Microstructural and surface texture analysis due to machining in Super Austenitic Stainless Steel

Inferior surface quality is a significant problem faced by machinist. The purpose of this study is to present a surface texture analysis undertaken as part of machinability assessment of Super Austenitic Stainless Steel alloy-AL6XN. The surface texture analysis includes measuring the surface roughness and investigating the microstructural behaviour of the machined surfaces. Eight milling trials were conducted using combination of cutting parameters under wet machining. An optical profilometer (non-contact), was used to evaluate the surface texture at three positions. The surface texture was represented using the parameter, average surface roughness. Scanning Electron Microscope was utilised to inspect the machined surface microstructure and co relate with the surface roughness results. Results showed that maximum roughness values recorded at the three positions in the longitudinal direction (perpendicular to the machining grooves) were 1.21 μm (trial 1), 1.63 μm (trial 6) and 1.68 μm (trial 7) respectively whereas the roughness values were greatly reduced in the lateral direction. Also, results showed that the feed rate parameter significantly influences the roughness values compared to the other cutting parameters. The microstructure of the machined surfaces was distorted by the existence of cracks, deformed edges and bands and wear deposition due to machining process.

Diagnosing dry eye with dynamic-area high-speed videokeratoscopy

Dry eye syndrome is one of the most commonly reported eye health conditions. Dynamic-area highspeed videokeratoscopy (DA-HSV) represents a promising alternative to the most invasive clinical methods for the assessment of the tear film surface quality (TFSQ), particularly as Placido-disk videokeratoscopy is both relatively inexpensive and widely used for corneal topography assessment. Hence, improving this technique to diagnose dry eye is of clinical significance and the aim of this work. First, a novel ray-tracing model is proposed that simulates the formation of a Placido image. This model shows the relationship between tear film topography changes and the obtained Placido image and serves as a benchmark for the assessment of indicators of the ring’s regularity. Further, a novel block-feature TFSQ indicator is proposed for detecting dry eye from a series of DA-HSV measurements. The results of the new indicator evaluated on data from a retrospective clinical study, which contains 22 normal and 12 dry eyes, have shown a substantial improvement of the proposed technique to discriminate dry eye from normal tear film subjects. The best discrimination was obtained under suppressed blinking conditions. In conclusion,this work highlights the potential of the DA-HSV as a clinical tool to diagnose dry eye syndrome.

Processing and fiber content effects on the machinability of compression moulded random direction short GFRP composites

The random direction short Glass Fiber Reinforced Plastics (GFRP) have been prepared by two compression moulding processes, namely the Preform and Sheet Moulding Compound (SMC) processes. Cutting force analysis and surface characterization are conducted on the random direction short GFRPs with varying fiber contents (25 similar to 40%). Edge trimming experiments are preformed using carbide inserts with varing the depth of cut and cutting speed. Machining characteristics of the Preform and SMC processed random direction short GFRPs are evaluated in terms of cutting forces, surface quality, and tool wear. It is found that composite primary processing and fiber contents are major contributing factors influencing the cutting force magnitudes and surface textures. The SMC composites show better surface finish over the Preform composites due to less delamination and fiber pullouts. Moreover, matrix damage and fiber protrusions at the machined edge are reduced by increasing fiber content in the random direction short GFRP composites.

Influence of melt pouring temperature and plate inclination on solidification and microstructure of A356 aluminum alloy produced using oblique plate

The preparation of semisolid slurry of A356 aluminum alloy using an oblique plate was investigated. A356 alloy melt undergoes partial solidification when it flows down on an oblique plate cooled from underneath by counter flowing water. It results in continuous formation of columnar dendrites on plate wall. Due to forced convection, these dendrites are sheared off into equiaxed/fragmented grains and then washed away continuously to produce semisolid slurry at plate exit. Melt pouring temperature provides required condition of solidification whereas plate inclination enables necessary shear for producing semisolid slurry of desired quality. Slurry obtained was solidified in metal mould to produce semisolid-cast billets of desired microstructure. Furthermore, semisolid-cast billets were heat treated to improve surface quality. Microstructures of both semisolid-cast and heat-treated billets were analyzed. Effects of melt pouring temperature and plate inclination on solidification and microstructure of billets produced using oblique plate were described. The investigations involved four different melt pouring temperatures (620, 625, 630 and 635 degrees C) associated with four different plate inclinations (30 degrees, 45 degrees, 60 degrees and 75 degrees). Melt pouring temperature of 625 degrees C with plate inclination of 60 degrees shows fine and globular microstructures and it is the optimum.

