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.

Ermittlung optimaler Bauteilorientierung zur Verbesserung der Prozessplanung in der CAD/RP-Kette

Ein wesentlicher Einflussfaktor auf die Bauteilqualität und Prozessgüte bei der generativen Herstellung von Prototypen ist die Orientierung der Bauteile. So kann eine optimierte Ausrichtung den Treppenstufeneffekt (Staircasing) sowie den Curling-Effekt minimieren und somit die Oberflächenqualität bzw. die Bauteilgenauigkeit erhöhen oder die Berücksichtigung von Formtoleranzen (z.B. Rundheit) ermöglichen. Des Weiteren können verschiedene Bauteilausrichtungen unterschiedliche Ausführungen von Stützkonstruktionen bewirken und die Bauteilstabilität beeinflussen. Diese und ähnliche Wechselwirkungen gilt es bei der Auswahl einer geeigneten Bauteilorientierung für RP-Anwendungen zu berücksichtigen. Dieser Vortrag stellt ein generisches System vor, welches unter Berücksichtigung der genannten Einflussfaktoren sowie weiterer Effekte eine rechnergestützte Optimierung der Bauteilorientierung durchführt. Neben der weiterhin notwendigen Erfahrung der Anwender zur endgültigen Festlegung der fallabhängigen Bauteilausrichtung liefert das System Vorschläge auf Basis einer intensiven Geometrieanalyse, die eine entsprechende Datenaufbereitung im Rahmen der Prozessplanung unterstützen.

„Pulverbettbasiertes Strahlschmelzen – neue Forschungserkenntnisse“

Auf dem Weg vom Rapid Prototyping zum Rapid Manufacturing ist erhöhte Prozesssicherheit sowie die Beherrschung verfahrensspezifischer Phänomene notwendig, um die immer weiter steigenden und konkreteren Bauteilanforderungen zu erfüllen. Dazu wurden diverse im SLM-Prozess auftretende Effekte untersucht. Basis der vorgestellten Entwicklungen sind grundlegende Erkenntnisse zur Oberflächenqualität von SLM-Bauteilen und Einflussgrößen auf Dichte und mechanische Eigenschaften der Bauteile verschiedener Werkstoffe. Ergebnis sind verschiedene Weiterentwicklungen der Standardbelichtungsstrategie, wodurch etwa Eigenspannungseffekte und Spritzerbildung positiv beeinflusst werden können.

Current measurements below the ice in Eclipse Sound

Velocity and direction of the current under the sea ice of the EcIipse Sound between Baffin lsland and Bylot Island were measured with specially developed devices and registered on a recorder. During the period of registration (May-June 1972) an easterly current of 5-7 cm/s superimposed by tidal and local influences (max. 12 cm/s) was found. In addition , measurements of friction between steelcone surfaces und corresponding conical ice bores are reported on. The plotted results show the influence of ice-temperature, surface quality and in some cases the influence of time.

Si(100) versus Ge(100): Watching the interface formation for the growth of III-V-based solar cells on abundant substrates

We investigated the atomic surface properties of differently prepared silicon and germanium (100) surfaces during metal-organic vapour phase epitaxy/chemical vapour deposition (MOVPE/MOCVD), in particular the impact of the MOVPE ambient, and applied reflectance anisotropy/difference spectroscopy (RAS/RDS) in our MOVPE reactor to in-situ watch and control the preparation on the atomic length scale for subsequent III-V-nucleation. The technological interest in the predominant opto-electronic properties of III-V-compounds drives the research for their heteroepitaxial integration on more abundant and cheaper standard substrates such as Si(100) or Ge(100). In these cases, a general task must be accomplished successfully, i.e. the growth of polar materials on non-polar substrates and, beyond that, very specific variations such as the individual interface formation and the atomic step structure, have to be controlled. Above all, the method of choice to grow industrial relevant high-performance device structures is MOVPE, not normally compatible with surface and interface sensitive characterization tools, which are commonly based on ultrahigh vacuum (UHV) ambients. A dedicated sample transfer system from MOVPE environment to UHV enabled us to benchmark the optical in-situ spectra with results from various surfaces science instruments without considering disruptive contaminants. X-ray photoelectron spectroscopy (XPS) provided direct observation of different terminations such as arsenic and phosphorous and verified oxide removal under various specific process parameters. Absorption lines in Fourier-transform infrared (FTIR) spectra were used to identify specific stretch modes of coupled hydrides and the polarization dependence of the anti-symmetric stretch modes distinguished different dimer orientations. Scanning tunnelling microscopy (STM) studied the atomic arrangement of dimers and steps and tip-induced H-desorption proved the saturation of dangling bonds after preparati- n. In-situ RAS was employed to display details transiently such as the presence of H on the surface at lower temperatures (T <; 800°C) and the absence of Si-H bonds at elevated annealing temperature and also surface terminations. Ge buffer growth by the use of GeH4 enables the preparation of smooth surfaces and leads to a more pronounced amplitude of the features in the spectra which indicates improvements of the surface quality.

