Surface modification of magnesium alloys using thermal and solid-state cold spray processes:Challenges and latest progresses

Potential engineering applications of magnesium(Mg)and Mg-based alloys,as the lightest structural metal,have made them a popular subject of study.However,the inferior corrosion and wear characteristics significantly limit their application range.It is widely recognized that surface treatment is the most commonly utilized technique for remarkably improving a substrate’s surface characteristics.Numerous methods have been introduced for the surface treatment of Mg and Mg-based alloys to improve their corrosion behavior and tribological performance.Among these,thermal spray(TS)technology provides several methods for deposition of various functional metallic,ceramic,cermet,or other coatings tailored to particular conditions.Recent researches have shown the tremendous potential for thermal spray coated Mg alloys for biomedical and industrial applications.In this context,the cold spray(CS)method,as a comparatively new TS coating technique,can generate the coating layer using kinetic energy rather than combined thermal and kinetic energies,like the high-velocity oxy-fuel(HVOF)spray method.Moreover,the CS process,as a revolutionary method,is able to repair and refurbish with a faster turnaround time;it also provides solutions that do not require dealing with the thermal stresses that are part of the other repair processes,such as welding or other TS processes using a high-temperature flame.In this review paper,the recently designed coatings that are specifically applied to Mg alloys(primarily for industrial applications)employing various coating processes are reviewed.Because of the increased utilization of CS technology for both 3D printed(additively manufactured)coatings and repair of structurally critical components,the most recent CS methods for the surface treatment,repair,and refurbishment of Mg alloys as well as their benefits and restrictions are then discussed and reviewed in detail.Lastly,the prospects of this field of study are briefly discussed,along with a summary of the presented work.

Experimental and Simulation Studies on Cold Welding Sealing Process of Heat Pipes

Sealing quality strongly affects heat pipe performance, but few studies focus on the process of heat pipe sealing. Cold welding sealing technology based on a stamping process is applied for heat pipe sealing. The bonding mechanism of the cold welding sealing process （CWSP） is investigated and compared with the experimental results obtained from the bonding interface analysis. An orthogonal experiment is conducted to observe the effects of various parameters, including the sealing gap, sealing length, sealing diameter, and sealing velocity on bonding strength. A method with the utilization of saturated vapor pressure inside a copper tube is proposed to evaluate bonding strength. A corresponding finite element model is developed to investigate the effects of sealing gap and sealing velocity on plastic deformation during the cold welding process. Effects of various parameters on the bonding strength are determined and it is found that the sealing gap is the most critical factor and that the sealing velocity contributes the least effect. The best parameter combination （AIB3CID3, with a 0.5 mm sealing gap, 6 mm sealing length, 3.8 mm sealing diameter, and 50 mm/s sealing velocity） is derived within the experimental parameters. Plastic deformation results derived from the finite element model are consistent with those from the experiment. The instruction for the CWSP of heat pipes and the design of sealing dies of heat pipes are provided.

Research on fault detection method for heat pump air conditioning system under cold weather

Building energy consumption accounts for nearly 40% of global energy consumption, HVAC （Heating, Ventilating, and Air Conditioning） systems are the major building energy consumers, and as one type of HVAC systems, the heat pump air conditioning system, which is more energy-efficient compared to the traditional air conditioning system, is being more widely used to save energy. However, in northern China, extreme climatic conditions increase the cooling and heating load of the heat pump air conditioning system and accelerate the aging of the equipment, and the sensor may detect drifted parameters owing to climate change. This non-linear drifted parameter increases the false alarm rate of the fault detection and the need for unnecessary troubleshooting. In order to overcome the impact of the device aging and the drifted parameter, a Kalman filter and SPC （statistical process control） fault detection method are introduced in this paper. In this method, the model parameter and its standard variance can he estimated by Kalman filter based on the gray model and the real-time data of the air conditioning system. Further, by using SPC to construct the dynamic control limits, false alarm rate is reduced. And this paper mainly focuses on the cold machine failure in the component failure and its soft fault detection. This approach has been tested on a simulation model of the ＂Sino-German Energy Conservation Demonstration Center＂ building heat pump air-conditioning system in Shenyang, China, and the results show that the Kalman filter and SPC fault detection method is simple and highly efficient with a low false alarm rate, and it can deal with the difficulties caused by the extreme environment and the non-linear influence of the parameters, and what＇s more, it provides a good foundation for dynamic fault diagnosis and fault prediction analysis.

