Solidification and solid-state transformation sciences in metals additive manufacturing

DOE PAGES

Kirka, Michael M.; Nandwana, Peeyush; Lee, Yousub; ...

2017-02-11

Additive manufacturing (AM) of metals is rapidly emerging as an established manufacturing process for metal components. Unlike traditional metals fabrication processes, metals fabricated via AM undergo localized thermal cycles during fabrication. As a result, AM presents the opportunity to control the liquid-solid phase transformation, i.e. material texture. But, thermal cycling presents challenges from the standpoint of solid-solid phase transformations. We will discuss the opportunities and challenges in metals AM in the context of texture control and associated solid-solid phase transformations in Ti-6Al-4V and Inconel 718.

Characterization of Metal Powders Used for Additive Manufacturing.

PubMed

Slotwinski, J A; Garboczi, E J; Stutzman, P E; Ferraris, C F; Watson, S S; Peltz, M A

2014-01-01

Additive manufacturing (AM) techniques can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process.

Characterization of Metal Powders Used for Additive Manufacturing

PubMed Central

Slotwinski, JA; Garboczi, EJ; Stutzman, PE; Ferraris, CF; Watson, SS; Peltz, MA

2014-01-01

Additive manufacturing (AM) techniques1 can produce complex, high-value metal parts, with potential applications as critical parts, such as those found in aerospace components. The production of AM parts with consistent and predictable properties requires input materials (e.g., metal powders) with known and repeatable characteristics, which in turn requires standardized measurement methods for powder properties. First, based on our previous work, we assess the applicability of current standardized methods for powder characterization for metal AM powders. Then we present the results of systematic studies carried out on two different powder materials used for additive manufacturing: stainless steel and cobalt-chrome. The characterization of these powders is important in NIST efforts to develop appropriate measurements and standards for additive materials and to document the property of powders used in a NIST-led additive manufacturing material round robin. An extensive array of characterization techniques was applied to these two powders, in both virgin and recycled states. The physical techniques included laser diffraction particle size analysis, X-ray computed tomography for size and shape analysis, and optical and scanning electron microscopy. Techniques sensitive to structure and chemistry, including X-ray diffraction, energy dispersive analytical X-ray analysis using the X-rays generated during scanning electron microscopy, and X-Ray photoelectron spectroscopy were also employed. The results of these analyses show how virgin powder changes after being exposed to and recycled from one or more Direct Metal Laser Sintering (DMLS) additive manufacturing build cycles. In addition, these findings can give insight into the actual additive manufacturing process. PMID:26601040

Additive Manufacturing of Reactive In Situ Zr Based Ultra-High Temperature Ceramic Composites

NASA Astrophysics Data System (ADS)

Sahasrabudhe, Himanshu; Bandyopadhyay, Amit

2016-03-01

Reactive in situ multi-material additive manufacturing of ZrB2-based ultra-high-temperature ceramics in a Zr metal matrix was demonstrated using LENS™. Sound metallurgical bonding was achieved between the Zr metal and Zr-BN composites with Ti6Al4V substrate. Though the feedstock Zr power had α phase, LENS™ processing of the Zr powder and Zr-BN premix powder mixture led to the formation of some β phase of Zr. Microstructure of the Zr-BN composite showed primary grains of zirconium diboride phase in zirconium metal matrix. The presence of ZrB2 ceramic phase was confirmed by X-ray diffraction (XRD) analysis. Hardness of pure Zr was measured as 280 ± 12 HV and, by increasing the BN content in the feedstock, the hardness was found to increase. In Zr-5%BN composite, the hardness was 421 ± 10 HV and the same for Zr-10%BN composite was 562 ± 10 HV. It is envisioned that such multi-materials additive manufacturing will enable products in the future that cannot be manufactured using traditional approaches particularly in the areas of high-temperature metal-ceramic composites with compositional and functional gradation.

Process for casting hard-faced, lightweight camshafts and other cylindrical products

DOEpatents

Hansen, Jeffrey S.; Turner, Paul C.; Argetsinger, Edward R.; Wilson, Rick D.

1996-01-01

A process for casting a hard-faced cylindrical product such as an automobile camshaft includes the steps of: (a) preparing a composition formed from a molten base metal and an additive in particle form and having a hardness value greater than the hardness value of the base metal; (b) introducing the composition into a flask containing a meltable pattern of a cylindrical product such as an automobile camshaft to be manufactured and encased in sand to allow the composition to melt the pattern and assume the shape of the pattern within the sand; and (c) rotating the flask containing the pattern about the longitudinal axes of both the flask and the pattern as the molten base metal containing the additive in particle form is introduced into the flask to cause particles of the additive entrained in the molten base metal to migrate by centrifugal action to the radial extremities of the pattern and thereby provide a cylindrical product having a hardness value greater at it's radial extremities than at its center when the molten base metal solidifies.

Decomposition Mechanism and Decomposition Promoting Factors of Waste Hard Metal for Zinc Decomposition Process (ZDP)

NASA Astrophysics Data System (ADS)

Pee, J. H.; Kim, Y. J.; Kim, J. Y.; Seong, N. E.; Cho, W. S.; Kim, K. J.

2011-10-01

Decomposition promoting factors and decomposition mechanism in the zinc decomposition process of waste hard metals which are composed mostly of tungsten carbide and cobalt were evaluated. Zinc volatility amount was suppressed and zinc steam pressure was produced in the reaction graphite crucible inside an electric furnace for ZDP. Reaction was done for 2 hrs at 650 °C, which 100 % decomposed the waste hard metals that were over 30 mm thick. As for the separation-decomposition of waste hard metals, zinc melted alloy formed a liquid composed of a mixture of γ-β1 phase from the cobalt binder layer (reaction interface). The volume of reacted zone was expanded and the waste hard metal layer was decomposed-separated horizontally from the hard metal. Zinc used in the ZDP process was almost completely removed-collected by decantation and volatilization-collection process at 1000 °C. The small amount of zinc remaining in the tungsten carbide-cobalt powder which was completely decomposed was fully removed by using phosphate solution which had a slow cobalt dissolution speed.

An In-Depth Review on Direct Additive Manufacturing of Metals

NASA Astrophysics Data System (ADS)

Azam, Farooq I.; Rani, Ahmad Majdi Abdul; Altaf, Khurram; Rao, T. V. V. L. N.; Aimi Zaharin, Haizum

2018-03-01

Additive manufacturing (AM), also known as 3D Printing, is a revolutionary manufacturing technique which has been developing rapidly in the last 30 years. The evolution of this precision manufacturing process from rapid prototyping to ready-to-use parts has significantly alleviated manufacturing constraints and design freedom has been outstandingly widened. AM is a non-conventional manufacturing technique which utilizes a 3D CAD model data to build parts by adding one material layer at a time, rather than removing it and fulfills the demand for manufacturing parts with complex geometric shapes, great dimensional accuracy, and easy to assemble parts. Additive manufacturing of metals has become the area of extensive research, progressing towards the production of final products and replacing conventional manufacturing methods. This paper provides an insight to the available metal additive manufacturing technologies that can be used to produce end user products without using conventional manufacturing methods. The paper also includes the comparison of mechanical and physical properties of parts produced by AM with the parts manufactured using conventional processes.

Towards Production of Additive Manufacturing Grade Metallic Powders on the Battlefield

DTIC Science & Technology

2017-10-01

ARL-RP-0618 ● OCT 2017 US Army Research Laboratory Towards Production of Additive Manufacturing Grade Metallic Powders on the...Research Laboratory Towards Production of Additive Manufacturing Grade Metallic Powders on the Battlefield by Marc Pepi Weapons and...REPORT TYPE Reprint 3. DATES COVERED (From - To) June 2016–June 2017 4. TITLE AND SUBTITLE Towards Production of Additive Manufacturing Grade

Soft metal plating enables hard metal seal to operate successfully in low temperature, high pressure environment

NASA Technical Reports Server (NTRS)

Lamvermeyer, D. J.

1967-01-01

Soft metal plating of hard metal lip seal enables successful operation of seal in a cryogenic fluid line under high pressure. The seal is coated with a thin film of 24 carat gold on the lip area to provide antigall and seal properties.

Applications of Metal Additive Manufacturing in Veterinary Orthopedic Surgery

NASA Astrophysics Data System (ADS)

Harrysson, Ola L. A.; Marcellin-Little, Denis J.; Horn, Timothy J.

2015-03-01

Veterinary medicine has undergone a rapid increase in specialization over the last three decades. Veterinarians now routinely perform joint replacement, neurosurgery, limb-sparing surgery, interventional radiology, radiation therapy, and other complex medical procedures. Many procedures involve advanced imaging and surgical planning. Evidence-based medicine has also become part of the modus operandi of veterinary clinicians. Modeling and additive manufacturing can provide individualized or customized therapeutic solutions to support the management of companion animals with complex medical problems. The use of metal additive manufacturing is increasing in veterinary orthopedic surgery. This review describes and discusses current and potential applications of metal additive manufacturing in veterinary orthopedic surgery.

Traceability in hardness measurements: from the definition to industry

NASA Astrophysics Data System (ADS)

Germak, Alessandro; Herrmann, Konrad; Low, Samuel

2010-04-01

The measurement of hardness has been and continues to be of significant importance to many of the world's manufacturing industries. Conventional hardness testing is the most commonly used method for acceptance testing and production quality control of metals and metallic products. Instrumented indentation is one of the few techniques available for obtaining various property values for coatings and electronic products in the micrometre and nanometre dimensional scales. For these industries to be successful, it is critical that measurements made by suppliers and customers agree within some practical limits. To help assure this measurement agreement, a traceability chain for hardness measurement traceability from the hardness definition to industry has developed and evolved over the past 100 years, but its development has been complicated. A hardness measurement value not only requires traceability of force, length and time measurements but also requires traceability of the hardness values measured by the hardness machine. These multiple traceability paths are needed because a hardness measurement is affected by other influence parameters that are often difficult to identify, quantify and correct. This paper describes the current situation of hardness measurement traceability that exists for the conventional hardness methods (i.e. Rockwell, Brinell, Vickers and Knoop hardness) and for special-application hardness and indentation methods (i.e. elastomer, dynamic, portables and instrumented indentation).

Process Modeling and Validation for Metal Big Area Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W.

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to acceleratemore » the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.« less

Annealing of Co-Cr dental alloy: effects on nanostructure and Rockwell hardness.