Polypropylene fiber-reinforced self-compacting concrete for the reconstruction of the cathedral of La Laguna, Canary Island, Spain

High performance materials are needed for the reconstruction of such a singular building as a cathedral, since in addition to special mechanical properties, high self compact ability, high durability and high surface quality, are specified. Because of the project’s specifications, the use of polypropylene fiber-reinforced, self-compacting concrete was selected by the engineering office. The low quality of local materials and the lack of experience in applying macro polypropylene fiber for structural reinforcement with these components materials required the development of a pretesting program. To optimize the mix design, performance was evaluated following technical, economical and constructability criteria. Since the addition of fibers reduces concrete self-compactability, many trials were run to determine the optimal mix proportions. The variables introduced were paste volume; the aggregate skeleton of two or three fractions plus limestone filler; fiber type and dosage. Two mix designs were selected from the preliminary results. The first one was used as reference for self-compactability and mechanical properties. The second one was an optimized mix with a reduction in cement content of 20 kg/m3and fiber dosage of 1 kg/m3. For these mix designs, extended testing was carried out to measure the compression and flexural strength, modulus of elasticity, toughness, and water permeability resistance

Radio-holografía de microondas para la optimización de la superficie de grandes antenas reflectoras

En el presente trabajo de tesis se afronta el problema de la optimización de la superficie de grandes antenas reflectoras. Es sabido que los grandes reflectores, formados por una superficie panelada, sufren deformaciones debidas al impacto del viento, a los cambios de temperatura y a los efectos gravitacionales derivados del gran peso de la estructura. Estos efectos hacen que los reflectores pierdan su forma ideal, generalmente de paraboloide, y se reduzca su eficiencia de apertura y, por tanto, se limite la máxima frecuencia de uso de los mismos. Es necesario, por tanto, disponer de técnicas que permitan medir el estado de la superficie de grandes reflectores, y derivar los ajustes necesarios a aplicar sobre los tornillos de soporte de cada uno de los paneles que conforman dicha superficie. De esta manera, se devolvería al reflector su forma óptima y aumentaría la eficiencia de apertura y el rango de frecuencias de uso. Hay que resaltar que el aumento de la eficiencia de un radiotelescopio supone una reducción en el tiempo de integración necesario para la detección de las debilísimas señales generadas por las radiofuentes naturales, ahorrando así valioso tiempo de observación. Además, el incremento en el rango de frecuencias permite la detección de nuevas líneas o especies moleculares en dichas radiofuentes. Tras un primer capítulo introductorio, se presenta, en el capítulo segundo, la geometría de estos grandes reflectores y la influencia de los distintos factores que afectan a la calidad de la superficie de los mismos, como la gravedad, el viento y la temperatura, particularizando para el caso del radiotelescopio de 40 metros del Centro Astronómico de Yebes. En el tercer capítulo, se presentan las diferentes técnicas metrológicas empleadas actualmente para abordar la determinación de estos ajustes, mostrándose las ventajas e inconvenientes de cada una de ellas. Actualmente, la técnica metrológica más precisa y rápida para llevar a cabo esta tarea de caracterización de la superficie de un gran reflector, es la radio-holografía de microondas presentada en el capítulo cuarto. A partir de las medidas proporcionadas por esta técnica, realizadas con la ayuda de un transmisor, y mediante transformaciones de campo, se calculan los errores de la superficie del reflector, respecto al paraboloide ideal, y se derivan los ajustes necesarios. En los capítulos quinto y sexto se presentan los resultados de la aplicación de esta técnica a dos radiotelescopios: el de 30 metros de IRAM en Pico de Veleta (Granada) y los prototipos de 12 metros de las antenas del proyecto ALMA. Por su parte, el capítulo séptimo contiene el núcleo fundamental de esta tesis y presenta el desarrollo de la técnica de radio-holografía de microondas para optimizar la superficie del radiotelescopio de 40 metros del Centro Astronómico de Yebes. Para ello, ha sido necesario diseñar, construir e instalar un receptor de doble canal en banda Ku en foco primario, y la instrumentación asociada para hacer las medidas de amplitud y fase del diagrama de radiación. Además, ha sido necesario desarrollar el software para llevar a cabo las transformaciones de campo y derivar los ajustes de los paneles. De las medidas holográficas iniciales resultó un error de la superficie del radiotelescopio de 485 μm WRMS, respecto al paraboloide ideal en dirección normal. Tras varias iteraciones del proceso de medida y ajuste, se consiguió reducir dicho error a 194 μm WRMS. Esta notable mejora de la calidad de la superficie ha supuesto