Investigation of Surface Damage in Forming of High Strength and Galvanized Steel Sheets

Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate. In this study, a special rectangular box was developed to investigate the behavior and characteristics of surface damage in sheet metal forming （SMF） processes. U-channel forming tests were conducted to study the effect of tool hardness on surface damage in the forming of high strength steels and galvanized steels （hot-dip galvanized and galvannealed steels）. Experimental results indicate that sheet deformation mode influences the severity of surface damage in SMF and surface damage occurs easily at the regions where sheet specimen deforms under the action of compressive stress. Die corner is the position where surface damage initiates. For HSS sheet, surface damage is of major interest due to high forming pressure. The HSS and hot-dip galvanized steels show improved ability of damage-resistance with increased hardness of the forming tool. However, for galvannealed steel it is not the forming tool with the highest hardness value that performs best.

The Effect of Laser Ablation Pulse Width and Feed Speed on Necrosis and Surface Damage of Cortical Bone

Bone cutting is of importance in orthopaedic surgery but is also challenging due to its nature of brittleness—where severe mechanical and thermal damages can be introduced easily in conventional machining.Laser machining is a new technology that can allow for complex cut geometries whilst minimising surface defects i.e.,smearing,which occur in mechanical methods.However,comparative studies on the influence of lasers with different pulse characteristics on necrotic damage and surface integrity have not been reported yet.This paper for the first time investigates the effects of laser type on the necrotic damage and surface integrity in fresh bovine cortical bone after ex-situ laser machining.Three lasers of different pulse widths,i.e.,picosecond,nanosecond and continuous wave lasers have been investigated with different feed speeds tested to study the machining efficiency.The cutting temperature,and geometrical outputs have been measured to investigate the thermal influence on the cooling behaviour of the bone samples while high-speed imaging was used to compare the material removal mechanisms between a pulsed and continuous wave laser.Furthermore,an in-depth histological analysis of the subsurface has revealed that the nanosecond laser caused the largest necrotic depth,owing to the high pulse frequency limiting the dissipation of heat.It has also been observed that surface cracks positioned perpendicular to the trench direction were produced after machining by the picosecond laser,indicative of the photomechanical effect induced by plasma explosions.Therefore,the choice of laser type(i.e.,in terms of its pulse width and frequency)needs to be critically considered for appropriate application during laser osteotomy with minimum damage and improved healing.

Bulk and surface damages in complementary bipolar junction transistors produced by high dose irradiation

Two complementary types NPN and PNP of bipolar junction transistors （BJTs） were exposed to higll dose of neutrons and gamma rays. The change in the base and collector currents, minority carriers lifetime, and current gain factor/3 with respect to the dose were analyzed. The contributions of the base current according to the defect types were also reported. It was declared that the radiation effect of neutrons was almost similar between the two transistor types, this effect at high dose may decrease the value of/3 to less than one. The Messenger-Spratt equation was used to describe the experimental results in this case. However, the experimental data demonstrated that the effect of gamma rays was generally higher on NPN than PNP transistors. This is mainly attributed to the difference in the behavior of the trapped positive charges in the SiO2 layers. Meanwhile, this difference tends to be small for high gamma dose.

Surface Damage in Wire cut Silicon Wafers

The surface damage and the damage depth in wire-cut silicon wafers and inner-diameter (ID) cut silicon wafers were studied by means of thickness meter, scanning electron microscopy (SEM) and double crystal X-ray diffractometer. The results show that the surface of wire-cut silicon wafers is rougher than that of ID-cut silicon wafers and the surface damage in wire-cut silicon wafers is more serious than that in ID-cut silicon wafers, while the damage depth in wire-cut silicon wafers is smaller than that in ID-cut silicon wafers. The possible reasons for the generation of surface damage in wire-cut silicon wafers were also discussed.

Characterization of surface damage of a solid plate under tensile loading using nonlinear Rayleigh waves

This letter reports experimental observation of a direct correlation between the acoustic nonlinearity parameter (NP) measured with nonlinear Rayleigh waves and the accumulation of plasticity damage in an AZ31 magnesium alloy plate specimen.Rayleigh waves are generated and detected with wedge transducers,and the NPs are measured at different stress levels.The results show that there is a significant increase in the NPs with monotonic tensile loads surpassing the material’s yielding stress.The research suggests an effective nondestructive evaluation method to track the surface damage in metals.

