Challenges and opportunities in the production of magnesium parts by directed energy deposition processes

Mg-alloys have gained considerable attention in recent years for their outstanding properties such as lightweight,high specific strength,and corrosion resistance,making them attractive for applications in medical,aerospace,automotive,and other transport industries.However,their widespread application is hindered by their low formability at room temperature due to limited slip systems.Cast Mg-alloys have low mechanical properties due to the presence of casting defects such as porosity and anisotropy in addition to the high scrap.While casting methods benefit from established process optimization techniques for these problems,additive manufacturing methods are increasingly replacing casting methods in Mg alloys as they provide more precise control over the microstructure and allow specific grain orientations,potentially enabling easier optimization of anisotropy properties in certain applications.Although metal additive manufacturing(MAM)technology also results in some manufacturing defects such as inhomogeneous microstructural evolution and porosity and additively manufactured Mg alloy parts exhibit lower properties than the wrought parts,they in general exhibit superior properties than the cast counterparts.Thus,MAM is a promising technique to produce Mg alloy parts.Directed energy deposition processes,particularly wire arc directed energy deposition(WA-DED),have emerged as an advantageous additive manufacturing(AM)technique for metallic materials including magnesium alloys,offering advantages such as high deposition rates,improved material efficiency,and reduced production costs compared to subtractive processes.However,the inherent challenges associated with magnesium,such as its high reactivity and susceptibility to oxidation,pose unique hurdles in the application of this technology.This review paper delves into the progress made in the application of DED technology to Mg-alloys,its challenges,and prospects.Furthermore,the predominant imperfections,notably inhomogeneous microstructure evolution and porosity,observed in Mg-alloy components manufactured through DED are discussed.Additionally,the preventive measures implemented to counteract the formation of these defects are explored.

Prediction Model of Wax Deposition Rate in Waxy Crude Oil Pipelines by Elman Neural Network Based on Improved Reptile Search Algorithm

A hard problem that hinders the movement of waxy crude oil is wax deposition in oil pipelines.To ensure the safe operation of crude oil pipelines,an accurate model must be developed to predict the rate of wax deposition in crude oil pipelines.Aiming at the shortcomings of the ENN prediction model,which easily falls into the local minimum value and weak generalization ability in the implementation process,an optimized ENN prediction model based on the IRSA is proposed.The validity of the new model was confirmed by the accurate prediction of two sets of experimental data on wax deposition in crude oil pipelines.The two groups of crude oil wax deposition rate case prediction results showed that the average absolute percentage errors of IRSA-ENN prediction models is 0.5476% and 0.7831%,respectively.Additionally,it shows a higher prediction accuracy compared to the ENN prediction model.In fact,the new model established by using the IRSA to optimize ENN can optimize the initial weights and thresholds in the prediction process,which can overcome the shortcomings of the ENN prediction model,such as weak generalization ability and tendency to fall into the local minimum value,so that it has the advantages of strong implementation and high prediction accuracy.

Effect of deposition rate on microstructure and mechanical properties of wire arc additive manufacturing of Ti-6Al-4V components

Wire arc additive manufacturing(WAAM)is a novel manufacturing technique by which high strength metal components can be fabricated layer by layer using an electric arc as the heat source and metal wire as feedstock,and offers the potential to produce large dimensional structures at much higher build rate and minimum waste of raw material.In the present work,a cold metal transfer(CMT)based additive manufacturing was carried out and the effect of deposition rate on the microstructure and mechanical properties of WAAM Ti-6Al-4V components was investigated.The microstructure of WAAM components showed similar microstructural morphology in all deposition conditions.When the deposition rate increased from 1.63 to 2.23 kg/h,the ultimate tensile strength(UTS)decreased from 984.6 MPa to 899.2 MPa and the micro-hardness showed a scattered but clear decline trend.

