Underwater Laser Welding/Cladding for High-performance Repair of Marine Metal Materials:A Review

With the rapid developments of marine resource exploitation,mounts of marine engineering equipment are settled on the ocean.When it is not possible to move the damaged equipment into a dry dock,welding operations must be performed in underwater environments.The underwater laser welding/cladding technique is a promising and advanced technique which could be widely applied to the maintenance of the damaged equipment.The present review paper aims to present a critical analysis and engineering overview of the underwater laser welding/cladding technique.First,we elaborated recent advances and key issues of drainage nozzles all over the world.Next,we presented the underwater laser processing and microstructural-mechanical behavior of repaired marine materials.Then,the newly developed powder-feeding based and wire-feeding based underwater laser direct metal deposition techniques were reviewed.The differences between the convection,conduction,and the metallurgical kinetics in the melt pools during underwater laser direct metal deposition and in-air laser direct metal deposition were illustrated.After that,several challenges that need to be overcame to achieve the full potential of the underwater laser welding/cladding technique are proposed.Finally,suggestions for future directions to aid the development of underwater laser welding/cladding technology and underwater metallurgical theory are provided.The present review will not only enrich the knowledge in the underwater repair technology,but also provide important guidance for the potential applications of the technology on the marine engineering.

Laguerre Simulation and Visualization for Microstructure of Metal Materials

Simulation method was designed to divide Laguerre diagram for right circle group with different weight; out-of-core incremental algorithm for Laguerre diagram was constructed; simulation program development and visualization was done and simulation was realized in user-specified arbitrary area for simulation of metal materials microstructure, which facilitated the practical application and secondary development of Laguerre diagram in the field of material science engineering. Finally, the utilization of a developed software package exemplified the simulation application of microstructure about metal materials and proved its validity.

Preparation of New Type Ni-P Micro/Nano Metal Material Based on Bacteria Shape

A new type of Ni-P alloy with rod-shape was prepared by electroless deposition method based on the shape of Nocadia, a kind of bacteria. The material was characterized by microbiological method, scanning electron microscope, energy dispersion spectroscopy, transmission electron microscopy, fourier transform infrared spectroscopy, X-ray diffraction and vibrant sample magnetometer. It was found that Ni-P alloy deposited on Nocadia surface was amorphous when pH=8.0. The amount of Ni crystalline increased with pH of plating solution. Ni-P nano-particles deposited on active locations on the surface at the initial stage, and then homogeneous Ni-P film formed with time. Nocadia remained their original rod shape after Ni-P nano-particles deposition. The new type metal material formed of Ni-P alloy with nano-particles was prepared. The mag- netization of the material prepared at pH=9.7 is greater than that prepared at pH=8.0. The magnetic loss of the material prepared at pH=9.7 is less than 0.1. The dielectric loss exceeds 0.3 when frequency is higher than 14 GHz, which is 1.5 at 18 GHz. The new type Ni-P metal material with Nocadia shape has dielectric loss property.

Comprehensive utilization of metal materials for steelmaking at Baosteel

Optimization of scrap utilization, through maintaining a reasonable heavy scrap ratio, determination of scrap yield, development of substitutes for scrap, recycling of high-alloy scrap and optimization of scrap utilization technology, was investigated in this paper, in terms of the supply of metal materials, production cost, production quality and environment protection. Then, recycling of solid waste resources was discussed, and the utilization conditions and methods of slag-steel, slag-iron, steel-slag, etc. were determined. Finally, the management system for comprehensive resource utilization was introduced.

Capillary Property of Entangled Porous Metallic Wire materials and Its Application in Fluid Buffers:Theoretical Analysis and Experimental Study

Strong impact does serious harm to the military industries so it is necessary to choose reasonable cushioning material and design effective buffers to prevent the impact of equipment.Based on the capillary property entangled porous metallic wire materials(EPMWM),this paper designed a composite buffer which uses EPMWM and viscous fluid as cushioning materials under the low-speed impact of the recoil force device of weapon equipment(such as artillery,mortar,etc.).Combined with the capillary model,porosity,hydraulic diameter,maximum pore diameter and pore distribution were used to characterize the pore structure characteristics of EPMWM.The calculation model of the damping force of the composite buffer was established.The low-speed impact test of the composite buffer was conducted.The parameters of the buffer under low-speed impact were identified according to the model,and the nonlinear model of damping force was obtained.The test results show that the composite buffer with EPMWM and viscous fluid can absorb the impact energy from the recoil movement effectively,and provide a new method for the buffer design of weapon equipment(such as artillery,mortar,etc.).