Optimization of Preservation on Fresh-cut Yam under Simulated Cold-chain Process

[Objectives]This study was conducted to investigate the effect of compound fresh-keeping liquid on the browning and quality of fresh-cut yam during the cold chain process.[Methods]Under the simulated cold chain condition of 4℃,a uniform design(U6*(64))experiment was carried out to optimize the compound preservative formula,and a better compound preservative formula was obtained using the regression equation.[Results]The compound preservative formula was:AA 0.25%,CA 0.5%,Nisin 0.09%,GSH 0.15%.The compound fresh-keeping liquid effectively delayed the browning of fresh-cut yam and the accumulation of MDA,maintained the content of TSS,inhibited the activity of PAL and delayed the appearance of the maximum activity of POD and POD.[Conclusions]This study provides technical support for the actual extension of the shelf life of fresh-cut yam.

Development of a Thermoplastic Magnesia Carbon Brick ——“A Cold Process Flexible System”

Conventional resin bonded MgO-C bricks, which are manufactured via cold mixing process, harden and attain brittleness during carbonization of resin due to the formation of isotropic glassy carbon. They do not exhibit thermo-plasticity, which can facilitate the release of huge amount of stresses generated during preheating or in operation. On the contrary, pitch bonded MgO-C bricks, show better pyro-plasticity due to formation of an anisotropic and graphitized coke structure during carbonization of pitch. Hence, pitch bonded bricks show a superior structural spalling resistance in comparison to resin-bonded bricks. One of the drawbacks of pitch-bonded bricks is that the manufacturing requires a hot mixing process and hot pressing facility. This paper describes how a combination of above two processes was optimized to make a MgO-C brick via cold process. These bricks exhibit a low Modulus of Elasticity and thereby facilitate release of stresses during operation. Normal coal tar pitch is considered as an environmental hazard due to the presence of polyaromatic hydrocarbons like benzopyrene B [ a ] P. So, a special binder with a low B[ a ] P was selected, which is eco-friendly in nature. Such bricks were made in our plant in China and supplied to an integrated steel plant in Europe for their ladle. The bricks supplied have given encouraging life.

STUDY OF THE NEW PROCESS OF COLD BOX ──COLD BOX PLUS PROCESS

The cold box plus process it discussed in principle When the proper heating to the corebox is given (65℃±2℃). the binder lever can be saved, also the core strength and surface hardnessare imtroved, the moisture-sensitvity is reduced. The mechanism of the cold box plus process isthat the proper heat increases the activity of resin function groups and promotes the crosslinking re-action The result of a scanning electron microscope analysis shows that the core surface strength isimproved by heat

The role ofγ-C2H5NO2 as a new transient liquid phase in cold sintering process of BaTiO3 composites

Dielectric materials,such as barium titanate(BT)-based materials,have excellent dielectric properties but require high temperatures(above 1300℃)for ceramic fabrication,leading to high costs and energy loss.The cold sintering process(CSP)offers a solution to these issues and is gaining worldwide attention as an innovative fabrication route.In this work,we proposed an alternative organic ferroelectric phase,gamma-glycine(γ-GC),which acts as a transient liquid phase to fabricate high-density composites with barium titanate(BT)at low temperatures through CSP.Our findings show that the density of 15γ-GC/85BT reached 96.7%±1.6%when it was sintered at 120℃for 6 h under 10 MPa uniaxial pressure.Scanning electron microscopy‒energy dispersive X-ray spectroscopy(SEM‒EDS)mappings of the composite suggested thatγ-GC completely underwent the precipitation-dissolution process and,therefore,filled between BT particles.Moreover,X-ray diffraction(XRD)and Fourier-transform infrared spectroscopy(FTIR)confirmed the preservation ofγ-GC without undesired phase transformation.In addition,the ferroelectric and dielectric properties ofγ-GC/BT composites have been reported.The high dielectric constant(εr)was 3600,and the low dielectric loss(tanδ)was 1.20 at 200℃and 100 kHz for the 15γ-GC/85BT composite.The hysteresis loop showed a remanent polarization(Pr)of 0.55µC·cm^(−2)and a coercive field(Ec)of 7.25 kV·cm^(−1).Our findings reaffirmed that an organic ferroelectric material(γ-GC)can act as a transient liquid phase in a CSP that can successfully and sustainably fabricateγ-GC/BT composites at low temperatures while delivering outstandingly high performance.

