Effects of Shielding Coatings on the Anode Shaping Process during Counter-rotating Electrochemical Machining

Electrochemical machining （ECM） has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is to a great extent limited by the stray corrosion of the unwanted material removal. Many attempts have been made to improve the ECM accuracy, such as the use of a pulse power, passivating electrolytes and auxiliary electrodes. However, they are sometimes insufficient for the reduction of the stray removal and have their limitations in many cases. To solve the stray corrosion problem in CRECM, insulating and conductive coatings are respectively used. The different implement processes of the two kinds of coatings are introduced. The effects of the two kinds of shielding coatings on the anode shaping process are investigated. Numerical simulations and experiments are conducted for the comparison of the two coatings. The simulation and experimental results show that both the two kinds of coatings are valid for the reduction of stray corrosion on the top surface of the convex structure. However, for insulating coating, the convex sidewall becomes concave when the height of the convex structure is over 1.26 ram. In addition, it is easy to peel off by the high-speed electrolyte. In contrast, the conductive coating has a strong adhesion, and can be well reserved during the whole machining process. The convex structure fabricated by using a conductive iron coating layer presents a favorable sidewall profile. It is concluded that the conductive coating is more effective for the improvement of the machining quality in CRECM. The proposed shielding coatings can also be employed to reduce the stray corrosion in other schemes of ECM.

Preparation and characterization of carbonyl iron soft magnetic composites with magnesioferrite insulating coating layer

Spherical carbonyl iron(Fe)powders were coated with magnesioferrite(MgFe2O4)insulating coating layer and then mixed with epoxy-modified silicone resin(ESR).Soft magnetic composites(SMCs)were fabricated by compaction of the coated powders and annealing treatment.Transmission electron microscopy(TEM),scanning electron microscopy(SEM),energy dispersive spectroscopy(EDS),X-ray diffractometry(XRD)and X-ray photoelectron spectroscopy(XPS)revealed that the MgFe2O4 layer was coated on the surface of the iron powders.The magnetic properties of SMCs were determined using a vibrating sample magnetometer and an auto testing system for magnetic materials.The results showed that the SMCs prepared at 800 MPa and 550℃ exhibited a significant core loss of 167.5 W/kg at 100 kHz and 50 mT.

Performance improvement of Fe-6.5Si soft magnetic composites with hybrid phosphate-silica insulation coatings

Fe-6.5Si soft magnetic composites(SMCs)with hybrid phosphate-silica insulation coatings have been designed to improve their comprehensive property via chemical coating combining sol-gel method in this work.The microstructure and magnetic performance of the Fe-6.5Si SMCs with hybrid phosphate-silica insulation coatings were investigated.The hybrid phosphate-silica coatings with high heat resistance and high withstand pressure,formed on the surface of the Fe-6.5Si ferromagnetic powders,were found stable in the composites.Compared with Fe-6.5Si SMCs coated by single phosphate or single silica,Fe-6.5Si SMCs with hybrid phosphate-silica show much higher permeability and lower core loss.The work provides a new way to optimize the magnetic performance of soft magnetic composites.

Analysis of MHD Pressure Drop in Liquid LiPb Flow in Chinese ITER DFLL-TBM with Insulating Coating

Magnetohydrodynamic （MHD） pressure drop in the Chinese Dual Functional Liquid Lithium-lead Test Blanket Module （DFLL-TBM） proposed for ITER is discussed in this paper. Electrical insulation between the coolant channel surfaces and the liquid metal is required to reduce the MHD pressure drop to a manageable level. Insulation can be provided by a thin insulating coating, such as Al2O3, which can also serve as a tritium barrier layer, at the channel surfaces in contact with LiPb. The coating＇s effectiveness for reducing the MHD pressure drop is analysed through three-dimensional numerical simulation. A MHD-based commercial computational fluid dynamic （CFD） software FLUENT is used to simulate the LiPb flow. The effect on the MHD pressure drop due to cracks or faults in the coating layer is also considered. The insulating performance requirement for the coating material in DFLL-TBM design is proposed according to the analysis.

