Crack elimination and strength enhancement mechanisms of selective laser melted Si-modified Al−Mn−Mg−Er−Zr alloy

In order to increase the processability and process window of the selective laser melting(SLM)-fabricated Al−Mn−Mg−Er−Zr alloy,a novel Si-modified Al−Mn−Mg−Er−Zr alloy was designed.The effect of Si alloying on the surface quality,processability,microstructure,and mechanical properties of the SLM-fabricated alloy was studied.The results showed that introducing Si into the Al−Mn−Mg−Er−Zr alloy prevented balling and keyhole formation,refined the grain size,and reduced the solidification temperature,which eliminated cracks and increased the processability and process window of the alloy.The maximum relative density of the SLM-fabricated Si/Al−Mn−Mg−Er−Zr alloy reached 99.6%.The yield strength and ultimate tensile strength of the alloy were(371±7)MPa and(518±6)MPa,respectively.These values were higher than those of the SLM-fabricated Al−Mn−Mg−Er−Zr and other Sc-free Al−Mg-based alloys.

Influence of high-speed milling parameter on 3D surface topography and fatigue behavior of TB6 titanium alloy

High-speed milling of titanium alloys is widely used in aviation and aerospace industries for its high efficiency and good quality.In order to optimize the machining parameters in high-speed milling TB6 titanium alloy,experiments of high-speed milling and fatigue were conducted to investigate the effect of parameters on 3D surface topography and fatigue life.Based on the fatigue fracture,the effect mechanism of surface topography on the fatigue crack initiation was proposed.The experiment results show that when the milling speed ranged from 100 m/min to 140 m/min,and the feed per tooth ranged from 0.02 mm/z to 0.06 mm/z,the obtained surface roughness were within the limit（0.8 μm）.Fatigue life decreased sharply with the increase of surface equivalent stress concentration factor.The average error of fatigue life between the established model and the experimental results was 6.25%.The fatigue cracks nucleated at the intersection edge of machined surface.

ANALYSIS ON SURFACE INTEGRITY DURING HIGH SPEED MILLING FOR NEW DAMAGE-TOLERANT TITANIUM ALLOY

Surface integrity of a new damage-tolerant titanium alloy （TC21）, including surface roughness, microhardness and metallurgical structure is investigated when normal and high speed milling are used at different tool wear status. Results show that good surface integrity of TC21 can be obtained in high speed milling. In addition, even in acutely worn stages, there is no so-called serious hardening layer （or white layer） according to the studies on microhardness and metallurgical structure.

Nanogrinding of SiC wafers with high flatness and low subsurface damage

Nanogrinding of SiC wafers with high flatness and low subsurface damage was proposed and nanogrinding experiments were carried out on an ultra precision grinding machine with fine diamond wheels. Experimental results show that nanogrinding can produce flatness less than 1.0μm and a surface roughness Ra of 0.42nm. It is found that nanogrinding is capable of producing much flatter SiC wafers with a lower damage than double side lapping and mechanical polishing in much less time and it can replace double side lapping and mechanical polishing and reduce the removal amount of chemical mechanical polishing.

Effects of surface roughness of substrate on properties of Ti/TiN/Zr/ZrN multilayer coatings

Ti/TiN/Zr/ZrN multilayer coatings were deposited on Cr_17Ni_2 steel substrates with different surface roughnesses by vacuum cathodic arc deposition method. Microstructure, micro-hardness, adhesion strength and cross-sectional morphology of the obtained multilayer coatings were investigated. The results show that the Vickers hardness of Ti/TiN/Zr/ZrN multilayer coating, with a film thickness of 11.37 μm, is 29.36 GPa. The erosion and salt spray resistance performance of Cr_17Ni_2 steel substrates can be evidently improved by Ti/TiN/Zr/ZrN multilayer coating. The surface roughness of Cr_17Ni_2 steel substrates plays an important role in determining the mechanical and erosion performances of Ti/TiN/Zr/ZrN multilayer coatings. Overall, a low value of the surface roughness of substrates corresponds to an improved performance of erosion and salt spray resistance of multilayer coatings. The optimized performance of Ti/TiN/Zr/ZrN multilayer coatings can be achieved provided that the surface roughness of Cr_17Ni_2 steel substrates is lower than 0.4μm.

