Effect of grain size on slow fatigue crack propagation and plastic deformation near crack tip

Fatigue crack growth and its threshold are investigated at a stress ratio of 0.5 for the three-point bend specimen made of Austenitic stainless steel. The effect of grain size on the crack tip plastic deformation is investigated. The results show that the threshold value Δkth increases linearly with the square root of grain size d and the growth rate is slower for materials with larger grain size. The plastic zone size and ratio for different grain sizes are different at the threshold. The maximum stress intensity factor is kmax and σys is the yield strength. At the same time, the characteristics of the plastic deformation development is discontinuous and anti-symmetric as the growth rate is increased from 2·10—8 to 10−7 mm/cycle.

Experimental relaxation behavior of chopped-strand mat glass-fiber reinforced polyester beams in 3 point bending

A dimensionless relation of the form for collating fatigue crack starting growth data is proposed in which Δkth represents the stress intensity factor range at the threshold. Based on experimental results, this relation attains the value of 0.6 for a fatigue crack to start growth in the Austenitic stainless steel investigated in this work. Metallurgical examinations were also carried out to show a transgranular shear mode of cyclic cleavage and plastic shear.

具有梯度结构表层301不锈钢的压缩性能

利用表面机械研磨处理技术,在301奥氏体不锈钢中得到晶粒尺度呈梯度分布的变形表层,进行了压缩试验和微观组织观察。结果表明,变形表层中晶粒可细化至100nm。相比原始态的屈服强度236MPa,具有变形梯度表层后屈服强度增加到436MPa,变形后的加工硬化指数为0.31,经400和700℃的退火后分别增加到0.32和0.35。另外,随着应变速率的增加,流变应力增大而加工硬化能力降低.

SEM and EDS Characterisation of Layering TiOx Growth onto the Cutting Tool Surface in Hard Drilling Processes of Ti-Al-V Alloys

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脉冲激光导致不锈钢表层温度场演化的模拟

采用焓方法对Nd:YAG脉冲激光导致的不锈钢材料表面熔凝过程的温度场进行了数值模拟.在此基础上,结合材料的结晶动力学和快速凝固理论,对材料微结构演化的几个重要参数,包括凝固速率、冷却速度和界面温度梯度做了估算和讨论.

Effects of Thermocapillary Convection on the Growth Process in Industrial 8-inch Silicon Czochralski Growth

Czochralski (CZ) crystal growth process is a widely used technique in manufacturing of silicon crystals and other semiconductor materials. The ultimate goal of the IC industry is to have the highest quality substrates, which are free of point defect, impurities and micro defect clusters. The scale up of silicon wafer size from 200 mm to 300 mm requires large crucible size and more heat power. Transport phenomena in crystal growth processes are quite complex due to melt and gas flows that may be oscillatory and/or turbulent, coupled convection and radiation, impurities and dopant distributions, unsteady kinetics of the growth process, melt crystal interface dynamics, free surface and meniscus, stoichiometry in the case of compound materials. A global model has been developed to simulate the temperature distribution and melt flow in an 8-inch system. The present program features the fluid convection, magnetohydrodynamics, and radiation models. A multi-zone method is used to divide the Cz system into different zones, e.g., the melt, the crystal and the hot zone. For calculation of temperature distribution, the whole system inside the stainless chamber is considered. For the convective flow, only the melt is considered. The widely used zonal method divides the surface of the radiation enclosure into a number of zones, which has a uniform distribution of temperature, radiative properties and composition. The integro-differential equations for the radiative heat transfer are solved using the matrix inversion technique. The zonal method for radiative heat transfer is used in the growth chamber, which is confined by crystal surface, melt surface, heat shield, and pull chamber. Free surface and crystal/melt interface are tracked using adaptive grid generation. The competition between the thermocapillary convection induced by non-uniform temperature distributions on the free surface and the forced convection by the rotation of the crystal determines the interface shape, dopant distribution, and striation pattern. The temperature gradients on the free surface are influenced by the effects of the thermocapillary force on the free surface and the rotation of the crystal and the crucible.

Performance of a small high-speed liquid jet apparatus

The performance of a small high-speed liquid jet apparatus is described. Water jets of 200m/s to 700m/s have been obtained by firing a deformable lead slug from an air rifle into a stainless steel nozzle containing water sealed with a rubber diaphragm. Nozzle devices of using the impact extrusion (IE) method and cumulation (CU) method are designed to generate jets. The injection sequences are visualized using schlieren photography. The difference between the IE and CU methods in the jet generation is found.