Cold sintering process for fabrication of a superhydrophobic ZnO-polytetrafluoroethylene(PTFE)ceramic composite

Composite coatings or films with polytetrafluoroethylene(PTFE)are typically utilized to offer superhydrophobic surfaces.However,the superhydrophobic surfaces usually have limited durability and require complicated fabrication methods.Herein,we report the successful integration of PTFE with ZnO ceramics to achieve superhydrophobicity via a one-step sintering method,cold sintering process(CSP),at 300℃.(1–x)ZnO–x PTFE ceramic composites with x ranging from 0 to 70 vol%are densified with relative density of over 97%.Micro/nano-scale PTFE polymer is dispersed among ZnO grains forming polymer grain boundary phases,which modulate surface morphology and surface energy of the ZnO–PTFE ceramic composites.For the 60 vol%ZnO–40 vol%PTFE ceramic composite,superhydrophobic properties are optimized with static water contact angles(WCAs)and sliding angles(SAs)of 162°and 7°,respectively.After abrading into various thicknesses(2.52,2.26,and 1.99 mm)and contaminating with graphite powders on the surface,WCA and SA are still maintained with a high level of 157°–160°and 7°–9.3°,respectively.This work indicates that CSP provides a promising pathway to integrate polymers with ceramics to realize stable superhydrophobicity.

A novel hole cold-expansion method and its effect on surface integrity of nickel-based superalloy

Preferred surface integrity around the hole wall is one of the key parameters to ensure the optimized performance of hole components for nickel-based superalloy.The novel hole cold expansion technique introduced in this work involves the laser texturing process(LTP)followed by the Hertz contact rotary expansion process(HCREP),where the cylindrical sleeve is the critical component connecting the abovementioned two processes.The purpose of LTP is to obtain the most optimized strengthened cylindrical sleeve surface,preparing for the following HCREP.Hereafter,the HCREP acts on the nickel-based hole components by the rotary extruding movements of the strengthened sleeve and conical mandrel tools.As compared to the as-received GH4169 material,the surface integrity characterization for the strengthened hole shows that a plastic deformation layer with finer grains,higher micro-hardness,deeper compressive residual stress(CRS)distribution and lower surface roughness is formed at the hole wall.In addition,transmission electron microscope(TEM)observations reveal the microstructure evolution mechanism in the strengthened hole.Grain refinement near the hole wall is regarded as the fundamental reason for improving the surface integrity,where the aggregated dislocations and recombined dislocation walls can be clearly observed.

Fabrication of form stable NaCl-Al2O3 composite for thermal energy storage by cold sintering process

A form stable NaCl-Al2O3(50-50 wt-%)composite material for high temperature thermal energy storage was fabricated by cold sintering process,a process recently applied to the densification of ceramics at low temperature 300℃ under uniaxial pressure in the presence of small amount o f transient liquid.The fabricated composite achieved as high as 98.65% of the theoretical density.The NaCl-Al2O3 composite also retained the chloride salt without leakage after 30 heating-cooling cycles between 750℃-850℃ together with a holding period o f 24h at 850℃.X-ray diffraction measurements indicated congruent solubility o f the alumina in chloride salt,excellent compatibility o f NaCl with Al2O3,and chemical stability at high temperature.Structural analysis by scanning electron microscope also showed limited grain growth,high density,uniform NaCl distribution and clear faceted composite structure without inter-diffusion.The latent heat storage density o f 252.5J/g was obtained from simultaneous thermal analysis.Fracture strength test showed high sintered strength around 5 GPa after 50 min.The composite was found to have fair mass losses due to volatilization.Overall,cold sintering process has the potential to be an efficient,safe and cost-effective strategy for the fabrication of high temperature thermal energy storage materials.

Combining cold sintering and Bi_(2)O_(3)-Activated liquid-phase sintering to fabricate high-conductivity Mg-doped NASICON at reduced temperatures

The cold sintering process(CSP)and Bi_(2)O_(3)-activated liquid-phase sintering(LPS)are combined to densify Mg-doped NASICON(Na_(3.256)Mg_(0.128)Zr_(1.872)Si_(2)PO_(12))to achieve high densities and conductivities at reduced temperatures.As an example,a cold-sintered specimen with the addition of 1.1wt%Bi_(2)O_(3)sintering additive achieved a high conductivity of 0.91 mS/cm(with~96%relative density)after annealing at 1000℃;this conductivity is>70%higher than that of a cold-sintered specimen without adding the Bi_(2)O_(3)sintering additive,and it is>700%of the conductivity of a dry-pressed counterpart with the same amount of Bi_(2)O_(3)added,all of which are subjected to the same heating profile.The highest conductivity achieved in this study via combining CSP and Bi_(2)O_(3)-activated LSP is>1.5 mS/cm.This study suggests an opportunity to combine the new CSP with the traditional LPS to sinter solid electrolytes to achieve high densities and conductivities at reduced temperatures.This combined CSP-LPS approach can be extended to a broad range of other materials to fabricate the“thermally fragile”solid electrolytes or solid-state battery systems,where reducing the processing temperature is often desirable.