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials,such as poor machinability,low cutting efficiency,and high energy consumption.High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids.However,the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials.The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing,making it a focus of academic and industrial research.In this review,the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials,including titanium alloys,nickel-based alloys,and high-strength steel,are systematically explored.The laser energy field,ultrasonic energy field,and cryogenic minimum quantity lubrication energy fields are introduced.By analyzing the effects of changing the energy field and cutting parameters on tool wear,chip morphology,cutting force,temperature,and surface quality of the workpiece during milling,the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated.Finally,the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail,providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

Corrosion behavior of pure metals(Ni and Ti)and alloys(316H SS and GH3535)in liquid GaInSn

In this study,the interactions between a Ga-based liquid metal,GaInSn,and several metal materials,including pure metals(Ni and Ti)and alloys(316H stainless steel(SS)and GH3535),at 650℃were investigated.The aim was to evaluate the corrosion performance and select a suitable candidate material for use as a molten salt manometer diaphragm in thermal energy storage systems.The results indicated that the alloys(316H SS and GH3535)exhibited less corrosion than pure metals(Ni and Ti)in liquid GaInSn.Ga-rich binary intermetallic compounds were found to form on the surfaces of all the tested metal materials exposed to liquid GaInSn,as a result of the decomposition of liquid GaInSn and its reaction with the constituent elements of the metal materials.The corrosion mechanism for all the tested materials exposed to liquid GaInSn was also investigated and proposed,which may aid in selecting the optimal candidate material when liquid GaInSn is used as the pressure-sensing medium.

Experimental study on the influences of cutter geometry and material on scraper wear during shield TBM tunnelling in abrasive sandy ground

When shield TBM tunnelling in abrasive sandy ground,the rational design of cutter parameters is critical to reduce tool wear and improve tunnelling efficiency.However,the influence mechanism of cutter parameters on scraper wear remains unclear due to the lack of a reliable test method.Geometry and material optimisation are often based on subjective experience,which is unfavourable for improving scraper geological adaptability.In the present study,the newly developed WHU-SAT soil abrasion test was used to evaluate the variation in scraper wear with cutter geometry,material and hardness.The influence mechanism of cutter parameters on scraper wear has been revealed according to the scratch characteristics of the scraper surface.Cutter geometry and material parameters have been optimised to reduce scraper wear.The results indicate that the variation in scraper wear with cutter geometry is related to the cutting resistance,frictional resistance and stress distribution.An appropriate increase in the front angle(or back angle)reduces the cutting resistance(or frictional resistance),while an excessive increase in the front angle(or back angle)reduces the edge angle and causes stress concentration.The optimal front angle,back angle and edge angle for quartz sand samples areα=25°,β=10°andγ=55°,respectively.The wear resistance of the modelled scrapers made of different metal materials is related to the chemical elements and microstructure.The wear resistances of the modelled scrapers made of 45#,06Cr19Ni10,42CrMo4 and 40CrNiMoA are 0.569,0.661,0.691 and 0.728 times those made of WC-Co,respectively.When the alloy hardness is less than 47 HRC(or greater than 58 HRC),scraper wear decreases slowly with increasing alloy hardness as the scratch depth of the particle asperity on the metal surface stabilizes at a high(or low)level.However,when the alloy hardness is between 47 HRC and 58 HRC,scraper wear decreases rapidly with increasing alloy hardness as the scratch depth transitions from high to low levels.The sensitive hardness interval and recommended hardness interval for quartz sand are[47,58]and[58,62],respectively.The present study provides a reference for optimising scraper parameters and improving cutterhead adaptability in abrasive sandy ground tunnelling.

