Recipe Development and Mechanical Characterization of Carbon Fibre Reinforced Recycled Polypropylene 3D Printing Filament

Recycled polypropylene filaments for fused filament fabrication were investigated with and without 14 wt% short fibre carbon reinforcements. The microstructure and mechanical properties of the filaments and 3D printed specimens were characterized using scanning electron microscopy and standard tensile testing. It was observed that recycled polypropylene filaments with 14 wt% short carbon fibre reinforcement contained pores that were dispersed throughout the microstructure of the filament. A two-stage filament extrusion process was observed to improve the spatial distribution of carbon fibre reinforcement but did not reduce the pores. Recycled polypropylene filaments without reinforcement extruded at high screw speeds above 20 rpm contained a centreline cavity but no spatially distributed pores. However, this cavity is eliminated when extrusion is carried out at screw speeds below 20 rpm. For 3D printed specimens, interlayer cavities were observed larger for specimens printed from 14 wt% carbon fibre reinforced recycled polypropylene than those printed from unreinforced filaments. The values of tensile strength for the filaments were 21.82 MPa and 24.22 MPa, which reduced to 19.72 MPa and 22.70 MPa, respectively, for 3D printed samples using the filaments. Likewise, the young’s modulus of the filaments was 1208.6 MPa and 1412.7 MPa, which reduced to 961.5 MPa and 1352.3 MPa, respectively, for the 3D printed samples. The percentage elongation at failure for the recycled polypropylene filament was 9.83% but reduced to 3.84% for the samples printed with 14 wt% carbon fiber reinforced polypropylene filaments whose elongation to failure was 6.58%. The SEM observations on the fractured tensile test samples showed interlayer gaps between the printed and the adjacent raster layers. These gaps accounted for the reduction in the mechanical properties of the printed parts.

Performance characterization of Ni60-WC coating on steel processed with supersonic laser deposition

Ni60-WC particles are used to improve the wear resistance of hard-facing steel due to their high hardness. An emerging technology that combines laser with cold spraying to deposit the hard-facing coatings is known as supersonic laser deposition. In this study, Ni60-WC is deposited on low-carbon steel using SLD. The microstructure and performance of the coatings are investigated through SEM, optical microscopy, EDS, XRD, microhardness and pin-on-disc wear tests. The experimental results of the coating processed with the optimal parameters are compared to those of the coating deposited using laser cladding.

Development of a one-axis manipulator for laser-assisted machining

Laser-assisted machining has been considered as a new alternative machining method of difficult-to-cut materials. A laser module with one-axis manipulator is developed to focus on preheating laser beam effectively. First of all, the thermal characteristic analysis was performed to verify the importance of laser module location. Laser module should be moved within 1 mm. Analysis conditions of three positions in driving range of the one-axis manipulator are selected. And a C coupling is used as a connection device for spindle and laser module. An initial model has one C coupling, and the number of C coupling has been increased from 1 to 2 in an improved model. And the analysis is carried out again for the one-axis manipulator. The results of the static analysis, the maximum displacement and the maximum stress are decreased by 22% and 11%, respectively, for the improved model when the laser module is located at farthest away from the spindle unit. As a result of the modal analysis, the first natural frequency mode is increased by 13%, 18% and 12% at these positions of the improved model, respectively. The harmonic analysis of the improved model was performed by analyzing the results of the modal analysis. The maximum deformation was 0.33 mm in driving unit at 222 Hz. And the maximum compliance of the ISO axis direction was 0.23 mm/N. Finally, the one-axis manipulator has been fabricated successfully using the analysis result.

NC code generation for laser assisted turn-mill of various type of clovers and square section members

Laser assisted turning (LAT) is one of the advanced machining technologies,which uses laser power to heat the surface of a workpiece before the material is removed.It has several advantages of low manufacturing costs,high productivity and high qualities to machine difficult-to-cut materials such as silicon nitride,mullite,zirconia and Ni.A large part of studies on LAT have been focused on a round bar.With increasing demands for high quality products and high performance engineering system,the researches on LAT for clover and square section members are necessary.But,these workpieces are impossible to be machined on conventional CNC lathe and to generate NC code with current CAM softwares.As a basic research for combining LAT with a tilting index table type 5-axis machining center,i.e.laser assisted turn-mill,a new method is suggested to generate NC code that can process various types of clover and square section members through development of C++ program.

