by input parameters and generation of carbides provides an opportunity to selectively control the hardness and wear resistance of the functionally graded material

Hardness Assurance Techniques for New Generation COTS Devices

Science.gov (United States)

Lee, C. I.; Rax, B. G.; Johnston, A. H.

1996-01-01

Hardness Assurance (HA) techniques and total dose radiation characterization data for new generation linear and COTS devices from various manufacturers are presented. A bipolar op amp showed significant degradation at HDR, not at low dose rate environment. New generation low-power op amps showed more degradation at low voltage applications. HA test techniques for COTS devices are presented in this paper.

Method of manufacturing gadolinium oxide-incorporated nuclear fuel sintering products

International Nuclear Information System (INIS)

Komono, Akira; Seki, Makoto; Omori, Sadayuki.

1987-01-01

Purpose: To manufacture nuclear fuel sintering products excellent in burning property and mechanical property. Constitution: In the manufacturing step for nuclear fuel sintering products, specific metal oxides are added for promoting the growth of crystal grains in the sintering. Those metal oxides melted at a temperature lower than the sintering temperature of a mixture of nuclear fuel oxide powder and oxide power, or those metal oxides causing eutectic reaction are used as the metal oxide. Particularly, those compounds having oxygen atom - metal atom ratio (O/M) of not less than 2 are preferably used. As such metal oxides usable herein transition metal oxides, e.g., Nb 2 O 5 , TiO 2 , MoO 3 and WO 3 are preferred, with Nb 2 O 3 and TiO 2 being preferred particularly. (Seki, T.)

Additive Manufacturing: Reproducibility of Metallic Parts

Directory of Open Access Journals (Sweden)

Konda Gokuldoss Prashanth

2017-02-01

Full Text Available The present study deals with the properties of five different metals/alloys (Al-12Si, Cu-10Sn and 316L—face centered cubic structure, CoCrMo and commercially pure Ti (CP-Ti—hexagonal closed packed structure fabricated by selective laser melting. The room temperature tensile properties of Al-12Si samples show good consistency in results within the experimental errors. Similar reproducible results were observed for sliding wear and corrosion experiments. The other metal/alloy systems also show repeatable tensile properties, with the tensile curves overlapping until the yield point. The curves may then follow the same path or show a marginal deviation (~10 MPa until they reach the ultimate tensile strength and a negligible difference in ductility levels (of ~0.3% is observed between the samples. The results show that selective laser melting is a reliable fabrication method to produce metallic materials with consistent and reproducible properties.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

Science.gov (United States)

King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubenchik, A. M.

2015-12-01

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

Energy Technology Data Exchange (ETDEWEB)

King, W. E., E-mail: weking@llnl.gov [Physical and Life Sciences Directorate, Lawrence Livermore National Laboratory, Livermore, California 94550 (United States); Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Khairallah, S. A. [Engineering Directorate, Lawrence Livermore National Laboratory, Livermore, California 94550 (United States); Kamath, C. [Computation Directorate, Lawrence Livermore National Laboratory, Livermore, California 94550 (United States); Rubenchik, A. M. [NIF and Photon Sciences Directorate, Lawrence Livermore National Laboratory, Livermore, California 94550 (United States)

2015-12-15

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

International Nuclear Information System (INIS)

King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Khairallah, S. A.; Kamath, C.; Rubenchik, A. M.

2015-01-01

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process

Additive manufacturing of Ti-6Al-4V components by shaped metal deposition: Microstructure and mechanical properties

International Nuclear Information System (INIS)

Baufeld, Bernd; Biest, Omer Van der; Gault, Rosemary

2010-01-01

Shaped metal deposition (SMD) is a relatively new technology of additive manufacturing, which creates near-net shaped components by additive manufacture utilizing tungsten inert gas welding. Especially for Ti alloys, which are difficult to shape by traditional methods and for which the loss of material during machining is also very costly, SMD has great advantages. In the case of Ti-6Al-4V the dense SMD components exhibit large, columnar prior β grains, with a Widmanstaetten α/β microstructure. These prior β grains are slightly tilted in a direction following the temperature field resulting from the moving welding torch. The ultimate tensile strength is between 929 and 1014 MPa, depending on orientation and location of the tensile specimens. Tensile testing vertically to the deposition layers exhibits a strain at failure of 16 ± 3%, while testing parallel to the layers gives a lower value of about 9%.

The Role of Laser Additive Manufacturing Methods of Metals in Repair, Refurbishment and Remanufacturing - Enabling Circular Economy

Science.gov (United States)

Leino, Maija; Pekkarinen, Joonas; Soukka, Risto

Circular economy is an economy model where products, components, and materials are aimed to be kept at their highest utility and value at all times. Repair, refurbishment and remanufacturing processes are procedures aiming at returning the value of the product during its life cycle. Additive manufacturing (AM) is expected to be an enabling technology in circular economy based business models. One of AM process that enables repair, refurbishment and remanufacturing is Directed Energy Deposition. Respectively Powder Bed Fusion enables manufacturing of replacement components on demand. The aim of this study is to identify the current research findings and state of art of utilizing AM in repair, refurbishment and remanufacturing processes of metallic products. The focus is in identifying possibilities of AM in promotion of circular economy and expected environmental benefits based on the found literature. Results of the study indicate significant potential in utilizing AM in repair, refurbishment and remanufacturing activities.

Micromanufacturing Of Hard To Machine Materials By Physical And Chemical Ablation Processes

International Nuclear Information System (INIS)

Schubert, A.; Edelmann, J.; Gross, S.; Meichsner, G.; Wolf, N.; Schneider, J.; Zeidler, H.; Hackert, M.

2011-01-01

Miniaturization leads to high requirements to the applied manufacturing processes especially in respect to the used hard to machine materials and the aims of structure size and geometrical accuracy. Traditional manufacturing processes reach their limits here. One alternative for these provide thermal and chemical ablation processes. These processes are applied for the production of different microstructures in different materials like hardened steel, carbides and ceramics especially for medical engineering and tribological applications.

Laser-Based Additive Manufacturing of Zirconium

Directory of Open Access Journals (Sweden)

Himanshu Sahasrabudhe

2018-03-01

Full Text Available Additive manufacturing of zirconium is attempted using commercial Laser Engineered Net Shaping (LENSTM technique. A LENSTM-based approach towards processing coatings and bulk parts of zirconium, a reactive metal, aims to minimize the inconvenience of traditional metallurgical practices of handling and processing zirconium-based parts that are particularly suited to small volumes and one-of-a-kind parts. This is a single-step manufacturing approach for obtaining near net shape fabrication of components. In the current research, Zr metal powder was processed in the form of coating on Ti6Al4V alloy substrate. Scanning electron microscopy (SEM and energy dispersive spectroscopy (EDS as well as phase analysis via X-ray diffraction (XRD were studied on these coatings. In addition to coatings, bulk parts were also fabricated using LENS™ from Zr metal powders, and measured part accuracy.

Evaluation of the adhesion strength of diamond films brazed on K-10 type hard metal

Directory of Open Access Journals (Sweden)

Santos Sérgio Ivan dos

2004-01-01

Full Text Available The coating of cutting tools with diamond films considerably increases the tool performance due to the combination of the unique tribological properties of diamond with the bulk properties of the substrate (toughness. The tool performance, however, is strongly related to the adhesion strength between the film and the substrate. In this work our main goal was to propose and to test a procedure, based on a tensile strength test, to evaluate the adhesion strength of a diamond wafer brazed on a hard metal substrate, taking into account the effect of the brazing temperature and time. The temperature range studied was from 800 to 980 °C and the brazing time ranged from 3 to 40 min. The obtained results could be used to optimize the costs and time required to the production of high performance cutting tools with brazed diamond wafers.

The effect of three whitening oral rinses on enamel micro-hardness

OpenAIRE

Potgieter, E; Osman, Y; Grobler, SR

2014-01-01

The purpose of this study was to determine the effect on human enamel micro-hardness of three over-the-counter whitening oral rinses available in South Africa. Enamel fragments were gathered into three groups of 15 each. One group was exposed to Colgate Plax Whitening Blancheur, the second group to White Glo 2 in 1 and the third to Plus White, in each case for periods recommended by the respective manufacturers. Surface micro-hardness of all groups was measured before and after a 14 day treat...

Metal-on-metal hip joint tribology.

Science.gov (United States)

Dowson, D; Jin, Z M

2006-02-01

The basic tribological features of metal-on-metal total hip replacements have been reviewed to facilitate an understanding of the engineering science underpinning the renaissance of these hard-on-hard joints. Metal-on-polymer hip replacements operate in the boundary lubrication regime, thus leading to the design guidance to reduce the femoral head diameter as much as is feasible to minimize frictional torque and volumetric wear. This explains why the gold-standard implant of this form from the past half-century had a diameter of only 22.225 mm (7/8 in). Metal-on-metal implants can operate in the mild mixed lubrication regime in which much of the applied load is supported by elastohydrodynamic films. Correct tribological design leads to remarkably low steady state wear rates. Promotion of the most effective elastohydrodynamic films calls for the largest possible head diameters and the smallest clearances that can reasonably be adopted, consistent with fine surface finishes, good sphericity and minimal structural elastic deformation of the cup on its foundations. This guidance, which is opposite in form to that developed for metal-on-polymer joints, is equally valid for solid (monolithic) metallic heads on metallic femoral stems and surface replacement femoral shells. Laboratory measurements of friction and wear in metal-on-metal joints have confirmed their potential to achieve a very mild form of mixed lubrication. The key lies in the generation of effective elastohydrodynamic lubricating films of adequate thickness compared with the composite roughness of the head and cup. The calculation of the film thickness is by no means easy, but the full procedure is outlined and the use of an empirical formula that displays good agreement with calculations based upon the full numerical solutions is explained. The representation of the lambda ratio, lambda, embracing both film thickness and composite roughness, is described.

Additive Manufacturing of Fuel Injectors

Energy Technology Data Exchange (ETDEWEB)

Sadek Tadros, Dr. Alber Alphonse [Edison Welding Institute, Inc., Columbus, OH (United States); Ritter, Dr. George W. [Edison Welding Institute, Inc., Columbus, OH (United States); Drews, Charles Donald [Edison Welding Institute, Inc., Columbus, OH (United States); Ryan, Daniel [Solar Turbines Inc., San Diego, CA (United States)

2017-10-24

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventional manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project

Optimization of Design and Manufacturing Process of Metal Foam Filled Anti-Intrusion Bars

International Nuclear Information System (INIS)

Villa, Andrea; Mussi, Valerio; Strano, Matteo

2011-01-01

The role of an anti-intrusion bar for automotive use is to absorb the kinetic energy of the colliding bodies that is partially converted into internal work of the bodies involved in the crash. The aim of this paper is to investigate the performances of a new kind of anti-intrusion bars for automotive use, filled with metallic foams. The reason for using a cellular material as a filler deals with its capacity to absorb energy during plastic deformation, while being lightweight. The study is the evolution of a previous paper presented by the authors at Esaform 2010 and will present new results and findings. It is conducted by evaluating some key technical issues of the manufacturing problem and by conducting experimental and numerical analyses. The evaluation of materials and shapes of the closed sections to be filled is made in the perspective of a car manufacturer (production costs, weight reduction, space availability in a car door, etc.). Experimentally, foams are produced starting from an industrial aluminium precursor with a TiH 2 blowing agent. Bars are tested in three point bending, in order to evaluate their performances in terms of force-displacement response and other specific performance parameters. In order to understand the role of interface between the inner surface of the tube and the external surface of the foam, different kinds of interface are tested.

In-situ acoustic signature monitoring in additive manufacturing processes

Science.gov (United States)

Koester, Lucas W.; Taheri, Hossein; Bigelow, Timothy A.; Bond, Leonard J.; Faierson, Eric J.

2018-04-01

Additive manufacturing is a rapidly maturing process for the production of complex metallic, ceramic, polymeric, and composite components. The processes used are numerous, and with the complex geometries involved this can make quality control and standardization of the process and inspection difficult. Acoustic emission measurements have been used previously to monitor a number of processes including machining and welding. The authors have identified acoustic signature measurement as a potential means of monitoring metal additive manufacturing processes using process noise characteristics and those discrete acoustic emission events characteristic of defect growth, including cracks and delamination. Results of acoustic monitoring for a metal additive manufacturing process (directed energy deposition) are reported. The work investigated correlations between acoustic emissions and process noise with variations in machine state and deposition parameters, and provided proof of concept data that such correlations do exist.

Copper Disk Manufactured at the Space Optics Manufacturing and Technology Center

Science.gov (United States)

2001-01-01

This photograph shows Wes Brown, Marshall Space Flight Center's (MSFC's) lead diamond tuner, an expert in the science of using diamond-tipped tools to cut metal, inspecting the mold's physical characteristics to ensure the uniformity of its more than 6,000 grooves. This king-size copper disk, manufactured at the Space Optics Manufacturing and Technology Center (SOMTC) at MSFC, is a special mold for making high resolution monitor screens. This master mold will be used to make several other molds, each capable of forming hundreds of screens that have a type of lens called a fresnel lens. Weighing much less than conventional optics, fresnel lenses have multiple concentric grooves, each formed to a precise angle, that together create the curvature needed to focus and project images. The MSFC leads NASA's space optics manufacturing technology development as a technology leader for diamond turning. The machine used to manufacture this mold is among many one-of-a-kind pieces of equipment of MSFC's SOMTC.

Elemental compositions of suspended particles released in glass manufacture

Energy Technology Data Exchange (ETDEWEB)

Mamuro, T; Mizohata, A; Kubota, T [Radiation Center of Osaka Prefecture, Sakai (Japan)

1980-03-01

Suspended particles released in glass manufacture were subjected to multielement analysis by means of instrumental neutron activation method and energy dispersive X-ray fluorescence spectrometry. Suspended particles emitted from glass manufacture generally consist of both particles emitted from glass fusion and those produced through fuel combustion (mainly oil combustion). Elemental compositions of suspended particles emitted from glass fusion were found to be strongly dependent on the kind and recipe of raw materials and additives. Of the various metallic elements involved in suspended particles emitted from glass fusion, the elements, As, Se, Cd, Sb, Pb and so on are regarded to produce the most serious air pollution. The amount of emission of these elements to the environment is, howerer, quite varied from manufacturer to manufacturer. The replacement of electric furnace by oil combustion in opal glass manufacture remarkably reduced the emission of metallic elements to the environment.