INVESTIGATION OF SURFACE DAMAGE OF LiNbO_3 IMPLANTED BY Ti ION

In this paper, damages and annealing effects of X,Y and Z cut LiNbO-3 implanted by 350keV high energy Ti (1.5 x 1017 / cm2) are studied. The surface damages of X,Y cut plates are nearly amorphous, but the surface damage of Z cut does not reach saturation. Radiation damage is mainly due to Nb moving atoms and Ti atoms occupy the interstitial sites. By annealing the sample at 1000℃, most damage is removed from the boundary between implanted layer and LiNbO3 base to surface.

The Innovation of Surface Damage Detectionof Metallic Members

Exoelectron is low energy electrons delayed emission from a metallic member surface.The fatigue damage of the metallic often happens under the action of a dynamic load. Theaccumulation of fatigue damage of metallic frames leads to the result of surface fatiguemicrocracks. Microcracks would result in the exoelectrons emission. In this paper therelationship between exoelectrons emission and the fatigue damage microcracks of metallicframes is studied. A new type of the Double Grid Air Counter (DGAC) was designed.Experiments have shown that the systems of the DGAC are sound and work efficiently, and themeasurement precision was important, and valuable in study and detection of formation andgrowth of microcracks of the metallic members surface in the initial stage offatigue da,nage.

A review of surface damage/microstructures and their effects on hydrogen/helium retention in tungsten

The change in surface damage/microstructures and its effects on the hydrogen(H)isotope/helium(He)dynamic behavior are the key factors for investigating issues of tungsten(W)-based plasma-facing materials(PFMs)in fusion such as surface erosion,H/He retention and tritium(T)inventory.Complex surface damage/microstructures are introduced in W by high-temperature plasma irradiation and new material design,typically including pre-damage and multi-ion co-deposition induced structures,solute elements and related composites,native defects like dislocations and interfaces,and nanostructures.Systematic experimental and theoretical researches were performed on H isotope/He retention in complex W-based materials in the past decades.In this review,we aim to provide an overview of typical surface damage/microstructures and their effects on H/He retention in W,both in the experiment and multiscale modeling.The distribution/state,dynamics evolution,and interaction with defects/microstructures of H/He are generally summarized at different scales.Finally,the current difficulties,challenges and future directions are also discussed about H/He retention in complex W-based PFMs.

Characteristics of Laser-Induced Surface and Bulk Damage of Large-Aperture Deuterated Potassium Dihydrogen Phosphate at 351 nm

Deuterated potassium dihydrogen phosphate damage performance at 351 nm is studied on a large-aperture laser system. Bulk and rear-surface damage are initiated under the 3ω fluences of 6.T J/cm2 and 33/cm2, and show different growth characteristics under multiple laser irradiations with the fluence of 6 J/cm2. The size and number of bulk damage keep unchanged once initiated. However, surface damage size also does not grow, while surface damage number increases linearly with laser shots. Different damage thresholds and growth behaviors suggest different formations of bulk and surface damage precursors. The cause of surface damage is supposed to be near-surface absorbing particles buried under the sol-gel coating.

Study on the influence of side-blown airflow velocities on plasma and combustion wave generated from fused silica induced by combined pulse laser

This study examines the impact of variations in side-blowing airflow velocity on plasma generation,combustion wave propagation mechanisms,and surface damage in fused silica induced by a combined millisecond-nanosecond pulsed laser.The airflow rate and pulse delay are the main experimental variables.The evolution of plasma motion was recorded using ultrafast time-resolved optical shadowing.The experimental results demonstrate that the expansion velocities of the plasma and combustion wave are influenced differently by the sideblowing airflow at different airflow rates(0.2 Ma,0.4 Ma,and 0.6 Ma).As the flow rate of the sideblow air stream increases,the initial expansion velocities of the plasma and combustion wave gradually decrease,and the side-blow air stream increasingly suppresses the plasma.It is important to note that the target vapor is always formed and ionized into plasma during the combined pulse laser action.Therefore,the side-blown airflow alone cannot completely clear the plasma.Depending on the delay conditions,the pressure of the side-blowing airflow,the influence of inverse Bremsstrahlung radiation absorption and target surface absorption mechanisms can lead to a phenomenon known as the double combustion waves when using a nanosecond pulse laser.Both simulation and experimental results are consistent,indicating the potential for further exploration of fused silica targets in the laser field.