PubMed

Ayyıldız, Simel; Soylu, Elif Hilal; Ide, Semra; Kılıç, Selim; Sipahi, Cumhur; Pişkin, Bulent; Gökçe, Hasan Suat

2013-11-01

The aim of the study was to evaluate the effect of annealing on the nanostructure and hardness of Co-Cr metal ceramic samples that were fabricated with a direct metal laser sintering (DMLS) technique. Five groups of Co-Cr dental alloy samples were manufactured in a rectangular form measuring 4 × 2 × 2 mm. Samples fabricated by a conventional casting technique (Group I) and prefabricated milling blanks (Group II) were examined as conventional technique groups. The DMLS samples were randomly divided into three groups as not annealed (Group III), annealed in argon atmosphere (Group IV), or annealed in oxygen atmosphere (Group V). The nanostructure was examined with the small-angle X-ray scattering method. The Rockwell hardness test was used to measure the hardness changes in each group, and the means and standard deviations were statistically analyzed by one-way ANOVA for comparison of continuous variables and Tukey's HSD test was used for post hoc analysis. P values of <.05 were accepted as statistically significant. The general nanostructures of the samples were composed of small spherical entities stacked atop one another in dendritic form. All groups also displayed different hardness values depending on the manufacturing technique. The annealing procedure and environment directly affected both the nanostructure and hardness of the Co-Cr alloy. Group III exhibited a non-homogeneous structure and increased hardness (48.16 ± 3.02 HRC) because the annealing process was incomplete and the inner stress was not relieved. Annealing in argon atmosphere of Group IV not only relieved the inner stresses but also decreased the hardness (27.40 ± 3.98 HRC). The results of fitting function presented that Group IV was the most homogeneous product as the minimum bilayer thickness was measured (7.11 Å). After the manufacturing with DMLS technique, annealing in argon atmosphere is an essential process for Co-Cr metal ceramic substructures. The dentists should be familiar with

Annealing of Co-Cr dental alloy: effects on nanostructure and Rockwell hardness

PubMed Central

Soylu, Elif Hilal; İde, Semra; Kılıç, Selim; Sipahi, Cumhur; Pişkin, Bulent; Gökçe, Hasan Suat

2013-01-01

PURPOSE The aim of the study was to evaluate the effect of annealing on the nanostructure and hardness of Co-Cr metal ceramic samples that were fabricated with a direct metal laser sintering (DMLS) technique. MATERIALS AND METHODS Five groups of Co-Cr dental alloy samples were manufactured in a rectangular form measuring 4 × 2 × 2 mm. Samples fabricated by a conventional casting technique (Group I) and prefabricated milling blanks (Group II) were examined as conventional technique groups. The DMLS samples were randomly divided into three groups as not annealed (Group III), annealed in argon atmosphere (Group IV), or annealed in oxygen atmosphere (Group V). The nanostructure was examined with the small-angle X-ray scattering method. The Rockwell hardness test was used to measure the hardness changes in each group, and the means and standard deviations were statistically analyzed by one-way ANOVA for comparison of continuous variables and Tukey's HSD test was used for post hoc analysis. P values of <.05 were accepted as statistically significant. RESULTS The general nanostructures of the samples were composed of small spherical entities stacked atop one another in dendritic form. All groups also displayed different hardness values depending on the manufacturing technique. The annealing procedure and environment directly affected both the nanostructure and hardness of the Co-Cr alloy. Group III exhibited a non-homogeneous structure and increased hardness (48.16 ± 3.02 HRC) because the annealing process was incomplete and the inner stress was not relieved. Annealing in argon atmosphere of Group IV not only relieved the inner stresses but also decreased the hardness (27.40 ± 3.98 HRC). The results of fitting function presented that Group IV was the most homogeneous product as the minimum bilayer thickness was measured (7.11 Å). CONCLUSION After the manufacturing with DMLS technique, annealing in argon atmosphere is an essential process for Co-Cr metal ceramic

Feasibility Study on 3-D Printing of Metallic Structural Materials with Robotized Laser-Based Metal Additive Manufacturing

NASA Astrophysics Data System (ADS)

Ding, Yaoyu; Kovacevic, Radovan

2016-07-01

Metallic structural materials continue to open new avenues in achieving exotic mechanical properties that are naturally unavailable. They hold great potential in developing novel products in diverse industries such as the automotive, aerospace, biomedical, oil and gas, and defense. Currently, the use of metallic structural materials in industry is still limited because of difficulties in their manufacturing. This article studied the feasibility of printing metallic structural materials with robotized laser-based metal additive manufacturing (RLMAM). In this study, two metallic structural materials characterized by an enlarged positive Poisson's ratio and a negative Poisson's ratio were designed and simulated, respectively. An RLMAM system developed at the Research Center for Advanced Manufacturing of Southern Methodist University was used to print them. The results of the tensile tests indicated that the printed samples successfully achieved the corresponding mechanical properties.

Modeling of additive manufacturing processes for metals: Challenges and opportunities

DOE PAGES

Francois, Marianne M.; Sun, Amy; King, Wayne E.; ...

2017-01-09

Here, with the technology being developed to manufacture metallic parts using increasingly advanced additive manufacturing processes, a new era has opened up for designing novel structural materials, from designing shapes and complex geometries to controlling the microstructure (alloy composition and morphology). The material properties used within specific structural components are also designable in order to meet specific performance requirements that are not imaginable with traditional metal forming and machining (subtractive) techniques.

Cleaning Process Development for Metallic Additively Manufactured Parts

NASA Technical Reports Server (NTRS)

Tramel, Terri L.; Welker, Roger; Lowery, Niki; Mitchell, Mark

2014-01-01

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

Additively Manufactured Metals in Oxygen Systems Project

NASA Technical Reports Server (NTRS)

Tylka, Jonathan

2015-01-01

Metals produced by additive manufacturing methods, such as Powder Bed Fusion Technology, are now mature enough to be considered for qualification in human spaceflight oxygen systems. The mechanical properties of metals produced through AM processes are being systematically studied. However, it is unknown whether AM metals in oxygen applications may present an increased risk of flammability or ignition as compared to wrought metals of the same metallurgical composition due to increased porosity. Per NASA-STD-6001B materials to be used in oxygen system applications shall be based on flammability and combustion test data, followed by a flammability assessment. Without systematic flammability and ignition testing in oxygen there is no credible method for NASA to accurately evaluate the risk of using AM metals in oxygen systems.

Fate of Mycobacterium avium subsp. paratuberculosis in Swiss hard and semihard cheese manufactured from raw milk.

PubMed

Spahr, U; Schafroth, K

2001-09-01

Raw milk was artificially contaminated with declumped cells of Mycobacterium avium subsp. paratuberculosis at a concentration of 10(4) to 10(5) CFU/ml and was used to manufacture model hard (Swiss Emmentaler) and semihard (Swiss Tisliter) cheese. Two different strains of M. avium subsp. paratuberculosis were tested, and for each strain, two model hard and semihard cheeses were produced. The survival of M. avium subsp. paratuberculosis cells was monitored over a ripening period of 120 days by plating out homogenized cheese samples onto 7H10-PANTA agar. In both the hard and the semihard cheeses, counts decreased steadily but slowly during cheese ripening. Nevertheless, viable cells could still be detected in 120-day cheese. D values were calculated at 27.8 days for hard and 45.5 days for semihard cheese. The most important factors responsible for the death of M. avium subsp. paratuberculosis in cheese were the temperatures applied during cheese manufacture and the low pH at the early stages of cheese ripening. Since the ripening period for these raw milk cheeses lasts at least 90 to 120 days, the D values found indicate that 10(3) to 10(4) cells of M. avium subsp. paratuberculosis per g will be inactivated.

Fate of Mycobacterium avium subsp. paratuberculosis in Swiss Hard and Semihard Cheese Manufactured from Raw Milk

PubMed Central

Spahr, U.; Schafroth, K.

2001-01-01

Raw milk was artificially contaminated with declumped cells of Mycobacterium avium subsp. paratuberculosis at a concentration of 104 to 105 CFU/ml and was used to manufacture model hard (Swiss Emmentaler) and semihard (Swiss Tisliter) cheese. Two different strains of M. avium subsp. paratuberculosis were tested, and for each strain, two model hard and semihard cheeses were produced. The survival of M. avium subsp. paratuberculosis cells was monitored over a ripening period of 120 days by plating out homogenized cheese samples onto 7H10-PANTA agar. In both the hard and the semihard cheeses, counts decreased steadily but slowly during cheese ripening. Nevertheless, viable cells could still be detected in 120-day cheese. D values were calculated at 27.8 days for hard and 45.5 days for semihard cheese. The most important factors responsible for the death of M. avium subsp. paratuberculosis in cheese were the temperatures applied during cheese manufacture and the low pH at the early stages of cheese ripening. Since the ripening period for these raw milk cheeses lasts at least 90 to 120 days, the D values found indicate that 103 to 104 cells of M. avium subsp. paratuberculosis per g will be inactivated. PMID:11526024

The rhizotoxicity of metal cations is related to their strength of binding to hard ligands.

PubMed

Kopittke, Peter M; Menzies, Neal W; Wang, Peng; McKenna, Brigid A; Wehr, J Bernhard; Lombi, Enzo; Kinraide, Thomas B; Blamey, F Pax C

2014-02-01

Mechanisms whereby metal cations are toxic to plant roots remain largely unknown. Aluminum, for example, has been recognized as rhizotoxic for approximately 100 yr, but there is no consensus on its mode of action. The authors contend that the primary mechanism of rhizotoxicity of many metal cations is nonspecific and that the magnitude of toxic effects is positively related to the strength with which they bind to hard ligands, especially carboxylate ligands of the cell-wall pectic matrix. Specifically, the authors propose that metal cations have a common toxic mechanism through inhibiting the controlled relaxation of the cell wall as required for elongation. Metal cations such as Al(3+) and Hg(2+), which bind strongly to hard ligands, are toxic at relatively low concentrations because they bind strongly to the walls of cells in the rhizodermis and outer cortex of the root elongation zone with little movement into the inner tissues. In contrast, metal cations such as Ca(2+), Na(+), Mn(2+), and Zn(2+) , which bind weakly to hard ligands, bind only weakly to the cell wall and move farther into the root cylinder. Only at high concentrations is their weak binding sufficient to inhibit the relaxation of the cell wall. Finally, different mechanisms would explain why certain metal cations (for example, Tl(+), Ag(+), Cs(+), and Cu(2+)) are sometimes more toxic than expected through binding to hard ligands. The data presented in the present study demonstrate the importance of strength of binding to hard ligands in influencing a range of important physiological processes within roots through nonspecific mechanisms. © 2013 SETAC.

The metallurgy and processing science of metal additive manufacturing

DOE PAGES

Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; ...

2016-03-07

Here, additive Manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire, or sheets in a process that proceeds layer-by-layer.Many techniques (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developedmore » for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.« less

Application of hard sphere perturbation theory for thermodynamics of model liquid metals

NASA Astrophysics Data System (ADS)

Mon, K. K.

2001-06-01

Hard sphere perturbation theory (HSPT) has contributed toward the fundamental understanding of dense fluids for over 30 years. In recent decades, other techniques have been more popular. In this paper, we argue for the revival of hard sphere perturbation theory for the study of thermodynamics of dense liquid in general, and in liquid metal in particular. The weakness of HSPT is now well understood, and can be easily overcome by using a simple convenient Monte Carlo method to calculate the intrinsic error of HSPT free energy density. To demonstrate this approach, we consider models of liquid aluminum and sodium. We obtain the intrinsic error of HSPT with the Monte Carlo method. HSPT is shown to provide a lower free energy upper bound than one-component plasma (OCP) for alkali metals and polyvalent metals. We are thus able to provide insight into the long standing observation that a OCP is a better reference system than a HS for alkali metals.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control.

PubMed

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part's porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented.

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

PubMed Central

Slotwinski, John A; Garboczi, Edward J; Hebenstreit, Keith M

2014-01-01

Additive manufacturing techniques can produce complex, high-value metal parts, with potential applications as critical metal components such as those found in aerospace engines and as customized biomedical implants. Material porosity in these parts is undesirable for aerospace parts - since porosity could lead to premature failure - and desirable for some biomedical implants - since surface-breaking pores allows for better integration with biological tissue. Changes in a part’s porosity during an additive manufacturing build may also be an indication of an undesired change in the build process. Here, we present efforts to develop an ultrasonic sensor for monitoring changes in the porosity in metal parts during fabrication on a metal powder bed fusion system. The development of well-characterized reference samples, measurements of the porosity of these samples with multiple techniques, and correlation of ultrasonic measurements with the degree of porosity are presented. A proposed sensor design, measurement strategy, and future experimental plans on a metal powder bed fusion system are also presented. PMID:26601041

Casting technology for manufacturing metal rods from simulated metallic spent fuels

NASA Astrophysics Data System (ADS)

Leeand, Y. S.; Lee, D. B.; Kim, C. K.; Shin, Y. J.; Lee, J. H.