aumentar la eficiencia de apertura desde 2,6% al 38,2% a 86 GHz, para un receptor a esta frecuencia situado en el foco primario que produjese la misma iluminación que el receptor de holografía. In this thesis the problem of large reflector antenna surface optimization is faced. It is well known that large reflectors, which are made of a panelled surface, suffer from deformations due to the impact of wind, temperature gradients and gravity loads coming from the high weigth of the structure. These effects distort the ideal reflector shape, which is a paraboloid in most cases, hence reducing the aperture efficiency of the reflector and limiting the maximum frequency of operation. Therefore, it is necessary to have some techniques to measure the status of large reflector surfaces and to derive the adjustment values to be applied to the screws that connect the surface panels to the reflector back-up structure. In this way, the reflector would recover its optimum shape and the aperture efficiency and frequency range would increase. It has to be stated that an increment in the radiotelescope aperture efficiency would imply a reduction in the integration time needed to detect such weak signals coming from natural radiosources in space and, hence, an important saving in observation time. In addition, the increase in the frequency range of operation would allow the detection of new molecular lines in those radiosources. After the introduction, the second chapter shows the geometry of large reflector antennas and the impact on its surface quality of different factors like gravity, wind and temperature, particularly for the case of the Centro Astronómico de Yebes 40 meter radiotelescope. The third chapter deals with the different metrology techniques used to determine the panel adjustments, including the advantages and drawbacks of each one Currently, the most accurate and fast metrologic technique to carry out the characterization of large reflector surfaces is microwave radio-holography2, which is shown in chapter four. From the measurements provided by microwave radio-holography, performed with the help of a transmitter, and with the use of field transformations, the reflector surface errors are computed and the panel adjustments are derived. Chapters five and six show the results of holographic measurements applied to two first class radiotelescopes: the IRAM 30 meter radiotelescope and the 12 meter prototype antennas for the ALMA project. Chapter seven contains the main work of this thesis. It presents the development of the microwave radio-holography technique for the optimization of the Centro Astronómico de Yebes 40m radiotelescope. The work implied the design, construction and instalation of a prime focus Ku-band dual channel receiver, together with the associated instrumentation to measure the amplitude and phase of the radiotelescope radiation pattern. In addition, the software to carry out field transformations and screw settings computations was developed too. Initial holography measurements came up with an surface error of 485 μmWRMS in normal direction with respect to the best-fit paraboloid. After a few iterations of the measurementadjustment cycle, the surface error was reduced to 194 μm WRMS. This remarkable improvement in surface quality means an increment in aperture efficiency from 2,6% to 38,2% at 86 GHz, assuming a receiver at this frequency in prime focus position which produces the same illumination as the holography receiver.

Influência da substituição de matérias primas nas propriedades dos fluxantes para lingotamento contínuo de aços médio carbono

O fluxante é uma escória sintética que influencia na qualidade superficial do aço e na estabilidade do processo de lingotamento contínuo. Este produto é aplicado diretamente sobre o aço líquido na região do molde de cobre refrigerado a água e atua diretamente no resfriamento primário do aço. O fluxante tem as propriedades físico-químicas adaptadas para cada tipo de aço e também para as condições de lingotamento. Na superfície do aço líquido, o fluxante funde e forma uma poça líquida, atuando como isolante térmico, protegendo o aço da reoxidação e absorvendo inclusões principalmente de Al2O3. A poça líquida escoa, lubrificando e controlando a transferência de calor na interface entre o molde e a pele de aço em solidificação. O problema de qualidade superficial do aço, quando relacionado ao fluxante, se resume a alarmes de colamento, trincas de quina, marcas de oscilação profundas e trincas longitudinais, sendo este último um problema particular do aço médio carbono. Neste trabalho, foram analisados diferentes fluxantes baseados inicialmente no fluxante comercial aplicado no lingotamento contínuo de placas de aço médio carbono. Todos os fluxantes foram desenvolvidos com composições químicas similares. O objetivo foi avaliar o impacto da substituição de fontes de matérias-primas em diferentes composições de modo a avaliar as propriedades físico-químicas com base no fluxante comercial de referência. Como resultado, de todas as propriedades físico-químicas, foi a temperatura de cristalização que sofreu a alteração mais significativa.