Weibull modulus of hardness, bend strength, and tensile strength of Ni−Ta−Co−X metallic glass ribbons

Energy Technology Data Exchange (ETDEWEB)

Neilson, Henry J., E-mail: hjn2@case.edu [Case Western Reserve University, 10900 Euclid Ave, Cleveland, OH (United States); Petersen, Alex S.; Cheung, Andrew M.; Poon, S. Joseph; Shiflet, Gary J. [University of Virginia, 395 McCormick Road, P.O. Box 400745, Charlottesville, VA 22904 (United States); Widom, Mike [Carnegie Mellon University, 5000 Forbes Avenue, Wean Hall 3325, Pittsburgh, PA 15213 (United States); Lewandowski, John J. [Case Western Reserve University, 10900 Euclid Ave, Cleveland, OH (United States)

2015-05-14

In this study, the variations in mechanical properties of Ni−Co−Ta-based metallic glasses have been analyzed. Three different chemistries of metallic glass ribbons were analyzed: Ni{sub 45}Ta{sub 35}Co{sub 20}, Ni{sub 40}Ta{sub 35}Co{sub 20}Nb{sub 5}, and Ni{sub 30}Ta{sub 35}Co{sub 30}Nb{sub 5}. These alloys possess very high density (approximately 12.5 g/cm{sup 3}) and very high strength (e.g. >3 GPa). Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) were used to characterize the amorphicity of the ribbons. Mechanical properties were measured via a combination of Vickers hardness, bending strength, and tensile strength for each chemistry. At least 50 tests were conducted for each chemistry and each test technique in order to quantify the variability of properties using both 2- and 3-parameter Weibull statistics. The variability in properties and their source(s) were compared to that of other engineering materials, while the nature of deformation via shear bands as well as fracture surface features have been determined using scanning electron microscopy (SEM). Toughness, the role of defects, and volume effects are also discussed.

Beyond the bed: Effects of metal contamination on recruitment to bedded sediments and overlying substrata

International Nuclear Information System (INIS)

Hill, Nicole A.; Simpson, Stuart L.; Johnston, Emma L.

2013-01-01

Metal-contaminated sediments pose a recognised threat to sediment-dwelling fauna. Re-mobilisation of contaminated sediments however, may impact more broadly on benthic ecosystems, including on diverse assemblages living on hard substrata patches immediately above sediments. We used manipulative field experiments to simultaneously test for the effects of metal contamination on recruitment to marine sediments and overlying hard substrata. Recruitment to sediments was strongly and negatively affected by metal contamination. However, while assemblage-level effects on hard-substratum fauna and flora were observed, most functional groups were unaffected or slightly enhanced by exposure to contaminated sediments. Diversity of hard-substratum fauna was also enhanced by metal contamination at one site. Metal-contaminated sediments appear to pose less of a hazard to hard-substratum than sediment-dwelling assemblages, perhaps due to a lower direct contaminant exposure or to indirect effects mediated by contaminant impacts on sediment fauna. Our results indicate that current sediment quality guidelines are protective of hard-substrata organisms. - Highlights: ► Potential for contaminated sediments to exert impacts beyond the sediment communities. ► We examine effects on recruitment to sediments and overlying hard substrata simultaneously. ► Metal-contaminated sediments had a strong negative impact on sediment fauna. ► Metal-contaminated sediments pose less of a hazard to hard-substratum fauna. ► Sediment quality guidelines are likely protective of hard-substrata organisms. - Under natural disturbance regimes, metal-contaminated sediments pose less of a direct risk to hard-substratum fauna than to sediment-dwelling fauna and SQG appear appropriate.

Hard electronics; Hard electronics

Energy Technology Data Exchange (ETDEWEB)

NONE

1997-03-01

Hard material technologies were surveyed to establish the hard electronic technology which offers superior characteristics under hard operational or environmental conditions as compared with conventional Si devices. The following technologies were separately surveyed: (1) The device and integration technologies of wide gap hard semiconductors such as SiC, diamond and nitride, (2) The technology of hard semiconductor devices for vacuum micro- electronics technology, and (3) The technology of hard new material devices for oxides. The formation technology of oxide thin films made remarkable progress after discovery of oxide superconductor materials, resulting in development of an atomic layer growth method and mist deposition method. This leading research is expected to solve such issues difficult to be easily realized by current Si technology as high-power, high-frequency and low-loss devices in power electronics, high temperature-proof and radiation-proof devices in ultimate electronics, and high-speed and dense- integrated devices in information electronics. 432 refs., 136 figs., 15 tabs.

How to assess exposure of aquatic organisms to manufactured nanoparticles?

DEFF Research Database (Denmark)

Quik, Joris T.K.; Vonk, Jan Arie; Hansen, Steffen Foss

2011-01-01

Ecological risk of chemicals is measured by the quotient of predicted no-effect concentrations and predicted exposure concentrations, which are hard to assess for manufactured nanomaterials (NMs). This paper proposes modifications to currently used models, in order to make them suitable for estim......Ecological risk of chemicals is measured by the quotient of predicted no-effect concentrations and predicted exposure concentrations, which are hard to assess for manufactured nanomaterials (NMs). This paper proposes modifications to currently used models, in order to make them suitable...... on sedimentation and dissolution of NMs in environmentally relevant systems. We deduce that the overall kinetics of water–sediment transport of NMs should be close to first order. The lack of data on dissolution of NMs under environmentally realistic conditions calls for a pragmatic decision on which rates...

Highly Damping Hard Coatings for Protection of Titanium Blades

National Research Council Canada - National Science Library

Movchan, Boris A; Ustinov, Anatolii I

2005-01-01

Sn-Cr-MgO system is used as an example to show the basic capability to produce by EBPVD protective metal-ceramic coatings with a high adhesion strength, high values of hardness and damping capacity...

Optical fibre sensing in metals by embedment in 3D printed metallic structures

Science.gov (United States)

Maier, R. R. J.; Havermann, D.; Schneller, O.; Mathew, J.; Polyzos, D.; MacPherson, W. N.; Hand, D. P.

2014-05-01

Additive manufacturing or 3D printing of structural components in metals has potential to revolutionise the manufacturing industry. Embedded sensing in such structures opens a route towards SMART metals, providing added functionality, intelligence and enhanced performance in many components. Such embedded sensors would be capable of operating at extremely high temperatures by utilizing regenerated fibre Bragg gratings and in-fibre Fabry-Perot cavities.

Laser polishing of additive manufactured Ti alloys

Science.gov (United States)

Ma, C. P.; Guan, Y. C.; Zhou, W.

2017-06-01

Laser-based additive manufacturing has attracted much attention as a promising 3D printing method for metallic components in recent years. However, surface roughness of additive manufactured components has been considered as a challenge to achieve high performance. In this work, we demonstrate the capability of fiber laser in polishing rough surface of additive manufactured Ti-based alloys as Ti-6Al-4V and TC11. Both as-received surface and laser-polished surfaces as well as cross-section subsurfaces were analyzed carefully by White-Light Interference, Confocal Microscope, Focus Ion Beam, Scanning Electron Microscopy, Energy Dispersive Spectrometer, and X-ray Diffraction. Results revealed that as-received Ti-based alloys with surface roughness more than 5 μm could be reduce to less than 1 μm through laser polishing process. Moreover, microstructure, microhardness and wear resistance of laser-polished zone was investigated in order to examine the thermal effect of laser polishing processing on the substrate of additive manufactured Ti alloys. This proof-of-concept process has the potential to effectively improve the surface roughness of additive manufactured metallic alloy by local polishing method without damage to the substrate.

A modified genetic algorithm for time and cost optimization of an additive manufacturing single-machine scheduling

Directory of Open Access Journals (Sweden)

M. Fera

2018-09-01

Full Text Available Additive Manufacturing (AM is a process of joining materials to make objects from 3D model data, usually layer by layer, as opposed to subtractive manufacturing methodologies. Selective Laser Melting, commercially known as Direct Metal Laser Sintering (DMLS®, is the most diffused additive process in today’s manufacturing industry. Introduction of a DMLS® machine in a production department has remarkable effects not only on industrial design but also on production planning, for example, on machine scheduling. Scheduling for a traditional single machine can employ consolidated models. Scheduling of an AM machine presents new issues because it must consider the capability of producing different geometries, simultaneously. The aim of this paper is to provide a mathematical model for an AM/SLM machine scheduling. The complexity of the model is NP-HARD, so possible solutions must be found by metaheuristic algorithms, e.g., Genetic Algorithms. Genetic Algorithms solve sequential optimization problems by handling vectors; in the present paper, we must modify them to handle a matrix. The effectiveness of the proposed algorithms will be tested on a test case formed by a 30 Part Number production plan with a high variability in complexity, distinct due dates and low production volumes.

Automobile sheet metal part production with incremental sheet forming

Directory of Open Access Journals (Sweden)

İsmail DURGUN

2016-02-01

Full Text Available Nowadays, effect of global warming is increasing drastically so it leads to increased interest on energy efficiency and sustainable production methods. As a result of adverse conditions, national and international project platforms, OEMs (Original Equipment Manufacturers, SMEs (Small and Mid-size Manufacturers perform many studies or improve existing methodologies in scope of advanced manufacturing techniques. In this study, advanced manufacturing and sustainable production method "Incremental Sheet Metal Forming (ISF" was used for sheet metal forming process. A vehicle fender was manufactured with or without die by using different toolpath strategies and die sets. At the end of the study, Results have been investigated under the influence of method and parameters used.Keywords: Template incremental sheet metal, Metal forming

Additive Manufacturing of Porous Metal

Energy Technology Data Exchange (ETDEWEB)

Dehoff, Ryan R. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kirka, Michael M. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

2017-06-01

Currently, helium is obtained through separation from natural gas. The current industrial process incurs significant costs and requires large energy resources to successfully achieve separation. Through utilizing Additive Manufacturing (AM) technologies it is possible to reduce both of these burdens when refining helium gas. The ability to engineer porosity levels within Inconel 718 discs for controlled separation of helium from natural gas was investigated. Arrays of samples fabricated using the electron beam melting process were analyzed for their relative porosity density. Based upon the measurements, full scale discs were fabricated, and subsequently tested to determine their effectiveness in separating helium from liquefied natural gas.

Comparison of local and imported osteosynthetic mandibular bone plates in terms of micro hardness in modified simulated body fluid at periodic intervals

International Nuclear Information System (INIS)

Anwar, R.; Kaleem, M.; Baig, AM.; Jamal, M.

2015-01-01

To determine the micro hardness of novel Pakistani manufactured osteosynthetic titanium bone mini plates (MPP) and imported osteosynthetic titanium bone mini plates (MPG) in body like conditions. Study Design: Descriptive study. Place and Duration of Study: This study was carried out at School of Chemical and Material Engineering, NUST from March to May 2013. Material and Methods: Microvicker hardness tester was used for assessment of micro hardness of two types of plates. The hardness was checked before conditioning and after conditioning at (six different places) on interval of 1, 7,14,21,28 and 40 days in modified simulated body fluid with ph 7.4 and temperature 37 degree C. Results: Result showed that hardness of MPG was higher than MPP and after conditioning in simulated body fluid at all time periods, hardness of both types of plates was increased. Conclusion: It can be concluded from this study that micro hardness of imported plates is more than local plates so recommendations should be sent to manufacturers of local industry of Pakistan to improve the hardness of local plates so that they can meet international standards. (author)

The development of additive manufacturing technique for nickel-base alloys: A review

Science.gov (United States)

Zadi-Maad, Ahmad; Basuki, Arif

2018-04-01

Nickel-base alloys are an attractive alloy due to its excellent mechanical properties, a high resistance to creep deformation, corrosion, and oxidation. However, it is a hard task to control performance when casting or forging for this material. In recent years, additive manufacturing (AM) process has been implemented to replace the conventional directional solidification process for the production of nickel-base alloys. Due to its potentially lower cost and flexibility manufacturing process, AM is considered as a substitute technique for the existing. This paper provides a comprehensive review of the previous work related to the AM techniques for Ni-base alloys while highlighting current challenges and methods to solving them. The properties of conventionally manufactured Ni-base alloys are also compared with the AM fabricated alloys. The mechanical properties obtained from tension, hardness and fatigue test are included, along with discussions of the effect of post-treatment process. Recommendations for further work are also provided.

Collaborative Manufacturing for Small-Medium Enterprises

Science.gov (United States)

Irianto, D.

2016-02-01

Manufacturing systems involve decisions concerning production processes, capacity, planning, and control. In a MTO manufacturing systems, strategic decisions concerning fulfilment of customer requirement, manufacturing cost, and due date of delivery are the most important. In order to accelerate the decision making process, research on decision making structure when receiving order and sequencing activities under limited capacity is required. An effective decision making process is typically required by small-medium components and tools maker as supporting industries to large industries. On one side, metal small-medium enterprises are expected to produce parts, components or tools (i.e. jigs, fixture, mold, and dies) with high precision, low cost, and exact delivery time. On the other side, a metal small- medium enterprise may have weak bargaining position due to aspects such as low production capacity, limited budget for material procurement, and limited high precision machine and equipment. Instead of receiving order exclusively, a small-medium enterprise can collaborate with other small-medium enterprise in order to fulfill requirements high quality, low manufacturing cost, and just in time delivery. Small-medium enterprises can share their best capabilities to form effective supporting industries. Independent body such as community service at university can take a role as a collaboration manager. The Laboratory of Production Systems at Bandung Institute of Technology has implemented shared manufacturing systems for small-medium enterprise collaboration.