Thickness Measurement of Insulation Coating by NIR Spectrometry Based on Boosting-KPLS

A novel thickness measurement method for surface insulation coating of silicon steel based on NIR spectrometry is explored.The NIR spectra of insulation coating of silicon steel were collected by acousto-optic tunable filter(AOTF) NIR spectrometer.To make full use of the effective information of NIR spectral data,discrete binary particle swarm optimization(DBPSO) algorithm was used to select the optimal wavelength variates.The new spectral data,composed of absorbance at selected wavelengths,were used to create the thickness quantitative analysis model by kernel partial least squares(KPLS) algorithm coupled with Boosting.The results of contrast experiments showed that the Boosting-KPLS model could efficiently improve the analysis accuracy and speed.It indicates that Boosting-KPLS is a more accurate and robust analysis method than KPLS for NIR spectral analysis.The maximal and minimal absolute error of 30 testing samples is respectively-0.02 μm and 0.19 μm,and the maximal relative error is 14.23%.These analysis results completely meet the practical measurement need.

Preparation and Recipe Optimization of Water-based Architectural Heat Insulation Coatings

Water-based architectural heat insulation coatings were studied to overcome the drawbacks of conventional inorganic silicate heat insulation coatings. The heat insulation coatings were prepared with the method of mechanical agitation when the mixed organic polymer emulsions were used as binder of the coatings and the mixed heat insulating aggregates were applied as powder, and some assistants were also added. Water temperature difference in the plastic container, which was coated with heat insulation coatings, represented the heat-insulating property of the coatings. The influences of components of mixed polymer emulsion, mass ratio of polymer emulsion to powder, particle size of heat insulating aggregates, added amount of air entraining admixture and the match of thickeners on the properties of the coatings were studied. The experimental results show that the heat insulation coatings with good finishing, heat-insulation property and artificial weathering can be prepared when the binder is composed of 66.92% styrene-acrylic emulsion, 16.59% elastic emulsion and 16.49% silicone-acrylic emulsion, the mass ratio of polymer emulsion to powder is 0.45, the particle size of heat insulating aggregates is in the rang of 200 and 250 mesh size, the added amount of sericite is 15%, and the added amount of air entraining admixture is in the range of 1.0% and 1.5% and the thickeners are the mixtures of ASE-60 and RM-5000.

Effects of two silicone resin coatings on performance of FeSiAl magnetic powder cores

Two silicon resins with excellent thermal stability,JH1123 and JH7102,are used as the insulated agents and binders for the gas-atomized FeSiAl powder,and corresponding magnetic powder cores(MPCs)are fabricated.The insulation capability and application prospects of the two silicon resins are evaluated by comparing the magnetic properties of the coated powder and MPCs.The scanning electron microscopy,energy dispersive X-ray spectroscopy and Fourier transform infrared spectroscopy results show that uniform insulation layers are both formed on the powder surfaces.JH1123 has stronger binding ability,and the JH1123-coated powder exhibits severe agglomeration,with d50(average particle size)approximately twice that of the JH7102-coated powder.Both as-prepared MPCs exhibit outstanding soft magnetic properties.Wherein,the permeability of FeSiAl@JH1123 is up to 74.0,which is 35.5%higher than that of FeSiAl@JH7102 because JH1123 can further improve the density of the MPCs.As for FeSiAl@JH7102,it has better direct current bias and lower core loss of 716.9 mW cm^(−3) at 20 mT and 1000 kHz due to its lower coercivity and greater anti-magnetic saturation ability.A comprehensive comparison shows that FeSiAl@JH1123 is suitable for medium and high frequency applications,while FeSiAl@JH7102 is more suitable for high frequency applications.This indicates that the use of JH1123 and JH7102 silicon resins for binding and insulated coating not only simplifies the preparation process of MPCs,but also enables the controlled production of MPCs for different applications.

