Tool wear evaluations in friction stir processing of commercial titanium Ti–6Al–4V

This research addresses the application of friction stir welding (FWS) of titanium alloy Ti–6Al–4V. Friction stir welding is a recent process, developed in the 1990s for aluminum joining; this joining process is being increasingly applied in many industries from basic materials, such as steel alloys, to high performance alloys, such as titanium. It is a process in great development and has its economic advantages when compared to conventional welding. For high performance alloys such as titanium, a major problem to overcome is the construction of tools that can withstand the extreme process environment. In the literature, the possibilities approached are only few tungsten alloys. Early experiments with tools made of cemented carbide (WC) showed optimistic results consistent with the literature. It was initially thought that WC tools may be an option to the FSW process since it is possible to improve the wear resistance of the tool. The metallographic analysis of the welds did not show primary defects of voids (tunneling) or similar internal defects due to processing, only defects related to tool wear which can cause loss of weld quality. The severe tool wear caused loss of surface quality and inclusions of fragments inside the joining, which should be corrected or mitigated by means of coating techniques on tool, or the replacement of cemented carbide with tungsten alloys, as found in the literature.

Structural and surface property characterization of titanium dioxide nanotubes for orthopedic implants

This research focused on the to modification of the surface structure of titanium implants with nanostructured morphology of TiO2 nanotubes and studied the interaction of nanotubes with osteoblast cells to understand the parameters that affect the cell growth. The electrical, mechanical, and structural properties of TiO2 nanotubes were characterized to establish a better understanding on the properties of such nanoscale morphological structures. To achieve the objectives of this research work I transformed the titanium and its alloys, either in bulk sheet form, bulk machined form, or thin film deposited on another substrate into a surface of titania nanotubes using a low cost and environmentally friendly process. The process requires only a simple electrolyte, low cost electrode, and a DC power supply. With this simple approach of scalable nanofabrication, a typical result is nanotubes that are each approximately 100nm in diameter and have a wall thickness of about 20nm. By changing the fabrication parameters, independent nanotubes can be fabricated with open volume between them. Titanium in this form is termed onedimensional since electron transport is narrowly confined along the length of the nanotube. My Ph.D. accomplishments have successfully shown that osteoblast cells, the cells that are the precursors to bone, have a strong tendency to attach to the inside and outside of the titanium nanotubes onto which they are grown using their filopodia – cell’s foot used for locomotion – anchored to titanium nanotubes. In fact it was shown that the cell prefers to find many anchoring sites. These sites are critical for cell locomotion during the first several weeks of maturity and upon calcification as a strongly anchored bone cell. In addition I have shown that such a surface has a greater cell density than a smooth titanium surface. My work also developed a process that uses a focused and controllably rastered ion beam as a nano-scalpel to cut away sections of the osteoblast cells to probe the attachment beneath the main cell body. Ultimately the more rapid growth of osteoblasts, coupled with a stronger cell-surface interface, could provide cost reduction, shorter rehabilitation, and fewer follow-on surgeries due to implant loosening.

The Electrical Resistance of Metals and Alloys in Their Hard and Soft States

It is known that the electrical resistance of annealed metals is usually smaller than that of metals in their cold worked state. The curve showing the relation between electrical resistance and annealing temperature reaches a minimum; continued annealing at higher temperature produces an increase in the electrical resistance. In the case of alloys it has been noted that a second decrease occurs at higher annealing temperature. The following work corroborates the observance of previous investigations. The electrical resistance of cold worked copper, gold, nickel, and iron decreased with annealing and then increased, the minimum being around 300° C. or 400° C. Monel metal showed a minimum resistance followed by an increase which in turn was followed by a second decrease.

The Electrical Conductivity of the Copper-Aluminum Alloys.

Among the many aluminum alloys which have been studied are the binary copper-aluminum alloys. These have proven to be among the most useful of the alumi­num alloys thus far worked upon.