2000-09-01

A uranium metal rod 13.5 mm in diameter and 1,150 mm long was produced from simulated metallic spent fuels with advanced casting equipment using the directional-solidification method. A vacuum casting furnace equipped with a four-zone heater to prevent surface oxidation and the formation of surface shrinkage holes was designed. By controlling the axial temperature gradient of the casting furnace, deformation by the surface shrinkage phenomena was diminished, and a sound rod was manufactured. The cooling behavior of the molten uranium was analyzed using the computer software package MAGMAsoft.

Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing

PubMed Central

Hofmann, Douglas C.; Roberts, Scott; Otis, Richard; Kolodziejska, Joanna; Dillon, R. Peter; Suh, Jong-ook; Shapiro, Andrew A.; Liu, Zi-Kui; Borgonia, John-Paul

2014-01-01

Interest in additive manufacturing (AM) has dramatically expanded in the last several years, owing to the paradigm shift that the process provides over conventional manufacturing. Although the vast majority of recent work in AM has focused on three-dimensional printing in polymers, AM techniques for fabricating metal alloys have been available for more than a decade. Here, laser deposition (LD) is used to fabricate multifunctional metal alloys that have a strategically graded composition to alter their mechanical and physical properties. Using the technique in combination with rotational deposition enables fabrication of compositional gradients radially from the center of a sample. A roadmap for developing gradient alloys is presented that uses multi-component phase diagrams as maps for composition selection so as to avoid unwanted phases. Practical applications for the new technology are demonstrated in low-coefficient of thermal expansion radially graded metal inserts for carbon-fiber spacecraft panels. PMID:24942329

Combined effect of smoking habits and occupational exposure to hard metal on total IgE antibodies.

PubMed

Shirakawa, T; Kusaka, Y; Morimoto, K

1992-06-01

A survey was made within a population of workers (n = 706) exposed to hard metal dust (an alloy including cobalt), an agent known to cause occupational allergy. Twenty-seven (4 percent) of 733 workers were eliminated from consideration in this study because of atopic status identified prior to starting work in the plant. Using a Phadebas PRIST, the subjects' total IgE levels were determined and related to their smoking and exposure status. Nonexposed male smokers (n = 135) had a higher geometric mean IgE level (39.7 IU/ml) than did nonexposed subjects who had never smoked (33.1 IU/ml; n = 99); those with a higher Brinkman index (greater than 300), a smoking index obtained by multiplying the number of cigarettes per day by the duration of smoking in years, had significantly (p less than 0.05) decreased IgE levels. Although ex-smokers (n = 72) had a higher geometric mean IgE level (73.3 IU/ml) than did those who had never smoked, their serum IgE level declined with age since the time they quit smoking, regardless of their hard metal exposure status. Hard metal (cobalt) exposure may play a significant role as an adjuvant in the production of total IgE. A multivariate analysis demonstrated that hard metal exposure and a smoking habit together arithmetically (p less than 0.05) increased total IgE levels. These two factors may be preventable risk factors for occupational allergy in hard metal workers.

Final Air Toxics Standards for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources Fact Sheet

EPA Pesticide Factsheets

This page contains a December 2007 fact sheet with information regarding the National Emissions Standards for Hazardous Air Pollutants (NESHAP) for Clay Ceramics Manufacturing, Glass Manufacturing, and Secondary Nonferrous Metals Processing Area Sources

Natural Indices for the Chemical Hardness/Softness of Metal Cations and Ligands

DOE Office of Scientific and Technical Information (OSTI.GOV)

Xu, Huifang; Xu, David C.; Wang, Yifeng

Quantitative understanding of reactivity and stability for a chemical species is fundamental to chemistry. The concept has undergone many changes and additions throughout the history of chemistry, stemming from the ideas such as Lewis acids and bases. For a given complexing ligand (Lewis base) and a group of isovalent metal cations (Lewis acids), the stability constants of metal–ligand (ML) complexes can simply correlate to the known properties of metal ions [ionic radii (r Mn+), Gibbs free energy of formation (ΔG° f,Mn+), and solvation energy (ΔG° s,Mn+)] by 2.303RT log K ML = (α* MLΔG° f,Mn+ – β* MLr Mn+ +more » γ* MLΔG° s,Mn+ – δ* ML), where the coefficients (α* ML, β* ML, γ* ML, and intercept δ* ML) are determined by fitting the equation to the existing experimental data. Coefficients β* ML and γ* ML have the same sign and are in a linear relationship through the origin. Gibbs free energies of formation of cations (ΔG° f,Mn+) are found to be natural indices for the softness or hardness of metal cations, with positive values corresponding to soft acids and negative values to hard acids. The coefficient α* ML is an index for the softness or hardness of a complexing ligand. Proton (H +) with the softness index of zero is a unique acid that has strong interactions with both soft and hard bases. The stability energy resulting from the acid–base interactions is determined by the term α* MLΔG° f,Mn+; a positive product of α* ML and ΔG° f,Mn+ indicates that the acid–base interaction between the metal cation and the complexing ligand stabilizes the complex. The terms β* MLr Mn+ and γ* MLΔG° s,Mn+, which are related to ionic radii of metal cations, represent the steric and solvation effects of the cations. The new softness indices proposed here will help to understand the interactions of ligands (Lewis bases) with metal cations (Lewis acids) and provide guidelines for engineering materials with desired chemical reactivity and

Natural Indices for the Chemical Hardness/Softness of Metal Cations and Ligands

DOE PAGES

Xu, Huifang; Xu, David C.; Wang, Yifeng

2017-10-26

Quantitative understanding of reactivity and stability for a chemical species is fundamental to chemistry. The concept has undergone many changes and additions throughout the history of chemistry, stemming from the ideas such as Lewis acids and bases. For a given complexing ligand (Lewis base) and a group of isovalent metal cations (Lewis acids), the stability constants of metal–ligand (ML) complexes can simply correlate to the known properties of metal ions [ionic radii (r Mn+), Gibbs free energy of formation (ΔG° f,Mn+), and solvation energy (ΔG° s,Mn+)] by 2.303RT log K ML = (α* MLΔG° f,Mn+ – β* MLr Mn+ +more » γ* MLΔG° s,Mn+ – δ* ML), where the coefficients (α* ML, β* ML, γ* ML, and intercept δ* ML) are determined by fitting the equation to the existing experimental data. Coefficients β* ML and γ* ML have the same sign and are in a linear relationship through the origin. Gibbs free energies of formation of cations (ΔG° f,Mn+) are found to be natural indices for the softness or hardness of metal cations, with positive values corresponding to soft acids and negative values to hard acids. The coefficient α* ML is an index for the softness or hardness of a complexing ligand. Proton (H +) with the softness index of zero is a unique acid that has strong interactions with both soft and hard bases. The stability energy resulting from the acid–base interactions is determined by the term α* MLΔG° f,Mn+; a positive product of α* ML and ΔG° f,Mn+ indicates that the acid–base interaction between the metal cation and the complexing ligand stabilizes the complex. The terms β* MLr Mn+ and γ* MLΔG° s,Mn+, which are related to ionic radii of metal cations, represent the steric and solvation effects of the cations. The new softness indices proposed here will help to understand the interactions of ligands (Lewis bases) with metal cations (Lewis acids) and provide guidelines for engineering materials with desired chemical reactivity and

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.

2015-01-01

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute, represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies to fabricate polymer matrix composite and ceramic matrix composite turbine engine components. The benefits include: 50 weight reduction compared to metallic parts, reduced manufacturing costs, reduced part count and rapid design iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature polymer filaments. The CMC effort uses a binder jet process to fabricate silicon carbide test coupons and demonstration articles. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The research project includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

Metal oxide multilayer hard mask system for 3D nanofabrication

NASA Astrophysics Data System (ADS)

Han, Zhongmei; Salmi, Emma; Vehkamäki, Marko; Leskelä, Markku; Ritala, Mikko

2018-02-01

We demonstrate the preparation and exploitation of multilayer metal oxide hard masks for lithography and 3D nanofabrication. Atomic layer deposition (ALD) and focused ion beam (FIB) technologies are applied for mask deposition and mask patterning, respectively. A combination of ALD and FIB was used and a patterning procedure was developed to avoid the ion beam defects commonly met when using FIB alone for microfabrication. ALD grown Al2O3/Ta2O5/Al2O3 thin film stacks were FIB milled with 30 keV gallium ions and chemically etched in 5% tetramethylammonium hydroxide at 50 °C. With metal evaporation, multilayers consisting of amorphous oxides Al2O3 and Ta2O5 can be tailored for use in 2D lift-off processing, in preparation of embedded sub-100 nm metal lines and for multilevel electrical contacts. Good pattern transfer was achieved by lift-off process from the 2D hard mask for micro- and nano-scaled fabrication. As a demonstration of the applicability of this method to 3D structures, self-supporting 3D Ta2O5 masks were made from a film stack on gold particles. Finally, thin film resistors were fabricated by utilizing controlled stiction of suspended Ta2O5 structures.

Measurement of fracture toughness of metallic materials produced by additive manufacturing

NASA Astrophysics Data System (ADS)

Quénard, O.; Dorival, O.; Guy, Ph.; Votié, A.; Brethome, K.

2018-04-01

This study focuses on the microstructure and mechanical properties of metallic materials produced by additive layer manufacturing (ALM), especially the laser beam melting process. The influence of the specimen orientation during the ALM process and that of two post-build thermal treatments were investigated. The identified metal powder is Ti-6Al-4V (titanium base). Metallographic analysis shows their effects on the microstructure of the metals. Mechanical experiments involving tensile tests as well as toughness tests were performed according to ASTM (American Society for Testing and Materials) norms. The results show that the main influence is that of the thermal treatments; however the manufacturing stacking direction may lead to some anisotropy in the mechanical properties.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing," evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door, were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.; Halbig, Michael C.; Singh, Mrityunjay

2015-01-01

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Variation of Hardness and Modulus across thickness of Zr-Cu-Al Metallic Glass Ribbons

Treesearch

Z. Humberto Melgarejo; J.E. Jakes; J. Hwang; Y.E. Kalay; M.J. Kramer; P.M. Voyles; D.S. Stone

2012-01-01

We investigate through-thickness hardness and modulus of Zr50Cu45Al5 metallic glass melt-spun ribbon. Because of their thinness, the ribbons are challenging to measure, so we employ a novel nanoindentation based-method to remove artifacts caused by ribbon flexing and edge effects. Hardness and modulus...

Effect of hardness on acute toxicity of metal mixtures using Daphnia magna: prediction of acid mine drainage toxicity.