Current understanding and applications of the cold sintering process

In traditional ceramic processing techniques,high sintering temperature is necessary to achieve fully dense microstructures.But it can cause various problems including warpage,overfiring,element evaporation,and polymorphic transformation.To overcome these drawbacks,a novel processing technique called“tcold sintering process(CSP)”has been explored by Randall et al.CSP enables densification of ceramics at ultra-low temperature(<300℃)with the assistance o f transient aqueous solution and applied pressure.In CSP,the processing conditions including aqueous solution,pressure,temperature,and sintering duration play critical roles in the densification and properties of ceramics,which will be reviewed.The review will also include the applications of CSP in solid-state rechargeable batteries.Finally,the perspectives about CSP is proposed.

Residual stress analysis of multi-pass cold spinning process

Uncontrolled residual stresses have significant effects on the service time and defects of the spun parts.Nowadays,X-Ray Diffraction(XRD)method has been widely used in the residual stress measurement of industry products with different forming processes.The calculated residual stress is usually obtained from the data fitting slope of strain and angle with Ordinary Least Squares(OLS)method.But this fitting method is not always suitable for the big fluctuant data.In this paper,the Weighted Least Square(WLS)method is used for the data fitting and compared with the OLS method.The nickel-based superalloy GH3030 and iron-based superalloy GH1140 are applied in the multi-pass cold spinning experiments.The residual stress distributions of normal,potential crack and wrinkle workpieces are discussed with the grain structure.The results show that WLS method has better goodness of fit compared with OLS method.The residual stress distributions have special relationship with potential crack,wrinkle workpiece and grain structure.

Realizing translucency in aluminosilicate glass at ultralow temperature via cold sintering process

Glass with high visible-light transparency is widely considered as the most important optical material,which typically requires a processing temperature higher than 1000℃.Here,we report a translucent aluminosilicate glass that can be prepared by cold sintering process(CSP)at merely 300℃.After eliminating structural pores in hexagonal faujasite(EMT)-type zeolite by heat treatment,the obtained highly active nanoparticles are consolidated to have nearly full density by adding NaOH solution as liquid aids.However,direct densification of EMT powder cannot remove the structural pores of zeolite completely,leading to an opaque compact after the CSP.It is proved that the chemical reaction between the NaOH-and zeolite-derived powders is highly beneficial to dissolution–precipitation process during sintering,leading to the ultra-low activation energy of 27.13 kJ/mol.Although the addition of 5 M NaOH solution greatly promotes the densification via the reaction with aluminosilicate powder,lower or higher concentration of solvent can deteriorate the transmittance of glass.Additionally,the CSP-prepared glass exhibits a Vickers hardness of 4.3 GPa,reaching 60%of the reported value for spark plasma sintering(SPS)-prepared sample.

NUMERICAL EXPERIMENT WITH PROCESSES FOR EFFECT OF AUSTRALIAN COLD AIR ACTIVITY ON EAST-ASIAN SUMMER MONSOON

Based on diagnostic results,a numerical study is made of the processes of Australian cold air activity affecting East Asian summer monsoon by using Kuo-Qian P-σ incorporated coordinate five-layer primitive equation spherical band model.Analysis is done of the response to the Southern Hemisphere circulation with and without cold air activity in Australia of the flow,rainfall and diabatic heating fields in the monsoon area of Asia,especially,East Asia,with special attention to the intensification and northward march of the monsoon due to the activity.It is found that the processes for the effect transmission are very analogous to the meridional propagation of quasi-40-day oscillation,together with the meridional wind disturbance showing south-north travel and the flow/rainfall fields exhibitirg corresponding movement in this direction,only with a 12-day lag.

Effect of Cold Rolling Parameters on the Longitudinal Residual Stress Distribution of GH4169 Alloy Sheet

For plastic deformed parts, the dimensional accuracy is significantly affected by residual stresses and so does the performance in service. Therefore, the rolling process of GH4169 alloy sheet at room temperature was investigated by finite element method. The effects of rolling reduction, friction coefficient, rolling velocity and initial stress on the longitudinal residual stress distribution over the thickness of GH4169 alloy sheet were analyzed. The results show that the values of longitudinal residual stress can be slightly reduced by increasing the rolling reduction and velocity. The longitudinal residual stress over the thickness distributes as ‘‘V＇＇ type or weak ‘‘W＇＇ type. The initial stress mainly has an effect on the longitudinal stress in the backward slip area. But the friction coefficient has remarkable influence on longitudinal residual stress. With the friction coefficient increasing from 0.1 to 0.5, the value of longitudinal residual stress on the sheet surface is reduced by 282 MPa. Simultaneously, the tensile stress turns into compressive stress with a strong‘‘W＇＇ type distribution.