Machining the Integral Impeller and Blisk of Aero-Engines:A Review of Surface Finishing and Strengthening Technologies

The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has signif- icant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and inte- grated finishing and strengthening technologies and dis- cusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.

Influence of Surface Finishing on High-Temperature Oxidation of AISI Type 444 Ferritic Stainless Steel Used in SOFC Stacks

This research is focused on the study of the samples, approximatively 15 × 30 mm^2 sized, that were mechanically cut from two sheets （0.4 and 0.2 mm thick, respectively） of AIS1444 Type ferritic stainless steel （FSS） （DIN 1.4521, Eu designation X2CrMoTil8-2）; this material was in the ＇as-rolled＇ state. Part of these specimens were treated superficially on one side using abrasive SiC papers with different average grit sizes （i.e., 46.2, 30.2, 18.3 gm） and diamond suspension （up to 1 tim） in order to obtain various surface roughness. Both the ＇as-rolled＇ and superficially treated samples were then aged in a muffle fumace in static air according to a thermal cycle corresponding to the curing phase of an experimental glass used as sealing in the solid oxide fuel cell stacks. After aging, the chemical compositions and mor- phological peculiarities of the scale formed depending on the thickness of the samples and their surface state were studied by scanning electron microscopy, energy-dispersive spectroscopy, micro-Raman spectroscopy, bright field light optical microscopy. The obtained results show that all scales formed consist of an inner Cr2O3 subscale and an outer （Mn,Cr）3O4 spinel layer; the relationship between FSS grain size and scale microstructural features is consistent on the samples with mirror-like surface only; the scale thicknesses on SiC grinded samples are comparable; the scales covering the ＇as-rolled＇ surfaces are morphologically similar to those grown on the surfaces finished with the 30.2 and 18.3 μm SiC papers, and their thicknesses show an intermediate situation between the abraded and the mirror-like specimens. The last described characteristics depend mainly on the surface and microstructural peculiarities resulting from the rolling process.

Parametric Optimization to Minimise the Surface Roughness on the Machining of GFRP Composites

The present investigation focuses on the parametric influence of machining parameters on the surface finish obtained in turning of glass fiber reinforced polymer （GFRP） composites. The experiments were conducted based on Taguchi＇s experimental design technique. Response surface methodology and analysis of variance （ANOVA） were used to evaluate the composite machining process to perform the optimization. The results revealed that the feed rate was main influencing parameter on the surface roughness. The surface roughness increased with increasing the feed rate but decreased with increasing the cutting speed. Among the other parameters, depth of cut was more insensitive. The predicted values and measured values were fairly close to each other, which indicates that the developed model can be effectively used to predict the surface roughness on the machining of GFRP composites with 95% confidence intervals. Using such model could remarkablely save the time and cost.

Surface finish of micro punch with ion beam irradiation

Ion beam irradiation was adopted for surface treatment of the micro punch manufactured by precision machining.Ar plasma was used for the ion irradiation process,which was generated by the electron cyclotron resonance(ECR)equipment.The surface finish processes of micro punch were carried out at irradiation angles of 45°and 10°,respectively.The surface roughness and topography were measured to estimate the quality of surface finish.The results show that the ion irradiation is very effective to reduce the surface roughness,which can be improved more significantly at irradiation angle of 10°than at 45°.The technology of surface finish with ion beam irradiation is suitable for the surface treatment of micro die.

An Expert System for the Prediction of Surface Finish in Turning Process

Prediction of surface finish in turning process is a difficult but important task. Artificial Neural Networks (ANN) can reliably pred ict the surface finish but require a lot of training data. To overcome this prob lem, an expert system approach is proposed, wherein it will be possible to predi ct the surface finish from limited experiments. The expert system contains a kno wledge base prepared from machining data handbooks and number of experiments con ducted by turning steel rods, over a wide range of cutting parameters. With this knowledge base, the expert system predicts surface finish for different tool-w ork-piece combinations, by carrying out few experiments for each case. The prop osed expert system model is validated by carrying out a number of experiments.

Comprehensive Study on Machinability of Titanium Composite

Metal framework composites have higher mechanical properties in examination to metals over an extensive variety of working conditions. This makes them an alluring alternative in swapping metals for different building applications. The present review is a study on the influence of composite titanium on the cutting parameters, mechanical behavior, reinforcements, structure and nanostructure. This review will provide an understanding into selecting the optimum machining parameters for machining titanium composites. It’s also an attempt to give brief explanation by suitably machining the titanium composite which can be made reasonable.

Surface processing for iron-based degradable alloys:A preliminary study on the importance of acid pickling

The formation of a heterogeneous oxidized layer,also called scale,on metallic surfaces is widely recognized as a rapid manufacturing event for metals and their alloys.Partial or total removal of the scale represents a mandatory integrated step for the industrial fabrication processes of medical devices.For biodegradable metals,acid pickling has already been reported as a preliminary surface preparation given further processes,such as electropolishing.Unfortunately,biodegradable medical prototypes presented discrepancies concerning acid pickling studies based on samples with less complex geometry(e.g.,non-uniform scale removal and rougher surface).Indeed,this translational knowledge lacks a detailed investigation on this process,deep characterization of treated surfaces properties,as well as a comprehensive discussion of the involved mechanisms.In this study,the effects of different acidic media(HCl,HNO_(3),H_(3)PO_(4),CH_(3)COOH,H_(2)SO_(4) and HF),maintained at different temperatures(21 and 60℃)for various exposition time(15-240 s),on the chemical composition and surface properties of a Fe-13Mn-1.2C biodegradable alloy were investigated.Changes in mass loss,morphology and wettability evidenced the combined effect of temperature and time for all conditions.Pickling in HCl and HF solutions favor mass loss(0.03-0.1 g/cm^(2))and effectively remove the initial scale.