Effect of frequency and pulse-on time of high power impulse magnetron sputtering on deposition rate and morphology of titanium nitride using response surface methodology

Titanium nitride thin films were deposited on silicon by high power impulse magnetron sputtering(HiPIMS)method at different frequencies(162-637 Hz)and pulse-on time(60-322μs).Response surface methodology(RSM)was employed to study the simultaneous effect of frequency and pulse-on time on the current waveforms and the crystallographic orientation,microstructure,and in particular,the deposition rate of titanium nitride at constant time and average power equal to 250 W.The crystallographic structure and morphology of deposited films were analyzed using XRD and FESEM,respectively.It is found that the deposition rate of HiPIMS samples is tremendously dependent on pulse-on time and frequency of pulses where the deposition rate changes from 4.5 to 14.5 nm/min.The regression equations and analyses of variance(ANOVA)reveal that the maximum deposition rate(equal to(17±0.8)nm/min)occurs when the frequency is 537 Hz and pulse-on time is 212μs.The experimental measurement of the deposition rate under this condition gives rise to the deposition rate of 16.7 nm/min that is in good agreement with the predicted value.

Investigation on the deposition rate and the dilution ratio of plasma surface welding

A new kind of plasma technology with both high deposition rate and low dilution ratio was developed under the calculation and analysis of the arc flame characteristics of plasma arc,the kinematics behavior of powder and powder's heating in the arc. Compared with normal plasma surfacing method, the idea using constricting nozzle with small orifice diameter, long plasma arc and increasing the distance from meeting point of the two beams of powder to workpiece, to achieve the goals of high deposition rate and low dilution ratio, was put forward here. In order to prove this idea, a set of experimental system was built up and obtained satisfied results including high deposition rate(more than 25 kg/h )and low dilution ratio(less than 5%). The success of this study offers a promising prospect for developing the powder plasma surface welding in China and may open a way to improve this technology further in efficiency and quality.

Anthropogenic Effect on Deposition Dynamics of Lake Sediments Based on ^(137)Cs and ^(210)Pb_(ex) Techniques in Jiuzhaigou National Nature Reserve,China

Radionuclide dating techniques characterized by137Cs and210Pbex have recently been applied in the study of lake sediments around the world.In this study,a chronological series of sediment cores was established based on137Cs and210Pbex analyses along with the evaluation of sediment properties,such as particle size distribution,total organic carbon(TOC),carbonate content,and acid-insoluble residue,to study sediment accumulation rates,sediment sources,and responses to human activities in the Jiuzhaigou National Nature Reserve in southwestern China.In terms of the particle size distribution of sediments,silt content was the highest,and clay and sand contents were relatively low.The sediments displayed high TOC contents because of the significant amounts of vegetation grown in the lakes.The carbonate content was also high due to the overall geological background of carbonates in Jiuzhaigou.Carbonate content tended to decline from top to bottom in the sediment cores,whereas the acid-insoluble residue tended to increase.These results suggested that the depth variation of the environmental parameters of the sediments in two lakes in Jiuzhaigou would correspond to each other.The results indicated that the sediment rate of Jiuzhaigou was generally high with strong siltation,indicating that serious soil loss was induced by intensive human activities in the basin over the past decades.The increases in the mass accumulation rate,contents of acid-insoluble residue,and mean particle size during the periods of 1840–1900s,late 1930s–early 1950s,1966–1978,and2003–2006 revealed the occurrence of severe soil and water loss as a result of extensive agricultural expansion,large-scale deforestation,and road construction in Jiuzhaigou.The deposition rate and the properties of lacustrine sediments could reflect the significant impact of human activities on lake sedimentation during Jiuzhaigou′s history.

Online evaluation of electroless deposition rate by electrochemical noise method

Continuous noise resistance calculation(CNRC)technique was used for online determination of the electroless nickel deposition rate on zirconium pretreated magnesium alloy.For this purpose,the noise resistance(R_n) variation with time was calculated for the pretreated alloy surface in the electroless plating solution.The CNRC results were described by energy dispersive X-ray spectroscopy(EDS)and scanning electron microscopy(SEM)techniques.Also,potentiodynamic polarization and gravimetric measurements were used for determination of the electroless deposition rate at the same time period and the results were compared with the CNRC results.The Rn variation with plating time shows that the electroless plating consists of different stages with various deposition rates.The results of the CNRC and polarization methods were not in acceptable agreement due to the limitations of the polarization method for online monitoring of the deposition rate.However,the results of the gravimetric measurements were in complete agreement with the CNRC technique and so,the CNRC can be considered as suitable tool for online evaluation of the electroless deposition rate.