Some Preliminary Investiagtions of the Magnetic Permeabilities of Alloys of the Ferromagnetic Metals

The problem presented for this thesis was an investigation of the magnetic properties of the alloys produced by the methods of powder metallurgy. The question behind this was the correlation of the magnetic properties with the bonding properties and with the diffusion of the constituents.

The Effects of Some Percentages of Nickel on the Annealing of Cartridge Brass

The most important element in the alloying of steels, has also been used quite extensively as a third constituent in copper-zinc alloys. The chief characteristics of nickel which make it desirable as an alloying element are its toughness, high strength, and resistance to corrosion.

Electroplating of Chromium upon a Nickel Plated Magnesium Alloy

A nickel plating operation for magnesium alloys was investigated and proved successful in plating a small sample of a typical commercial magnesium alloy, Dowmetal J1.

Element concentrations and Osmium, Platinum and Rhenium isotope ratios of ODP Site 153-920 abyssal peridotites

Abyssal peridotites are normally thought to be residues of melting of the mid-ocean ridge basalt (MORB) source and are presumably a record of processes affecting the upper mantle. Samples from a single section of abyssal peridotite from the Kane Transform area in the Atlantic Ocean were examined for 190Pt-186Os and 187Re-187Os systematics. They have uniform 186Os/188Os ratios with a mean of 0.1198353 +/- 7, identical to the mean of 0.1198340 +/-12 for Os-Ir alloys and chromitites believed to be representative of the upper mantle. While the Pt/Os ratios of the upper mantle may be affected locally by magmatic processes, these data show that the Pt/Os ratio for the bulk upper mantle has not deviated by more than about +/- 30% from a chondritic Pt/Os ratio over 4.5 billion years. These observations are consistent with the addition of a chondritic late veneer after core separation as the primary control on the highly siderophile element budget of the terrestrial upper mantle. The 187Os/188Os of the samples range from 0.12267 to 0.12760 and correlate well with Pt and Pt/Os, but not Re/Os. These relationships may be explained by variable amounts of partial melting with changing D(Re), reflecting in part garnet in the residue, with a model-dependent melting age between about 600 and 1700 Ma. A model where the correlation between Pt/Os and 187Os/188Os results from multiple ancient melting events, in mantle peridotites that were later juxtaposed by convection, is also consistent with these data. This melting event or events are evidently unrelated to recent melting under mid-ocean ridges, because recent melting would have disturbed the relationship between Pt/Os and 187Os/188Os. Instead, this section of abyssal peridotite may be a block of refractory mantle that remained isolated from the convecting portions of the upper mantle for 600 Ma to >1 Ga. Alternatively, Pt and Os may have been sequestered during more recent melting and possibly melt/rock reaction processes, thereby preserving an ancient melting history. If representative of other abyssal peridotites, then the rocks from this suite with subchondritic 187Os/188Os are not simple residues of recent MORB source melting at ridges, but instead have a more complex history. This suite of variably depleted samples projects to an undepleted present-day Pt/Os of about 2.2 and 187Os/188Os of about 0.128-0.129, consistent with estimates for the primitive upper mantle.