Influence of plate length and plate cooling rate on solidification and microstructure of A356 alloy produced by oblique plate

A356 alloy melt solidifies partially when it flows down on an oblique plate cooled from bottom by counter flowing water. Columnar dendrites are continuously formed on the plate wall. Because of the forced convection, these dendrites are sheared off into equiaxed/fragmented grains and then washed away continuously by producing semisolid slurry at plate exit. Plate cooling rate provides required extent/amount of solidification whereas plate length enables necessary shear for producing semisolid slurry of desired quality. Slurry obtained is solidified in metal mould to produce semisolid-cast billets of desired microstructure. Furthermore, semisolid-cast billets are also heat-treated to improve surface quality. Microstructures of both semisolid-cast and heat-treated billets are compared. The effects of plate length and plate cooling rate on solidification and microstructure of billets produced by using oblique plate are illustrated. Three different plate lengths (200 mm, 250 mm, 300 mm) associated with three different heat transfer coefficients (1000, 2000 and 2500 W/(m(2).K)) are involved. Plate length of 250 mm with heat transfer coefficient of 2000 W/(m(2).K) gives fine and globular microstructures and is the optimum as there is absolutely no possibility of sticking of slurry to plate wall.

Lightweight deformable mirrors for future space telescopes

This thesis presents a concept for ultra-lightweight deformable mirrors based on a thin substrate of optical surface quality coated with continuous active piezopolymer layers that provide modes of actuation and shape correction. This concept eliminates any kind of stiff backing structure for the mirror surface and exploits micro-fabrication technologies to provide a tight integration of the active materials into the mirror structure, to avoid actuator print-through effects. Proof-of-concept, 10-cm-diameter mirrors with a low areal density of about 0.5 kg/m² have been designed, built and tested to measure their shape-correction performance and verify the models used for design. The low cost manufacturing scheme uses replication techniques, and strives for minimizing residual stresses that deviate the optical figure from the master mandrel. It does not require precision tolerancing, is lightweight, and is therefore potentially scalable to larger diameters for use in large, modular space telescopes. Other potential applications for such a laminate could include ground-based mirrors for solar energy collection, adaptive optics for atmospheric turbulence, laser communications, and other shape control applications.

The immediate application for these mirrors is for the Autonomous Assembly and Reconfiguration of a Space Telescope (AAReST) mission, which is a university mission under development by Caltech, the University of Surrey, and JPL. The design concept, fabrication methodology, material behaviors and measurements, mirror modeling, mounting and control electronics design, shape control experiments, predictive performance analysis, and remaining challenges are presented herein. The experiments have validated numerical models of the mirror, and the mirror models have been used within a model of the telescope in order to predict the optical performance. A demonstration of this mirror concept, along with other new telescope technologies, is planned to take place during the AAReST mission.

Scalable Methods for Deterministic Integration of Quantum Emitters in Photonic Crystal Cavities

We investigated four unique methods for achieving scalable, deterministic integration of quantum emitters into ultra-high Q{V photonic crystal cavities, including selective area heteroepitaxy, engineered photoemission from silicon nanostructures, wafer bonding and dimensional reduction of III-V quantum wells, and cavity-enhanced optical trapping. In these areas, we were able to demonstrate site-selective heteroepitaxy, size-tunable photoluminescence from silicon nanostructures, Purcell modification of QW emission spectra, and limits of cavity-enhanced optical trapping designs which exceed any reports in the literature and suggest the feasibility of capturing- and detecting nanostructures with dimensions below 10 nm. In addition to process scalability and the requirement for achieving accurate spectral- and spatial overlap between the emitter and cavity, these techniques paid specific attention to the ability to separate the cavity and emitter material systems in order to allow optimal selection of these independently, and eventually enable monolithic integration with other photonic and electronic circuitry.

We also developed an analytic photonic crystal design process yielding optimized cavity tapers with minimal computational effort, and reported on a general cavity modification which exhibits improved fabrication tolerance by relying exclusively on positional- rather than dimensional tapering. We compared several experimental coupling techniques for device characterization. Significant efforts were devoted to optimizing cavity fabrication, including the use of atomic layer deposition to improve surface quality, exploration into factors affecting the design fracturing, and automated analysis of SEM images. Using optimized fabrication procedures, we experimentally demonstrated 1D photonic crystal nanobeam cavities exhibiting the highest Q/V reported on substrate. Finally, we analyzed the bistable behavior of the devices to quantify the nonlinear optical response of our cavities.

Talbot-SNOM method for non-contact evaluation of high-density gratings

A Talbot scanning near-field optical microscopy (SNOM) method for non-contact evaluating of high-density gratings was described. This method combines the Talbot self-imaging effect of the gratings and the conventional SNOM technique without damage. The significant advantages of this method are its simple structure, reliable and fast measurement for the surface quality of the tested gratings. Experimental results of three different kinds of gratings were demonstrated to indicate that this method is effective for evaluation surface quality of high-density gratings. (c) 2004 Elsevier B.V. All rights reserved.

Ensayos NDT de piezas fabricadas por Láser Cladding.

[ES]Este trabajo consiste en realizar ensayos NDT de Líquidos Penetrantes sobre unas piezas fabricadas por Láser Cladding. Su objetivo es comprobar la integridad superficial y verificar si se producen discontinuidades superficiales relevantes, de modo que se pueda comprobar la calidad superficial que se obtiene en piezas fabricadas por este proceso.