PubMed

Yim, Jin Hee; Kim, Kyoung W; Kim, Sang D

2006-11-02

In this study, the effect of hardness on the combined outcome of metal mixtures was investigated using Daphnia magna. The toxic unit (TU) was calculated using modified LC(50) values based on the hardness (i.e., LC(50-soft) and LC(50-hard)). From a bioassay test, the degree of sensitivity to hardness on the toxicity changes was in the order: Cdhard test solution was replaced with a soft test solution. In mixture toxicity tests, the difference in the test solution hardness was found to clearly cause different toxicities, as determined by the TU calculated by the LC(50-hard), using the toxicity of a standard culture medium as the reference. That is, approximately four to five times higher toxicity was observed in soft (i.e., 44+/-4 mg/L as CaCO(3)) rather than hard water (i.e., 150+/-10mg/L as CaCO(3)) test solutions. In the tests where the modified reference toxicity values (i.e., LC(50-soft) and LC(50-hard) for soft and hard test solution, respectively) obtained from the individual metal toxicity tests with different hardness were used to calculate the TU, the results showed very similar D. magna toxicities to those of the TU from the mixture of soft and hard test solutions, regardless of the hardness. According to the toxicity results of the mixture, the aquatic toxic effects of the acid mine drainage (AMD) collected from mine areas that contained metal mixtures were investigated using Daphnia magna and the modified LC(50) value of the TU hardness function calculated for varying solution hardness. The results of the biological WET test closely matched our overall prediction, with significant correlation, having a p-value of 0.513 in one way ANOVA test (n=19). Therefore, this study revealed that the predicted toxicity of the metal mixture agreed well with the biological toxicity test when the modified LC(50) value was employed as the basis of hardness in the TU calculation.

Assessment of the hardness of different orthodontic wires and brackets produced by metal injection molding and conventional methods

PubMed Central

Alavi, Shiva; Kachuie, Marzie

2017-01-01

Background: This study was conducted to assess the hardness of orthodontic brackets produced by metal injection molding (MIM) and conventional methods and different orthodontic wires (stainless steel, nickel-titanium [Ni-Ti], and beta-titanium alloys) for better clinical results. Materials and Methods: A total of 15 specimens from each brand of orthodontic brackets and wires were examined. The brackets (Elite Opti-Mim which is produced by MIM process and Ultratrimm which is produced by conventional brazing method) and the wires (stainless steel, Ni-Ti, and beta-titanium) were embedded in epoxy resin, followed by grinding, polishing, and coating. Then, X-ray energy dispersive spectroscopy (EDS) microanalysis was applied to assess their elemental composition. The same specimen surfaces were repolished and used for Vickers microhardness assessment. Hardness was statistically analyzed with Kruskal–Wallis test, followed by Mann–Whitney test at the 0.05 level of significance. Results: The X-ray EDS analysis revealed different ferrous or co-based alloys in each bracket. The maximum mean hardness values of the wires were achieved for stainless steel (SS) (529.85 Vickers hardness [VHN]) versus the minimum values for beta-titanium (334.65 VHN). Among the brackets, Elite Opti-Mim exhibited significantly higher VHN values (262.66 VHN) compared to Ultratrimm (206.59 VHN). VHN values of wire alloys were significantly higher than those of the brackets. Conclusion: MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness. PMID:28928783

Assessment of the hardness of different orthodontic wires and brackets produced by metal injection molding and conventional methods.

PubMed

Alavi, Shiva; Kachuie, Marzie

2017-01-01

This study was conducted to assess the hardness of orthodontic brackets produced by metal injection molding (MIM) and conventional methods and different orthodontic wires (stainless steel, nickel-titanium [Ni-Ti], and beta-titanium alloys) for better clinical results. A total of 15 specimens from each brand of orthodontic brackets and wires were examined. The brackets (Elite Opti-Mim which is produced by MIM process and Ultratrimm which is produced by conventional brazing method) and the wires (stainless steel, Ni-Ti, and beta-titanium) were embedded in epoxy resin, followed by grinding, polishing, and coating. Then, X-ray energy dispersive spectroscopy (EDS) microanalysis was applied to assess their elemental composition. The same specimen surfaces were repolished and used for Vickers microhardness assessment. Hardness was statistically analyzed with Kruskal-Wallis test, followed by Mann-Whitney test at the 0.05 level of significance. The X-ray EDS analysis revealed different ferrous or co-based alloys in each bracket. The maximum mean hardness values of the wires were achieved for stainless steel (SS) (529.85 Vickers hardness [VHN]) versus the minimum values for beta-titanium (334.65 VHN). Among the brackets, Elite Opti-Mim exhibited significantly higher VHN values (262.66 VHN) compared to Ultratrimm (206.59 VHN). VHN values of wire alloys were significantly higher than those of the brackets. MIM orthodontic brackets exhibited hardness values much lower than those of SS orthodontic archwires and were more compatible with NiTi and beta-titanium archwires. A wide range of microhardness values has been reported for conventional orthodontic brackets and it should be considered that the manufacturing method might be only one of the factors affecting the mechanical properties of orthodontic brackets including hardness.

Structural and electronic properties of OsB2 : A hard metallic material

NASA Astrophysics Data System (ADS)

Chen, Z. Y.; Xiang, H. J.; Yang, Jinlong; Hou, J. G.; Zhu, Qingshi

2006-07-01

We calculate the structural and electronic properties of OsB2 using density functional theory with or without taking into account the spin-orbit (SO) interaction. Our results show that the bulk modulus with and without SO interactions are 364 and 365GPa , respectively, both are in good agreement with experiment (365-395GPa) . The evidence of covalent bonding of Os-B, which plays an important role to form a hard material, is indicated both in charge density, atoms in molecules analysis, and density of states analysis. The good metallicity and hardness of OsB2 might suggest its potential application as hard conductors.

Hard metal lung disease: a case series.

PubMed

Mizutani, Rafael Futoshi; Terra-Filho, Mário; Lima, Evelise; Freitas, Carolina Salim Gonçalves; Chate, Rodrigo Caruso; Kairalla, Ronaldo Adib; Carvalho-Oliveira, Regiani; Santos, Ubiratan Paula

2016-01-01

To describe diagnostic and treatment aspects of hard metal lung disease (HMLD) and to review the current literature on the topic. This was a retrospective study based on the medical records of patients treated at the Occupational Respiratory Diseases Clinic of the Instituto do Coração, in the city of São Paulo, Brazil, between 2010 and 2013. Of 320 patients treated during the study period, 5 (1.56%) were diagnosed with HMLD. All of those 5 patients were male (mean age, 42.0 ± 13.6 years; mean duration of exposure to hard metals, 11.4 ± 8.0 years). Occupational histories were taken, after which the patients underwent clinical evaluation, chest HRCT, pulmonary function tests, bronchoscopy, BAL, and lung biopsy. Restrictive lung disease was found in all subjects. The most common chest HRCT finding was ground glass opacities (in 80%). In 4 patients, BALF revealed multinucleated giant cells. In 3 patients, lung biopsy revealed giant cell interstitial pneumonia. One patient was diagnosed with desquamative interstitial pneumonia associated with cellular bronchiolitis, and another was diagnosed with a hypersensitivity pneumonitis pattern. All patients were withdrawn from exposure and treated with corticosteroid. Clinical improvement occurred in 2 patients, whereas the disease progressed in 3. Although HMLD is a rare entity, it should always be included in the differential diagnosis of respiratory dysfunction in workers with a high occupational risk of exposure to hard metal particles. A relevant history (clinical and occupational) accompanied by chest HRCT and BAL findings suggestive of the disease might be sufficient for the diagnosis. Descrever aspectos relacionados ao diagnóstico e tratamento de pacientes com doença pulmonar por metal duro (DPMD) e realizar uma revisão da literatura. Estudo retrospectivo dos prontuários médicos de pacientes atendidos no Serviço de Doenças Respiratórias Ocupacionais do Instituto do Coração, localizado na cidade de S�

Additively manufactured metallic pentamode meta-materials

NASA Astrophysics Data System (ADS)

Hedayati, R.; Leeflang, A. M.; Zadpoor, A. A.

2017-02-01

Mechanical metamaterials exhibit unusual mechanical properties that originate from their topological design. Pentamode metamaterials are particularly interesting because they could be designed to possess any thermodynamically admissible elasticity tensor. In this study, we additively manufacture the metallic pentamode metamaterials from a biocompatible and mechanically strong titanium alloy (Ti-6Al-4V) using an energy distribution method developed for the powder bed fusion techniques. The mechanical properties of the developed materials were a few orders of magnitude higher than those of the similar topologies fabricated previously from polymers. Moreover, the elastic modulus and yield stress of the presented pentamode metamaterials were decoupled from their relative density, meaning that the metallic meta-biomaterials with independently tailored elastic and mass transport (permeability) properties could be designed for tissue regeneration purposes.

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems

PubMed Central

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan

2017-01-01

PURPOSE To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. MATERIALS AND METHODS One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). RESULTS The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups (P<.001). In the marginal area where pontic was present, the largest gap was 149.39 ± 42.30 µm in the AM group, and the lowest gap was 24.40 ± 11.92 µm in the SM group. CONCLUSION Three-unit metal frameworks made by subtractive manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically. PMID:29279766

Evaluation of marginal and internal gap of three-unit metal framework according to subtractive manufacturing and additive manufacturing of CAD/CAM systems.

PubMed

Kim, Dong-Yeon; Kim, Eo-Bin; Kim, Hae-Young; Kim, Ji-Hwan; Kim, Woong-Chul

2017-12-01

To evaluate the fit of a three-unit metal framework of fixed dental prostheses made by subtractive and additive manufacturing. One master model of metal was fabricated. Twenty silicone impressions were made on the master die, working die of 10 poured with Type 4 stone, and working die of 10 made of scannable stone. Ten three-unit wax frameworks were fabricated by wax-up from Type IV working die. Stereolithography files of 10 three-unit frameworks were obtained using a model scanner and three-dimensional design software on a scannable working die. The three-unit wax framework was fabricated using subtractive manufacturing (SM) by applying the prepared stereolithography file, and the resin framework was fabricated by additive manufacturing (AM); both used metal alloy castings for metal frameworks. Marginal and internal gap were measured using silicone replica technique and digital microscope. Measurement data were analyzed by Kruskal-Wallis H test and Mann-Whitney U-test (α=.05). The lowest and highest gaps between premolar and molar margins were in the SM group and the AM group, respectively. There was a statistically significant difference in the marginal gap among the 3 groups ( P <.001). In the marginal area where pontic was present, the largest gap was 149.39 ± 42.30 µm in the AM group, and the lowest gap was 24.40 ± 11.92 µm in the SM group. Three-unit metal frameworks made by subtractive manufacturing are clinically applicable. However, additive manufacturing requires more research to be applied clinically.

Electrochemical removal of metallic implants from Technovit 9100 New embedded hard and soft tissues prior to histological sectioning.

PubMed

Willbold, Elmar; Reebmann, Mattias; Jeffries, Richard; Witte, Frank

2013-11-01

Solid metallic implants in soft or hard tissues are serious challenges for histological processing. However, metallic implants are more frequently used in e.g. cardiovascular or orthopaedic therapies. Before clinical use, these devices need to be tested thoroughly in a biological environment and histological analysis of their biocompatibility is a major requirement. To allow the histological analysis of metallic implants in tissues especially in calcified hard tissues, we describe a method for embedding these tissues in the resin Technovit 9100 New and removing the metallic implants by electrochemical dissolution. With the combination of these two processes, we are able to achieve 5 μm thick sections from soft or hard tissues with a superior preservation of tissue architecture and especially the implant-tissue interface. These sections can be stained by classical stainings, immunohistochemical and enzymehistochemical as well as DNA-based staining methods.

Friction Stir Additive Manufacturing: Route to High Structural Performance

NASA Astrophysics Data System (ADS)

Palanivel, S.; Sidhar, H.; Mishra, R. S.