Effect of surface roughness on plasticity of Zr_(52.5)Cu_(17.9)Ni_(14.6)Al_(10)Ti_5 bulk metallic glass

Zr52.5Cu17.9Ni14.6Al10Ti5 bulk metallic glass （BMG） rods were abraded to different surface roughnesses using different types of waterproof abrasive papers and sometimes polishing pastes, and the compressive deformation behavior was examined. The results show that the yield strength of the BMG is hardly affected while the compressive plasticity increases from 2.3% to 4.5% with decreasing the surface roughness. Observation of the fractured samples under a scanning electron microscope indicates that the rise in plasticity is accompanied with an increase in shear band density. The results suggest that it is necessary to reduce the surface roughness of BMGs for achieving a large plasticity.

MACHINING OF METAL MATRIX COMPOSITES

Two types of aluminium-based composites reinforced respectively with 20 vol short fibre alumina and with a hybrid of 15 vol SiC particle and 5 vol short alumina fibre are machined with different tool materials:cemented carbide,ceramic,cubic boron nitride(CBN)and polycrystalline diamond(PCD).The analysis on tool wear shows that the various tool materials exhibite different tool wear behaviours,and the tool wear mechanisma are discussed.Apparently,PCD tools do not necessarily guarantee dimensional stability but they can provide the most economic means for machining all sorts of composites.Consequently,a suitable tool material is suggested for machining each metal matrix composite(MMC) from the standpoints of tool wear and machined surface finish.

Pipe reduction of miniature inner grooved copper tubes through rotary swaging process

A rotary swaging machine was applied to fabricating pipe reduction for miniature inner grooved copper tube （MIGCT） heat pipes. Compared with conventional swaging method, the axial feed of the designed rotary swaging machine was reached by a constant pushing force. The deformation of grooves in pipe reduced section during rotary swaging was analyzed. The shrinkage and extensibility of pipe reduction were measured and calculated. Furthermore, four aspects, including outer diameter, surface roughness, extensibility and processing time of pipe reduction, which were influenced by the pushing force, were considered. The results show that the tube wall thickness increases gradually along the z-axis at sinking section. However, the outer diameters, surface roughness and micro-cracks at reduced section tend to decrease along the z-axis. Besides, the effect of variation in the pushing force on the extensibility is limited while an increase in the pushing force results in a decrease of surface roughness. Therefore, a large pushing force within the limit is beneficial to pipe reduction manufacturing during rotary swaging process.

Effects of Steam Heat Treatment on the Surface Contact Angle of Chinese Fir

The aim of this study was investigate the effects of heat treatment on the contact angle of Chinese fir, and the indicators affecting the change of contact an-gle change. It was determined that the duration of treatment had significant effect on the change curves of contact angle of Chinese fir wood due to the change curves of contact angle became more centralized and orderly after the specimens heat treated at 180 ℃. Compared with the untreated wood, the contact angle in-creased from 51＆#176; to 124＆#176; after 4 h treatment, and hydroxyl absorbance of hy-drophilic functional groups decreased from 2.08 to 1.63, while carbonyl absorbance from 0.92 to 0.62. The surface roughness has not significant influence on the con-tact angle. Heat treatment of the Chinese fir caused surface morphological change, which produced hol owed-out phenomenon. The increased surface contact angle caused by heat treatment can be used for outdoor and sauna facilities.

机械图样中技术要求的程控注法

本文以Auto CAD10.0绘图软件为基础,建立符合国际规定的技术要求的软件标注系统,论述开发该软件的过程和方法,并通过标注图例说明其实用价值。

SURFACE ROUGHNESS EVOLUTION AND FORMABILITY OF INTERSTITIAL FREE SHEET STEEL TO GRAIN SIZE AND SHEET THICKNESS

Experimental study has been conducted for an interstitial free(IF) sheet steel on its surface roughness evolution and formability with respect to grain size and sheet thickness effect. The surface roughness of IF sheet steel is proportional to effective strain, grain size and inversely proportional to sheet thickness; the larger grain reduces the formability by accelerating the surface roughening rate and enhance formability by raising the workhardening rate, while the latter effect plays the dominate role. The grain size effect on surface roughening and formability is more obvious when the sheets are thinner.