Effect of ion nitridation process on hardness and the corrosion resistance of biomaterials

International Nuclear Information System (INIS)

Wirjoadi; Lely Susita; Bambang Siswanto; Sudjatmoko

2012-01-01

Ion nitriding process has been performed on metal biomaterials to improve their mechanical properties of materials, particularly to increase hardness and corrosion resistance. This metallic biomaterials used for artificial bone or a prosthetic graft and used as devices of orthopedic biomaterials are usually of 316L SS metal-type and Ti-6Al-4V alloy. The purpose of this study is to research the development and utilization of ion nitridation method in order to get iron and titanium nitride thin films on the metallic biomaterials for artificial bone that has wear resistance and corrosion resistance is better. Microhardness of the samples was measured using a microhardness tester, optimum hardness of SS 316L samples are about 582 VHN, this was obtained at the nitriding temperature of 500 °C, the nitriding time of 3 hours and the nitrogen gas pressure of 1.6 mbar, while optimum hardness of Ti-6Al-4V alloy is 764 VHN, this was obtained at the nitriding temperature of 500 °C, the nitriding time of 4 hours and the nitrogen gas pressure of 1.6 mbar. The hardness value of SS 316L sample and Ti-6Al-4V alloy increase to 143% and 153%, if compared with standard samples. The optimum corrosion resistance at temperature of 350 °C for SS 316L and Ti-6Al-4V are 260,12 and 110,49 μA/cm 2 or corrosion rate are 29,866 and 15,189 mpy, respectively. (author)

Surface Roughness Analysis in the Hard Milling of JIS SKD61 Alloy Steel

Directory of Open Access Journals (Sweden)

Huu-That Nguyen

2016-06-01

Full Text Available Hard machining is an efficient solution that can be used to replace the grinding operation in the mold and die manufacturing industry. In this study, an attempt is made to analyze the effect of process parameters on workpiece surface roughness (Ra in the hard milling of JIS (Japanese Industrial Standard SKD61 steel, based on a combination of the Taguchi method and response surface methodology (RSM. The cutting parameters are selected based on the structural dynamic analysis of the machine tool. A set of experiments is designed according to the Taguchi technique. The average Ra is measured by a Mitutoyo Surftest SJ-400, and then analysis of variance (ANOVA is performed to determine the influences of cutting parameters on the given Ra. Quadratic mathematical modeling is introduced for prediction of the Ra during the hard milling process. The predicted values are in reasonable agreement with the observation of experiments. In an effort to obtain the minimizing Ra, a single objective optimization is employed based on the desirability function. The result shows that the percentage error between measured and predicted values of Ra is 3.2%, which is found to be insignificant. Eventually, the milled surface roughness under the optimized machining conditions is 0.122 µm. This finding shows that grinding may be replaced by finish hard milling in the mold and die manufacturing field.

Cobalt deposition in mineralized bone tissue after metal-on-metal hip resurfacing: Quantitative μ-X-ray-fluorescence analysis of implant material incorporation in periprosthetic tissue.

Science.gov (United States)

Hahn, Michael; Busse, Björn; Procop, Mathias; Zustin, Jozef; Amling, Michael; Katzer, Alexander

2017-10-01

Most resurfacing systems are manufactured from cobalt-chromium alloys with metal-on-metal (MoM) bearing couples. Because the quantity of particulate metal and corrosion products which can be released into the periprosthetic milieu is greater in MoM bearings than in metal-on-polyethylene (MoP) bearings, it is hypothesized that the quantity and distribution of debris released by the MoM components induce a compositional change in the periprosthetic bone. To determine the validity of this claim, nondestructive µ-X-ray fluorescence analysis was carried out on undecalcified histological samples from 13 femoral heads which had undergone surface replacement. These samples were extracted from the patients after gradient time points due to required revision surgery. Samples from nonintervened femoral heads as well as from a MoP resurfaced implant served as controls. Light microscopy and µ-X-ray fluorescence analyses revealed that cobalt debris was found not only in the soft tissue around the prosthesis and the bone marrow, but also in the mineralized bone tissue. Mineralized bone exposed to surface replacements showed significant increases in cobalt concentrations in comparison with control specimens without an implant. A maximum cobalt concentration in mineralized hard tissue of up to 380 ppm was detected as early as 2 years after implantation. Values of this magnitude are not found in implants with a MoP surface bearing until a lifetime of more than 20 years. This study demonstrates that hip resurfacing implants with MoM bearings present a potential long-term health risk due to rapid cobalt ion accumulation in periprosthetic hard tissue. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 1855-1862, 2017. © 2016 Wiley Periodicals, Inc.

A new, bright and hard aluminum surface produced by anodization

Science.gov (United States)

Hou, Fengyan; Hu, Bo; Tay, See Leng; Wang, Yuxin; Xiong, Chao; Gao, Wei

2017-07-01

Anodized aluminum (Al) and Al alloys have a wide range of applications. However, certain anodized finishings have relatively low hardness, dull appearance and/or poor corrosion resistance, which limited their applications. In this research, Al was first electropolished in a phosphoric acid-based solution, then anodized in a sulfuric acid-based solution under controlled processing parameters. The anodized specimen was then sealed by two-step sealing method. A systematic study including microstructure, surface morphology, hardness and corrosion resistance of these anodized films has been conducted. Results show that the hardness of this new anodized film was increased by a factor of 10 compared with the pure Al metal. Salt spray corrosion testing also demonstrated the greatly improved corrosion resistance. Unlike the traditional hard anodized Al which presents a dull-colored surface, this newly developed anodized Al alloy possesses a very bright and shiny surface with good hardness and corrosion resistance.

INFLUENCE OF ANNEALING ON HARDNESS OF Cr-Mn-Ni CAST IRONS

Directory of Open Access Journals (Sweden)

V. V. Netrebko

2015-01-01

Full Text Available The necessary level of material’s hardness is determined by the exploitation conditions and presence of technological operations during manufacturing of articles. Mechanical edge cutting machining of wear resistant materials is impeded because of their high hardness. It is recommended to apply annealing in order to decrease hardness and improve machinability. The purpose of the work consisted in obtaining of regression dependences of cast iron’s macrohardness on its chemical content after annealing at 730 °С. With the use of mathematical experimental design the regression dependences of cast iron’s macrohardness and structural components’ microhardness on С, Cr, Mn, Ni content have been established. The minimal hardness of 27,6 HRC after annealing at 730 °С is obtained in the cast iron containing: 3,9% С; 11,4% Cr; 0,6% Mn; 0,2% Ni. The maximal hardness of 70,4 HRC is obtained when the content is as follows: 1,1% С; 25,6% Cr; 5,4% Mn; 3,0% Ni. Annealing at 730 °С decreases the cast irons’ hardness containing the minimal amount of Cr, Mn and Ni. Annealing at 730 °С is recommended for cast irons alloyed by Mn and Ni for increasing of hardness.

Hardness and microstructural characterization of API 5L X70 steel pipes welded by HF/ERW process; Caracterizacao microestrutural e de dureza em tubos de aco API 5L X70 soldados pelo processo HF/ERW

Energy Technology Data Exchange (ETDEWEB)

Calcada, Mauricio Vieira; Voorwald, Herman Jacobus Cornelis; Nascimento, Marcelino Pereira do [UNESP, Guaratingueta, SP (Brazil). Faculdade de Engenharia

2010-07-01

The materials that stand in the manufacture of steel pipes are called API, that should have, high mechanical resistance, high corrosion resistance, high fatigue resistance, good weldability, and other properties. Thus, the purpose of this project was to evaluate the microstructure and hardness of welded joints by the HF/ERW process of API 5L X70 steel pipes. The microstructural analysis was performed using a surface finish with grit sizes from 220 to 25 {mu}m e polishing with diamond paste from 9 {mu}m to 0.05 {mu}m; the revelation was made with 3% Nital attack. The Vickers hardness was performed across the welded joint by 33 points to indentation. The results were: 80.5 {+-} 3.4% of ferrite and 19.5 {+-} 3.4% of perlite for microanalysis. As for hardness, the values were: 215.69 HV10 for weld line, 218.65 HV10 for ZTA and 218.95 HV10 for base metal. (author)

Beyond the Interconnections: Split Manufacturing in RF Designs

Directory of Open Access Journals (Sweden)

Yu Bi

2015-08-01

Full Text Available With the globalization of the integrated circuit (IC design flow of chip fabrication, intellectual property (IP piracy is becoming the main security threat. While most of the protection methods are dedicated for digital circuits, we are trying to protect radio-frequency (RF designs. For the first time, we applied the split manufacturing method in RF circuit protection. Three different implementation cases are introduced for security and design overhead tradeoffs, i.e., the removal of the top metal layer, the removal of the top two metal layers and the design obfuscation dedicated to RF circuits. We also developed a quantitative security evaluation method to measure the protection level of RF designs under split manufacturing. Finally, a simple Class AB power amplifier and a more sophisticated Class E power amplifier are used for the demonstration through which we prove that: (1 the removal of top metal layer or the top two metal layers can provide high-level protection for RF circuits with a lower request to domestic foundries; (2 the design obfuscation method provides the highest level of circuit protection, though at the cost of design overhead; and (3 split manufacturing may be more suitable for RF designs than for digital circuits, and it can effectively reduce IP piracy in untrusted off-shore foundries.

Beyond packing of hard spheres: The effects of core softness, non-additivity, intermediate-range repulsion, and many-body interactions on the glass-forming ability of bulk metallic glasses

Energy Technology Data Exchange (ETDEWEB)

Zhang, Kai; Fan, Meng; Liu, Yanhui; Schroers, Jan [Department of Mechanical Engineering and Materials Science, Yale University, New Haven, Connecticut 06520 (United States); Center for Research on Interface Structures and Phenomena, Yale University, New Haven, Connecticut 06520 (United States); Shattuck, Mark D. [Department of Mechanical Engineering and Materials Science, Yale University, New Haven, Connecticut 06520 (United States); Department of Physics and Benjamin Levich Institute, The City College of the City University of New York, New York, New York 10031 (United States); O’Hern, Corey S. [Department of Mechanical Engineering and Materials Science, Yale University, New Haven, Connecticut 06520 (United States); Center for Research on Interface Structures and Phenomena, Yale University, New Haven, Connecticut 06520 (United States); Department of Physics, Yale University, New Haven, Connecticut 06520 (United States); Department of Applied Physics, Yale University, New Haven, Connecticut 06520 (United States)

2015-11-14

When a liquid is cooled well below its melting temperature at a rate that exceeds the critical cooling rate R{sub c}, the crystalline state is bypassed and a metastable, amorphous glassy state forms instead. R{sub c} (or the corresponding critical casting thickness d{sub c}) characterizes the glass-forming ability (GFA) of each material. While silica is an excellent glass-former with small R{sub c} < 10{sup −2} K/s, pure metals and most alloys are typically poor glass-formers with large R{sub c} > 10{sup 10} K/s. Only in the past thirty years have bulk metallic glasses (BMGs) been identified with R{sub c} approaching that for silica. Recent simulations have shown that simple, hard-sphere models are able to identify the atomic size ratio and number fraction regime where BMGs exist with critical cooling rates more than 13 orders of magnitude smaller than those for pure metals. However, there are a number of other features of interatomic potentials beyond hard-core interactions. How do these other features affect the glass-forming ability of BMGs? In this manuscript, we perform molecular dynamics simulations to determine how variations in the softness and non-additivity of the repulsive core and form of the interatomic pair potential at intermediate distances affect the GFA of binary alloys. These variations in the interatomic pair potential allow us to introduce geometric frustration and change the crystal phases that compete with glass formation. We also investigate the effect of tuning the strength of the many-body interactions from zero to the full embedded atom model on the GFA for pure metals. We then employ the full embedded atom model for binary BMGs and show that hard-core interactions play the dominant role in setting the GFA of alloys, while other features of the interatomic potential only change the GFA by one to two orders of magnitude. Despite their perturbative effect, understanding the detailed form of the intermetallic potential is important for

Microjet formation and hard x-ray production from a liquid metal target irradiated by intense femtosecond laser pulses

Energy Technology Data Exchange (ETDEWEB)

Lar' kin, A., E-mail: alexeylarkin@yandex.ru; Uryupina, D.; Ivanov, K.; Savel' ev, A., E-mail: abst@physics.msu.ru [International Laser Center and Faculty of Physics, Lomonosov Moscow State University, Moscow 119991 (Russian Federation); Bonnet, T.; Gobet, F.; Hannachi, F.; Tarisien, M.; Versteegen, M. [Centre d' Études Nucléaires de Bordeaux-Gradignan, University of Bordeaux-CNRS-IN2P3, 33170 Gradignan (France); Spohr, K. [School of Engineering, University of the West of Scotland, Paisley, Scotland PA1 2BE (United Kingdom); Breil, J.; Chimier, B.; Dorchies, F.; Fourment, C.; Leguay, P.-M.; Tikhonchuk, V. T. [Centre Lasers Intenses et Applications, University of Bordeaux-CNRS-CEA, Talence 33405 (France)

2014-09-15

By using a liquid metal as a target one may significantly enhance the yield of hard x-rays with a sequence of two intense femtosecond laser pulses. The influence of the time delay between the two pulses is studied experimentally and interpreted with numerical simulations. It was suggested that the first arbitrary weak pulse produces microjets from the target surface, while the second intense pulse provides an efficient electron heating and acceleration along the jet surface. These energetic electrons are the source of x-ray emission while striking the target surface. The microjet formation is explained based on the results given by both optical diagnostics and hydrodynamic modeling by a collision of shocks originated from two distinct zones of laser energy deposition.

Microjet formation and hard x-ray production from a liquid metal target irradiated by intense femtosecond laser pulses

International Nuclear Information System (INIS)

Lar'kin, A.; Uryupina, D.; Ivanov, K.; Savel'ev, A.; Bonnet, T.; Gobet, F.; Hannachi, F.; Tarisien, M.; Versteegen, M.; Spohr, K.; Breil, J.; Chimier, B.; Dorchies, F.; Fourment, C.; Leguay, P.-M.; Tikhonchuk, V. T.

2014-01-01

By using a liquid metal as a target one may significantly enhance the yield of hard x-rays with a sequence of two intense femtosecond laser pulses. The influence of the time delay between the two pulses is studied experimentally and interpreted with numerical simulations. It was suggested that the first arbitrary weak pulse produces microjets from the target surface, while the second intense pulse provides an efficient electron heating and acceleration along the jet surface. These energetic electrons are the source of x-ray emission while striking the target surface. The microjet formation is explained based on the results given by both optical diagnostics and hydrodynamic modeling by a collision of shocks originated from two distinct zones of laser energy deposition

Microjet formation and hard x-ray production from a liquid metal target irradiated by intense femtosecond laser pulses

Science.gov (United States)

Lar'kin, A.; Uryupina, D.; Ivanov, K.; Savel'ev, A.; Bonnet, T.; Gobet, F.; Hannachi, F.; Tarisien, M.; Versteegen, M.; Spohr, K.; Breil, J.; Chimier, B.; Dorchies, F.; Fourment, C.; Leguay, P.-M.; Tikhonchuk, V. T.

2014-09-01

By using a liquid metal as a target one may significantly enhance the yield of hard x-rays with a sequence of two intense femtosecond laser pulses. The influence of the time delay between the two pulses is studied experimentally and interpreted with numerical simulations. It was suggested that the first arbitrary weak pulse produces microjets from the target surface, while the second intense pulse provides an efficient electron heating and acceleration along the jet surface. These energetic electrons are the source of x-ray emission while striking the target surface. The microjet formation is explained based on the results given by both optical diagnostics and hydrodynamic modeling by a collision of shocks originated from two distinct zones of laser energy deposition.