2015-03-01

Aerospace and automotive industries provide the next big opportunities for additive manufacturing. Currently, the additive industry is confronted with four major challenges that have been identified in this article. These challenges need to be addressed for the additive technologies to march into new frontiers and create additional markets. Specific potential success in the transportation sectors is dependent on the ability to manufacture complicated structures with high performance. Most of the techniques used for metal-based additive manufacturing are fusion based because of their ability to fulfill the computer-aided design to component vision. Although these techniques aid in fabrication of complex shapes, achieving high structural performance is a key problem due to the liquid-solid phase transformation. In this article, friction stir additive manufacturing (FSAM) is shown as a potential solid-state process for attaining high-performance lightweight alloys for simpler geometrical applications. To illustrate FSAM as a high-performance route, manufactured builds of Mg-4Y-3Nd and AA5083 are shown as examples. In the Mg-based alloy, an average hardness of 120 HV was achieved in the built structure and was significantly higher than that of the base material (97 HV). Similarly for the Al-based alloy, compared with the base hardness of 88 HV, the average built hardness was 104 HV. A potential application of FSAM is illustrated by taking an example of a simple stiffener assembly.

Metal Coatings

NASA Technical Reports Server (NTRS)

1994-01-01

During the Apollo Program, General Magnaplate Corporation developed process techniques for bonding dry lubricant coatings to space metals. The coatings were not susceptible to outgassing and offered enhanced surface hardness and superior resistance to corrosion and wear. This development was necessary because conventional lubrication processes were inadequate for lightweight materials used in Apollo components. General Magnaplate built on the original technology and became a leader in development of high performance metallurgical surface enhancement coatings - "synergistic" coatings, - which are used in applications from pizza making to laser manufacture. Each of the coatings is designed to protect a specific metal or group of metals to solve problems encountered under operating conditions.

Targeted Structural Optimization with Additive Manufacturing of Metals

NASA Technical Reports Server (NTRS)

Burt, Adam; Hull, Patrick

2015-01-01

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

Study on the Effect of Heavy metals toxicity according to changing Hardness concentration using D.magna

NASA Astrophysics Data System (ADS)

Chun Sang, H.

2016-12-01

n order to determine and prevent the number of ecological effects of heavy metals in the materials, we have to accurately measure the heavy metals present in the water-based protection ecosystems and may determine the effects to humans. Heavy metals occurred in the industrial effluent which is a state in which the monitor, based on the emission standards are made by the Ministry of Environment and managed and waste water contained Copper, Zinc, lead, etc. These heavy metals are able to express the toxic effects only when present in the free-ions in the aqueous condition, which appears differently affected by the degree to hardness change in accordance with the season, precipitation. Generally changing hardness concentration can not precisely evaluate toxic effects of heavy metals in the water system. Anderson announced a study on bioassay for heavy metals from industrial waste water using Daphnia magna(Anderson, 1944, 1948). Breukelman published study the resitivity difference for the mercury Chloride(HgCl2). Braudouin(1974) compared the zooplankton(Daphnia sp.) acute toxicity of the different heavy metals and confirmed the sensitivity. Shcherban(1979) presented for toxicity evaluation results for the heavy metal of the Daphnia magna according to different temperature conditions. In the United States Environmental Protection Agency(EPA) established a standard test method for water fleas, managed and supervised water ecosystems, and announced the adoption of a bioassay standard method. This study was performed to evaluate acute inhibition using the Daphnia magna for the biological effect of heavy metal ions in water-based toxicity in the hardness change. Evaluation methods were conducted in EPA Water Quality process test criteria. TU(Toxic Unit), NOEC (No Observable Effect Concentration), LOEC (Lowest Observable Effect Concentration), EC50 (Median Effective Concentration) was calculated by Toxcalc 5.0 Program. Keywords : D. magna, Hardness, Toxic Unit, Heavy metal

Additive Manufacturing of Functional Elements on Sheet Metal

NASA Astrophysics Data System (ADS)

Schaub, Adam; Ahuja, Bhrigu; Butzhammer, Lorenz; Osterziel, Johannes; Schmidt, Michael; Merklein, Marion

Laser Beam Melting (LBM) process with its advantages of high design flexibility and free form manufacturing methodology is often applied limitedly due to its low productivity and unsuitability for mass production compared to conventional manufacturing processes. In order to overcome these limitations, a hybrid manufacturing methodology is developed combining the additive manufacturing process of laser beam melting with sheet forming processes. With an interest towards aerospace and medical industry, the material in focus is Ti-6Al-4V. Although Ti-6Al-4V is a commercially established material and its application for LBM process has been extensively investigated, the combination of LBM of Ti-6Al-4V with sheet metal still needs to be researched. Process dynamics such as high temperature gradients and thermally induced stresses lead to complex stress states at the interaction zone between the sheet and LBM structure. Within the presented paper mechanical characterization of hybrid parts will be performed by shear testing. The association of shear strength with process parameters is further investigated by analyzing the internal structure of the hybrid geometry at varying energy inputs during the LBM process. In order to compare the hybrid manufacturing methodology with conventional fabrication, the conventional methodologies subtractive machining and state of the art Laser Beam Melting is evaluated within this work. These processes will be analyzed for their mechanical characteristics and productivity by determining the build time and raw material consumption for each case. The paper is concluded by presenting the characteristics of the hybrid manufacturing methodology compared to alternative manufacturing technologies.

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

NASA Technical Reports Server (NTRS)

Grady, Joseph E.

2014-01-01

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in

Grain Structure Control of Additively Manufactured Metallic Materials

PubMed Central

Faierson, Eric J.

2017-01-01

Grain structure control is challenging for metal additive manufacturing (AM). Grain structure optimization requires the control of grain morphology with grain size refinement, which can improve the mechanical properties of additive manufactured components. This work summarizes methods to promote fine equiaxed grains in both the additive manufacturing process and subsequent heat treatment. Influences of temperature gradient, solidification velocity and alloy composition on grain morphology are discussed. Equiaxed solidification is greatly promoted by introducing a high density of heterogeneous nucleation sites via powder rate control in the direct energy deposition (DED) technique or powder surface treatment for powder-bed techniques. Grain growth/coarsening during post-processing heat treatment can be restricted by presence of nano-scale oxide particles formed in-situ during AM. Grain refinement of martensitic steels can also be achieved by cyclic austenitizing in post-processing heat treatment. Evidently, new alloy powder design is another sustainable method enhancing the capability of AM for high-performance components with desirable microstructures.

Diode-based additive manufacturing of metals using an optically-addressable light valve.

PubMed

Matthews, Manyalibo J; Guss, Gabe; Drachenberg, Derrek R; Demuth, James A; Heebner, John E; Duoss, Eric B; Kuntz, Joshua D; Spadaccini, Christopher M

2017-05-15

Selective Laser Melting (SLM) of metal powder bed layers, whereby 3D metal objects can be printed from a digital file with unprecedented design flexibility, is spurring manufacturing innovations in medical, automotive, aerospace and textile industries. Because SLM is based on raster-scanning a laser beam over each layer, the process is relatively slow compared to most traditional manufacturing methods (hours to days), thus limiting wider spread use. Here we demonstrate the use of a large area, photolithographic method for 3D metal printing, using an optically-addressable light valve (OALV) as the photomask, to print entire layers of metal powder at once. An optical sheet of multiplexed ~5 kW, 20 ms laser diode and ~1 MW, 7 ns Q-switched laser pulses are used to selectively melt each layer. The patterning of near infrared light is accomplished by imaging 470 nm light onto the transmissive OALV, which consists of polarization-selective nematic liquid crystal sandwiched between a photoconductor and transparent conductor for switching.

Application of Contact Mode AFM to Manufacturing Processes

NASA Astrophysics Data System (ADS)

Giordano, Michael A.; Schmid, Steven R.

A review of the application of contact mode atomic force microscopy (AFM) to manufacturing processes is presented. A brief introduction to common experimental techniques including hardness, scratch, and wear testing is presented, with a discussion of challenges in the extension of manufacturing scale investigations to the AFM. Differences between the macro- and nanoscales tests are discussed, including indentation size effects and their importance in the simulation of processes such as grinding. The basics of lubrication theory are presented and friction force microscopy is introduced as a method of investigating metal forming lubrication on the nano- and microscales that directly simulates tooling/workpiece asperity interactions. These concepts are followed by a discussion of their application to macroscale industrial manufacturing processes and direct correlations are made.

Design and manufacture of high absorption metal dielectric coatings for the reduction of straylight

NASA Astrophysics Data System (ADS)

Cathelinaud, Michel; Lemarquis, Frédéric; Torchio, Philippe; Amra, Claude

2017-11-01

This paper describes the design and manufacture of broadband metal dielectric absorbers. First, we give some design principles to obtain achromatic absorption properties. Then, we describe a new method to determine the complex refractive index of metallic layers. A graded index model is developed to take account of the evolution of the film packing density. Manufacturing is detailed in the last section. Absorption levels higher than 99.9% have been measured over the visible range.

The role of nanocrystalline binder metallic coating into WC after additive manufacturing

NASA Astrophysics Data System (ADS)

Cavaleiro, A. J.; Fernandes, C. M.; Farinha, A. R.; Gestel, C. V.; Jhabvala, J.; Boillat, E.; Senos, A. M. R.; Vieira, M. T.

2018-01-01

Tungsten carbide with microsized particle powders are commonly used embedded in a tough binder metal. The application of these composites is not limited to cutting tools, WC based material has been increasingly used in gaskets and other mechanical parts with complex geometries. Consequently, additive manufacturing processes as Selective Laser Sintering (SLS) might be the solution to overcome some of the manufacturing problems. However, the use of SLS leads to resolve the problems resulting from difference of physical properties between tungsten carbide and the metallic binder, such as laser absorbance and thermal conductivity. In this work, an original approach of powder surface modification was considered to prepare WC-metal composite powders and overcome these constraints, consisting on the sputter-coating of the WC particle surfaces with a nanocrystalline thin film of metallic binder material (stainless steel). The coating improves the thermal behavior and rheology of the WC particles and, at the same time, ensures a binder homogenous distribution. The feasibility of the SLS technology as manufacturing process for WC powder sputter-coated with 13 wt% stainless steel AISI 304L was explored with different laser power and scanning speed parameters. The SLS layers were characterized regarding elemental distribution, phase composition and morphology, and the results are discussed emphasizing the role of the coating on the consolidation process.

Metallic Scaffolds for Bone Regeneration

PubMed Central

Alvarez, Kelly; Nakajima, Hideo

2009-01-01

Bone tissue engineering is an emerging interdisciplinary field in Science, combining expertise in medicine, material science and biomechanics. Hard tissue engineering research is focused mainly in two areas, osteo and dental clinical applications. There is a lot of exciting research being performed worldwide in developing novel scaffolds for tissue engineering. Although, nowadays the majority of the research effort is in the development of scaffolds for non-load bearing applications, primarily using soft natural or synthetic polymers or natural scaffolds for soft tissue engineering; metallic scaffolds aimed for hard tissue engineering have been also the subject of in vitro and in vivo research and industrial development. In this article, descriptions of the different manufacturing technologies available to fabricate metallic scaffolds and a compilation of the reported biocompatibility of the currently developed metallic scaffolds have been performed. Finally, we highlight the positive aspects and the remaining problems that will drive future research in metallic constructs aimed for the reconstruction and repair of bone.

