Preparation of Coated Microtools for Electrochemical Machining Applications

PREPARATION OF COATED MICROTOOLS FOR ELECTROCHEMICAL MACHINING APPLICATIONS Ajaya K. Swain, M.S. University of Nebraska, 2010 Advisor: K.P. Rajurkar Coated tools have improved the performance of both traditional and nontraditional machining processes and have resulted in higher material removal, better surface finish, and increased wear resistance. However, a study on the performance of coated tools in micromachining has not yet been adequately conducted. One possible reason is the difficulties associated with the preparation of coated microtools. Besides the technical requirement, economic and environmental aspects of the material and the coating technique used also play a significant role in coating microtools. This, in fact, restricts the range of coating materials and the type of coating process. Handling is another major issue in case of microtools purely because of their miniature size. This research focuses on the preparation of coated microtools for pulse electrochemical machining by electrodeposition. The motivation of this research is derived from the fact that although there were reports of improved machining by using insulating coatings on ECM tools, particularly in ECM drilling operations, not much literature was found relating to use of metallic coating materials in other ECM process types. An ideal ECM tool should be good thermal and electrical conductor, corrosion resistant, electrochemically stable, and stiff enough to withstand electrolyte pressure. Tungsten has almost all the properties desired in an ECM tool material except being electrochemically unstable. Tungsten can be oxidized during machining resulting in poor machining quality. Electrochemical stability of a tungsten ECM tool can be improved by electroplating it with nickel which has superior electrochemical resistance. Moreover, a tungsten tool can be coated in situ reducing the tool handling and breakage frequency. The tungsten microtool was electroplated with nickel with direct and pulse current. The effect of the various input parameters on the coating characteristics was studied and performance of the coated microtool was evaluated in pulse ECM. The coated tool removed more material (about 28%) than the uncoated tool under similar conditions and was more electrochemical stable. It was concluded that nickel coated tungsten microtool can improve the pulse ECM performance.

Millennial-Scale Climate Variability during the Last Glacial Period in the Tropical Andes

Millennial-scale climate variation during the Last Glacial period is evident in many locations worldwide, but it is unclear if such variation occurred in the interior of tropical South America, and, if so, how the low-latitude variation was related to its high-latitude counterpart. A high-resolution record, derived from the deep drilling of sediments on the floor of Lake Titicaca in the southern tropical Andes, is presented that shows clear evidence of millennial-scale climate variation between ~60 and 20 ka BP. This variation is manifested by alternations of two interbedded sedimentary units. The two units have distinctive sedimentary, geochemical, and paleobiotic properties that are controlled by the relative abundance of terrigenous or nearshore components versus pelagic components. The sediments of more terrigenous or nearshore nature likely were deposited during regionally wetter climates when river transport of water and sediment was higher, whereas the sediments of more pelagic character were deposited during somewhat drier climates regionally. The majority of the wet periods inferred from the Lake Titicaca sediment record are correlated with the cold events in the Greenland ice cores and North Atlantic sediment cores, indicating that increased intensity of the South American summer monsoon was part of near-global scale climate excursions.

High Resolution Paleoceanography of the Guaymas Basin, Gulf of California, During the Past 15 000 Years

Deep Sea Drilling Project Site 480 (27°54.10’N, 111°39.34’W; 655 m water depth) contains a high resolution record of paleoceanographic change of the past 15 000 years for the Guaymas Basin, a region of very high diatom productivity within the central Gulf of California. Analyses of diatoms and silicoflagellates were completed on samples spaced every 40-50 yr, whereas ICP-AES geochemical analyses were completed on alternate samples (sample spacing 80-100 yr). The Bolling-Allerod interval (14.6-12.9 ka) (note, ka refers to 1000 calendar years BP throughout this report) is characterized by an increase in biogenic silica and a decline in calcium carbonate relative to surrounding intervals, suggesting conditions somewhat similar to those of today. The Younger Dryas event (12.9-11.6 ka) is marked by a major drop in biogenic silica and an increase in calcium carbonate. Increasing relative percentage contributions of Azpeitia nodulifera and Dictyocha perlaevis (a tropical diatom and silicoflagellate, respectively) and reduced numbers of the silicoflagellate Octactis pulchra are supportive of reduced upwelling of nutrient-rich waters. Between 10.6 and 10.0 ka, calcium carbonate and A. nodulifera abruptly decline at DSDP 480, while Roperia tesselata, a diatom indicative of winter upwelling in the modern-day Gulf, increases sharply in numbers. A nearly coincident increase in the silicoflagellate Dictyocha stapedia suggests that waters above DSDP 480 were more similar to the cooler and slightly more saline waters of the northern Gulf during much of the early and middle parts of the Holocene (~10 to 3.2 ka). At about 6.2 ka a stepwise increase in biogenic silica and the reappearance of the tropical diatom A. nodulifera marks a major change in oceanographic conditions in the Gulf. A winter shift to more northwesterly winds may have occurred at this time along with the onset of periodic northward excursions (El Nino-driven?) of the North Equatorial Countercurrent during the summer. Beginning between 2.8 and 2.4 ka, the amplitude of biogenic silica and wt% Fe, Al, and Ti (proxies of terrigenous input) increase, possibly reflecting intensification of ENSO cycles and the establishment of modern oceanographic conditions in the Gulf. Increased numbers of O. pulchra after 2.8 ka suggest enhanced spring upwelling.

Late Pliocene diatoms in a diatomite from Prydz Bay, East Antarctica

Very well-preserved Pliocene diatoms from a diatomite unit interbedded within glacial sediments at Ocean Drilling Program Site 742 in Prydz Bay, Antarctica are documented and illustrated. The presence of Thalassiosira kolbei, T torokina, Actinocyclus actinochilus, A karstenii and the absence of Nitzschia interfrigidaria, T. insigna and T. vulnifica in Sample 119-742A-15R-4, 44-46 cm constrain its age to ca. 2.2-1.8 Ma (late Pliocene). Diatoms associated with sea ice constitute 35% of the Pliocene diatom assemblage, compared with 71% of the modern sediment assemblage at the site, suggesting that sea ice was present during the late Pliocene period of deposition of the sample, although it probably was not the significant feature it is today.