Numerical simulation of metallic wire arc additive manufacturing (WAAM)

Science.gov (United States)

Graf, M.; Pradjadhiana, K. P.; Hälsig, A.; Manurung, Y. H. P.; Awiszus, B.

2018-05-01

Additive-manufacturing technologies have been gaining tremendously in popularity for some years in the production of single-part series with complex, close-to-final-contour geometries and the processing of special or hybrid materials. In principle, the processes can be subdivided into wire-based and powder-based processes in accordance with the Association of German Engineers (VDI) Guideline 3405. A further subdivision is made with respect to the smelting technology. In all of the processes, the base material is applied in layers at the points where it is needed in accordance with the final contour. The process that was investigated was wire-based, multi-pass welding by means of gas-metal arc welding. This was accomplished in the present study by determining the material parameters (thermo-mechanical and thermo-physical characteristics) of the welding filler G3Si1 (material number: 1.5125) that were necessary for the numerical simulation and implementing them in a commercial FE program (MSC Marc Mentat). The focus of this paper was on simulation and validation with respect to geometry and microstructural development in the welding passes. The resulting minimal deviation between reality and simulation was a result of the measurement inertia of the thermocouples. In general, however, the FE model can be used to make a very good predetermination of the cooling behaviour, which affects the microstructural development and thus the mechanical properties of the joining zone, as well as the geometric design of the component (distortion, etc.).

Surface Roughness Analysis in the Hard Milling of JIS SKD61 Alloy Steel

OpenAIRE

Huu-That Nguyen; Quang-Cherng Hsu

2016-01-01

Hard machining is an efficient solution that can be used to replace the grinding operation in the mold and die manufacturing industry. In this study, an attempt is made to analyze the effect of process parameters on workpiece surface roughness (Ra) in the hard milling of JIS (Japanese Industrial Standard) SKD61 steel, based on a combination of the Taguchi method and response surface methodology (RSM). The cutting parameters are selected based on the structural dynamic analysis of the machine ...

Additive Manufacturing of High-Entropy Alloys by Laser Processing

NARCIS (Netherlands)

Ocelik, V.; Janssen, Niels; Smith, Stefan; De Hosson, J. Th M.

This contribution concentrates on the possibilities of additive manufacturing of high-entropy clad layers by laser processing. In particular, the effects of the laser surface processing parameters on the microstructure and hardness of high-entropy alloys (HEAs) were examined. AlCoCrFeNi alloys with

Using Innovative Techniques for Manufacturing Rocket Engine Hardware

Science.gov (United States)

Betts, Erin M.; Reynolds, David C.; Eddleman, David E.; Hardin, Andy

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using the Workhorse Gas Generator (WHGG) test setup at MSFC?s East Test Area test stand 116, the duct was subject to extreme J-2X gas generator environments and endured a total of 538 seconds of hot-fire time. The duct survived the testing and was inspected after the test. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

A method for manufacturing monocrystals

International Nuclear Information System (INIS)

Faure, Jacqueline; Malmejac, Yves; Schaub, Bernard.

1973-01-01

Description is given of a method for manufacturing monocrystals, substantially free of disorder, of a metal showing an allotropic transformation at a temperature lower than its melting point. Monocrystals of the raw metal having undergone a uni-directional solidification are heated to a temperature between the allotropic transformation point and the metal melting point; the monocrystals are maintained in the vicinity of that temperature for a given period of time; they are cooled down to a temperature lower than the allotropic transformation point, then they are annealed and cooled down to room temperature. Such monocrystals are used in neutron monochromators [fr

Microstructure and High Temperature Oxidation Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Powder Injection Molding Process

Science.gov (United States)

Joo, Yeun-Ah; Kim, Young-Kyun; Yoon, Tae-Sik; Lee, Kee-Ahn

2018-03-01

This study investigated the microstructure and high temperature oxidation property of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding process. Observations of initial microstructure showed a unique structure where α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performed at 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84 and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented parabolic curves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identified Cr2O3 and SiO2 at 900 and 1000 °C. In addition to Cr2O3 and SiO2, CrBO3 and FeCr2O4 formed due to phase decomposition of boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidation mechanism of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding, and the possibility of its application as a high temperature component material was also discussed.

ASSESSMENT OF SURFACE FINISH AND DIMENSIONAL ACCURACY OF TOOLS MANUFACTURED BY METAL CASTING IN RAPID PROTOTYPING SAND MOULDS

Directory of Open Access Journals (Sweden)

Nyembwe, K.

2012-11-01

Full Text Available In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final quality of the cast tool. The best surface finish obtained for the cast die had arithmetic average roughness (Ra and mean average roughness (Rz respectively equal to 3.23m and 11.38m. In terms of dimensional accuracy, 82% of cast-die points coincided with the Computer Aided Design (CAD data, which is within the typical tolerances of sand cast products. The investigation shows that mould coating contributes slightly to the improvement of the cast tool surface finish. The study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. These findings indicate that machining will always be required to improve the surface finish and the dimensional accuracy of cast tools in RP sand moulds.

New Nomenclatures for Heat Treatments of Additively Manufactured Titanium Alloys

Science.gov (United States)

Baker, Andrew H.; Collins, Peter C.; Williams, James C.

2017-07-01

The heat-treatment designations and microstructure nomenclatures for many structural metallic alloys were established for traditional metals processing, such as casting, hot rolling or forging. These terms do not necessarily apply for additively manufactured (i.e., three-dimensionally printed or "3D printed") metallic structures. The heat-treatment terminology for titanium alloys generally implies the heat-treatment temperatures and their sequence relative to a thermomechanical processing step (e.g., forging, rolling). These designations include: β-processing, α + β-processing, β-annealing, duplex annealing and mill annealing. Owing to the absence of a thermomechanical processing step, these traditional designations can pose a problem when titanium alloys are first produced via additive manufacturing, and then heat-treated. This communication proposes new nomenclatures for heat treatments of additively manufactured titanium alloys, and uses the distinct microstructural features to provide a correlation between traditional nomenclature and the proposed nomenclature.

Powder metallurgy of refractory metals

International Nuclear Information System (INIS)

Eck, R.

1979-01-01

This paper reports on the powder metallurgical methods for the production of high-melting materials, such as pure metals and their alloys, compound materials with a tungsten base and hard metals from liquid phase sintered carbides. (author)

Current use and potential of additive manufacturing for optical applications

Science.gov (United States)

Brunelle, Matthew; Ferralli, Ian; Whitsitt, Rebecca; Medicus, Kate

2017-10-01

Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. Because the parts are created in a layer-by-layer manner, the flexibility of additive manufacturing is unparalleled and has opened the design space to enable features like undercuts and internal channels which cannot exist on traditional, subtractively manufactured parts. This flexibility can also be leveraged for optical applications. This paper outlines some of the current uses of 3D printing in the optical manufacturing process at Optimax. Several materials and additive technologies are utilized, including polymer printing through fused deposition modeling, which creates parts by depositing a softened thermoplastic filament in a layerwise fashion. Stereolithography, which uses light to cure layers of a photopolymer resin, will also be discussed. These technologies are used to manufacture functional prototypes, fixtures, sealed housings, and other components. Additionally, metal printing through selective laser melting, which uses a laser to melt metal powder layers into a dense solid, will be discussed due to the potential to manufacture thermally stable opticalmechanical assembly frameworks and functional optics. Examples of several additively manufactured optical components will be shown.

The Influence of Wheel/Rail Contact Conditions on the Microstructure and Hardness of Railway Wheels

Directory of Open Access Journals (Sweden)

Paul Molyneux-Berry

2014-01-01

Full Text Available The susceptibility of railway wheels to wear and rolling contact fatigue damage is influenced by the properties of the wheel material. These are influenced by the steel composition, wheel manufacturing process, and thermal and mechanical loading during operation. The in-service properties therefore vary with depth below the surface and with position across the wheel tread. This paper discusses the stress history at the wheel/rail contact (derived from dynamic simulations and observed variations in hardness and microstructure. It is shown that the hardness of an “in-service” wheel rim varies significantly, with three distinct effects. The underlying hardness trend with depth can be related to microstructural changes during manufacturing (proeutectoid ferrite fraction and pearlite lamellae spacing. The near-surface layer exhibits plastic flow and microstructural shear, especially in regions which experience high tangential forces when curving, with consequentially higher hardness values. Between 1 mm and 7 mm depth, the wheel/rail contacts cause stresses exceeding the material yield stress, leading to work hardening, without a macroscopic change in microstructure. These changes in material properties through the depth of the wheel rim would tend to increase the likelihood of crack initiation on wheels toward the end of their life. This correlates with observations from several train fleets.

Metal chelate conjugated monoclonal antibodies, wherein the metal is an α emitter

International Nuclear Information System (INIS)

Gansow, O.A.; Strand, M.

1984-01-01

Methods of manufacturing and purifying metal chelate conjugated monoclonal antibodies are described, wherein the chelated metal emits alpha radiation. The conjugates are suited for therapeutic uses being substantially free of nonchelated radiometal. (author)

Influence of transfer gate design and bias on the radiation hardness of pinned photodiode CMOS image sensors

International Nuclear Information System (INIS)

Goiffon, V.; Estribeau, M.; Cervantes, P.; Molina, R.; Magnan, P.; Gaillardin, M.

2014-01-01

The effects of Cobalt 60 gamma-ray irradiation on pinned photodiode (PPD) CMOS image sensors (CIS) are investigated by comparing the total ionizing dose (TID) response of several transfer gate (TG) and PPD designs manufactured using a 180 nm CIS process. The TID induced variations of charge transfer efficiency (CTE), pinning voltage, equilibrium full well capacity (EFWC), full well capacity (FWC) and dark current measured on the different pixel designs lead to the conclusion that only three degradation sources are responsible for all the observed radiation effects: the pre-metal dielectric (PMD) positive trapped charge, the TG sidewall spacer positive trapped charge and, with less influence, the TG channel shallow trench isolation (STI) trapped charge. The different FWC evolutions with TID presented here are in very good agreement with a recently proposed analytical model. This work also demonstrates that the peripheral STI is not responsible for the observed degradations and thus that the enclosed layout TG design does not improve the radiation hardness of PPD CIS. The results of this study also lead to the conclusion that the TG OFF voltage bias during irradiation has no influence on the radiation effects. Alternative design and process solutions to improve the radiation hardness of PPD CIS are discussed. (authors)

Sustainable manufacturing: Effect of material selection and design on the environmental impact in the manufacturing process

International Nuclear Information System (INIS)

Harun, Mohd Hazwan Syafiq; Salaam, Hadi Abdul; Taha, Zahari

2013-01-01

The environmental impact of a manufacturing process is also dependent on the selection of the material and design of a product. This is because the manufacturing of a product is directly connected to the amount of carbon emitted in consuming the electrical energy for that manufacturing process. The difference in the general properties of materials such as strength, hardness and impact will have significant effect on the power consumption of the machine used to complete the product. In addition the environmental impact can also be reduced if the proposed designs use less material. In this study, an LCA tool called Eco-It is used. Evaluate the environmental impact caused by manufacturing simple jig. A simple jig with 4 parts was used as a case study. Two experiments were carried out. The first experiment was to study the environmental effects of different material, and the second experiment was to study the environmental impact of different design. The materials used for the jig are Aluminium and mild steel. The results showed a decrease in the rate of carbon emissions by 60% when Aluminium is use instead from mild steel, and a decrease of 26% when the-design is modified

Investigations on the corrosion resistance of metallic bipolar plates (BPP) in proton exchange membrane fuel cells (PEMFC) - understanding the effects of material, coating and manufacturing

Science.gov (United States)

Dur, Ender

Polymer Electrolyte Membrane Fuel Cell (PEMFC) systems are promising technology for contributing to meet the deficiency of world`s clean and sustainable energy requirements in the near future. Metallic bipolar plate (BPP) as one of the most significant components of PEMFC device accounts for the largest part of the fuel cell`s stack. Corrosion for metallic bipolar plates is a critical issue, which influences the performance and durability of PEMFC. Corrosion causes adverse impacts on the PEMFC`s performance jeopardizing commercialization. This research is aimed at determining the corrosion resistance of metallic BPPs, particularly stainless steels, used in PEMFC from different aspects. Material selection, coating selection, manufacturing process development and cost considerations need to be addressed in terms of the corrosion behavior to justify the use of stainless steels as a BPP material in PEMFC and to make them commercially feasible in industrial applications. In this study, Ti, Ni, SS304, SS316L, and SS 430 blanks, and BPPs comprised of SS304 and SS316L were examined in terms of the corrosion behavior. SS316L plates were coated to investigate the effect of coatings on the corrosion resistance performance. Stamping and hydroforming as manufacturing processes, and three different coatings (TiN, CrN, ZrN) applied via the Physical Vapor Deposition (PVD) method in three different thicknesses were selected to observe the effects of manufacturing processes, coating types and coating thicknesses on the corrosion resistance of BPP, respectively. Uncoated-coated blank and formed BPP were subjected to two different corrosion tests: potentiostatic and potentiodynamic. Some of the substantial results: 1- Manufacturing processes have an adverse impact on the corrosion resistance. 2- Hydroformed plates have slightly higher corrosion resistance than stamped samples. 3- BPPs with higher channel size showed better corrosion resistance. 4- Since none of the uncoated samples

Manufacturing Process Simulation of Large-Scale Cryotanks

Science.gov (United States)

Babai, Majid; Phillips, Steven; Griffin, Brian

2003-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing

Benefits of Hot Isostatic Pressure/Powdered Metal (HIP/PM) and Additive Manufacturing (AM) To Fabricate Advanced Energy System Components

Energy Technology Data Exchange (ETDEWEB)

Horton, Nancy [Energy Industries of Ohio, Cleveland, OH (United States); Sheppard, Roy [Energy Industries of Ohio, Cleveland, OH (United States)

2016-12-31

Advanced Energy systems require large, complex components produced from materials capable of withstanding severe operating environments (high temperature, pressure, corrosivity). Such parts can be difficult to source, as conventional material processing technologies must be tailored to ensure a safe and cost effective approach to large-scale manufacture of quality structural advanced alloy components that meet the performance specifications of AE systems. (HIP/PM) has shown advantages over other manufacturing methods when working with these materials. For example, using HIP’ing in lieu of casting means significant savings in raw material costs, which for expensive, high-nickel alloys can be considerable for large-scale production. Use of HIP/PM also eliminates the difficulties resulting from reactivity of these materials in the molten state and facilitates manufacture of the large size requirements of the AE industry, producing a part that is defect and porosity free, thus further reducing or eliminating time and expense of post processing machining and weld repair. New advances in Additive Manufacturing (AM) techniques make it possible to further expand the benefits of HIP/PM in producing AE system components to create an even more robust manufacturing approach. Traditional techniques of welding and forming sheet metal to produce the HIP canisters can be time consuming and costly, with limitations on the complexity of part which can be achieved. A key benefit of AM is the freedom of design that it offers, so use of AM could overcome such challenges, ultimately enabling redesign of complete energy systems. A critical step toward this goal is material characterization of the required advanced alloys, for use in AM. Using Haynes 282, a high nickel alloy of interest to the Fossil Energy community, particularly for Advanced-UltraSuperCritical (AUSC) operating environments, as well as the crosscutting interests of the aerospace, defense and medical markets, this

Metallization of bacterial cellulose for electrical and electronic device manufacture

Science.gov (United States)

Evans, Barbara R [Oak Ridge, TN; O'Neill, Hugh M [Knoxville, TN; Jansen, Valerie Malyvanh [Memphis, TN; Woodward, Jonathan [Knoxville, TN

2010-09-28

A method for the deposition of metals in bacterial cellulose and for the employment of the metallized bacterial cellulose in the construction of fuel cells and other electronic devices is disclosed. The method for impregnating bacterial cellulose with a metal comprises placing a bacterial cellulose matrix in a solution of a metal salt such that the metal salt is reduced to metallic form and the metal precipitates in or on the matrix. The method for the construction of a fuel cell comprises placing a hydrated bacterial cellulose support structure in a solution of a metal salt such that the metal precipitates in or on the support structure, inserting contact wires into two pieces of the metal impregnated support structure, placing the two pieces of metal impregnated support structure on opposite sides of a layer of hydrated bacterial cellulose, and dehydrating the three layer structure to create a fuel cell.