Effect of hydrogen peroxide concentration on surface properties of Ni-Cr alloys

The effect of concentration of hydrogen peroxide （H2O2） on the surface properties of Ni-Cr alloys was studied. Surface roughness and surface morphology of Ni-Cr alloys were evaluated by surface profiler and scanning electron microscopy after being immersed in different concentrations of H2O2 for 112 h. Surface corrosion products of Ni-Cr alloys were analyzed by photoelectron spectrograph after being immersed in 0% and 30% H2O2. The order of increasing surface roughness of Ni-Cr alloys after being immersed in different concentrations of H2O2 was 0〈3.6%〈10%〈30%. As the concentration of hydrogen peroxide increased, the surface roughness of Ni-Cr alloys increased and the surface morphology showed different degrees of corrosion. According to the XPS results, the corrosion products formed on the outmost surface layer of the studied samples are Ni（OH）2 and BeO.

STUDIES ON MAGNETIC ABRASIVE MACHINING

This paper deals with the machining process using magnetic abrasives. Using an apparatus designed and made, a series of experiments are carried out, where the workpiece is cylindrical and the magnetic abrasives used are mainly Fe and Al 2O 3, for investigating the effects of machining time, working gap, rotating speed of workpieces, magnetic flux density on machining efficiency and surface roughness. At the end of this paper, the machining mechanism is also discussed.

NONLINEAR EFFECT OF LOCAL ROUGH WALL ON LARGE EDDY STRUCTURE IN BOUNDARY LAYER

Based on the building of a theoretical model for the large eddy structure, the nonlinear effect of the local rough wall on the large eddy structure in the boundary layer is studied by direct numerical simulation. Numerical results show that factors of the local rough feature, the distributing structure and the intensity, etc. play an important role in the evolution of the large eddy structure in the boundary layer.

NONLINEAR EVOLUTION OF TWO-DIMENSIONAL T-S WAVE IN LOCALIZED ROUGH BOUNDARY LAYER

Numerical simulations are carried out to investigate the mechanism of the nonlinear evolution of two- dimensional （2-D） Tollmien-Schlichting （T-S） wave on a localized rough boundary layer. The three-dimensional （3-D） numerical solution of a base flow on a boundary layer is obtained for the localized rough wall with the local- ized ejection, the localized suction and the combination of ejection and suction. Based on numerical simulations, the processes of stable and the most instable nonlinear evolution of the 2-D disturbance T-S wave are studied. The effects of the form on the localized roughness, the intensity, and the distribution structure on the nonlinear evolution of 2-D T-S wave and the growth rate are discussed. Results show that the basic flow induced by the lo- calized rough wall is a key factor causing the fast growth of the disturbance wave. Due to the change of the aver- age flow profile and the existence of the spanwise velocity, the localized rough wall enhances the instability of the flow. Consequently, the instable region of the neutral curve is enlargened, and the maximnum growth rate of the 2-D T-S wave is increased. In the process of the nonlinear evolution of 2-D disturbance T-S wave, with the in- crease of the nonlinear interaction, the most instable 2-D disturbance wave triggers the appearance of the 3-D dis- turbance wave and the high-frequency harmonic wave. Its streamwise wave number and the frequency are the same as those of 2-D disturbance wave. The spanwise velocity can excite the growth of the 2-D disturbance wave, the instability of 2-D wave, the formation of the streamwise vortex, and the generation of 3-D disturbance wave. Simulation results agree well with experimental results.

Morphology Simulation for Ion-Assisted Deposition Process

The molecular dynamics simulation is applied to investigate the influence of the incident ion energy and incident angular distribution upon ion-assisted deposition process. The Cu-Cu and Ar-Cu interactions are modeled using the many body tight-binding potential and the Moliere potential, respectively, and the interface width is used to characterize the surface roughness properties at both transient and final state conditions. The results show that the surface roughness of the deposition film is lower when more Ar-to-Cu ratio is used at the same incident energy and angle. For the relative low or high incident energy, the film morphologies are not sensitive to the incident angle. However, if the incident energy of the argon ions is too high, the film morphology will be worse than that without using the ion-assisted deposition.