Finished surface morphology, microstructure and magnetic properties of selective laser melted Fe-50wt% Ni permalloy

This work focuses on the structure and magnetic properties of Fe-50wt% Ni permalloy manufactured from the pre-alloyed powder by selective laser melting (SLM). The selective laser melted (SLMed) alloys were characterized by a 3D profilometer,optical microscope, scanning electron microscope, X-ray diffraction, etc. The effects of the volume energy density of laser(LVED) on structure, and magnetic properties with coercivity ( H), remanence ( B), and power losses ( P), were evaluated and discussed systematically. The results show that the relative porosity rate and the surface roughness of the SLMed specimens decreased with the increase in LVED. Only the γ-(FeNi) phase was detected in the X-ray diffraction patterns of the SLMed permalloys fabricated from the different LVEDs. Statistical analysis of optical microscopy images indicated that the grain coarsened at higher LVED. Furthermore, the microstructure of the SLMed parts was a typical columnar structure with an oriented growth of building direction. The highest microhardness reached 198 HV. Besides, the magnetic properties including B, H, and Pof SLMed samples decreased when the LVED ranged from 33.3 to 60.0 J/mm ~3 firstly and then increased while LVED further up to 93.3 J/mm, which is related to the decrease in porosity and the increase in grain size, while the higher residual stress and microcracks presented in the samples manufactured using very high LVED. The observed evolution of magnetic properties and LVED provides a good compromise in terms of reduced porosity and crack formation for the fabrication of SLMed Fe-50 wt% Ni permalloy. The theoretical mechanism in this study can offer guidance to further investigate SLMed soft magnetic alloys.

Controlled preparation of PAMS hollow core microcapsules with high uniformity and its application in the production of GDP fuel capsules for ICF engineering

Uniform poly-α-methylstyrene(PAMS)hollow core microcapsules(HCMs)are widely used as templates to fabricate glow discharge polymer(GDP)fuel capsules,which are fundamental devices for inertial confinement fusion(ICF)engineering.The sphericity and surface finish uniformity of PAMS HCMs are critical for achieving highquality GDP fuel capsules.In this work,millimeter-scale PAMS HCMs were fabricated by a microencapsulation technique.The sphericity and surface finish uniformity were concurrently improved using di-t-butyl peroxide(DTBP).The mechanisms of these effects were also experimentally and theoretically investigated.The results show that DTBP distributes at the O-W2 interface of W1/O/W2 compound droplets,which resists the diffusion of molecules through the O-W2 interface bidirectionally.The resisted diffusion of H_(2)O molecules into the O phase eliminates PAMS HCM surface defects.Additionally,the resistance of fluorobenzene(FB)molecules from diffusing from the O phase into the W2 phase can effectively extend the solidification of W1/O/W2 compound droplets and thus improve the spherical uniformity of the HCMs.Using these improved PAMS HCMs,GDP fuel capsules meeting the stringent requirements for ICF engineering are prepared,and the quality of which is beyond the National Ignition Facility standard.

Short-time Oxidation of Alloy 690 in High-temperature and High-pressure Steam and Water

The oxidation behavior of alloy 690 exposed to high-temperature and high-pressure steam and water at 280℃ for 1 h was investigated by scanning electron microscopy （SEM）, atomic force microscopy （AFM） and X-ray photoelectron spectroscopy （XPS）. In high-temperature and high-pressure steam, the oxide film is composed of an outermost Ni-rich hydroxides layer, an intermediate layer of hydroxides and oxides enriched in Cr, an inner oxide layer. The film formed in high-temperature water is similar to that in steam, except for missing the Ni-rich hydroxides layer. Samples with different surface finishes （electropolished, mechanically polished, ground, and as-received） were prepared for comparison. A general increase of the oxide thickness with the degree of surface roughness is observed. The equivalent oxide thicknesses lie in the range of 100-200 nm for the as-received samples, 150-250 nm for the samples ground to 400# and 10-20 nm for the samples ground to 1500#, mechanically polished, and electropolished.

Optimal cutting condition determination for milling thin-walled details

This paper presents an approach for determiningthe optimal cutting condition for milling thin-walled ele-ments with complex shapes. The approach is based on theinteraction between the thin-walled detail and its periodicexcitation by tooth passing, taking into account the highintermittency of such a process. The influence of theexcitation frequency on the amplitude of the detail oscil-lation during milling was determined by simulation andexperiments. It was found that the analytical results agreedwith experimental data. The position of the detail when thetooth starts to cut was evaluated through experiments. Theinfluence of this parameter on the processing state is pre-sented herein. The processing stability is investigated andcompared with the proposed approach. Thereafter, spectralanalyses are conducted to determine the contribution of thevibrating frequencies to the detail behavior during processing.