Metal Big Area Additive Manufacturing: Process Modeling and Validation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long rangemore » effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress

Accelerating Industrial Adoption of Metal Additive Manufacturing Technology

NASA Astrophysics Data System (ADS)

Vartanian, Kenneth; McDonald, Tom

2016-03-01

While metal additive manufacturing (AM) technology has clear benefits, there are still factors preventing its adoption by industry. These factors include the high cost of metal AM systems, the difficulty for machinists to learn and operate metal AM machines, the long approval process for part qualification/certification, and the need for better process controls; however, the high AM system cost is the main barrier deterring adoption. In this paper, we will discuss an America Makes-funded program to reduce AM system cost by combining metal AM technology with conventional computerized numerical controlled (CNC) machine tools. Information will be provided on how an Optomec-led team retrofitted a legacy CNC vertical mill with laser engineered net shaping (LENS®—LENS is a registered trademark of Sandia National Labs) AM technology, dramatically lowering deployment cost. The upgraded system, dubbed LENS Hybrid Vertical Mill, enables metal additive and subtractive operations to be performed on the same machine tool and even on the same part. Information on the LENS Hybrid system architecture, learnings from initial system deployment and continuing development work will also be provided to help guide further development activities within the materials community.

Microstructural Analysis of Ti-6Al-4V Components Made by Electron Beam Additive Manufacturing

NASA Astrophysics Data System (ADS)

Coleman, Rashadd L.

Electron Beam Additive Manufacturing (EBAM) is a relatively new additive manufacturing (AM) technology that uses a high-energy electron beam to melt and fuse powders to build full-density parts in a layer by layer fashion. EBAM can fabricate metallic components, particularly, of complex shapes, in an efficient and cost-effective manner compared to conventional manufacturing means. EBAM is an enabling technology for rapid manufacturing (RM) of metallic components, and thus, can efficiently integrate the design and manufacturing of aerospace components. However, EBAM for aerospace-related applications remain limited because the effect of the EBAM process on part characteristics is not fully understood. In this study, various techniques including microhardness, optical microscopy (OM), X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), and electron backscatter diffraction (EBSD) were used to characterize Ti-6Al-4V components processed using EBAM. The results were compared to Ti-6Al-4V components processed using conventional techniques. In this study it is shown that EBAM built Ti-64 components have increased hardness, elastic modulus, and yield strength compared to wrought Ti-6Al-4V. Further, it is also shown in this study that the horizontal build EBAM Ti-6Al-4V has increased hardness, elastic modulus, and yield strength compared to vertical build EBAM due to a preferential growth of the beta phase.

Method of manufacturing metallic products such as sheet by cold working and flash anealing

DOEpatents

Hajaligol, Mohammad R.; Sikka, Vinod K.

2001-01-01

A metallic alloy composition is manufactured into products such as press formed or stamped products or rolled products such as sheet, strip, rod, wire or band by one or more cold working steps with intermediate or final flash annealing. The method can include cold rolling an iron, nickel or titanium aluminide alloy and annealing the cold worked product in a furnace by infrared heating. The flash annealing is preferably carried out by rapidly heating the cold worked product to an elevated temperature for less than one minute. The flash annealing is effective to reduce surface hardness of the cold worked product sufficiently to allow further cold working. The product to be cold worked can be prepared by casting the alloy or by a powder metallurgical technique such as tape casting a mixture of metal powder and a binder, roll compacting a mixture of the powder and a binder or plasma spraying the powder onto a substrate. In the case of tape casting or roll compaction, the initial powder product can be heated to a temperature sufficient to remove volatile components. The method can be used to form a cold rolled sheet which is formed into an electrical resistance heating element capable of heating to 900.degree. C. in less than 1 second when a voltage up to 10 volts and up to 6 amps is passed through the heating element.

Method of manufacturing metallic products such as sheet by cold working and flash annealing

DOEpatents

Hajaligol, Mohammad R.; Sikka, Vinod K.

2000-01-01

A metallic alloy composition is manufactured into products such as press formed or stamped products or rolled products such as sheet, strip, rod, wire or band by one or more cold working steps with intermediate or final flash annealing. The method can include cold rolling an iron, nickel or titanium aluminide alloy and annealing the cold worked product in a furnace by infrared heating. The flash annealing is preferably carried out by rapidly heating the cold worked product to an elevated temperature for less than one minute. The flash annealing is effective to reduce surface hardness of the cold worked product sufficiently to allow further cold working. The product to be cold worked can be prepared by casting the alloy or by a powder metallurgical technique such as tape casting a mixture of metal powder and a binder, roll compacting a mixture of the powder and a binder or plasma spraying the powder onto a substrate. In the case of tape casting or roll compaction, the initial powder product can be heated to a temperature sufficient to remove volatile components. The method can be used to form a cold rolled sheet which is formed into an electrical resistance heating element capable of heating to 900.degree. C. in less than 1 second when a voltage up to 10 volts and up to 6 amps is passed through the heating element.

Diode-based additive manufacturing of metals using an optically-addressable light valve

DOE PAGES

Matthews, Manyalibo J.; Guss, Gabe; Drachenberg, Derrek R.; ...

2017-05-10

We present that Selective Laser Melting (SLM) of metal powder bed layers, whereby 3D metal objects can be printed from a digital file with unprecedented design flexibility, is spurring manufacturing innovations in medical, automotive, aerospace and textile industries. Because SLM is based on raster-scanning a laser beam over each layer, the process is relatively slow compared to most traditional manufacturing methods (hours to days), thus limiting wider spread use. Here we demonstrate the use of a large area, photolithographic method for 3D metal printing, using an optically-addressable light valve (OALV) as the photomask, to print entire layers of metal powdermore » at once. An optical sheet of multiplexed ~5 kW, 20 ms laser diode and ~1 MW, 7 ns Q-switched laser pulses are used to selectively melt each layer. Finally, the patterning of near infrared light is accomplished by imaging 470 nm light onto the transmissive OALV, which consists of polarization-selective nematic liquid crystal sandwiched between a photoconductor and transparent conductor for switching.« less

Fluid mechanics of additive manufacturing of metal objects by accretion of droplets - a survey

NASA Astrophysics Data System (ADS)

Tesař, Václav

2016-03-01

Paper presents a survey of principles of additive manufacturing of metal objects by accretion of molten metal droplets, focusing on fluid-mechanical problems that deserve being investigated. The main problem is slowness of manufacturing due to necessarily small size of added droplets. Increase of droplet repetition rate calls for basic research of the phenomena that take place inside and around the droplets: ballistics of their flight, internal flowfield with heat and mass transfer, oscillation of surfaces, and the ways to elimination of satellite droplets.

Novel Structured Metal Bipolar Plates for Low Cost Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Conghua

2013-08-15

Bipolar plates are an important component in fuel cell stacks and accounts for more than 75% of stack weight and volume, and 20% of the stack cost. The technology development of metal bipolar plates can effectively reduce the fuel cells stack weight and volume over 50%. The challenge is to protect metal plate from corrosion at low cost for the broad commercial applications. While most of today’s PEM fuel cell metallic bipolar plate technologies use some precious metal, the focus of this SBIR project is to develop a low cost, novel nano-structured metal bipolar plate technology without using any preciousmore » metal. The technology will meet the performance and cost requirements for automobile applications. Through the Phase I project, TreadStone has identified the corrosion resistant and electrically conductive titanium oxide for the metal bipolar plate surface protection for automotive PEM fuel cell applications. TreadStone has overcome the manufacturing issues to apply the coating on metal substrate surface, and has demonstrated the feasibility of the coated stainless steel plates by ex-situ evaluation tests and the in-situ fuel cell long term durability test. The test results show the feasibility of the proposed nano-structured coating as the low cost metal bipolar plates of PEM fuel cells. The plan for further technology optimization is also outlined for the Phase II project.« less

Controlled modulation of hard and soft X-ray induced tunneling currents utilizing coaxial metal-insulator-metal probe tips

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cummings, Marvin; Shirato, Nozomi; Kersell, Heath

Here, the effect of a local external electric field on the barrier potential of a tunneling gap is studied utilizing an emerging technique, synchrotron x-ray scanning tunneling microscopy. Here, we demonstrate that the shape of the potential barrier in the tunneling gap can be altered by a localized external electric field, generated by voltages placed on the metallic outer shield of a nanofabricated coaxial metal-insulator-metal tip, resulting in a controlled linear modulation of the tunneling current. Experiments at hard and soft x-ray synchrotron beamlines reveal that both the chemical contrast and magnetic contrast signals measured by the tip can bemore » drastically enhanced, resulting in improved local detection of chemistry and magnetization at the surface.« less

Controlled modulation of hard and soft X-ray induced tunneling currents utilizing coaxial metal-insulator-metal probe tips

DOE PAGES

Cummings, Marvin; Shirato, Nozomi; Kersell, Heath; ...

2017-01-05

Here, the effect of a local external electric field on the barrier potential of a tunneling gap is studied utilizing an emerging technique, synchrotron x-ray scanning tunneling microscopy. Here, we demonstrate that the shape of the potential barrier in the tunneling gap can be altered by a localized external electric field, generated by voltages placed on the metallic outer shield of a nanofabricated coaxial metal-insulator-metal tip, resulting in a controlled linear modulation of the tunneling current. Experiments at hard and soft x-ray synchrotron beamlines reveal that both the chemical contrast and magnetic contrast signals measured by the tip can bemore » drastically enhanced, resulting in improved local detection of chemistry and magnetization at the surface.« less

The association of occupational metals exposure and oxidative damage, telomere shortening in fitness equipments manufacturing workers

PubMed Central

KO, Jiunn-Liang; CHENG, Yu-Jung; LIU, Guan-Cen; HSIN, I-Lun; CHEN, Hsiu-Ling

2017-01-01

The welding is the major working process in fitness equipment manufacturing industry, and International Agency for Research on Cancer has classified welding fumes as possibly carcinogenic to humans (Group 2B). The present study aimed to evaluate associations between the occupational exposure of metals and oxidative damage and telomere length shortening in workers involved in the manufacture of fitness equipment. The blood metal concentrations were monitored and malondialdehyde (MDA), alkaline Comet assay was determined as oxidative damage in 117 workers from two representative fitness equipment manufacturing plants. MDA levels varied according to workers’ roles at the manufacturing plants, and showed a trend as cutting>painting>welding>administration workers. Welders had marginally shorter average telomere lengths than the administrative workers (p=0.058). Cr and Mn levels were significantly greater in welders than they were in administrative workers. There were significantly positive correlations between MDA and Cr and Mn levels, the major components of welding fume. However, the association would be eliminated if co-metals exposure were considered simultaneously. In future, telomere length and MDA might be potential biomarkers for predicting cardiovascular disease in co-metals exposed workers. PMID:28420806

Mechanical properties of sheet metal components with local reinforcement produced by additive manufacturing

NASA Astrophysics Data System (ADS)

Ünsal, Ismail; Hama-Saleh, R.; Sviridov, Alexander; Bambach, Markus; Weisheit, A.; Schleifenbaum, J. H.