Rail RCF damage quantification and comparison for different damage models

There are several fatigue-based approaches that estimate the evolution of rolling contact fatigue(RCF) on rails over time and built to be used in tandem with multibody simulations of vehicle dynamics. However, most of the models are not directly comparable with each other since they are based on different physical models even though they shall predict the same RCF damage at the end.This article studies different approaches to quantifying RCF and puts forward a measure for the degree of agreement between them. The methodological framework studies various steps in the RCF quantification procedure within the context of one another, identifies the ‘primary quantification step’ in each approach and compares results of the fatigue analyses. In addition to this, two quantities—‘similarity’ and ‘correlation’—have been put forward to give an indication of mutual agreement between models.Four widely used surface-based and sub-surface-based fatigue quantification approaches with varying complexities have been studied. Different operational cases corresponding to a metro vehicle operation in Austria have been considered for this study. Results showed that the best possible quantity to compare is the normalized damage increment per loading cycle coming from different approaches. Amongst the methods studied, approaches that included the load distribution step on the contact patch showed higher similarity and correlation in their results.While the different approaches might qualitatively agree on whether contact cases are ‘damaging’ due to RCF, they might not quantitatively correlate with the trends observed for damage increment values.

CORRELATION BETWEEN TENSILE STRENGTH AND SURFACE MORPHOLOGY OF SiC FILAMENT

The surface morphology of the continuous SiC filament,prepared by radio frequency heating CVD technique,has been observed and the tensile strength of the filament related to the technological parameters of preparation has also been investigated.The tensile strength is found to be dependent directly upon the surface smoothness,grain size and uniformity.How- ever,the CVD temperature,the composition and flow rate of reactive gases,as well as the cleansing of W wire substrate,etc.,are the very important factors.A protective layer coated over the outer surface of SiC filament may effectively improve the smoothness,susceptibility to surface damage and properties of the SiC filament.

Hardening Effect on Machined Surface for Precise Hard Cutting Process with Consideration of Tool Wear

During hard cutting process there is severe thermodynamic coupling effect between cutting tool and workpiece, which causes quenching effect on finished surfaces under certain conditions. However, material phase transformation mechanism of heat treatment in cutting process is different from the one in traditional process, which leads to changes of the formation mechanism of damaged layer on machined workpiece surface. This paper researches on the generation mechanism of damaged layer on machined surface in the process of PCBN tool hard cutting hardened steel Cr12MoV. Rules of temperature change on machined surface and subsurface are got by means of finite element simulation. In phase transformation temperature experiments rapid transformation instrument is employed, and the effect of quenching under cutting conditions on generation of damaged layer is revealed. Based on that, the phase transformation points of temperature under cutting conditions are determined. By experiment, the effects of cutting speed and tool wear on white layer thickness in damaged layer are revealed. The temperature distribution law of third deformation zone is got by establishing the numerical prediction model, and thickness of white layer in damaged layer is predicted, taking the tool wear effect into consideration. The experimental results show that the model prediction is accurate, and the establishment of prediction model provides a reference for wise selection of parameters in precise hard cutting process. For the machining process with high demanding on surface integrity, the generation of damaged layer on machined surface can be controlled precisely by using the prediction model.

Fatigue Life Analysis of Coiled Tubing in Deep Well Jet Plugging Removal

The coiled tubing plugging has become the main means of plugging in gas Wells in Xinjiang. These Wells are deep and have high pressure, which can easily affect the fatigue life of the operating coiled tubing. In order to improve the life of coiled tubing in high-pressure gas Wells, this paper studies the plugging conditions of coiled tubing in high-pressure ultra-deep Wells. Firstly, the cross section deformation of coiled tubing under high internal pressure is analyzed. Secondly, the factors influencing the fatigue life of coiled tubing and the influence of surface damage on the fatigue life of coiled tubing were studied. Finally, the mechanism of furrow damage caused by coiled tubing and the main measures to reduce furrow damage are analyzed. The following suggestions are made to improve the life of coiled tubing: select the right material and the right size coiled tubing;Use appropriate measures to prevent premature coiled tubing failure and reduce operating costs.