Defects Detection and Assessment in Concrete Surfaces

Aside from cracks, the impact of other surface defects, such as air pockets and discoloration, can be detrimental to the quality of concrete in terms of strength, appearance and durability. For this reason, local and national codes provide standards for quantifying the quality impact of these concrete surface defects and owners plan for regular visual inspections to monitor surface conditions. However, manual visual inspection of concrete surfaces is a qualitative (and subjective) process with often unreliable results due to its reliance on inspectors’ own criteria and experience. Also, it is labor intensive and time-consuming. This paper presents a novel, automated concrete surface defects detection and assessment approach that addresses these issues by automatically quantifying the extent of surface deterioration. According to this approach, images of the surface shot from a certain angle/distance can be used to automatically detect the number and size of surface air pockets, and the degree of surface discoloration. The proposed method uses histogram equalization and filtering to extract such defects and identify their properties (e.g. size, shape, location). These properties are used to quantify the degree of impact on the concrete surface quality and provide a numerical tool to help inspectors accurately evaluate concrete surfaces. The method has been implemented in C++ and results that validate its performance are presented.

Control of material transport through pulse shape manipulation-a development toward designer pulses

The variety of laser systems available to industrial laser users is growing and the choice of the correct laser for a material target application is often based on an empirical assessment. Industrial master oscillator power amplifier systems with tuneable temporal pulse shapes have now entered the market, providing enormous pulse parameter flexibility in an already crowded parameter space. In this paper, an approach is developed to design interaction parameters based on observations of material responses. Energy and material transport mechanisms are studied using pulsed digital holography, post process analysis techniques and finite-difference modelling to understand the key response mechanisms for a variety of temporal pulse envelopes incident on a silicon (1/1/1) substrate. The temporal envelope is shown to be the primary control parameter of the source term that determines the subsequent material response and the resulting surface morphology. A double peak energy-bridged temporal pulse shape designed through direct application of holographic imaging data is shown to substantially improve surface quality. © 2014 IEEE.

Multistage etching process for microscopically smooth tellurite glass surfaces in optical fibers

Bulk samples of tellurite glass with composition 75TeO(2)-20ZnO-5Na(2)O (TZN) were fabricated by melting and quenching techniques. In order to improve the surface quality of optical fiber preform made with this tellurite glass, the authors developed a multistage etching process. The relationship between successive etching treatments and roughness of the TZN glass surface was probed by using an atomic force microscope. The results demonstrate that this multistage etching method effectively improves this tellurite glass surface smoothness to a level comparable with that of a reference silica glass slide, and the corresponding chemical micromechanisms and fundamentals are discussed and confirmed by atomic force microscopy, potentially contributing to the development of multicomponent soft glass fibers and devices. (C) 2010 American Vacuum Society. [DOI: 10.1116/1.3437017]

机器人研磨抛光工艺研究

以有机玻璃为研究对象,介绍了机器人研磨抛光工艺,讨论了研磨抛光参数优化设计方法,并进行了研磨抛光试验。试验结果表明,研磨抛光后的工件,能够达到产品外形和表面质量的要求,且提高了磨抛效率。

Casting of Self-Compacting Concrete

Increased productivity and improved working environment have had high priority in the development of concrete construction over the last decade. Development of a material not needing vibration for compaction—i.e. selfcompacting concrete (SCC)—has successfully met the challenge and is now increasingly being used in routine practice. The key to the improvement of fresh concrete performance has been nanoscale tailoring of molecules for surface active admixtures, as well as improved understanding of particle packing and of the role of mineral surfaces in cementitious matrixes. Fundamental studies of rheological behaviour of cementitious particle suspensions were soon expanded to extensive innovation programmes incorporating applied research, site experiments, instrumented full scale applications supporting technology, standards and guides, information efforts as well as training programmes. The major impact of the introduction of SCC is connected to the production process. The choice and handling of constituents are modified as well as mix design, batching, mixing and transporting. The productivity is drastically improved through elimination of vibration compaction and process reorganisation. The working environment is significantly enhanced through avoidance of vibration induced damages, reduced noise and improved safety. Additionally, the technology is improving performance in terms of hardened material properties like surface quality, strength and durability.

3D die shape optimisation for net-shape forging of aerofoil blades

This paper reports on work in developing a finite element (FE) based die shape optimisation for net-shape forging of 3D aerofoil blades for aeroengine applications. Quantitative representations of aerofoil forging tolerances were established to provide a correlation between conventional dimensional and shape specifications in forging production and those quantified in FE simulation. A new direct compensation method was proposed, employing variable weighting factors to minimise the total forging tolerances in forging optimisation computations. A surface approximation using a B-spline surface was also developed to ensure improved die surface quality for die shape representation and design. For a Ni-alloy blade test case, substantial reduction in dimensional and shape tolerances was achieved using the developed die shape optimisation system.