2018-05-01

New technological challenges like electro-mobility pose an increasing demand for cost-efficient processes for the production of product variants. This demand opens the possibility to combine established die-based manufacturing methods and innovative, dieless technologies like additive manufacturing [1, 2]. In this context, additive manufacturing technologies allow for the weight-efficient local reinforcement of parts before and after forming, enabling manufacturers to produce product variants from series parts [3]. Previous work by the authors shows that the optimal shape of the reinforcing structure can be determined using sizing optimization. Sheet metal parts can then be reinforced using laser metal deposition. The material used is a pearlite-reduced, micro-alloyed steel (ZE 630). The aim of this paper is to determine the effect of the additive manufacturing process on the material behavior and the mechanical properties of the base material and the resulting composite material. The parameters of the AM process are optimized to reach similar material properties in the base material and the build-up volume. A metallographic analysis of the parts is presented, where the additive layers, the base material and also the bonding between the additive layers and the base material are analyzed. The paper shows the feasibility of the approach and details the resulting mechanical properties and performance.

Investigations on the osmoregulation of freshwater fish (Oreochromis niloticus) following exposures to metals (Cd, Cu) in differing hardness.

PubMed

Saglam, Dilek; Atli, Gülüzar; Canli, Mustafa

2013-06-01

Hardness is one of the most important factors in water chemistry as it affects fish physiology and metal toxicity. The aim of this study was to investigate osmoregulatory responses in the Nile tilapia Oreochromis niloticus exposed to copper and cadmium (1.0μg/mL) in soft water (SW) (hardness 80mg CaCO3/L and conductivity 1.77mS/cm) and hard water (HW) (hardness 320mg CaCO3/L and conductivity 5.80mS/cm) for 0, 1, 7 and 14 days. Following the exposures, Na(+)/K(+)-ATPase activity, ion and Cu levels in the gill, kidney and intestine were measured. There was no fish mortality within 14 days, except Cu exposure in SW which killed all fish between 8 and 12 days. Generally, Na(+)/K(+)-ATPase activity was altered by both metal exposures in the gill and kidney as it increased in HW condition, but decreased in SW condition. There were also alterations in Na(+)/K(+)-ATPase activity in the intestine as its activity generally decreased. Data, in general, showed that Cd was more effective on Na(+)/K(+)-ATPase activity comparing to Cu. However, ion levels altered mainly in the kidney and intestine. Tissue metal accumulation was higher in fish tissues from SW condition comparing to HW condition. Data represented here showed that the effects of metals differed in differing water hardness. This suggests that special attention should be paid to the water chemistry when natural monitoring studies are carried out. This study also suggests that the response of osmoregulation system of fish may be a sensitive indicator under stressful conditions in different natural waters. Copyright © 2013 Elsevier Inc. All rights reserved.

Additive Manufacturing of Metal Structures at the Micrometer Scale.

PubMed

Hirt, Luca; Reiser, Alain; Spolenak, Ralph; Zambelli, Tomaso

2017-05-01

Currently, the focus of additive manufacturing (AM) is shifting from simple prototyping to actual production. One driving factor of this process is the ability of AM to build geometries that are not accessible by subtractive fabrication techniques. While these techniques often call for a geometry that is easiest to manufacture, AM enables the geometry required for best performance to be built by freeing the design process from restrictions imposed by traditional machining. At the micrometer scale, the design limitations of standard fabrication techniques are even more severe. Microscale AM thus holds great potential, as confirmed by the rapid success of commercial micro-stereolithography tools as an enabling technology for a broad range of scientific applications. For metals, however, there is still no established AM solution at small scales. To tackle the limited resolution of standard metal AM methods (a few tens of micrometers at best), various new techniques aimed at the micrometer scale and below are presently under development. Here, we review these recent efforts. Specifically, we feature the techniques of direct ink writing, electrohydrodynamic printing, laser-assisted electrophoretic deposition, laser-induced forward transfer, local electroplating methods, laser-induced photoreduction and focused electron or ion beam induced deposition. Although these methods have proven to facilitate the AM of metals with feature sizes in the range of 0.1-10 µm, they are still in a prototype stage and their potential is not fully explored yet. For instance, comprehensive studies of material availability and material properties are often lacking, yet compulsory for actual applications. We address these items while critically discussing and comparing the potential of current microscale metal AM techniques. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Electrochemical synthesis of hard-alloy compositions based on tungsten carbide and an iron triad metal

NASA Astrophysics Data System (ADS)

Kushkhov, Kh. B.; Adamokova, M. N.; Kvashin, V. A.; Kardanov, A. L.

2010-08-01

Single and cyclic voltammetry is used to study the electrode processes that occur during electrochemical synthesis of hard-alloy compositions based on tungsten carbide and an iron triad metal in tungstate and tungstate-carbonate Na2WO4-Li2WO4-Li2CO3 (5.0-22.0 wt %) melts. The conditions of bringing the electroprecipitation potentials of tungsten, carbon, and an iron triad metal into coincidence are determined.

Comparative study of material loss at the taper interface in retrieved metal-on-polyethylene and metal-on-metal femoral components from a single manufacturer.

PubMed

Bills, Paul; Racasan, Radu; Bhattacharya, Saugatta; Blunt, Liam; Isaac, Graham

2017-08-01

There have been a number of reports on the occurrence of taper corrosion and/or fretting and some have speculated on a link to the occurrence of adverse local tissue reaction specifically in relation to total hip replacement which have a metal-on-metal bearing. As such a study was carried out to compare the magnitude of material loss at the taper in a series of retrieved femoral heads used in metal-on-polyethylene bearings with that in a series of retrieved heads used in metal-on-metal bearings. A total of 36 metal-on-polyethylene and 21 metal-on-metal femoral components were included in the study all of which were received from a customer complaint database. Furthermore, a total of nine as-manufactured femoral components were included to provide a baseline for characterisation. All taper surfaces were assessed using an established corrosion scoring method and measurements were taken of the female taper surface using a contact profilometry. In the case of metal-on-metal components, the bearing wear was also assessed using coordinate metrology to determine whether or not there was a relationship between bearing and taper material loss in these cases. The study found that in this cohort the median value of metal-on-polyethylene taper loss was 1.25 mm 3 with the consequent median value for metal-on-metal taper loss being 1.75 mm 3 . This study also suggests that manufacturing form can result in an apparent loss of material from the taper surface determined to have a median value of 0.59 mm 3 . Therefore, it is clear that form variability is a significant confounding factor in the measurement of material loss from the tapers of femoral heads retrieved following revision surgery.

Manufacturing and Application of Metalized Ore-Coal Pellets in Synthetic Pig Iron Smelting

NASA Astrophysics Data System (ADS)

Nokhrina, O. I.; Rozhikhina, I. D.; Khodosov, I. E.

2016-08-01

The article presents research data on manufacturing and application of metalized ore-coal pellets in synthetic pig iron smelting. A technology of pellets metallization by means of solid-phase reduction of iron from oxides using hematite-magnetite iron ore and low-caking coal as raw materials is described. Industrial testing of replacing 10, 15, and 20% of waste metal by the metalized ore-coal pellets in the coreless induction furnace IST-1 is described. Optimal temperature and time conditions of feeding the metalized pellets into the furnace in smelting pig iron of SCh-40-60 grade are determined.

Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo

DOE PAGES

Rodgers, Theron M.; Madison, Jonathan D.; Tikare, Veena

2017-04-19

Additive manufacturing (AM) is of tremendous interest given its ability to realize complex, non-traditional geometries in engineered structural materials. But, microstructures generated from AM processes can be equally, if not more, complex than their conventionally processed counterparts. While some microstructural features observed in AM may also occur in more traditional solidification processes, the introduction of spatially and temporally mobile heat sources can result in significant microstructural heterogeneity. While grain size and shape in metal AM structures are understood to be highly dependent on both local and global temperature profiles, the exact form of this relation is not well understood. Wemore » implement an idealized molten zone and temperature-dependent grain boundary mobility in a kinetic Monte Carlo model to predict three-dimensional grain structure in additively manufactured metals. In order to demonstrate the flexibility of the model, synthetic microstructures are generated under conditions mimicking relatively diverse experimental results present in the literature. Simulated microstructures are then qualitatively and quantitatively compared to their experimental complements and are shown to be in good agreement.« less

A Novel Method for Fabricating Additive Manufactured Lightweight, Optical Quality Metallic Mirrors

DTIC Science & Technology

2016-01-04

lighter  mirrors  can  lead to great reductions of mass in full systems [3,4].    The state of the art in this industry is ULE™,  Zerodur ™, or beryllium...1    A Novel Method for Fabricating Additive Manufactured  Lightweight, Optical Quality Metallic  Mirrors   Michael Stern, Joseph Bari  Distribution A...metallic  mirrors  fabricated by growing an additive manufactured blank, post  processing the faces, coating with electroless nickel, and diamond turning

A reliable method of manufacturing metallic hierarchical superhydrophobic surfaces

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pogreb, Roman; Whyman, Gene; Barayev, Reuven

2009-06-01

A method of manufacturing hierarchical metallic surfaces demonstrating superhydrophobic properties is presented. The surfaces showed apparent contact angles as high as 153 deg. and sliding angles of 10 deg. for 50-100 {mu}l droplets. The Cassie-like model [A. B. D. Cassie and S. Baxter, Trans. Faraday Soc. 40, 546 (1944)], considering the hierarchical topography of the relief, predicts apparent contact angles in a satisfactory agreement with the measured values.

Determining the Effect of Material Hardness During the Hard Turning of AISI4340 Steel

NASA Astrophysics Data System (ADS)

Kambagowni, Venkatasubbaiah; Chitla, Raju; Challa, Suresh

2018-05-01

In the present manufacturing industries hardened steels are most widely used in the applications like tool design and mould design. It enhances the application range of hard turning of hardened steels in manufacturing industries. This study discusses the impact of workpiece hardness, feed and depth of cut on Arithmetic mean roughness (Ra), root mean square roughness (Rq), mean depth of roughness (Rz) and total roughness (Rt) during the hard turning. Experiments have been planned according to the Box-Behnken design and conducted on hardened AISI4340 steel at 45, 50 and 55 HRC with wiper ceramic cutting inserts. Cutting speed is kept constant during this study. The analysis of variance was used to determine the effects of the machining parameters. 3-D response surface plots drawn based on RSM were utilized to set up the input-output relationships. The results indicated that the feed rate has the most significant parameter for Ra, Rq and Rz and hardness has the most critical parameter for the Rt. Further, hardness shows its influence over all the surface roughness characteristics.

A bis(3-hydroxy-4-pyridinone)-EDTA derivative as a strong chelator for M3+ hard metal ions: complexation ability and selectivity.

PubMed

Gama, Sofia; Dron, Paul; Chaves, Silvia; Farkas, Etelka; Santos, M Amélia

2009-08-21

The study of chelating compounds is very important to solve problems related to human metal overload. 3-Hydroxy-3-pyridinones (HP), namely deferiprone, have been clinically used for chelating therapy of Fe and Al over the last decade. A multi-disciplinary search for alternative molecules led us to develop poly-(3-hydroxy-4-pyridinones) to increase metal chelation efficacy. We present herein a complexation study of a new bis-(3-hydroxy-4-pyridinone)-EDTA derivative with a set of M(3+) hard metal ions (M = Fe, Al, Ga), as well as Zn(2+), a biologically relevant metal ion. Thus a systematic aqueous solution equilibrium study was performed using potentiometric and spectroscopic techniques (UV-Vis, NMR methods). These set of results enables the establishment of specific models as well as the determination of thermodynamic stability constants and coordination modes of the metal complexes. The results indicate that this ligand has a higher affinity for chelating to these hard metal ions than deferiprone, and that the coordination occurs mostly through the HP moieties. Furthermore, it was also found that this ligand has a higher selectivity for chelating to M(3+) hard metal ions (M = Fe, Al, Ga) than Zn(2+).