Analysis on Suspended Sediment Deposition Rate for Muddy Coast of Reclaimed Land

A new expression for calculating suspended fine-sediment deposition rate is developed based on theoretic analysis and experiments. The resulting equation is applied to simulation of fine sediment deposition in the reclaimed land in the Hangzhou Bay, China. The hydrodynamic environment in this area is solved by use of a long wave model, which gives the 2D-velocity field and considers bathymetric changes due to fine sediment deposition. The expression is proved convenient to use in engineering practice, and the predicted deposition rate agrees with the annual data available from field measurements from the first year to the third year after the construction of the long groin as a reclaiming method.

Study on the Structures and Properties of Ni-W-B-CeO_2 Composite Coatings Prepared by Pulse Electrodeposition

The aim of this research is to pulse co-deposit nano-CeO2 particles into Ni-W-B alloy coatings in order to improve the surface properties. The influence of pulse frequency and duty circle on deposition rate, microhardness and microstructures, and the influence of heat treatment temperature on phase structures, microhardness and abrasivity of Ni-W-B-CeO2 composite coatings were investigated. The results indicated that the pulse co-deposition of nickel, tungsten, boron and nano-CeO2 particle from the bath which nano-CeO2 particle was suspended by high speed mechanical stirring led to the Ni-W-B-CeO2 composite coatings, possessing better microhardness and abrasion resistance when heat-treated at 400 ℃ for 1 h. The microhardness as-deposited with 636 Hz and the deposition rate with 0.0281 mm·h-1 was the highest at pulse frequency with 1000 Hz and pulse duty circle with 10%. Microstructures analysis displays that decreasing pulse duty cycle leads to refinement in grain structures and the improvement of microstructures. X-ray diffraction shows that the composite coating as-deposited was mainly in the amorphous state and partially crystallized, but when heat treated at 400 ℃, the crystallization trend was strengthened further.

Spatial and temporal gradients in the rate of dust deposition and aerosol optical thickness in southwestern Iran

The southwestern Iran is one of the regions that are most prone to dust events.The objective of this study is the analysis of the spatial and temporal distributions of dust deposition rate as a key factor for finding the relative impact of the dust.First,the monthly mean aerosol optical thickness(AOT)from Moderate Resolution Imaging Spectroradiometer(MODIS)was analyzed and compared with the dust amount variations from ground deposition rate(GDR),and the results were further used to investigate the spatial and temporal distributions of dust events in southwestern Iran for the period between 2014 and 2015.Moving air mass trajectories,using the Hybrid Single-Particle Lagrangian Integrated Trajectory(HYSPLIT)model,were proven to be a discriminator of their local and regional origin.The results from GDR analysis produced a correlation coefficient between dust event history and deposition rates at dust magnitudes of>0.93 that is meaningful at the 95%confidence level.Furthermore,the deposition rates varied from 3 g/m2 per month in summer to 10 g/m2 per month in spring and gave insight into the transport direction of the dust.Within the same time series,AOT correspondences with MODIS on Terra in four aerosol thickness layers(clean,thin,thick,and strong thick)were shown in relation to each other.The deepest mixed layers were observed in spring and summer with a thickness of approximately 3500 m above ground level in the study area.Investigations of ground-based observations were correlated with the same variations for each aerosol thickness layer from MODIS images and they can be applied to discriminate layers of aeolian dust from layers of other aerosols.Together,dust distribution plots from AOT participated to enhance mass calculations and estimation deposition rates from the thick and strong thick aerosol thickness layers using the results from GDR.Despite all the advances of AOT,under certain circumstances,ground-based observations are better able to represent aerosol conditions over the study area,which were tested in southwestern Iran,even though the low number of observations is a commonly acknowledged drawback of GDR.

Deposition rate and morphology of carbon nanotubes at different positions in a CVD reactor

Carbon nanotubes （CNTs） were synthesized through the catalytic decomposition of a ferrocene-xylene mixture in a horizontal chemical vapor deposition reactor. The deposition rate of CNTs along the axial direction was measured. The morphology of CNTs was observed by scanning electron microscopy （SEM） and transmission electron microscopy （TEM）. The results showed that the deposition rate of CNTs along the axial direction first increased and later decreased, the position achieving the maximum deposition rate was influenced by the operating conditions. The morphologies of CNTs also changed along the axial direction.