Cleaner Technology in the Hard Disk Drive Manufacturing Industry: A Case Study

Science.gov (United States)

Moolla, Premchai; Chompu-inwai, Rungchat

2010-10-01

The objectives of this research are to improve raw material and energy consumption efficiency, as well as reduce defects and the use of chemicals in the arm coil assembly process of hard disk drive manufacturing in the case study company by applying the Cleaner Technology concepts. The four main sequential steps used in this research were: (1) pre-assessment, (2) assessment, (3) feasibility study, and (4) implementation. In the first step, raw data, such as process flows, raw material usage and defects data were collected. In the second step, the loss during production and causes of loss were analyzed. Opportunities to reduce raw material, chemical and energy wastage could then be recommended. The next step was to evaluate the feasibility and potential benefits of a particular Cleaner Technology opportunity. Finally, in the last step, after a thorough evaluation and implementation of the opportunities to apply Cleaner Technology, the results showed that arm coil defects could be reduced by improving the production process using the ECRS technique. ECRS stands for Eliminate, Combine, Rearrange and Simplify. This improvement reduced arm coil defect rates from 0.48% to 0.15%, thus saving approximately 139,638 Thai Baht per month. In addition, production stoppage decision made by workers was used to increase employee involvement in defect detection. Allowing workers to participate in such a decision was an effective way to reduce defect rate and could motivate workers to produce a better quality job. This resulted in arm coil defects reducing from 0.41% to 0.025%, with about 74,562 Thai Baht per month saving. Additionally, an increase in the efficiency of electricity consumption occurred, by increasing the speed of the infrared oven conveyor belt, improving average productivity from 533 pieces/hour to 560 pieces/hour, without adversely affecting product costs and quality, thus producing products of up to the value of 206,242 Thai Baht per month. Furthermore, the new

TOPICAL REVIEW Progress in cold roll bonding of metals

Directory of Open Access Journals (Sweden)

Long Li, Kotobu Nagai and Fuxing Yin

2008-01-01

Full Text Available Layered composite materials have become an increasingly interesting topic in industrial development. Cold roll bonding (CRB, as a solid phase method of bonding same or different metals by rolling at room temperature, has been widely used in manufacturing large layered composite sheets and foils. In this paper, we provide a brief overview of a technology using layered composite materials produced by CRB and discuss the suitability of this technology in the fabrication of layered composite materials. The effects of process parameters on bonding, mainly including process and surface preparation conditions, have been analyzed. Bonding between two sheets can be realized when deformation reduction reaches a threshold value. However, it is essential to remove surface contamination layers to produce a satisfactory bond in CRB. It has been suggested that the degreasing and then scratch brushing of surfaces create a strong bonding between the layers. Bonding mechanisms, in which the film theory is expressed as the major mechanism in CRB, as well as bonding theoretical models, have also been reviewed. It has also been showed that it is easy for fcc structure metals to bond compared with bcc and hcp structure metals. In addition, hardness on bonding same metals plays an important part in CRB. Applications of composites produced by CRB in industrial fields are briefly reviewed and possible developments of CRB in the future are also described.

Hardness and adhesion performances of nanocoating on carbon steel

Science.gov (United States)

Hasnidawani, J. N.; Azlina, H. N.; Norita, H.; Bonnia, N. N.

2018-01-01

Nanocoatings industry has been aggressive in searching for cost-effective alternatives and environmental friendly approaches to manufacture products. Nanocoatings represent an engineering solution to prevent corrosion of the structural parts of ships, insulation and pipelines industries. The adhesion and hardness properties of coating affect material properties. This paper reviews ZnO-SiO2 as nanopowder in nano coating formulation as the agent for new and improved coating performances. Carbon steel on type S50C used as common substrate in nanocoating industry. 3wt% ZnO and 2wt% SiO2 addition of nanoparticles into nanocoating showed the best formulation since hardness and adhesion of nanocoating was good on carbon steel substrate. Incorporation of nanoparticles into coating increased the performances of coating.

Hardness and microstructure analysis of damaged gear caused by adhesive wear

Science.gov (United States)

Mahendra, Rizky Budi; Nugroho, Sri; Ismail, Rifky

2018-03-01

This study was a result from research on repairing project of damaged elevator gear box. The objective of this research is to analyze the failure part on elevator gearbox at flourmill factory. The equipment was damaged after one year installed and running on factory. Severe wear was occurred on high speed helical gear. These helical gear was one of main part of elevator gearbox in flour mill manufacture. Visually, plastic deformation didn't occurred and not visible on the failure helical gear shaft. Some test would be performed to check the chemical composition, microstructure and hardness of failure helical gear. The material of failure helical gear shaft was a medium carbon steel alloy. The microstructure was showed a martensitic phase formed on the surface to the center area of gear shaft. Otherwise, the depth of hardness layer slight formed on surface and lack depth of hardness layer was a main trigger of severe wear. It was not enough to resist wear due to friction caused by rolling and sliding on surface between high speed gear and low speed gear. Enhancement of hardness layer on surface and depth of hardness layer will make the component has more long life time. Furthermore, to perform next research is needed to analyze the reliability of enhanced hardness on layer and depth of hardness layer on helical gear shaft.

Additive Manufacturing of Near-net Shaped Permanent Magnets

Energy Technology Data Exchange (ETDEWEB)

Paranthaman, M Parans [ORNL

2016-07-26

The technical objective of this technical collaboration phase I proposal is to fabricate near net-shaped permanent magnets using alloy powders utilizing direct metal deposition technologies at the ORNL MDF. Direct Manufacturing using the POM laser system was used to consolidate Nd₂Fe₁₄B (NdFeB) magnet powders into near net-shape parts efficiently and with virtually no wasted material as part of the feasibility study. We fabricated builds based on spherical NdFeB magnet particles. The results show that despite the ability to fabricate highly reactive materials in the laser deposition process, the magnetic coercivity and remanence of the NdFeB hard magnets is significantly reduced. X-ray powder diffraction in conjunction with electron microscopy showed that the material experienced a primary Nd₂Fe₁₇B_x solidification due to the undercooling effect (>60K). Consequently the presence of alpha iron phase resulted in deterioration of the build properties. Further optimization of the processing parameters is needed to maintain the Nd₂Fe₁₄B phase during fabrication.

Acylinder and freeform optical manufacturing

Science.gov (United States)

Fess, Edward; Wolfs, Frank; DeFisher, Scott; Ross, James

2015-10-01

Aspheric cylinders have the ability to improve optical performance over standard cylindrical surfaces. Over the last several years there has also been development into the application and functionality of utilizing freeform surfaces to improve optical performance. Freeforms have the ability to not only improve image quality over a greater field of view, but can open up the design space of an optical system making it more compact. Freeform geometries, much like aspheric cylinders, may not have an axis of rotation to spin the optic about during manufacturing. This leads to costly fabrication processes and custom metrology set ups, which may inhibit their use. Over the last several years, OptiPro Systems has developed and optimized our eSX grinding, UFF and USF polishing, UltraSurf metrology, and ProSurf software programming technologies to make the processing of these complex geometries much easier and deterministic. In this paper we will discuss the challenges associated with manufacturing complex shapes like aspheric cylinders as well as freeform geometries, and how several technologies working together can overcome them. The technologies focus on metrology feedback to a grinding and polishing machine that is controlled through an iterative computer aided manufacturing software system. We will also present examples of these hard to manufacture shapes with results.

Using Innovative Technologies for Manufacturing Rocket Engine Hardware

Science.gov (United States)

Betts, E. M.; Eddleman, D. E.; Reynolds, D. C.; Hardin, N. A.

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As the United States enters into the next space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, rapid manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on NASA s Space Launch System (SLS) upper stage engine, J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator (GG) discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using a workhorse gas generator (WHGG) test fixture at MSFC's East Test Area, the duct was subjected to extreme J-2X hot gas environments during 7 tests for a total of 537 seconds of hot-fire time. The duct underwent extensive post-test evaluation and showed no signs of degradation. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Manufacture of functional surfaces through combined application of tool manufacturing processes and Robot Assisted Polishing

DEFF Research Database (Denmark)

Eriksen, Rasmus Solmer; Arentoft, Mogens; Grønbæk, J.

2012-01-01

The tool surface topography is often a key parameter in the tribological performance of modern metal forming tools. A new generation of multifunctional surfaces is achieved by combination of conventional tool manufacturing processes with a novel Robot Assisted Polishing process. This novel surface...

Manufacture of good-weldable low oxygen molybdenum by powder metallurgy

International Nuclear Information System (INIS)

Hiraoka, Yutaka; Okada, Masatoshi; Akiyama, Takashi; Yamafuchi, Yasuo.

1984-01-01

In general most of commercial molybdenum is produced by the powder metallurgy method and is utilized as a superior heat-resisting material in many fields. Moreover, molybdenum is expected to be used as the first-wall components of JT-60 (JAERI Tokamak-60). However, one of major problems on molybdenum, particularly on powder metallurgy molybdenum, is that any sound welded joint is hard to be obtainable. In many cases weld pores are formed on welding and, therefore, ductility of the welded joint is severely degraded. The object of the present work is to get a sound welded joint without any weld pores by reducing impurity levels in the material. The materials were produced by modifying one or several parts in the ordinary manufacturing process of powder metallurgy molybdenum. Oxygen, nitrogen, carbon and other principal metallic impurities were chemically analysed. The above materials were then subjected to electron-beam-welding by using a melt-run technique, and the soundness of the welded joints was examined by optical microscopy. (author)

Water soluble nano-scale transient material germanium oxide for zero toxic waste based environmentally benign nano-manufacturing

KAUST Repository

Almuslem, A. S.; Hanna, Amir; Yapici, Tahir; Wehbe, N.; Diallo, Elhadj; Kutbee, Arwa T.; Bahabry, Rabab R.; Hussain, Muhammad Mustafa

2017-01-01

, in addition to transiency, we also show an environmentally friendly manufacturing process for a complementary metal oxide semiconductor (CMOS) technology. Every year, trillions of complementary metal oxide semiconductor (CMOS) electronics are manufactured

Distributions, sources and pollution status of 17 trace metal/metalloids in the street dust of a heavily industrialized city of central China.

Science.gov (United States)

Li, Zhonggen; Feng, Xinbin; Li, Guanghui; Bi, Xiangyang; Zhu, Jianming; Qin, Haibo; Dai, Zhihui; Liu, Jinling; Li, Qiuhua; Sun, Guangyi

2013-11-01

A series of representative street dust samples were collected from a heavily industrialized city, Zhuzhou, in central China, with the aim to investigate the spatial distribution and pollution status of 17 trace metal/metalloid elements. Concentrations of twelve elements (Pb, Zn, Cu, Cd, Hg, As, Sb, In, Bi, Tl, Ag and Ga) were distinctly amplified by atmospheric deposition resulting from a large scale Pb/Zn smelter located in the northwest fringe of the city, and followed a declining trend towards the city center. Three metals (W, Mo and Co) were enriched in samples very close to a hard alloy manufacturing plant, while Ni and Cr appeared to derive predominantly from natural sources. Other industries and traffic had neglectable effects on the accumulation of observed elements. Cd, In, Zn, Ag and Pb were the five metal/metalloids with highest pollution levels and the northwestern part of city is especially affected by heavy metal pollution. Copyright © 2013 Elsevier Ltd. All rights reserved.

Direct Numerical Simulations of Microstructure Effects During High-Rate Loading of Additively Manufactured Metals

Science.gov (United States)

Battaile, Corbett; Owen, Steven; Moore, Nathan

2017-06-01

The properties of most engineering materials depend on the characteristics of internal microstructures and defects. In additively manufactured (AM) metals, these can include polycrystalline grains, impurities, phases, and significant porosity that qualitatively differ from conventional engineering materials. The microscopic details of the interactions between these internal defects, and the propagation of applied loads through the body, act in concert to dictate macro-observable properties like strength and compressibility. In this work, we used Sandia's ALEGRA finite element software to simulate the high-strain-rate loading of AM metals from laser engineered net shaping (LENS) and thermal spraying. The microstructural details of the material were represented explicitly, such that internal features like second phases and pores are captured and meshed as individual entities in the computational domain. We will discuss the dependence of the high-strain-rate mechanical properties on microstructural characteristics such as the shapes, sizes, and volume fractions of second phases and pores. In addition, we will examine how the details of the microstructural representation affect the microscopic material response to dynamic loads, and the effects of using ``stair-step'' versus conformal interfaces smoothed via the SCULPT tool in Sandia's CUBIT software. Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the US DOE NNSA under contract DE-AC04-94AL85000.