Mechanical behavior of entangled metallic wire materials-polyurethane interpenetrating composites

Composite materials exhibit the impressive mechanical properties of high damping and stiffness,which cannot be attained by employing conventional single materials.Along these lines,a novel material architecture is presented in this work in order to fabricate composites with enhanced mechanical characteristics.More specifically,entangled metallic wire materials were used as the active matrix,whereas polyurethane was employed as the reinforcement elements.As a result,an entangled metallic wire material-polyurethane composite with high damping and stiffness was prepared by enforcing the vacuum infiltration method.On top of that,the mechanical properties(loss factor,energy consumption,and average stiffness)of the proposed composite materials were characterized by performing dynamic tests,and its fatigue characteristics were verified by the micro-interface bonding,as well as the macro-damage factor.The impact of the density,preloading spacing,loading amplitude,and exciting frequency on the mechanical properties of the composites were also thoroughly analyzed.The extracted results indicate that the mechanical properties of the composites were significantly enhanced than those of the pure materials due to the introduction of interface friction.Moreover,the average stiffness of the composites was about 10 times the respective value of the entangled metallic wire material.Interestingly,a rise in the loading period leads to some failure between the composite interfaces,which reduces the stiffness property but enhances the damping dissipation properties.Finally,a comprehensive dynamic mechanical model of the composites was established,while it was experimentally verified.The proposed composites possess higher damping features,i.e.,stiffness characteristics,and maintain better fatigue characteristics,which can broaden the application range of the composites.In addition,we provide a theoretical and experimental framework for the research and applications in the field of metal matrix composites.

Quasi-static and low-velocity impact mechanical behaviors of entangled porous metallic wire material under different temperatures

To improve the defense capability of military equipment under extreme conditions,impact-resistant and high-energy-consuming materials have to be developed.The damping characteristic of entangled porous metallic wire materials(EPMWM)for vibration isolation was previously investigated.In this paper,a study focusing on the impact-resistance of EPMWM with the consideration of ambient temperature is presented.The quasi-static and low-velocity impact mechanical behavior of EPMWM under different temperatures(25℃-300℃)are systematically studied.The results of the static compression test show that the damping energy dissipation of EPMWM increases with temperature while the nonlinear damping characteristics are gradually enhanced.During the impact experiments,the impact energy loss rate of EPMWM was between 65%and 85%,while the temperatures increased from 25℃to 300℃.Moreover,under the same drop impact conditions,the overall deformation of EPMWM decreases in the temperature range of 100℃-200℃.On the other hand,the impact stiffness,energy dissipation,and impact loss factor of EPMWM significantly increase with temperature.This can be attributed to an increase in temperature,which changes the thermal expansion coefficient and contact state of the internal wire helixes.Consequently,the energy dissipation mode(dry friction,air damping,and plastic deformation)of EPMWM is also altered.Therefore,the EPMWM may act as a potential candidate material for superior energy absorption applications.

Numerical and experimental evaluation for density-related thermal insulation capability of entangled porous metallic wire material

Entangled porous metallic wire material(EPMWM)has the potential as a thermal insulation material in defence and engineering.In order to optimize its thermophysical properties at the design stage,it is of great significance to reveal the thermal response mechanism of EPMWM based on its complex structural effects.In the present work,virtual manufacturing technology(VMT)was developed to restore the physics-based 3D model of EPMWM.On this basis,the transient thermal analysis is carried out to explore the contact-relevant thermal behavior of EPMWM,and then the spiral unit containing unique structural information are further extracted and counted.In particular,the thermal resistance network is numerically constructed based on the spiral unit through the thermoelectric analogy method to accurately predict the effective thermal conductivity(ETC)of EPMWM.Finally,the thermal diffusivity and specific heat of the samples were obtained by the laser thermal analyzer to calculate the ETC and thermal insulation factor of interest.The results show that the ETC of EPMWM increases with increasing temperature or reducing density under the experimental conditions.The numerical prediction is consistent with the experimental result and the average error is less than 4%.