Analyse der Beifangreduktion durch Gitternetze in der kommerziellen Garnelenfischerei

Trials for the determination of the magnitude of bycatch reduction by sorting grids used in the commercial brown shrimp fishery were carried out from September to December 1997. Trawls with 9 m beam length were used on different fishing grounds in the estuary of the Elbe River near Cuxhaven. The sorting grids tested were made of stainless steel bars spaced at 18, 20, 22, 26 and 30 mm, built into a cylindrical stainless steel frame with a diameter of 65 cm at an angle of attack of 45 degrees. This frame was positioned between the forenet and codend. Simultaneous hauls were made with a trawl of equal construction but without a sorting grid, and the weighed catch components (fish, discard shrimps and commercial size shrimps) separated by means of a riddle were compared. The composition of the sorted out part of the catch of the sorting grid net could be calculated by comparise the corresponding catch components in both the standard trawl and the sorting grid trawl. According to this the total catch of the beam trawl with the sorting grid is reduced by 18 to 38 % depending on the space between the bars. 7 to 31 % of the sorted out part of the catch consists of fish. The use of the sorting grid, however, also leads to losses of 4 to 12 % in Oktober. Per hour of towing this means a loss of 10,3 % commerical size shrimps with a sorting grid of 18 mm space between the bars and of 12,4 % for a 26 mm grid.

Erster Einsatz von Trenngittern in der kommerziellen Garnelenfischerei

Comparative fishing trials were conducted in the river Elbe estuary using 9 m commercial brown shrimp beam trawls. To avoid the bycatch of fish a metal sorting grid of the Nordmöre type was used. The elliptical grid was constructed of 6 mm stainless steel bar with a spacing of 20 mm between the bars and housed in a cylindrical frame of 800 mm diameter. It was installed in the extension piece just in front of the codend. The inclination of the grid was 45 degrees. A fish outlet was provided in the upper panel of the trawl at the upper edge of the grid. A series of 8 tows of 15 min duration at a towing speed of 3 kns was done. For evaluation the catch of the main codend was compared to the portion of the catch escaped through the grid. The presence of the grid caused a 97.4 % reduction of the catch of lump sucker, a 90.6 % reduction of the catch of sea scorpion, a 79.3 % reduction of the catch of cod, a 58.8 % reduction of the catch of armed bullhead, a 39.6 % reduction of the catch of dab, a 34.7 % reduction of the catch of flounder, a 32.3 % reduction of the catch of smelt, a 19.8 % reduction of the catch of plaice and a 14.5 % reduction of the catch of brown shrimp.

Planar reflection of gaseous detonations

Pipes containing flammable gaseous mixtures may be subjected to internal detonation. When the detonation normally impinges on a closed end, a reflected shock wave is created to bring the flow back to rest. This study built on the work of Karnesky (2010) and examined deformation of thin-walled stainless steel tubes subjected to internal reflected gaseous detonations. A ripple pattern was observed in the tube wall for certain fill pressures, and a criterion was developed that predicted when the ripple pattern would form. A two-dimensional finite element analysis was performed using Johnson-Cook material properties; the pressure loading created by reflected gaseous detonations was accounted for with a previously developed pressure model. The residual plastic strain between experiments and computations was in good agreement.

During the examination of detonation-driven deformation, discrepancies were discovered in our understanding of reflected gaseous detonation behavior. Previous models did not accurately describe the nature of the reflected shock wave, which motivated further experiments in a detonation tube with optical access. Pressure sensors and schlieren images were used to examine reflected shock behavior, and it was determined that the discrepancies were related to the reaction zone thickness extant behind the detonation front. During these experiments reflected shock bifurcation did not appear to occur, but the unfocused visualization system made certainty impossible. This prompted construction of a focused schlieren system that investigated possible shock wave-boundary layer interaction, and heat-flux gauges analyzed the boundary layer behind the detonation front. Using these data with an analytical boundary layer solution, it was determined that the strong thermal boundary layer present behind the detonation front inhibits the development of reflected shock wave bifurcation.

Trenngitter - eine Alternative zu den Trichternetzen in der Garnelenfischerei

Experimental fishing trials were conducted in the Elbe Estuary using an experimental 3 m-standard beamtrawl. To avoid the by-catch of fish, a sorting grid was used. The elliptical grid was constructed of 6 mm diameter stainless steel bars with a spacing of 13 mm between the bars and housed in a cylindrical frame of 400 mm diameter. It was installed in the extension piece just in front of the codend angled at 45°, with a fish outlet at the top. A series of 10 tows of 15 minutes duration at a towing speed of 3 kn was done. The catch of the main codend was compared with the catch separated by the sorting grid. This achieved a reduction of 56 % of plaice (Pleuronectes platessa), 75 % of flounder (Platichthys flesus), 99 % of whiting (Merlangius merlangus), 94 % of cod (Gadus morhua) and 49 % of smelt (Osmerus eperlanus) with a mean loss of 43 % of shrimps (Crangon crangon). English grid trials in the Humber estuary using a flapper set or guiding funnel in front of the sorting grid device demonstrated reasonable lower escapement rates for fish and shrimps.