Effects of selective laser melting parameters on surface quality and densification behaviours of pure nickel

The effects of laser power and scanning speed on the forming characteristic of scanning tracks,densification behaviours and surface roughness of pure nickel fabricated with selective laser melting(SLM)were studied.The results indicate that the scanning tracks showed continuous,regular and flat surface with increasing laser power and decreasing scanning speed in a specific range,which could avoid the defects(like holes and balling structures)forming in SLM processing.The optimal process window was identified as the scanning speed of 900 mm/s and the laser power of 255−275 W by comparing the surface qualities and densification behaviours.With the suitable processing parameters,the relative density could achieve 99.16%,the tensile strength was(359.49±2.74)MPa,and the roughnesses of the top and side surfaces were(12.88±2.23)and(14.98±0.69)μm,respectively.

Surface roughness prediction model in ultrasonic vibration assisted grinding of BK7 optical glass

Pre-knowledge of machined surface roughness is the key to improve whole machining efficiency and meanwhile reduce the expenditure in machining optical glass components.In order to predict the surface roughness in ultrasonic vibration assisted grinding of brittle materials,the surface morphologies of grinding wheel were obtained firstly in the present work,the grinding wheel model was developed and the abrasive trajectories in ultrasonic vibration assisted grinding were also investigated,the theoretical model for surface roughness was developed based on the above analysis.The prediction model was developed by using Gaussian processing regression(GPR)due to the influence of brittle fracture on machined surface roughness.In order to validate both the proposed theoretical and GPR models,32sets of experiments of ultrasonic vibration assisted grinding of BK7optical glass were carried out.Experimental results show that the average relative errors of the theoretical model and GPR prediction model are13.11%and8.12%,respectively.The GPR prediction results can match well with the experimental results.

Research of the electrical anisotropic characteristics of water-conducting fractured zones in coal seams

Water flooding disasters are one of the five natural coal-mining disasters that threaten the lives of coal miners. The main causes of this flooding are water-conducting fractured zones within coal seams. However, when resistivity methods are used to detect water-conducting fractured zones in coal seams, incorrect conclusions can be drawn because of electrical anisotropy within the water-conducting fractured zones. We present, in this paper, a new geo-electrical model based on the geology of water-conducting fractured zones in coal seams. Factors that influence electrical anisotropy were analyzed, including formation water resistivity, porosity, fracture density, and fracture surface roughness, pressure, and dip angle. Numerical simulation was used to evaluate the proposed electrical method. The results demonstrate a closed relationship between the shape of apparent resistivity and the strike and dip of a fracture. Hence, the findings of this paper provide a practical resistivity method for coal-mining production.

Effect of laser textured surface with different patterns on tribological characteristics of bearing material AISI 52100

Chrome steels are used in bearings since they possess high strength and wear resistance.However,when those parts are in service,failure happens due to sliding friction before the lifetime.To improve the durability of the American Iron and Steel Institute(AISI)52100 chromium steel,in this work,the effect of laser surface texturing(LST)was analyzed.With the different patterns of circle and ellipse comparing with the untextured samples,the wear behavior was investigated using the pin-on-disc tribometer.The lubricant used for wear analysis is semisolid lithium grease National Lubricating Grease Institute lubricant(SKF NLGI-3).Sliding wear analysis was conducted at different loads of 10 N,30 N and 50 N for the sliding speed of 750 r/min and 1400 r/min.The wear morphology was analyzed using a scanning electron microscope(SEM).The roughness of the samples was found using a white light interferometer.The effect of different patterns like circle and ellipse,alter the friction and wear properties of chromium alloy was observed compared with the untextured samples.LST shows considerable reduction in friction and wear for ellipsoidal pattern compared with the circular pattern because of wear debris and lubricant getting trapped.