Liquid metal material genome： Initiation of a new research track towards discovery of advanced energy materials

As the basis of modern industry, the roles materials play are becoming increasingly vital in this day and age. With many superior physical properties over conventional fluids, the low melting point liquid metal material, especially room-temperature liquid metal, is recently found to be uniquely useful in a wide variety of emerging areas from energy, electronics to medical sciences. However, with the coming enormous utilization of such materials, serious issues also arise which urgently need to be addressed. A biggest concern to impede the large scale application of room-temperature liquid metal technologies is that there is currently a strong shortage of the materials and species available to meet the tough requirements such as cost, melting point, electrical and thermal conductivity, etc. Inspired by the Material Genome Initiative as issued in 2011 by the United States of America, a more specific and focused project initiative was proposed in this paper--the liquid metal material genome aimed to discover advanced new functional alloys with low melting point so as to fulfill various increasing needs. The basic schemes and road map for this new research program, which is expected to have a worldwide significance, were outlined. The theoretical strategies and experimental methods in the research and development of liquid metal material genome were introduced. Particularly, the calculation of phase diagram （CALPHAD） approach as a highly effective way for material design was discussed. Further, the first-principles （FP） calculation was suggested to combine with the statistical thermo- dynamics to calculate the thermodynamic functions so as to enrich the CALPHAD database of liquid metals. When the experimental data are too scarce to perform a regular treatment, the combination of FP calculation, cluster variation method （CVM） or molecular dynamics （MD）, and CALPHAD, referred to as the mixed FP-CVM- CALPHAD method can be a promising way to solve the problem. Except for the theoretical strategies, several parallel processing experimental methods were also analyzed, which can help improve the efficiency of finding new liquid metal materials and reducing the cost. The liquid metal material genome proposal as initiated in this paper will accelerate the process of finding and utilization of new functional materials.

Tongling Nonferrous Metals Group Holding Co., Ltd. Develops the Metal Materials for Aircraft Engines

Tongling Nonferrous Metals Group Holding Co.,Ltd.has signed a joint venture agreement with a subsidiary of Aero Engine Corporation of China,proposing to establish a JV to engage in the R&D and production of special aerial metal materials.Presently,the JV project

EFFECT OF STRAIN RATE(?) ON STRAIN HARDENING EXPONENT n OF SOME METALLIC MATERIALS

Variable strain rate tension tests for 4 metallic materials show that as the strain rate in creases the strain hardening exponent n decreases. The trend follows a two stage linear relation between n and Ig (?). When (?) < (?)cp, i.e. under quasi-static loading, n can be considered as a constant, but when (?)>(?)cp, n decreases rapidly till an ideal plastic state. n = 0. The characterizations and mechanisms of softening induced by high (?) are discussed.

Degree of polarization based on the three-component pBRDF model for metallic materials

An expression of degree of polarization（DOP） for metallic material is presented based on the three-component polarized bidirectional reflectance distribution function（p BRDF） model with considering specular reflection, directional diffuse reflection and ideal diffuse reflection. The three-component p BRDF model with a detailed reflection assumption is validated by comparing simulations with measurements. The DOP expression presented in this paper is related to surface roughness, which makes it more reasonable in physics. Test results for two metallic samples show that the DOP based on the three-component p BRDF model accords well with the measurement and the error of existing DOP expression is significantly reduced by introducing the diffuse reflection. It indicates that our DOP expression describes the polarized reflection properties of metallic surfaces more accurately.

IGNITING SHS BY LASER AND ITS APPLICATION TO SELECTIVE LASER SINTERING OF METALLIC POWDER MATERIAL

How to directly fabricate metallic functional parts with selective laser sintering (SLS) process is a potential technique that scientists are researching. Existent problems during directly fabricating metal part by use of SLS are analyzed. For the sake of solving the problems, a new idea of adding self-propagating high-temperature synthesis (SHS) material into metallic powder material to form new type of SLS metallic powder material is put forward. This powder material can release controllable amount of heat during its interaction with the laser beam energy to reduce the requirement to laser power during directly sintering metallic part, to prolong the time of metallic liquid phase existing, and to improve the intensity and accuracy of SLS part. For this reason, SHS material′s interaction with the CO2 laser beam energy is researched, which proves that CO2 laser beam energy may instantly ignite SHS reaction. On the basis of the above-mentioned researches, the effect of sintering the metal powder material mixing SHS material with CO2 laser is also researched, which shows: there is an optimal blending ratio of various material in the new metallic powder material. Under the optimal blending ratio and SLS process parameters, this new metallic powder material can indeed release amount of heat and SHS reaction may be controlled within the laser sintering. This research result makes it possible that the metallic part is directly sintered with small CO2 laser (less than 50W), which may greatly reduce the volume, cost and running expenditure of SLS machine, be propitious to application.