Modeling of Mechanical Behavior of Fractal Rock Joint

The present study shows that naturally developed fracture surfaces in rocks display the properties of self-affine fractals. Surface roughness can be quantitatively characterized by fractal dimension D and the intercept A on the log-log plot of variance: the former describes the irregularity and the later is statistically analogues to the slopes of asperities. In order to confirm the effects of these fractalparameters on the properties and mechanical behavior of rock joints, which have been observed in experiments under both normal andshear loadings, a theoretic model of rock joint is proposed on the basis of contact mechanics. The shape of asperity at contact is assumed to have a sinusoidal form in its representative scale r, with fractal dimension D and the intercept A. The model considers different local contact mechanisms, such as elastic deformation, frictional sliding and tensile fracture of the asperity. The empirical evolution law of surface damage developed in experiment is implemented into the model to up-date geometry of asperity in loading history. The effects of surface roughness characterized by D, A and re on normal and shear deformation of rock joint have been elaborated.

Postprocessing treatments to improve the laser damage resistance of fused silica optical surfaces and SiO_2 coatings

The combination of deep wet etching and a magneto-rheological finishing （MRF） process is investigated to simultaneously improve laser damage resistance of a fused-silica surface at 355 nm. The subsequently deposited SiO2 coatings are researched to clarify the impact of substrate finishing technology on the coatings. It is revealed that a deep removal proceeding from the single side or double side had a significant impact on the laser-induced damage threshold （LIDT） of the fused silica, especially for the rear surface. After the deep etching, the MRF process that followed does not actually increase the LIDT, but it does ameliorate the surface qualities without additional LIDT degradation. The combination guarantee both the integrity of the surface＇s finish and the laser damage resistance of the fused silica and subsequent SiO2 coatings.

Towards a unified classification of wear

Since the beginning of the systematic study of wear,many classification schemes have been devised.However,though covering the whole field in sum,they stay only loosely connected to each other and do not build a complete general picture.To this end,here we try to combine and integrate existing approaches into a general simple scheme unifying known wear types into a consistent system.The suggested scheme is based on three classifying criterions answering the questions“why”,“how”and“where”and defining a 3-D space filled with the known wear types.The system can be used in teaching to introduce students to such complex phenomena as wear and also in engineering practice to guide wear mitigation initiatives.

Examination on the wear process of polyformaldehyde gears under dry and lubricated conditions

This study presents the results of detailed wear process examination on polyformaldehyde gears under both dry and lubricated conditions.A multi-purpose durability test rig was employed to study the wear performance of polyformaldehyde gear pairs.The wear behaviors of polyformaldehyde gears under dry and oil-lubricated operating conditions were characterized via measurements of gear tooth surface micro-topography and tooth profile deviation.Under the dry running condition,a hump and a gully appear on the tooth surface in the pitch line area of the driving gear and the driven wheel,respectively.The largest amount of wear was observed around the tooth root of the driving gear.However,the gear tooth wear pattern with lubrication is different from that under the dry running condition.

Mechanical Analysis and Strength Checking of Current Collector Failure in the Winding Process of Lithium-Ion Batteries

The current collector fracture failure of lithium-ion batteries(LIBs)occurs during its winding production process frequently,and the consequent damages are usually large,but little research has been conducted on this phenomenon.This work stems from the difficulty and obstacles in the winding process of actual production of LIBs.The fracture failure of the current collectors is easily caused by the evolution and mutation of the mechanical behavior during the winding process,resulting in safety hazards and poor efficiency.The purpose of this work is to reveal the evolution and distribution mechanism of circumferential strain of the current collectors on the fracture failure under the constraint of winding process.Experimental tests,finite element calculations and theoretical model are used to study the evolution and distribution of circumferential strain.The dynamic evolution process of circumferential strain is tested accurately,and the mechanism of fracture failure of current collectors is revealed.The criterion for current collector strength is proposed based on the results of strain analysis and SEM observation.

Brittle-plastic Theory and Identification of Material Properties for Elastoplastic Structure

The paper is concerned with brittle plastic problems. A formulation of damage surface perturbation is proposed. The regularized least square methods for solving the inverse problems of elastoplastic rock structures have been proposed. The techniques have been applied to some specific examples which give the evidence that the method is satisfactory and efficient.