Effect of screw position on bone tissue differentiation within a fixed femoral fracture

Plate and screw constructs are routinely used in the treatment of long bone fractures. Despite considerable advancements in technology and techniques, there can still be complications in the healing of long bone fractures. Non-unions, delayed unions, and hardware failures are common complications observed in clinical practice following open reduction and internal fixation of fractures [1]. Potential causes of these adverse clinical effects may be disruptive to the periosteal and endosteal blood supply, stress shielding effects, and inadequate mechanical stability. The goal of the present study was to explore the effect of screw position on the fracture healing and formation of new bone tissue with mechanoregulatory algorithms in a computational model. An idealized poroelastic 3D finite element (FE) model of a femur with a 5 mm fracture gap, including a plate-screw construct was developed. Nineteen different plate-screw combinations, created by varying the number and position of screws within the plate, were created to identify a construct with the most favourable attributes for fracture healing. The first phase of the study evaluated constructs through mechanical stress analyses to identify those constructs with high loadsupport capability. The second phase of the study evaluated healing and bone formation with a biphasic mechanoregulatory algorithm to simulate tissue differentiation for fixation within selected constructs. The results of our analysis demonstrated a 4-screw symmetrical construct with the largest distance between screws to provide the most favourable balance of stability and optimized conditions to promote fracture healing.

Laser Beam Welding of 600 MPa Quenched and Tempered High-Strength Steel

Conventional fusion arc welding of high-strength quenched and tempered steel can be improved through the use of non-conventional laser beam welding. This article presents the investigations of autogenous bead on plate and butt CO2 Laser Welding (LW) of 7 mm thick high-strength quenched and tempered low alloy SM570 (JIS) steel plates. The influence of laser welding parameters, mainly welding speed, defocusing distance and shielding gas flow rate on the weld profile, i.e., weld zone penetration depth and width, microstructure and mechanical properties of welded joints was determined. All welded joints showed smooth and uniform weld beads free from superficial porosity and undercuts. The selected best welding conditions were a laser power of 5.0 kW, welding speed of 500 mm/min, argon gas shielding flow rate of 30 L/min and a defocusing distance of -0.5 mm. It was observed that these conditions gave complete penetration and minimized the width of the weld bead. The microstructure of the welded joints was evaluated by light optical microscopy. The weld metal (WM) and heat-affected zone (HAZ) near weld metal achieved maximum hardness (355 HV). The tensile fractured samples showed the ductile mode of failure and ultimate tensile strength of 580 MPa.

Al2024-T3合金热变形加工工艺的流变应力预测（英文）

为了预测Al2024-T3合金热变形加工工艺的流变应力行为,在应变速率(0.001~100 s^(-1))、应变(0.1~0.5)和温度(573~773 K)条件下,进行了等温压缩试验。采用统计参数,如平均相对误差绝对值(AARE)和相关系数(R)评估了Al2024合金不同的本构模型和最新构建的本构模型的预测能力。与其他的模型相比,最新构建的模型能得到最低的AARE(4.6%)和最高的相关系数(0.99)。因此,与其他模型相比,该模型能更精确地描述Al2027-T3合金的变形行为。

Toughness and characterization of reactive powder concrete with ultra-high strength

A number of three-point bending and fracture tests of 200 MPa-level reactive powder concrete (RPC) with the various fiber contents have been conducted to probe the nature and characteristics of tough- ness of RPC200. The contribution of the embedded fibers to improving the crack-resistant capacity, energy absorption capacity and toughness with various deformation mechanisms has been analyzed. Taking account of that the first-crack deformation, peak-load deformation and their improvement varied with the fiber contents and that the deformation mechanism affected differently the performance at the first crack and the peak load, we took the peak-load deformation of plain RPC200 as the reference de- formation to measure the toughness of fibered RPC200. Two toughness indices T2(n?1)(n) and FT2(n?1)(n) have been formulated based on P-δ responses and P-CMOD responses. The indices quantify the tough- ness of RPC200 with the various deformation mechanisms relative to perfectly elastoplastic materials by setting the toughness level 2(n?1) as the initial reference. It is shown that the toughness index T2(n?1)(n) reflects the function of fibers to improve the toughness of RPC with the deformation throughout specimens, but overestimates the contribution to enhancing the toughness in post-peak periods. It underestimates, on other hands, the contribution to improving the toughness in the period from the first crack to the peak load. In contrast, the toughness index FT2(n?1)(n) properly presents the capability that fibers absorb energy and constrain crack propagation in the matrix when the deformation is con- centrated on the open crack. The proposed index unveils the contribution of fibers to toughening RPC200 both in the period from the first-crack to the peak load and in the period of post peak. This characterization method not only reveals the nature of toughness but also levels the toughness of RPC200. It could provide a way to establish an objective toughness characterization for RPC200 and facilitate its applications.