Technology Innovation and Future Research Needs in Net Shape Manufacturing

International Nuclear Information System (INIS)

Yang, Dong-Yol

2005-01-01

The rapid change in customer needs and industrial environment has demanded innovations in the manufacturing sector. Metal forming industries have been confronted with new challenges of innovations in products, processes, machines, materials and production systems. From the viewpoints of competitiveness of products, new paradigms are required for innovation in manufacturing, especially in net shape manufacturing. Product innovations are increasingly put under emphasis beyond manufacturing innovations based on the holistic concurrent engineering approach. The presentation covers not only the innovation methodologies, but also the innovation directions in net shape manufacturing

Additive Manufactured Very Light Weight Diamond Turned Aspheric Mirror, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — Selective laser melting, referred to as "Direct Metal Laser Sintering"(DMLS), "Metal Powder Bed Fusion" or "3D Printing" is an additive manufacturing process which...

Using Innovative Technologies for Manufacturing and Evaluating Rocket Engine Hardware

Science.gov (United States)

Betts, Erin M.; Hardin, Andy

2011-01-01

Many of the manufacturing and evaluation techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing and evaluating hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) and white light scanning are being adopted and evaluated for their use on J-2X, with hopes of employing both technologies on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powdered metal manufacturing process in order to produce complex part geometries. The white light technique is a non-invasive method that can be used to inspect for geometric feature alignment. Both the DMLS manufacturing method and the white light scanning technique have proven to be viable options for manufacturing and evaluating rocket engine hardware, and further development and use of these techniques is recommended.

Considerations on the Construction of a Powder Bed Fusion Platform for Additive Manufacturing

DEFF Research Database (Denmark)

Andersen, Sebastian Aagaard; Nielsen, Karl-Emil; Pedersen, David Bue

2017-01-01

As the demand for moulds and other tools becomes increasingly specific and complex, an additive manufacturing approach to production is making its way to the industry through laser based consolidation of metal powder particles by a method known as powder bed fusion. This paper concerns a variety...... of design choices facilitating the development of an experimental powder bed fusion machine tool, capable of manufacturing metal parts with strength matching that of conventional manufactured parts and a complexity surpassing that of subtractive processes. To understand the different mechanisms acting...

Microstructure and High Temperature Mechanical Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Metal Injection Molding Process

Science.gov (United States)

Lee, Kee-Ahn; Gwon, Jin-Han; Yoon, Tae-Sik

2018-03-01

This study investigated the microstructure and the room and high temperature mechanical properties of Fe-Cr-B alloy manufactured by metal injection molding. In addition, hot isostatic pressing was performed to increase the density of the material, and a comparison of properties was made. Microstructural observation confirmed a bi-continuous structure composed of a three-dimensional network of α-Fe phase and (Cr,Fe)2B phase. The HIPed specimen featured a well-formed adhesion between the α-Fe phase and boride, and the number of fine pores was significantly reduced. The tensile results confirmed that the HIPed specimen (RT to 900 °C) had higher strengths compared to the as-sintered specimen, and the change of elongation starting from 700 °C was significantly greater in the HIPed specimen. Fractography suggested that cracks propagated mostly along the interface between the α-Fe matrix and boride in the as-sintered specimen, while direct fracture of boride was observed in addition to interface separation in the HIPed specimen.

Tungsten and other heavy metal contamination in aquatic environments receiving wastewater from semiconductor manufacturing

International Nuclear Information System (INIS)

Hsu, Shih-Chieh; Hsieh, Hwey-Lian; Chen, Chang-Po; Tseng, Chun-Mao; Huang, Shou-Chung; Huang, Chou-Hao; Huang, Yi-Tang; Radashevsky, Vasily; Lin, Shuen-Hsin

2011-01-01

Through analyses of water and sediments, we investigate tungsten and 14 other heavy metals in a stream receiving treated effluents from a semiconductor manufacturer-clustered science park in Taiwan. Treated effluents account for ∼50% of total annual river discharge and <1% of total sediment discharge. Dissolved tungsten concentrations in the effluents abnormally reach 400 μg/L, as compared to the world river average concentration of <0.1 μg/L. Particulate tungsten concentrations are up to 300 μg/g in suspended and deposited sediments, and the corresponding enrichment factors are three orders of magnitude higher than average crust composition. Surprisingly, the estimated amount of tungsten exported to the adjacent ocean is 23.5 t/yr, which can approximate the amount from the Yangtze River should it be unpolluted. This study highlights the urgency of investigating the biological effect of such contamination.

Remediating sites contaminated with heavy metals

International Nuclear Information System (INIS)

Swartzbaugh, J.; Sturgill, J.; Cormier, B.; Williams, H.D.

1992-01-01

This article is intended to serve as a reference for decision makers who must choose an approach to remediate sites contaminated with heavy metals. Its purpose is to explain pertinent chemical and physical characteristics of heavy metals, how to use these characteristics to select remedial technologies, and how to interpret and use data from field investigations. Different metal species are typically associated with different industrial processes. The contaminant species behave differently in various media (i.e., groundwater, soils, air), and require different technologies for containment and treatment. We focus on the metals that are used in industries that generate regulated waste. These include steelmaking, paint and pigment manufacturing, metal finishing, leather tanning, papermaking, aluminum anodizing, and battery manufacturing. Heavy metals are also present in refinery wastes as well as in smelting wastes and drilling muds

SQUID sensor application for small metallic particle detection

International Nuclear Information System (INIS)

Tanaka, Saburo; Hatsukade, Yoshimi; Ohtani, Takeyoshi; Suzuki, Shuichi

2009-01-01

High-Tc superconducting quantum interference device (SQUID) is an ultra-sensitive magnetic sensor. Since the performance of the SQUID is improved and stabilized, now it is ready for application. One strong candidate for application is a detection system of magnetic foreign matters in industrial products or beverages. There is a possibility that ultra-small metallic foreign matter has been accidentally mixed with industrial products such as lithium ion batteries. If this happens, the manufacturer of the product suffers a great loss recalling products. The outer dimension of metallic particles less than 100 μm cannot be detected by an X-ray imaging, which is commonly used for the inspection. Ionization of the material is also a big issue for beverages in the case of the X-ray imaging. Therefore a highly sensitive and safety detection system for small foreign matters is required. We developed detection systems based on high-Tc SQUID with a high-performance magnetic shield. We could successfully measure small iron particles of 100 μm on a belt conveyer and stainless steel balls of 300 μm in water. These detection levels were hard to be achieved by a conventional X-ray detection or other methods

Characterization of Ti-6Al-4V produced via electron beam additive manufacturing

Science.gov (United States)

Hayes, Brian J.

In recent years, additive manufacturing (AM) has become an increasingly promising method used for the production of structural metallic components. There are a number of reasons why AM methods are attractive, including the ability to produce complex geometries into a near-net shape and the rapid transition from design to production. Ti-6Al-4V is a titanium alloy frequently used in the aerospace industry which is receiving considerable attention as a good candidate for processing via electron beam additive manufacturing (EBAM). The Sciaky EBAM method combines a high-powered electron beam, weld-wire feedstock, and a large build chamber, enabling the production of large structural components. In order to gain wide acceptance of EBAM of Ti-6Al-4V as a viable manufacturing method, it is important to understand broadly the microstructural features that are present in large-scale depositions, including specifically: the morphology, distribution and texture of the phases present. To achieve such an understanding, stereological methods were used to populate a database quantifying key microstructural features in Ti-6Al-4V including volume fraction of phases, alpha lath width, colony scale factor, and volume fraction of basket weave type microstructure. Microstructural features unique to AM, such as elongated grains and banded structures, were also characterized. Hardness and tensile testing were conducted and the results were related to the microstructural morphology and sample orientation. Lastly, fractured surfaces and defects were investigated. The results of these activities provide insight into the process-structure-properties relationships found in EBAM processed Ti-6Al-4V.

Rubber pad forming - Efficient approach for the manufacturing of complex structured sheet metal blanks for food industry

Science.gov (United States)

Spoelstra, Paul; Djakow, Eugen; Homberg, Werner

2017-10-01

The production of complex organic shapes in sheet metals is gaining more importance in the food industry due to increasing functional and hygienic demands. Hence it is necessary to produce parts with complex geometries promoting cleanability and general sanitation leading to improvement of food safety. In this context, and especially when stainless steel has to be formed into highly complex geometries while maintaining desired surface properties, it is inevitable that alternative manufacturing processes will need to be used which meet these requirements. Rubber pad forming offers high potential when it comes to shaping complex parts with excellent surface quality, with virtually no tool marks and scratches. Especially in cases where only small series are to be produced, rubber pad forming processes offers both technological and economic advantages. Due to the flexible punch, variation in metal thickness can be used with the same forming tool. The investments to set-up Rubber pad forming is low in comparison to conventional sheet metal forming processes. The process facilitates production of shallow sheet metal parts with complex contours and bends. Different bending sequences in a multiple tool set-up can also be conducted. The planned contribution thus describes a brief overview of the rubber pad technology. It shows the prototype rubber pad forming machine which can be used to perform complex part geometries made from stainless steel (1.4301). Based on an analysis of the already existing systems and new machines for rubber pad forming processes, together with their process properties, influencing variables and areas of application, some relevant parts for the food industry are presented.

Rapid die manufacturing using direct laser metal deposition

CSIR Research Space (South Africa)

Pereira, MFVT

2009-01-01

Full Text Available This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die...

Influence of Ni-P Coated SiC and Laser Scan Speed on the Microstructure and Mechanical Properties of IN625 Metal Matrix Composites

Science.gov (United States)

Sateesh, N. H.; Kumar, G. C. Mohan; Krishna, Prasad

2015-12-01

Nickel based Inconel-625 (IN625) metal matrix composites (MMCs) were prepared using pre-heated nickel phosphide (Ni-P) coated silicon carbide (SiC) reinforcement particles by Direct Metal Laser Sintering (DMLS) additive manufacturing process under inert nitrogen atmosphere to obtain interface influences on MMCs. The distribution of SiC particles and microstructures were characterized using optical and scanning electron micrographs, and the mechanical behaviours were thoroughly examined. The results clearly reveal that the interface integrity between the SiC particles and the IN625 matrix, the mixed powders flowability, the SiC ceramic particles and laser beam interaction, and the hardness, and tensile characteristics of the DMLS processed MMCs were improved effectively by the use of Ni-P coated SiC particles.

DETERMINATION OF THE OPTIMAL TEMPERING TEMPERATURE IN HARD FACING OF THE FORGING DIES

Directory of Open Access Journals (Sweden)

Milan Mutavdžić

2012-06-01

Full Text Available Here is analyzed selection of the optimal technology for heat treatment during the reparation of the damaged forging dies. Those tools are manufactured from alloyed tool steels for operation at elevated temperatures. Those steels are prone to self-hardening, so in reparatory hard-facing they must be preheated, additionally heated and tempered. During the tempering, in temperature interval 500-600°C, a secondary increase of hardness and decrease of impact toughness occurs, the so-called reversible tempering brittleness. Here is shown that it can be avoided by application of metallurgical and technological measures. Metallurgical measures assume adequate selection of steels. Since the considered steels are per se prone to tempering brittleness, we conducted experimental investigations to define the technological measures to avoid it. Tests on models were conducted: tempering from different temperatures, slow heating and cooling in still air. Hardness measurements showed that at 520°C, the secondary increase of hardness occurs, with drop of the impact toughness. Additional hard-facing tests included samples tempered at various regimes. Samples were prepared for mechanical and metallographic investigations. Results presented illustrate influence of additional heat treatment on structure, hardness and mechanical properties of the hard-faced layers. This enabled establishing the possibility of avoiding the tempering brittleness through technological measures.

Determination of the optimal tempering temperature in hard facing of the forging dies

Directory of Open Access Journals (Sweden)

Milan Mutavdžić

2012-05-01

Full Text Available Here is analyzed selection of the optimal technology for heat treatment during the reparation of the damaged forging dies. Those tools are manufactured from alloyed tool steels for operation at elevated temperatures. Those steels are prone to self-hardening, so in reparatory hard-facing they must be preheated, additionally heated and tempered. During the tempering, in temperature interval 500-600°C, a secondary increase of hardness and decrease of impact toughness occurs, the so-called reversible tempering brittleness. Here is shown that it can be avoided by application of metallurgical and technological measures. Metallurgical measures assume adequate selection of steels. Since the considered steels are per se prone to tempering brittleness, we conducted experimental investigations to define the technological measures to avoid it. Tests on models were conducted: tempering from different temperatures, slow heating and cooling in still air. Hardness measurements showed that at 520°C, the secondary increase of hardness occurs, with drop of the impact toughness. Additional hard-facing tests included samples tempered at various regimes. Samples were prepared for mechanical and metallographic investigations. Results presented illustrate influence of additional heat treatment on structure, hardness and mechanical properties of the hard-faced layers. This enabled establishing the possibility of avoiding the tempering brittleness through technological measures. 

Using hardness to model yield and tensile strength

Energy Technology Data Exchange (ETDEWEB)

Hawk, Jeffrey A.; Dogan, Omer N.; Schrems, Karol K.

2005-02-01

The current direction in hardness research is towards smaller and smaller loads as nano-scale materials are developed. There remains, however, a need to investigate the mechanical behavior of complex alloys for severe environment service. In many instances this entails casting large ingots and making numerous tensile samples as the bounds of the operating environment are explored. It is possible to gain an understanding of the tensile strength of these alloys using room and elevated temperature hardness in conjunction with selected tensile tests. The approach outlined here has its roots in the work done by Tabor for metals and low alloy and carbon steels. This research seeks to extend the work to elevated temperatures for multi-phase, complex alloys. A review of the approach will be given after which the experimental data will be examined. In particular, the yield stress and tensile strength will be compared to their corresponding hardness based values.

Progress in cold roll bonding of metals

International Nuclear Information System (INIS)

Li Long; Nagai, Kotobu; Yin Fuxing

2008-01-01

Layered composite materials have become an increasingly interesting topic in industrial development. Cold roll bonding (CRB), as a solid phase method of bonding same or different metals by rolling at room temperature, has been widely used in manufacturing large layered composite sheets and foils. In this paper, we provide a brief overview of a technology using layered composite materials produced by CRB and discuss the suitability of this technology in the fabrication of layered composite materials. The effects of process parameters on bonding, mainly including process and surface preparation conditions, have been analyzed. Bonding between two sheets can be realized when deformation reduction reaches a threshold value. However, it is essential to remove surface contamination layers to produce a satisfactory bond in CRB. It has been suggested that the degreasing and then scratch brushing of surfaces create a strong bonding between the layers. Bonding mechanisms, in which the film theory is expressed as the major mechanism in CRB, as well as bonding theoretical models, have also been reviewed. It has also been showed that it is easy for fcc structure metals to bond compared with bcc and hcp structure metals. In addition, hardness on bonding same metals plays an important part in CRB. Applications of composites produced by CRB in industrial fields are briefly reviewed and possible developments of CRB in the future are also described. Corrections were made to the abstract and conclusion of this article on 18 June 2008. The corrected electronic version is identical to the print version. (topical review)

Out-of-autoclave manufacturing of GLARE panels using resistance heating

NARCIS (Netherlands)

Muller, B.; Palardy, G.; Teixeira De Freitas, S.; Sinke, J.