Developing and characterizing bulk metallic glasses for extreme applications

Metallic glasses have typically been treated as a “one size fits all” type of material. Every alloy is considered to have high strength, high hardness, large elastic limits, corrosion resistance, etc. However, similar to traditional crystalline materials, properties are strongly dependent upon the constituent elements, how it was processed, and the conditions under which it will be used. An important distinction which can be made is between metallic glasses and their composites. Charpy impact toughness measurements are performed to determine the effect processing and microstructure have on bulk metallic glass matrix composites (BMGMCs). Samples are suction cast, machined from commercial plates, and semi-solidly forged (SSF). The SSF specimens have been found to have the highest impact toughness due to the coarsening of the dendrites, which occurs during the semi-solid processing stages. Ductile to brittle transition (DTBT) temperatures are measured for a BMGMC. While at room temperature the BMGMC is highly toughened compared to a fully glassy alloy, it undergoes a DTBT by 250 K. At this point, its impact toughness mirrors that of the constituent glassy matrix. In the following chapter, BMGMCs are shown to have the capability of being capacitively welded to form single, monolithic structures. Shear measurements are performed across welded samples, and, at sufficient weld energies, are found to retain the strength of the parent alloy. Cross-sections are inspected via SEM and no visible crystallization of the matrix occurs.

Next, metallic glasses and BMGMCs are formed into sheets and eggbox structures are tested in hypervelocity impacts. Metallic glasses are ideal candidates for protection against micrometeorite orbital debris due to their high hardness and relatively low density. A flat single layer, flat BMG is compared to a BMGMC eggbox and the latter creates a more diffuse projectile cloud after penetration. A three tiered eggbox structure is also tested by firing a 3.17 mm aluminum sphere at 2.7 km/s at it. The projectile penetrates the first two layers, but is successfully contained by the third.

A large series of metallic glass alloys are created and their wear loss is measured in a pin on disk test. Wear is found to vary dramatically among different metallic glasses, with some considerably outperforming the current state-of-the-art crystalline material (most notably Cu₄₃Zr₄₃Al₇Be₇). Others, on the other hand, suffered extensive wear loss. Commercially available Vitreloy 1 lost nearly three times as much mass in wear as alloy prepared in a laboratory setting. No conclusive correlations can be found between any set of mechanical properties (hardness, density, elastic, bulk, or shear modulus, Poisson’s ratio, frictional force, and run in time) and wear loss. Heat treatments are performed on Vitreloy 1 and Cu₄₃Zr₄₃Al₇Be₇. Anneals near the glass transition temperature are found to increase hardness slightly, but decrease wear loss significantly. Crystallization of both alloys leads to dramatic increases in wear resistance. Finally, wear tests under vacuum are performed on the two alloys above. Vitreloy 1 experiences a dramatic decrease in wear loss, while Cu₄₃Zr₄₃Al₇Be₇ has a moderate increase. Meanwhile, gears are fabricated through three techniques: electrical discharge machining of 1 cm by 3 mm cylinders, semisolid forging, and copper mold suction casting. Initial testing finds the pin on disk test to be an accurate predictor of wear performance in gears.

The final chapter explores an exciting technique in the field of additive manufacturing. Laser engineered net shaping (LENS) is a method whereby small amounts of metallic powders are melted by a laser such that shapes and designs can be built layer by layer into a final part. The technique is extended to mixing different powders during melting, so that compositional gradients can be created across a manufactured part. Two compositional gradients are fabricated and characterized. Ti 6Al¬ 4V to pure vanadium was chosen for its combination of high strength and light weight on one end, and high melting point on the other. It was inspected by cross-sectional x-ray diffraction, and only the anticipated phases were present. 304L stainless steel to Invar 36 was created in both pillar and as a radial gradient. It combines strength and weldability along with a zero coefficient of thermal expansion material. Only the austenite phase is found to be present via x-ray diffraction. Coefficient of thermal expansion is measured for four compositions, and it is found to be tunable depending on composition.