Study on the performance of lightweight roadway wall thermal insulation coating containing EP-GHB mixed ceramsite

As the mining depth increases,the problem of high-temperature thermal damage mainly caused by heat dissipation of surrounding rock is becoming more and more obvious.It is very important to solve the environmental problem of mine heat damage to improve the efficiency of mineral resource exploitation and protect the physical and mental health of workers.One can apply thermal insulation coating on the walls of mine roadways as a means of implementing active heat insulation.In this paper,expanded perlite(EP)and glazed hollow bead(GHB)are used as the main thermal insulation materials,ceramsite and sand as aggregate,plus glass fiber and sodium dodecyl sulfate to develop a new lightweight composite thermal insulation coating through orthogonal experiment method.According to the plate heat flow meter method and mechanical test method,the thermal insulation and mechanical properties of EP-GHB mixed ceramsite coating were studied by making specimens with different parameter ratios,and according to the analysis of the experimental results,the optimal mix ratio of the coating was selected.In addition,Fluent numerical simulation software was used to establish the roadway model,and the thermal insulation effect of the coating in the roadway under different working conditions was studied.The results show that the thermal conductivity of the prepared composite thermal insulation coating material is only 8.5% of that of ordinary cement mortar,and the optimal thickness of adding thermal insulation coating is 0.2 m,which can reduce the outlet air temperature of the roadway with a length of 1000 m by 4.87 K at this thickness.The thermal insulation coating developed in this study has the advantages of simple technology and strong practicability,and has certain popularization and application value in mine heat damage control.

EFFECTS OF ELECTRODE INSULATION THICKNESS ON ELECTROCHEMICAL DRILLING STABILITY AND ACCURACY

Effect of electrode insulation on the electric field and the flow field of the machining gap during electrochemical drilling（ECD） is numerically studied. Electric field simulation shows that the current density along the side gap decreases with increasing the thickness of electrode insulation. And the analysis of the electrolyte flow in the frontal gap shows that the insulation thickness has a remarkable influence on the pressure distributions. Ex- periments investigate the influence of the insulation thickness on the main characteristics of the machined hole, i.e. , radial overcut, entrance conicity, and current stability. The poor hole is observed and identified as most likely to occur with a combination of the low tool feed rate and the low insulation thickness. The appropriate thickness of the insulating layer leads to an improvement on hole accuracy and machining stability.

Development of a large nanocrystalline soft magnetic alloy core with highμ'_(p)Qf products for CSNS-Ⅱ

A waterproof nanocrystalline soft magnetic alloy core with a size of O.D.850 mm×I.D.316 mm×H.25 mm for radio frequency acceleration was successfully developed by winding 18μm 1k107b MA ribbons.Theμ'_(p)Qf products reached 7.5,10,and 12 GHz at 1,3,and 5 MHz,respectively.Theμ'_(p)Qf products of the MA core(O.D.250 mm×I.D.100 mm×H.25 mm)manufactured using a 13μm MA ribbon further increased by 30%.Detailed improvements on the MA core manufacture process are discussed herein.Continuous high-power tests on the new MA cores demonstrated its good performance of waterproofness,particularly its stability of highμ'_(p)Qf products.The MA core with highμ'pQf product and large size can operate under a high average RF power,high electric field,and in deionized water,which will be used in the China Spallation Neutron Source PhaseⅡ(CSNS-Ⅱ).

Microclimatic Experimentation Applied to Insulating Horizontal Coverage in Mexicali, Mexico