Experimental Research of Electronic Devices Thermal Control Using Metallic Phase Change Materials

A Phase-change thermal control unit( PTCU) filled with metallic phase change material( PCM) Bismuth alloy for electric devices thermal protection was developed and investigated experimentally. The PTCU filled with PCM was designed and manufactured. Resistance heating components( RCHs) produced 1 W,3 W, 5 W,7W,and 10 W for simulating heat generation of electronic devices. At various heating power levels,the performance of PTCU were tested during heating period and one duty cycle period. The experimental results show that the PTCU delays RCH reaching the maximum operating temperature. Also,a numerical model was developed to enable interpretation of experimental results and to perform parametric studies. The results confirmed that the PTCU is suitable for electric devices thermal control.

Experimental Investigation of the Effect of the Material Damage Induced in Sheet Metal Forming Process on the Service Performance of 22MnB5 Steel

The use of ultra-high strength steels through sheet metal forming process offers a practical solution to the lightweight design of vehicles.However,sheet metal forming process not only produces desirable changes in material properties but also causes material damage that may adversely influence the service performance of the material formed.Thus,an investigation is conducted to experimentally quantify such influence for a commonly used steel（the 22MnB5 steel） based on the hot and cold forming processes.For each process,a number of samples are used to conduct a uniaxial tensile test to simulate the forming process.After that,some of the samples are trimmed into a standard shape and then uniaxially extended until fracture to simulate the service stage.Finally,a microstructure test is conducted to analyze the microdefects of the remaining samples.Based on the results of the first two tests,the effect of material damage on the service performance of 22MnB5 steel is analyzed.It is found that the material damages of both the hot and cold forming processes cause reductions in the service performance,such as the failure strain,the ultimate stress,the capacity of energy absorption and the ratio of residual strain.The reductions are generally lower and non-linear in the former process but higher and linear in the latter process.Additionally,it is found from the microstructure analysis that the difference in the reductions of the service performance of 22MnB5 by the two forming processes is driven by the difference in the micro damage mechanisms of the two processes.The findings of this research provide a useful reference in terms of the selection of sheet metal forming processes and the determination of forming parameters for 22MnB5.

Model of bidirectional reflectance distribution function for metallic materials

Based on the three-component assumption that the reflection is divided into specular reflection,directional diffuse reflection,and ideal diffuse reflection,a bidirectional reflectance distribution function（BRDF） model of metallic materials is presented.Compared with the two-component assumption that the reflection is composed of specular reflection and diffuse reflection,the three-component assumption divides the diffuse reflection into directional diffuse and ideal diffuse reflection.This model effectively resolves the problem that constant diffuse reflection leads to considerable error for metallic materials.Simulation and measurement results validate that this three-component BRDF model can improve the modeling accuracy significantly and describe the reflection properties in the hemisphere space precisely for the metallic materials.

Novel Ring Compression Test Method to Determine the Stress-Strain Relations and Mechanical Properties of Metallic Materials

Although there are methods for testing the stress-strain relation and strength,which are the most fundamental and important properties of metallic materials,their application to small-volume materials and tube components is lim-ited.In this study,based on energy density equivalence,a new dimensionless elastoplastic load-displacement model for compressed metal rings with isotropy and constitutive power law is proposed to describe the relations among the geometric dimensions,Hollomon law parameters,load,and displacement.Furthermore,a novel test method was developed to determine the elastic modulus,stress-strain relation,yield and tensile strength via ring compression test.The universality and accuracy of the method were verified within a wide range of imaginary materials using finite element analysis(FEA),and the results show that the stress-strain curves obtained by this method are consistent with those inputted in the FEA program.Additionally,a series of ring compression tests were performed for seven metallic materials.It was found that the stress-strain curves and mechanical properties predicted by the method agreed with the uniaxial tensile results.With its low material consumption,the ring compression test has the potential to be as an alternative to traditional tensile test when direct tension method is limited.