Morphology Analysis of Nickel-boron/diamond Eleetroless Deposition

The influences of mass concentration of nickel chloride hexahydrate, sodium borohydride, ethylenediamine, pH value, bath temperature on deposition rate were studied with orthogonal experiments by a series of pre-treatments on micro-diamond particle, and the optimized parameters were obtained. Both the morphology and the composition of original diamond and the diamond with Ni-B coating were analyzed by SEM and XRD respectively. The SEM image shows that the spherical Ni-B particle is coated upon diamond. XRD pattern shows that the coating compositions are Ni and Ni2B.

Effect of 3-Amino-5-mercapto-1,2,4-triazole on Electroless Nickel Deposition

The effects of organic additive, 3-amino-5-mercapto-1,2,4-triazole （AMTA） on bath stability, deposition rate, reaction activation energy, and Ni-P coating composition in acidic electroless nickel plating were investigated. Polarization curve method and infrared reflection spectroscopy were used to analyze the mechanism of the effect of AMTA on electroless nickel deposition. It was observed that AMTA improved bath stability, decreased the deposition rate, and increased the reaction activation energy. It was also revealed that AMTA decreased the phosphorus content and increased the sulfur content in Ni-P coating. In addition, AMTA inhibited the anodic oxidation of hypophosphite and accelerated the cathodic reduction of Ni^2＋. Infrared reflection spectroscopy result indicates that AMTA was adsorbed on the surface of Ni-P and interacted with Ni^2＋ to form an AMTA-Ni^2＋ compound. On the basis of the results of this study, the mechanism of the effect of AMTA on electroless nickel deposition was deduced.

A 150-year Isotopic Record of Lead Deposition in Yancheng Coastal Wetland,China

Radioactive markers are useful in dating lead （Pb） deposition patterns from industrialization in sedimentary archives. As a well-known natural reserve in the world, Yancheng coastal wetland in Jiangsu Province is one of areas most sensitive to global sea level change and is located in the most developed and polluted region of China. Two cores were collected in Yancheng wetland in October 2013 and dated using 210pb and 137Cs radiometric techniques. Sediments in both cores were sectioned into depth bands and examined systematically for dry bulk density, water content, magnetic susceptibility and grain-size. Multiple elements including Pb were also measured using inductively coupled plasma systems. Unsupported 21~Pb activities decreased with depth in both of the two cores, and 21~pb chronologies were established （covering 150 years） using the constant rate of supply （CRS） model. The measured Pb contents ranged from 14.97 mg/kg to 29.40 mg/kg with average values of 17.17-22.79 mg/kg, and the Pb fluxes ranged from 41.70 mg/（m2·yr） to 172.70 mg/（m2·yr） with averages of 95.59-123.41 mg/（m2·yr）. Temporal variations of Pb flux, enrichment factors and Pb isotopes show a gradual and continuous increase over time and clearly reflect increased emissions from anthropogenic activities in the region. The Pb isotopic compositions show that most of Pb deposition in Yancheng wetland is input from natural sources by water flows and has the same levels of Pb as in the surface sediment of the Yangtze River and the Pacific mineral aerosol. We also stress the anthropogenic Pb contribution in Yangcheng wetland sediment and the reason of our Pb isotopes not showing anthropogenic signature is likely the insta- bility of anthropogenic Pb in high Fe/Mn oxide conditions. Therefore, more attention should be paid to current local pollution problems, and society should take action to seek a balance between economic development and environmental protection.

EFFECTS OF DEPOSITION PROCESS ON PHOSPHORUS CONTENT IN ELECTROLESS Ni－P COATINGS

There are many factors that affect the phosphorus content in the electroless Ni-P coatings The effects of the compositions of plating solution,the PH values of plat ing solution and the deposition temperature on the phosphorus content in Ni-P coatings were investigated in this paper It is found that the phosphorus content in Ni-P coatings increases and the deposition rate decreases with decreasing PH values,nickel sulphate NiSO4 content of plating solution and the deposition temperature.