The thermal response of hedges alters the urban climate, resulting in energy and comfort affectations that impact city dwellers, so the aim of this study is to analyze the energy fluxes of urban horizontal coverage, especially expanded polystyrene waterproofed with elastomeric paint in the city of Mexicali, Baja California, located northwest of Mexico. The experiment was realized on summer of 2011 and 2012 by using four components radiometric sensor, eddy covariance equipment, which was possible to analyze the behavior and intensities of heat fluxes using the model Q＊ = QE ＋ QG ＋ QH ＋ QF ＋ QD. The results show that in both campaigns the sensible heat flux exceeds the net radiation, in 2011 the net radiation was 31.41 W/mE and sensible heat flux of 74.9 W/m2, in 2012 resulted 43.46 W/m2 and 87.32 W/mE, respectively. This additional heat flux is attributed to the thermal influence of the air conditioning units, which changes the energy balance model to Q＊ = QH ＋ QF ＋ QD. With the results arise the need for experimentation on a larger scale in which it is possible to model the flow in housing development. The knowledge of the energy balance model will help to propose materials that minimize the thermal impact to the city of Mexicali.

Dynamic performance and energy efficiency of reflective and insulative composite coating on building exterior wall

Reflective and insulative composite coatings are a new energy-saving material with high solar reflectance and extremely low thermal conductivity for buildings.The optimization and impact of high solar reflectance and low thermal conductivity on the insulating capacity of walls remain uncertain.This work investigates the dynamic thermal performance and energy efficiency of a reflective and insulative composite coating in regions with hot summer and warm winter.A simplified thermal resistance-heat capacitance model of an exterior building wall is established to predict thermal performance.The dynamic temperature and heat flow of the wall are predicted to reduce heat loss through the interior surface of the wall and compared to the conventional coating.The specific impact of the thermal conductivity and solar reflectance of the coating on the heat loss is further investigated to minimize heat loss of the wall.This research shows that the composite coating shows better performance on adjusting outdoor climate change than the other coating.Compared with cement,it reduces the maximum temperature of the exterior surface of the wall by 7.45°C,and the heat loss through the interior surface of the wall by 38%.The heat loss is reduced with the increase of solar reflectance and the reduction of thermal conductivity.The results can provide a useful reference and guidance for the application of reflective and insulative composite coating on building exterior wall to promote their energy-saving use on building envelopes.

Dual-sized hollow particle incorporated fibroin thermal insulating coatings on catheter for cerebral therapeutic hypothermia

Selective endovascular hypothermia has been used to provide cooling-induced cerebral neuroprotection,but current catheters do not support thermally-insulated transfer of cold infusate,which results in an increased exit temperature,causes hemodilution,and limits its cooling efficiency.Herein,air-sprayed fibroin/silica-based coatings combined with chemical vapor deposited parylene-C capping film was prepared on catheter.This coating features in dual-sized-hollow-microparticle incorporated structures with low thermal conductivity.The infusate exit temperature is tunable by adjusting the coating thickness and infusion rate.No peeling or cracking was observed on the coatings under bending and rotational scenarios in the vascular models.Its efficiency was verified in a swine model,and the outlet temperature of coated catheter(75μm thickness)was 1.8-2.0◦C lower than that of the uncoated one.This pioneering work on catheter thermal insulation coatings may facilitate the clinical translation of selective endovascular hypothermia for neuroprotection in patients with acute ischemic stroke.

Reaction Mechanism and Thermal Insulation Property of Al-deposited 7YSZ Thermal Barrier Coating

To increase the performance and efficiency of thermal barrier coating （TBC）, it is important to improve the thermal insulation property. In this work, a columnar AI film was deposited at the top of 7 wt% yttria- stabilized zirconia （7YSZ） TBC by magnetron sputtering. A vacuum heat treatment was then carried out to improve the insulation property of Al-deposited TBC. Reaction mechanism of AI-ZrO2 system in AIdeposited TBC was studied by differential thermal analysis （DTA）. The phase structures of the assprayed TBC, the Al-deposited and vacuum-treated TBC were characterized. The microstructure evolution of M-deposited TBC was illustrated after vacuum heat treatment. And the insulation property of the assprayed TBC and treated TBC was compared. The results show that a multi-scaled layer, consisting of micron/ nano structured α-Al2O3 and AI3Zr grain was in situ synthesized at the top of 7YSZ coating via vacuum heat treatment. The TBC with the multi-scaled overlay has better insulation property than the asspraved TBC.