Mecanizado por torneado en duro

[ES]Los objetivos del siguiente trabajo consisten en analizar e optimizar el proceso del torneado en duro del acero ASP-23 indagando de especial manera en la realización de diferentes soluciones para brochas. En este caso, este proyecto nace de la importancia de reducir así como los costes económicos y los costes temporales de fabricación de elementos basados en el acero ASP-23 mediante el torneado en duro; proceso de mecanizado, cuya importancia cada vez es mayor como en las industrias de automoción o aeronáutica. El desarrollo del proyecto es fruto de la necesidad de EKIN S. Coop, uno de los líderes en los procesos de máquina-herramienta de alta precisión para el brochado, de desarrollar un proceso de mecanizado más eficaz de las brochas que produce. Así en el aula máquina-herramienta (ETSIB) se han intentado demostrar los beneficios que tiene el torneado en duro en el mecanizado del ASP-23. Hoy en día, con el rápido desarrollo de nuevos materiales, los procesos de fabricación se están haciendo cada vez más complejos, por la amplia variedad de maquinas con las que se realizan los procesos, por la variedad de geometría/material de las herramientas empleadas, por las propiedades del material de la pieza a mecanizar, por los parámetros de corte tan variados con los que podemos implementar el proceso (profundidad de corte, velocidad, alimentación...) y por la diversidad de elementos de sujeción utilizados. Además debemos ser conscientes de que tal variedad implica grandes magnitudes de deformaciones, velocidades y temperaturas. He aquí la justificación y el gran interés en el proyecto a realizar. Por ello, en este proyecto intentamos dar un pequeño paso en el conocimiento del proceso del torneado en duro de aceros con poca maquinabilidad, siendo conscientes de la amplia variedad y dificultad del avance en la ingeniería de fabricación y del mucho trabajo que queda por hacer.

Wastewater Electrolysis Cell for Environmental Pollutants Degradation and Molecular Hydrogen Generation

This study proposes a wastewater electrolysis cell (WEC) for on-site treatment of human waste coupled with decentralized molecular H₂ production. The core of the WEC includes mixed metal oxides anodes functionalized with bismuth doped TiO₂ (BiO_x/TiO₂). The BiO_x/TiO₂ anode shows reliable electro-catalytic activity to oxidize Cl- to reactive chlorine species (RCS), which degrades environmental pollutants including chemical oxygen demand (COD), protein, NH4⁺, urea, and total coliforms. The WEC experiments for treatment of various kinds of synthetic and real wastewater demonstrate sufficient water quality of effluent for reuse for toilet flushing and environmental purposes. Cathodic reduction of water and proton on stainless steel cathodes produced molecular H2 with moderate levels of current and energy efficiency. This thesis presents a comprehensive environmental analysis together with kinetic models to provide an in-depth understanding of reaction pathways mediated by the RCS and the effects of key operating parameters. The latter part of this thesis is dedicated to bilayer hetero-junction anodes which show enhanced generation efficiency of RCS and long-term stability.

Chapter 2 describes the reaction pathway and kinetics of urea degradation mediated by electrochemically generated RCS. The urea oxidation involves chloramines and chlorinated urea as reaction intermediates, for which the mass/charge balance analysis reveals that N₂ and CO₂ are the primary products. Chapter 3 investigates direct-current and photovoltaic powered WEC for domestic wastewater treatment, while Chapter 4 demonstrates the feasibility of the WEC to treat model septic tank effluents. The results in Chapter 2 and 3 corroborate the active roles of chlorine radicals (Cl•/Cl₂^-•) based on iR-compensated anodic potential (thermodynamic basis) and enhanced pseudo-first-order rate constants (kinetic basis). The effects of operating parameters (anodic potential and [Cl^-] in Chapter 3; influent dilution and anaerobic pretreatment in Chapter 4) on the rate and current/energy efficiency of pollutants degradation and H₂ production are thoroughly discussed based on robust kinetic models. Chapter 5 reports the generation of RCS on Ir_0.7Ta_0.3O_y/Bi_xTi_1-xO_z hetero-junction anodes with enhanced rate, current efficiency, and long-term stability compared to the Ir_0.7Ta_0.3O_y anode. The effects of surficial Bi concentration are interrogated, focusing on relative distributions between surface-bound hydroxyl radical and higher oxide.

Measurement of small vibration amplitudes of a rough surface by an interferometer with a self-pumped phase-conjugate mirror

The application of a Michelson interferometer with a self-pumped phase-conjugate mirror to measure small vibration amplitudes of a rough surface is described. The distorted wave front of the light that is diffusely reflected from the rough surface is restored by phase conjugation to provide an interference signal with a high signal-to-noise ratio. The vibration amplitudes of a stainless-steel sample are measured with a precision of similar to 5 nm. (C) 2000 Optical Society of America OCIS codes: 120.3180, 190.5040, 120.7280.