2017-01-01

Autoclave manufacturing of fibre metal laminates, such as GLARE, is an expensive process.Therefore, there is an increasing interest to find cost effective out-of-autoclave manufacturing processes without diminishing the laminate quality. The aim of this study is to

Fabrication of a metallic roll stamp with low internal stress and high hardness for large area display applications by a pulse reverse current electroforming process

International Nuclear Information System (INIS)

Kim, Joongeok; Han, Jungjin; Kim, Taekyung; Kang, Shinill

2014-01-01

With the increasing demand for large scale micro/nano components in the fields of display, energy and electrical devices, etc, the establishment of a roll imprinting process has become a priority. The fabrication of a roll stamp with high dimensional accuracy and uniformity is one of the key issues in the roll imprinting process, because the roll stamp determines the properties of the replicated micro/nano structures. In this study, a method to fabricate a metallic roll stamp with low internal stress, high flatness, and high hardness was proposed by a pulse reverse current (PRC) electroforming process. The effects of PRC electroforming processes on the internal stress, hardness, and grain size of the electroformed stamp were examined, and the optimum process conditions were suggested. As a practical example of the proposed method, various micro-patterns for electronic circuits were fabricated via the roll imprinting process using a PRC electroformed stamp. (paper)

Hardness survey of cold-worked and heat-treated JBK-75 stainless steel alloy

International Nuclear Information System (INIS)

Jackson, R.J.; Lucas, R.L.

1977-01-01

The alloy JBK-75, an age-hardenable austenitic stainless steel, is similar to commercial A-286, but has certain chemistry modifications to improve weldability and hydrogen compatibility. The principal changes are an increase in nickel and a decrease in manganese with lower limits on carbon, phosphorus, sulfur, silicon, and boron. In this study, the effects of solutionizing time and temperature, quench rate, cold working, and the effects of cold working on precipitation kinetics were examined. Findings show that the solutionizing temperature has a moderate effect on the as-quenched hardness, while times greater than that required for solutionizing do not significantly affect hardness. Quench rate was found to have a small effect on as-quenched hardness, however, hardness gradients did not develop in small bars. It was found that JBK-75 can be significantly strengthened by cold working. Cold working alone produced hardness increases from Rockwell-A 49 to R/sub A/ 68. A recovery-related hardness change was noted on heat treating at 300 and 400 0 C for both as-quenched and as-worked JBK-75. Significant age-hardening was observed at temperatures as low as 500 0 C for as-worked metal. Aging at 600 0 C resulted in maximum hardness in the 75 percent worked sample at about 6 hours (R/sub A/ 73.5) while the 50 percent worked sample was near maximum hardness (R/sub A 72.5) after seven days. THE 25 and 0 percent worked samples were considerably underaged after seven days. Similar type kinetic data were obtained for worked and nonworked metal at 650, 700, 800, 850, 900, 1000, and 1100 0 C for times from 10 minutes to 10,000 minutes (6.7 days). The overall purpose of the hardness survey was to better define the effects of cold work on the stress-relieving range, coherent precipitation range, incoherent precipitation range, recrystallization range, solutionizing range, and grain-growth range

Combined Application of QEM-SEM and Hard X-ray Microscopy to Determine Mineralogical Associations and Chemcial Speciation of Trace Metals

Energy Technology Data Exchange (ETDEWEB)

M Grafe; M Landers; R Tappero; P Austin; B Gan; A Grabsch; C Klauber

2011-12-31

We describe the application of quantitative evaluation of mineralogy by scanning electron microscopy in combination with techniques commonly available at hard X-ray microprobes to define the mineralogical environment of a bauxite residue core segment with the more specific aim of determining the speciation of trace metals (e.g., Ti, V, Cr, and Mn) within the mineral matrix. Successful trace metal speciation in heterogeneous matrices, such as those encountered in soils or mineral residues, relies on a combination of techniques including spectroscopy, microscopy, diffraction, and wet chemical and physical experiments. Of substantial interest is the ability to define the mineralogy of a sample to infer redox behavior, pH buffering, and mineral-water interfaces that are likely to interact with trace metals through adsorption, coprecipitation, dissolution, or electron transfer reactions. Quantitative evaluation of mineralogy by scanning electron microscopy coupled with micro-focused X-ray diffraction, micro-X-ray fluorescence, and micro-X-ray absorption near edge structure (mXANES) spectroscopy provided detailed insights into the composition of mineral assemblages and their effect on trace metal speciation during this investigation. In the sample investigated, titanium occurs as poorly ordered ilmenite, as rutile, and is substituted in iron oxides. Manganese's spatial correlation to Ti is closely linked to ilmenite, where it appears to substitute for Fe and Ti in the ilmenite structure based on its mXANES signature. Vanadium is associated with ilmenite and goethite but always assumes the +4 oxidation state, whereas chromium is predominantly in the +3 oxidation state and solely associated with iron oxides (goethite and hematite) and appears to substitute for Fe in the goethite structure.

Nano-Magnets and Additive Manufacturing for Electric Motors

Science.gov (United States)

Misra, Ajay K.

2014-01-01

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

In-Process Monitoring of Additive Manufacturing, Phase I

Data.gov (United States)

National Aeronautics and Space Administration — The key innovation in this project is the implementation of an Imaging Fourier Transform Spectrometer (IFTS) for in situ metal additive manufacturing process...

Hard X-ray sources from miniature plasma focus devices

International Nuclear Information System (INIS)

Raspa, V.; Silva, P.; Moreno, J.; Zambra, M.; Soto, L.

2004-01-01

As first stage of a program to design a repetitive pulsed radiation generator for industrial applications, two miniature plasma foci have been designed and constructed at the Chilean commission of nuclear energy. The devices operate at an energy level of the order of tens of joules (PF-50 J, 160 nF capacitor bank, 20-35 kV, 32-100 J, ∼ 150 ns time to peak current) and hundred of joules (PF-400 J, 880 nF, 20-35 kV, 176-539 J, ∼ 300 ns time to peak current). Hard X-rays are being studied in these devices operating with hydrogen. Images of metallic plates with different thickness were obtained on commercial radiographic film, Agfa Curix ST-G2, in order to characterize the energy of the hard X-ray outside of the discharge chamber of PF-400 J. An effective energy of the order of 90 keV was measured under those conditions. X ray images of different metallic objects also have been obtained. (authors)

Hard X-ray sources from miniature plasma focus devices

Energy Technology Data Exchange (ETDEWEB)

Raspa, V. [Buenos Aires Univ., PLADEMA, CONICET and INFIP (Argentina); Silva, P.; Moreno, J.; Zambra, M.; Soto, L. [Comision Chilena de Energia Nuclear, Santiago (Chile)

2004-07-01

As first stage of a program to design a repetitive pulsed radiation generator for industrial applications, two miniature plasma foci have been designed and constructed at the Chilean commission of nuclear energy. The devices operate at an energy level of the order of tens of joules (PF-50 J, 160 nF capacitor bank, 20-35 kV, 32-100 J, {approx} 150 ns time to peak current) and hundred of joules (PF-400 J, 880 nF, 20-35 kV, 176-539 J, {approx} 300 ns time to peak current). Hard X-rays are being studied in these devices operating with hydrogen. Images of metallic plates with different thickness were obtained on commercial radiographic film, Agfa Curix ST-G2, in order to characterize the energy of the hard X-ray outside of the discharge chamber of PF-400 J. An effective energy of the order of 90 keV was measured under those conditions. X ray images of different metallic objects also have been obtained. (authors)

EVALUATING THE ROLE OF ION COMPOSITION ON THE TOXICITY OF COPPER TO CERIODAPHNIA DUBIA IN VERY HARD WATERS

Science.gov (United States)

The mitigating effect of increasing hardness on metal toxicity is reflected in water quality criteria in the United States. - - - Copper toxicity did not consistently vary as a function of hardness, but likely as a function of other water quality characteristics (e.g. alkalinity ...

Corrosion performance of some titanium-based hard coatings

International Nuclear Information System (INIS)

Matthes, B.; Broszeit, E.; Aromaa, J.; Ronkainen, H.; Hannula, S.P.; Leyland, A.; Matthews, A.

1991-01-01

Tools and machine parts which could benefit from wear-resistant titanium-based hard films are often subject to corrosive environments. Physically vapour-deposited coatings frequently exhibit porosity and even small defects, which can cause rapid local corrosion of the substrate material; there is therefore a requirement for dense and chemically inert coatings. This paper presents corrosion data for titanium-based hard coatings such as TiN, (Ti, Al)N, Ti(B, N) and TiB 2 and also for multilayered structures where additional aluminium-based insulating surface layers (AlN and Al 2 O 3 ) were deposited. The corrosion resistance and porosity of the films were analysed by electrochemical techniques. The degree of metallic bonding can play a significant role in influencing the corrosion resistance of refractory transition-metal-based ceramic coatings. Here we demonstrate that, under potentiodynamic corrosion test conditions, resistance to corrosive attack was relatively poor for TiB 2 , better for (Ti, Al)N and Ti(B, N) and best for TiN. It is also shown that applying the additional protective aluminium-based insulating surface layers on the coating can further improve corrosion resistance. (orig.)

Investigation on the Accuracy of CT Porosity Analysis of Additive Manufactured Metallic Parts

NARCIS (Netherlands)

Zanini, Filippo; Hermanek, Petr; Rathore, Jitendra; Wits, Wessel W; Carmignato, Simone

2015-01-01

Additive manufacturing (AM) is emerging as an important manufacturing sector, due to its almost unlimited design freedom, the capability to produce personalized parts and the efficient material use. A reliable knowledge about material porosity of manufactured parts is crucial for optimizing AM

Quality of Metal Deposited Flux Cored Wire With the System Fe-C-Si-Mn-Cr-Mo-Ni-V-Co

Science.gov (United States)

Gusev, Aleksander I.; Kozyrev, Nikolay A.; Osetkovskiy, Ivan V.; Kryukov, Roman E.; Kozyreva, Olga A.

2017-10-01

Studied the effect of the introduction of vanadium and cobalt into the charge powder fused wire system Fe-C-Si-Mn-Cr-Ni-Mo-V, used in cladding assemblies and equipment parts and mechanisms operating under abrasive and abrasive shock loads. the cored wires samples were manufactured in the laboratory conditions and using appropriate powder materials and as a carbonfluoride contained material were used the dust from gas purification of aluminum production, with the following components composition, %: Al2O3 = 21-46.23; F = 18-27; Na2O = 8-15; K2O = 0.4-6; CaO = 0.7-2.3; Si2O = 0.5-2.48; Fe2O3 = 2.1-3.27; C = 12.5-30.2; MnO = 0.07-0.9; MgO = 0.06-0.9; S = 0.09-0.19; P = 0.1-0.18. Surfacing was produced on the St3 metal plates in 6 layers under the AN-26C flux by welding truck ASAW-1250. Cutting and preparation of samples for research had been implemented. The chemical composition and the hydrogen content of the weld metal were determined by modern methods. The hardness and abrasion rate of weld metal had been measured. Conducted metallographic studies of weld metal: estimated microstructure, grain size, contamination of oxide non-metallic inclusions. Metallographic studies showed that the microstructure of the surfaced layer by cored wire system Fe-C-Si-Mn-Cr-Mo-Ni-V-Co is uniform, thin dendrite branches are observed. The microstructure consists of martensite, which is formed inside the borders of the former austenite grain retained austenite present in small amounts in the form of separate islands, and thin layers of δ-ferrite, which is located on the borders of the former austenite grains. Carried out an assessment the effect of the chemical composition of the deposited metal on the hardness and wear and hydrogen content. In consequence of multivariate correlation analysis, it was determined dependence to the hardness of the deposited layer and the wear resistance of the mass fraction of the elements included in the flux-cored wires of the system Fe

Analysis of Deformation and Failure Behaviors of TIG Welded Dissimilar Metal Joints Using Miniature Tensile Specimens

Energy Technology Data Exchange (ETDEWEB)

Shin, Ji-Hwan; Jahanzeb, Nabeel; Kim, Min-Seong; Hwang, Ji-Hyun; Choi, Shi-Hoon [Sunchon National University, Suncheon (Korea, Republic of)

2017-02-15

The deformation and failure behaviors of dissimilar metal joints between SS400 steel and STS316L steel were investigated. The dissimilar metal joints were fabricated using the tungsten inert gas (TIG) welding process with STS309 steel as a filler metal. The microstructures of the dissimilar metal joints were investigated using an optical microscope and EBSD technique. The mechanical properties of the base metal (BM), heat affected zone (HAZ) and weld metal (WM) were measured using a micro-hardness and micro-tension tester combined with the digital image correlation (DIC) technique. The HAZ of the STS316L steel exhibited the highest micro-hardness value, and yield/tensile strengths, while the BM of the SS440 steel exhibited the lowest micro-hardness value and yield /tensile strengths. The grain size refinement in the HAZ of SS400 steel induced an enhancement of micro-hardness value and yield/tensile strengths compared to the BM of the SS400 steel. The WM, which consists of primary δ-ferrite and a matrix of austenite phase, exhibited relatively a high micro-hardness value, yield /tensile strengths and elongation compared to the BM and HAZ of the SS400 steel.

Method of manufacturing nuclear fuel pellet

International Nuclear Information System (INIS)

Oguma, Masaomi; Masuda, Hiroshi; Hirai, Mutsumi; Tanabe, Isami; Yuda, Ryoichi.

1989-01-01

In a method of manufacturing nuclear fuel pellets by compression molding an oxide powder of nuclear fuel material followed by sintering, a metal nuclear material is mixed with an oxide powder of the nuclear fuel material. As the metal nuclear fuel material, whisker or wire-like fine wire or granules of metal uranium can be used effectively. As a result, a fuel pellet in which the metal nuclear fuel is disposed in a network-like manner can be obtained. The pellet shows a great effect of preventing thermal stress destruction of pellets upon increase of fuel rod power as compared with conventional pellets. Further, the metal nuclear fuel material acts as an oxygen getter to suppress the increase of O/M ratio of the pellets. Further, it is possible to reduce the swelling of pellet at high burn-up degree. (T.M.)