Selective Area Growth and Characterization of GaN Nanorods Fabricated by Adjusting the Hydrogen Flow Rate and Growth Temperature with Metal Organic Chemical Vapor Deposition

CaN nanorods are successfully fabricated by adjusting the flow rate ratio of hydrogen （H2）/nitrogen （N2） and growth temperature of the selective area growth （SAG） method with metal organic chemical vapor deposition （MOCVD）. The SAG template is obtained by nanospherical-lens photolithography. It is found that increasing the flow rate of 1-12 will change the CaN crystal shape from pyramid to vertical rod, while increasing the growth temperature will reduce the diameters of GaN rods to nanometer scale. Finally the CaN nanorods with smooth lateral surface and relatively good quality are obtained under the condition that the H2：N2 ratio is 1：1 and the growth temperature is 1030℃. The good crystal quality and orientation of GaN nanorods are confirmed by high resolution transmission electron microscopy. The cathodoluminescence spectrum suggests that the crystal and optical quality is also improved with increasing the temperature.

Effect of Spraying Parameters on Deposition Efficiency and Wear Behavior of Plasma Sprayed Alumina-Titania Composite Coatings

The effects of parameters, in the process of plasma-sprayed ceramic coating, upon the deposition efficiency of alumina-13 wt.% titania composite coatings are reported. The coatings were prepared by the atmospheric plasma spray process. The plasma torch input power, flow rates of primary, secondary and carrier gas, powder feed rate and spraying distance were considered as variables. The results show that the variations in all the selected spraying parameters strongly affect the deposition efficiency. The micro-hardness, as well as erosive and sliding wear rates of the coating are also affected by these parameters. Especially the input power strongly affects the phase and microstructure of the coatings.

Deposition of Silicon Nitride Films by Silane Hydrazine Process

A new catalytic chemical vapor process for depositing silicon nitride films using silane hydrazine gaseous mixture is described. This system can be useful at a temperature of lower than 400 ℃. The catalytic process gives more rapid deposition rate than 10 nm/min. The atomic composition ratio, N/Si, which is evaluated by Rutherfold backscattering method is about 1.4 under a given experimental conditions more than the stoichiometric value of 1.33 in Si 3N 4. The infrared transmission spectra show a large dip at 850 cm -1 due to Si-N bonds and no clear dip due to Si-O bonds. High N-H bond density is the evidence that the deposition mechanism is limited by N-N bond breaking of the hydrazine. The H contents, evaluated from Si-H and N-H bonds in the infrared absorption spectra, and the deposition rate are measured as a function of the substrate temperature. In addition some film properties such as the resistivity and the breakdown electric field are presented.

Effects of Temperature on the Deposition Rate of Supersaturated Silicic Acid on Ca-type Bentonite Tsuyoshi Sasagawa, Taiji Chida and Yuichi Niibori

Na-type bentonite is commonly used as a tunnel backfilling material to prevent groundwater and radionuclide migration during the construction of a geological disposal system for high-level radioactive waste in Japan. However, host rock fractures with strong water flow can develop groundwater paths in the backfilling material. Especially, the alteration to Ca-type bentonite causes degradation of the barrier performance and accelerates the development of groundwater paths. Additionally, using cementitious materials gradually changes pH between 13 and 8. High alkaline groundwater results in high solubility of silicic acid; therefore, silicic acid is eluted from the host rock. Downstream, in the low alkaline area, the groundwater becomes supersaturated in silicic acid. This acid is deposited on Ca-type bentonite, thus leading to the clogging of the groundwater paths. In the present study, we investigate the silicic acid deposition rate on Ca-type bentonite under 288-323 K for depths greater or equal to 500 m. The results indicate that temperature does not affect the silicic acid deposition rate up to 323 K. However, in this temperature range, the deposition of silicic acid on Ca-type bentonite in backfilled tunnels results in clogging of the flow paths.

Study of bias voltage effect on the performance of ta-C coating prepared by high power impulse magnetron sputtering

The mechanical and frictional properties of ta-C coatings deposited on the substrate surface affect applications in the field of cutting tools and wear-resistant components.In this paper,the effect of bias parameters on the performance of ta-C coatings was investigated based on high power impulse magnetron sputtering(HiPIMS)technology.The results show that bias voltage has a significant effect on the deposition rate,structure,and wear resistance of the coating.In the range of bias voltage−50 V to−200 V,the ta-C coating performance was the best under bias voltage−150 V.The thickness reached 530.4 nm,the hardness value reached 35.996 GPa,and the bonding force in-creased to 14.2 N.The maximum sp3 bond content was 59.53% at this condition.