Flow and fracture behaviour of high performance alloys

Based on our needs, that is to say, through precise simulation of the impact phenomena that may occur inside a jet engine turbine with an explicit non-linear finite element code, four new material models are postulated. Each one of is calibrated for four high-performance alloys that can be encountered in a modern jet engine. A new uncoupled material model for high strain and ballistic is proposed. Based on a Johnson-Cook type model, the proposed formulation introduces the effect of the third deviatoric invariant by means of three different Lode angle dependent functions. The Lode dependent functions are added to both plasticity and failure models. The postulated model is calibrated for a 6061-T651 aluminium alloy with data taken from the literature. The fracture pattern predictability of the JCX material model is shown performing numerical simulations of various quasi-static and dynamic tests. As an extension of the above-mentioned model, a modification in the thermal softening behaviour due to phase transformation temperatures is developed (JCXt). Additionally, a Lode angle dependent flow stress is defined. Analysing the phase diagram and high temperature tests performed, phase transformation temperatures of the FV535 stainless steel are determined. The postulated material model constants for the FV535 stainless steel are calibrated. A coupled elastoplastic-damage material model for high strain and ballistic applications is presented (JCXd). A Lode angle dependent function is added to the equivalent plastic strain to failure definition of the Johnson-Cook failure criterion. The weakening in the elastic law and in the Johnson-Cook type constitutive relation implicitly introduces the Lode angle dependency in the elastoplastic behaviour. The material model is calibrated for precipitation hardened Inconel 718 nickel-base superalloy. The combination of a Lode angle dependent failure criterion with weakened constitutive equations is proven to predict fracture patterns of the mechanical tests performed and provide reliable results. A transversely isotropic material model for directionally solidified alloys is presented. The proposed yield function is based a single linear transformation of the stress tensor. The linear operator weighs the degree of anisotropy of the yield function. The elastic behaviour, as well as the hardening, are considered isotropic. To model the hardening, a Johnson-Cook type relation is adopted. A material vector is included in the model implementation. The failure is modelled with the Cockroft-Latham failure criterion. The material vector allows orienting the reference orientation in any other that the user may need. The model is calibrated for the MAR-M 247 directionally solidified nickel-base superalloy.

Nickel alloy steels.

Mode of access: Internet.

Microstructure control in Sn-0.7mass%Cu alloys

Soldering alloys based oft the Sn-Cu alloy system are amongst the most favourable lead-free alternatives due to a range of attractive properties. Trace additions of Ni have been found to significantly improve the soldering characteristics of these alloys (reduced bridging etc.). This paper examines the mechanisms underlying the improvement in soldering properties of Sn-0.7 mass%Cu eutectic alloys modified with concentrations of Ni ranging front 0 to 1000 ppm. The alloys were investigated by thermal analysis during solidification, as well as optical/SEM microanalyses of fully solidified samples anti samples quenched during solidification. It is concluded that Ni additions dramatically alter the nucleation patterns and solidification behaviour of the Sn-Cu6Sn5 eutectic anti that these changes are related to the superior soldering characteristics of the Ni-modified Sn-0.7 mass%Cu alloys.

Segregation of particles and its influence on the morphology of the eutectic silicon phase in Al-7 wt.% Si alloys

A new modification phenomenon is reported for Al-Si alloys, where the Al-Si eutectic is refined by segregated TiB2 particles. The TiB2 particles are pushed to the Al-Si phase boundary during solidification of the eutectic and it is believed that at high concentrations the TiB2 particles restrict solute redistribution causing refinement of the Si. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Brush plating of bearing alloys on aluminium alloy shells

The turbocharging of diesel engines has led to increase in temperature, load and corrosive attack of plain bearings. To meet these requirements, overlay plated aluminium alloys are now preferred. Currently, lead-tin alloys are deposited using a zincate layer and nickel strike, as intermediate stages in the process. The nickel has undesirable seizure characteristics and the zincate can given rise to corrosion problems. Consequently, brush plating allows the possible elimination of these stages and a decrease in process together with greater automation. The effect of mode application, on the formation of zincate films, using film growth weight measurements, potential-time studies, peel adhesion testing and Scanning Electron Microscopy was studied, for both SIC and AS15 aluminium alloys. The direct plating of aluminium was also successfully achieved. The results obtained indicate that generally, although lower adhesion resulted when a brush technique was used, satisfactory adhesion for fatigue testing was achieved. Both lead-tin and tin-cobalt overlays were examined and a study of the parameters governing brush plating were carried out using various electrolytes. An experimentally developed small scale rig, was used to produce overlay plated bearings that were fatigue tested until failure. The bearings were then examined and an analysis of the failure mechanisms undertaken. The results indicated that both alloy systems are of the regular codeposition type. Tin-cobalt overlays were superior to conventional lead-tin overlays and remained in good condition, although the lining (substrate) failed. Brush plated lead-tin was unsatisfactory. Sufficient understanding has now been gained, to enable a larger scale automated plant to be produced. This will allow a further study of the technique to be carried out, on equipment that more closely resembles that of a full scale production process.