Radiation hardness of CMOS monolithic active pixel sensors manufactured in a 0.18 μm CMOS process

Energy Technology Data Exchange (ETDEWEB)

Linnik, Benjamin [Goethe-Universitaet Frankfurt (Germany); Collaboration: CBM-MVD-Collaboration

2015-07-01

CMOS Monolithic Active Pixels Sensors (MAPS) are considered as the technology of choice for various vertex detectors in particle and heavy-ion physics including the STAR HFT, the upgrade of the ALICE ITS, the future ILC detectors and the CBM experiment at FAIR. To match the requirements of those detectors, their hardness to radiation is being improved, among others in a joined research activity of the Goethe University Frankfurt and the IPHC Strasbourg. It was assumed that combining an improved high resistivity (1-8 kΩcm) sensitive medium with the features of a 0.18 μm CMOS process, is suited to reach substantial improvements in terms of radiation hardness as compared to earlier sensor designs. This strategy was tested with a novel generation of sensor prototypes named MIMOSA-32 and MIMOSA-34. We show results on the radiation hardness of those sensors and discuss its impact on the design of future vertex detectors.

Studies and manufacture of plutonium fuel

International Nuclear Information System (INIS)

Bussy, P.; Mustelier, J.P.; Pascard, R.

1964-01-01

The studies carried out at the C.E.A. on the properties of fast neutron reactor fuels, the manufacture of fuel elements and their behaviour under irradiation are broadly outlined. The metal fuels studied are the ternary alloys U Pu Mo, U Pu Nb, U Pa Ti, U Pa Zr, the ceramic fuels being mixed uranium and plutonium oxides, carbides and nitrides obtained by sintering. Results are given on the manufacture of uranium fuel elements containing a small proportion of plutonium, used in a critical experiment, and on the first experiments in the manufacture of fuel elements for the reactor Rapsodie. Finally the results of irradiation tests carried out on the prototype fuel pins for Rapsodie are described. (authors) [fr

Comparison of Maraging Steel Micro- and Nanostructure Produced Conventionally and by Laser Additive Manufacturing

Directory of Open Access Journals (Sweden)

Eric A. Jägle

2016-12-01

Full Text Available Maraging steels are used to produce tools by Additive Manufacturing (AM methods such as Laser Metal Deposition (LMD and Selective Laser Melting (SLM. Although it is well established that dense parts can be produced by AM, the influence of the AM process on the microstructure—in particular the content of retained and reversed austenite as well as the nanostructure, especially the precipitate density and chemistry, are not yet explored. Here, we study these features using microhardness measurements, Optical Microscopy, Electron Backscatter Diffraction (EBSD, Energy Dispersive Spectroscopy (EDS, and Atom Probe Tomography (APT in the as-produced state and during ageing heat treatment. We find that due to microsegregation, retained austenite exists in the as-LMD- and as-SLM-produced states but not in the conventionally-produced material. The hardness in the as-LMD-produced state is higher than in the conventionally and SLM-produced materials, however, not in the uppermost layers. By APT, it is confirmed that this is due to early stages of precipitation induced by the cyclic re-heating upon further deposition—i.e., the intrinsic heat treatment associated with LMD. In the peak-aged state, which is reached after a similar time in all materials, the hardness of SLM- and LMD-produced material is slightly lower than in conventionally-produced material due to the presence of retained austenite and reversed austenite formed during ageing.

Comparison of Maraging Steel Micro- and Nanostructure Produced Conventionally and by Laser Additive Manufacturing.

Science.gov (United States)

Jägle, Eric A; Sheng, Zhendong; Kürnsteiner, Philipp; Ocylok, Sörn; Weisheit, Andreas; Raabe, Dierk

2016-12-24

Maraging steels are used to produce tools by Additive Manufacturing (AM) methods such as Laser Metal Deposition (LMD) and Selective Laser Melting (SLM). Although it is well established that dense parts can be produced by AM, the influence of the AM process on the microstructure-in particular the content of retained and reversed austenite as well as the nanostructure, especially the precipitate density and chemistry, are not yet explored. Here, we study these features using microhardness measurements, Optical Microscopy, Electron Backscatter Diffraction (EBSD), Energy Dispersive Spectroscopy (EDS), and Atom Probe Tomography (APT) in the as-produced state and during ageing heat treatment. We find that due to microsegregation, retained austenite exists in the as-LMD- and as-SLM-produced states but not in the conventionally-produced material. The hardness in the as-LMD-produced state is higher than in the conventionally and SLM-produced materials, however, not in the uppermost layers. By APT, it is confirmed that this is due to early stages of precipitation induced by the cyclic re-heating upon further deposition-i.e., the intrinsic heat treatment associated with LMD. In the peak-aged state, which is reached after a similar time in all materials, the hardness of SLM- and LMD-produced material is slightly lower than in conventionally-produced material due to the presence of retained austenite and reversed austenite formed during ageing.

Analyzing the Drivers of Advanced Sustainable Manufacturing System Using AHP Approach

Directory of Open Access Journals (Sweden)

K. Madan Shankar

2016-08-01

Full Text Available A number of current manufacturing sectors are striving hard to introduce innovative long-term strategies into their operations. As a result, many scholarly studies have found it fruitful to investigate advanced manufacturing strategies such as agile, computer-integrated, and cellular manufacturing. Through the example of downstream cases, manufacturing sectors have learned that financial benefits garnered through automated technologies cannot be counted on as a sole measure to ensure their success in today’s competitive and fluctuating marketplaces. The objective of this study is to integrate those advanced techniques with sustainable operations, to promote advanced sustainable manufacturing so those manufacturing sectors can thrive even in uncertain markets. To establish this connection, this study analyzes the drivers of advanced sustainable manufacturing through a proposed framework validated through a case study in India. Common drivers are collected from the literature, calibrated with opinions from experts, and analyzed through an analytical hierarchy process (AHP, which is a multi-criteria decision making (MCDM approach. This study reveals that quality is the primary driver that pressures manufacturing sectors to adopt advanced sustainable manufacturing. Manufacturers can easily note the top ranked driver and adopt it to soundly implement advanced sustainable manufacturing. In addition, some key future scopes are explored along with possible recommendations for effective implementation of advanced sustainable manufacturing systems.

Alternative Manufacturing Concepts for Solid Oral Dosage Forms From Drug Nanosuspensions Using Fluid Dispensing and Forced Drying Technology.

Science.gov (United States)

Bonhoeffer, Bastian; Kwade, Arno; Juhnke, Michael

2018-03-01

Flexible manufacturing technologies for solid oral dosage forms with a continuous adjustability of the manufactured dose strength are of interest for applications in personalized medicine. This study explored the feasibility of using microvalve technology for the manufacturing of different solid oral dosage form concepts. Hard gelatin capsules filled with excipients, placebo tablets, and polymer films, placed in hard gelatin capsules after drying, were considered as substrates. For each concept, a basic understanding of relevant formulation parameters and their impact on dissolution behavior has been established. Suitable matrix formers, present either on the substrate or directly in the drug nanosuspension, proved to be essential to prevent nanoparticle agglomeration of the drug nanoparticles and to ensure a fast dissolution behavior. Furthermore, convection and radiation drying methods were investigated for the fast drying of drug nanosuspensions dispensed onto polymer films, which were then placed in hard gelatin capsules. Changes in morphology and in drug and matrix former distribution were observed for increasing drying intensity. However, even fast drying times below 1 min could be realized, while maintaining the nanoparticulate drug structure and a good dissolution behavior. Copyright © 2018 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.

CSIR eNews: Materials science and manufacturing

CSIR Research Space (South Africa)

CSIR

2009-09-01

Full Text Available knowledge and networks within these fields. A major competitive advantage is the wide coverage of materials (e.g. fibres, textiles, polymers, ceramics, composites, metals) and manufacturing disciplines within one unit. This enables CSIR Materials Science...

CSIR eNews: Materials science and manufacturing

CSIR Research Space (South Africa)

CSIR

2007-12-01

Full Text Available knowledge and networks within these fields. A major competitive advantage is the wide coverage of materials (e.g. fibres, textiles, polymers, ceramics, composites, metals) and manufacturing disciplines within one unit. This enables CSIR Materials Science...

CSIR eNews: Materials science and manufacturing

CSIR Research Space (South Africa)

CSIR

2008-12-01

Full Text Available knowledge and networks within these fields. A major competitive advantage is the wide coverage of materials (e.g. fibres, textiles, polymers, ceramics, composites, metals) and manufacturing disciplines within one unit. This enables CSIR Materials Science...

CSIR eNews: Materials science and manufacturing

CSIR Research Space (South Africa)

CSIR

2008-03-01

Full Text Available knowledge and networks within these fields. A major competitive advantage is the wide coverage of materials (e.g. fibres, textiles, polymers, ceramics, composites, metals) and manufacturing disciplines within one unit. This enables CSIR Materials Science...

Manufacturing of Porous Ceramic Preforms Based on Halloysite Nanotubes (Hnts

Directory of Open Access Journals (Sweden)

Kujawa M.

2016-06-01

Full Text Available The aim of this study was to determine the influence of manufacturing conditions on the structure and properties of porous halloysite preforms, which during pressure infiltration were soaked with a liquid alloy to obtain a metal matrix composite reinforced by ceramic, and also to find innovative possibilities for the application of mineral nanotubes obtained from halloysite. The method of manufacturing porous ceramic preforms (based on halloysite nanotubes as semi-finished products that are applicable to modern infiltrated metal matrix composites was shown. The ceramic preforms were manufactured by sintering of halloysite nanotubes (HNT, Natural Nano Company (USA, with the addition of pores and canals forming agent in the form of carbon fibres (Sigrafil C10 M250 UNS SGL Group, the Carbon Company. The resulting porous ceramic skeletons, suggest innovative application capabilities mineral nanotubes obtained from halloysite.

Studies of the process of an unsteady formation of hard nitride coatings in an arc plasma flow

International Nuclear Information System (INIS)

Zake, M.

1996-01-01

The kinetic studies of an unsteady formation of hard ZrN and TiN coatings on the surface of metallic (Zr, Ti) samples in an Ar-N plasma flow are carried out. The obtained result is that at the initial stage of an unsteady heating of titanium samples nitrogen atoms penetrate into metal lattice and form interstitial compounds of hard nitrogen solutions in α-phase of Ti. This process is followed by a growth of thin surface layers of titanium nitrides with subsequent changes of surface radiance of exposed samples. Unsteady formation of ZrN is a similar two-stage process which includes the ZrN film growth and formation of a α-hard solution with subsequent changes of total normal emissivity of the surface. (author). 1 ref., 1 fig

Honeycomb metal panel

International Nuclear Information System (INIS)

1979-01-01

Product constituted by a honeycomb metal panel that can be employed to advantage for manufacturing lagging by sandwiching it between two plane sheets, utilized in particular in the nuclear industry where lagging has to have a very long life strength. The honeycomb metal panel is made of an expanded metal extrusion previously cut so as to form, after additional drawing, a honeycomb structure with square or rectangular cells with a plane surface [fr

Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing.

Science.gov (United States)

Luecke, William E; Slotwinski, John A

2014-01-01

Using uniaxial tensile and hardness testing, we evaluated the variability and anisotropy of the mechanical properties of an austenitic stainless steel, UNS S17400, manufactured by an additive process, selective laser melting. Like wrought materials, the mechanical properties depend on the orientation introduced by the processing. The recommended stress-relief heat treatment increases the tensile strength, reduces the yield strength, and decreases the extent of the discontinuous yielding. The mechanical properties, assessed by hardness, are very uniform across the build plate, but the stress-relief heat treatment introduced a small non-uniformity that had no correlation to position on the build plate. Analysis of the mechanical property behavior resulted in four conclusions. (1) The within-build and build-to-build tensile properties of the UNS S17400 stainless steel are less repeatable than mature engineering structural alloys, but similar to other structural alloys made by additive manufacturing. (2) The anisotropy of the mechanical properties of the UNS S17400 material of this study is larger than that of mature structural alloys, but is similar to other structural alloys made by additive manufacturing. (3) The tensile mechanical properties of the UNS S17400 material fabricated by selective laser melting are very different from those of wrought, heat-treated 17-4PH stainless steel. (4) The large discontinuous yielding strain in all tests resulted from the formation and propagation of Lüders bands.

Internal fit of three-unit fixed dental prostheses produced by computer-aided design/computer-aided manufacturing and the lost-wax metal casting technique assessed using the triple-scan protocol.

Science.gov (United States)

Dahl, Bjørn E; Dahl, Jon E; Rønold, Hans J

2018-02-01

Suboptimal adaptation of fixed dental prostheses (FDPs) can lead to technical and biological complications. It is unclear if the computer-aided design/computer-aided manufacturing (CAD/CAM) technique improves adaptation of FDPs compared with FDPs made using the lost-wax and metal casting technique. Three-unit FDPs were manufactured by CAD/CAM based on digital impression of a typodont model. The FDPs were made from one of five materials: pre-sintered zirconium dioxide; hot isostatic pressed zirconium dioxide; lithium disilicate glass-ceramic; milled cobalt-chromium; and laser-sintered cobalt-chromium. The FDPs made using the lost-wax and metal casting technique were used as reference. The fit of the FDPs was analysed using the triple-scan method. The fit was evaluated for both single abutments and three-unit FDPs. The average cement space varied between 50 μm and 300 μm. Insignificant differences in internal fit were observed between the CAD/CAM-manufactured FDPs, and none of the FPDs had cement spaces that were statistically significantly different from those of the reference FDP. For all FDPs, the cement space at a marginal band 0.5-1.0 mm from the preparation margin was less than 100 μm. The milled cobalt-chromium FDP had the closest fit. The cement space of FDPs produced using the CAD/CAM technique was similar to that of FDPs produced using the conventional lost-wax and metal casting technique. © 2017 Eur J Oral Sci.

Manufacturing of golf club using wood-plastic combination produced by γ-irradiation

International Nuclear Information System (INIS)

Yamagami, Masayuki; Tsujii, Yukio; Ohnishi, Tokuhiro; Miyoshi, Hirofumi; Chubachi, Mitsuo; Takada, Hisatoshi.

1992-01-01

Wood-plastic combination (WPC) was produced by γ-irradiation of persimmon impregnated with acrylonitrile and styrene. The hardness and strength of WPC obtained were higher than those of an unmodified wood. Thus, it was found that the WPC is suited for a head of golf club, because the Shore hardness value of WPC is 36% greater than that of unmodified wood. An impregnation method of monomers with some pigments could produce colored WPC without diminishing natural grain. Head of golf club could be manufactured from colored WPC in practice. (auhtor)