TSCA Chemical Data Reporting Fact Sheet: Reporting Manufactured Chemical Substances from Metal Mining and Related Activities

EPA Pesticide Factsheets

This fact sheet provides guidance on the Chemical Data Reporting (CDR) rule requirements related to the reporting of mined metals, intermediates, and byproducts manufactured during metal mining and related activities.

Laser additive manufacturing bulk graphene-copper nanocomposites.

PubMed

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J

2017-11-03

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Laser additive manufacturing bulk graphene-copper nanocomposites

NASA Astrophysics Data System (ADS)

Hu, Zengrong; Chen, Feng; Lin, Dong; Nian, Qiong; Parandoush, Pedram; Zhu, Xing; Shao, Zhuqiang; Cheng, Gary J.

2017-11-01

The exceptional mechanical properties of graphene make it an ideal nanofiller for reinforcing metal matrix composites (MMCs). In this work, graphene-copper (Gr-Cu) nanocomposites have been fabricated by a laser additive manufacturing process. Transmission electron microscopy (TEM), x-ray diffraction (XRD) and Raman spectroscopy were utilized to characterize the fabricated nanocomposites. The XRD, Raman spectroscopy, energy dispersive spectroscopy and TEM results demonstrated the feasibility of laser additive manufacturing of Gr-Cu nanocomposites. The microstructures were characterized by high resolution TEM and the results further revealed the interface between the copper matrix and graphene. With the addition of graphene, the mechanical properties of the composites were enhanced significantly. Nanoindentation tests showed that the average modulus value and hardness of the composites were 118.9 GPa and 3 GPa respectively; 17.6% and 50% increases were achieved compared with pure copper, respectively. This work demonstrates a new way to manufacture graphene copper nanocomposites with ultra-strong mechanical properties and provides alternatives for applications in electrical and thermal conductors.

Hard-on-hard lubrication in the artificial hip under dynamic loading conditions.

PubMed

Sonntag, Robert; Reinders, Jörn; Rieger, Johannes S; Heitzmann, Daniel W W; Kretzer, J Philippe

2013-01-01

The tribological performance of an artificial hip joint has a particularly strong influence on its success. The principle causes for failure are adverse short- and long-term reactions to wear debris and high frictional torque in the case of poor lubrication that may cause loosening of the implant. Therefore, using experimental and theoretical approaches models have been developed to evaluate lubrication under standardized conditions. A steady-state numerical model has been extended with dynamic experimental data for hard-on-hard bearings used in total hip replacements to verify the tribological relevance of the ISO 14242-1 gait cycle in comparison to experimental data from the Orthoload database and instrumented gait analysis for three additional loading conditions: normal walking, climbing stairs and descending stairs. Ceramic-on-ceramic bearing partners show superior lubrication potential compared to hard-on-hard bearings that work with at least one articulating metal component. Lubrication regimes during the investigated activities are shown to strongly depend on the kinematics and loading conditions. The outcome from the ISO gait is not fully confirmed by the normal walking data and more challenging conditions show evidence of inferior lubrication. These findings may help to explain the differences between the in vitro predictions using the ISO gait cycle and the clinical outcome of some hard-on-hard bearings, e.g., using metal-on-metal.

Hard-on-Hard Lubrication in the Artificial Hip under Dynamic Loading Conditions

PubMed Central

Sonntag, Robert; Reinders, Jörn; Rieger, Johannes S.; Heitzmann, Daniel W. W.; Kretzer, J. Philippe

2013-01-01

The tribological performance of an artificial hip joint has a particularly strong influence on its success. The principle causes for failure are adverse short- and long-term reactions to wear debris and high frictional torque in the case of poor lubrication that may cause loosening of the implant. Therefore, using experimental and theoretical approaches models have been developed to evaluate lubrication under standardized conditions. A steady-state numerical model has been extended with dynamic experimental data for hard-on-hard bearings used in total hip replacements to verify the tribological relevance of the ISO 14242-1 gait cycle in comparison to experimental data from the Orthoload database and instrumented gait analysis for three additional loading conditions: normal walking, climbing stairs and descending stairs. Ceramic-on-ceramic bearing partners show superior lubrication potential compared to hard-on-hard bearings that work with at least one articulating metal component. Lubrication regimes during the investigated activities are shown to strongly depend on the kinematics and loading conditions. The outcome from the ISO gait is not fully confirmed by the normal walking data and more challenging conditions show evidence of inferior lubrication. These findings may help to explain the differences between the in vitro predictions using the ISO gait cycle and the clinical outcome of some hard-on-hard bearings, e.g., using metal-on-metal. PMID:23940772

Alkali-metal silicate binders and methods of manufacture

NASA Technical Reports Server (NTRS)

Schutt, J. B. (Inventor)

1979-01-01

A paint binder is described which uses a potassium or sodium silicate dispersion having a silicon dioxide to alkali-metal oxide mol ratio of from 4.8:1 to 6.0:1. The binder exhibits stability during both manufacture and storage. The process of making the binder is predictable and repeatable and the binder may be made with inexpensive components. The high mol ratio is achieved with the inclusion of a silicon dioxide hydrogel. The binder, which also employs a silicone, is in the final form of a hydrogel sol.

Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review.

PubMed

Wang, Xiaojian; Xu, Shanqing; Zhou, Shiwei; Xu, Wei; Leary, Martin; Choong, Peter; Qian, M; Brandt, Milan; Xie, Yi Min

2016-03-01

One of the critical issues in orthopaedic regenerative medicine is the design of bone scaffolds and implants that replicate the biomechanical properties of the host bones. Porous metals have found themselves to be suitable candidates for repairing or replacing the damaged bones since their stiffness and porosity can be adjusted on demands. Another advantage of porous metals lies in their open space for the in-growth of bone tissue, hence accelerating the osseointegration process. The fabrication of porous metals has been extensively explored over decades, however only limited controls over the internal architecture can be achieved by the conventional processes. Recent advances in additive manufacturing have provided unprecedented opportunities for producing complex structures to meet the increasing demands for implants with customized mechanical performance. At the same time, topology optimization techniques have been developed to enable the internal architecture of porous metals to be designed to achieve specified mechanical properties at will. Thus implants designed via the topology optimization approach and produced by additive manufacturing are of great interest. This paper reviews the state-of-the-art of topological design and manufacturing processes of various types of porous metals, in particular for titanium alloys, biodegradable metals and shape memory alloys. This review also identifies the limitations of current techniques and addresses the directions for future investigations. Copyright © 2016 Elsevier Ltd. All rights reserved.

Statistical experiments using the multiple regression research for prediction of proper hardness in areas of phosphorus cast-iron brake shoes manufacturing

NASA Astrophysics Data System (ADS)

Kiss, I.; Cioată, V. G.; Ratiu, S. A.; Rackov, M.; Penčić, M.

2018-01-01

Multivariate research is important in areas of cast-iron brake shoes manufacturing, because many variables interact with each other simultaneously. This article focuses on expressing the multiple linear regression model related to the hardness assurance by the chemical composition of the phosphorous cast irons destined to the brake shoes, having in view that the regression coefficients will illustrate the unrelated contributions of each independent variable towards predicting the dependent variable. In order to settle the multiple correlations between the hardness of the cast-iron brake shoes, and their chemical compositions several regression equations has been proposed. Is searched a mathematical solution which can determine the optimum chemical composition for the hardness desirable values. Starting from the above-mentioned affirmations two new statistical experiments are effectuated related to the values of Phosphorus [P], Manganese [Mn] and Silicon [Si]. Therefore, the regression equations, which describe the mathematical dependency between the above-mentioned elements and the hardness, are determined. As result, several correlation charts will be revealed.

Development of coatings for ultrasonic additive manufacturing sonotrode using laser direct metal deposition process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridharan, Niyanth; Dehoff, Ryan R.; Jordan, Brian H.

2016-10-01

ORNL partnered with Fabrisonic, LLC to develop galling resistant hard facing coatings on sonotrodes used to fabricate 3D printed materials using ultrasonic additive manufacturing. The development and deployment of a coated sonotrode is expected to push the existing state of the art to facilitate the solidstate additive manufacturing of hard steels and titanium alloys. To this effect a structurally amorphous stainless steel material and cobalt chrome material were deposited on the sonotrode material. Both the deposits showed good adhesion to the substrate. The coatings made using the structurally amorphous steel materials showed cracking during the initial trials and cracking wasmore » eliminated by deposition on a preheated substrate. Both the coatings show hardness in excess of 600 HVN. Thus the phase 1 of this project has been used to identify suitable materials to use to coat the sonotrode. Despite the fact that successful deposits were obtained, the coatings need to be evaluated by performing detailed galling tests at various temperatures. In addition field tests are also necessary to test the stability of these coatings in a high cycle ultrasonic vibration mode. If awarded, phase 2 of the project would be used to optimize the composition of the deposit material to maximize galling resistance. The industrial partner would then use the coated sonotrode to fabricate builds made of austenitic stainless steel to test the viability of using a coated sonotrode.« less

Ultrafine Ceramic Grains Embedded in Metallic Glass Matrix: Achieving Superior Wear Resistance via Increase in Both Hardness and Toughness.

PubMed

Yang, Lina; Wen, Mao; Dai, Xuan; Cheng, Gang; Zhang, Kan

2018-05-09

As structural materials, crystalline or metallic glass materials have attracted scientific and practical interests. However, some mechanisms involving critical size and shear bands have adverse effects on their mechanical properties. Here, we counter these two effects by introducing a special structure with ultrafine ceramic grains (with a diameter of ∼2.0 nm) embedded into a metallic glass matrix, wherein the grains are mainly composed of a Ta-W-N solid solution structure in nature, surrounded by a W-based amorphous matrix that contains Ta and N atoms. Such a structure is in situ formed during preparation, which combines the merits of both phases to achieve simultaneous increase in hardness and toughness relative to references (pure TaN and W) and thus superior wear resistance. Even more remarkable, a favorable variation of increased hardness but reduced elasticity modulus can be induced by this structure. Intrinsically, ultrafine ceramic grains (free of dislocations), embedded in the metallic glass matrix, could prevent shear band propagation within the glass matrix and further improve the hardness of the matrix material. In return, such glass matrix allows for stiffness neutralization and structural relaxation to reduce the elasticity modulus of ceramic grains. This study will offer a new guidance to fabricate ultrahigh-performance metal-based composites.

WHO water quality standards Vs Synergic effect(s) of fluoride, heavy metals and hardness in drinking water on kidney tissues.

PubMed

Wasana, Hewa M S; Perera, Gamage D R K; Gunawardena, Panduka De S; Fernando, Palika S; Bandara, Jayasundera

2017-02-14

Despite WHO standards, waterborne diseases among the human being are rising alarmingly. It is known that the prolong exposure to contaminated water has major impact on public health. The effect of chemical contaminations in drinking water on human being is found to be chronic rather than acute and hence can be defined "consumption of contaminated drinking water could be a silent killer". As the WHO recommended water quality standards are only for individual element and synergic effects of trace metals and anions have not been considered, investigation of synergic effects of trace metals and anions and their effect on human being is of prime important research. By an animal trial, we investigated the synergic effect(s) of heavy metals, aluminium, arsenic, fluoride and hardness in drinking water on kidney tissues of mice. Our investigation strongly suggests existing of a synergic effect especially among Cd, F and hardness of water which could lead to severe kidney damage in mice, even at WHO maximum recommended levels. Hence, the synergic effect(s) of trace metals, fluoride and hardness present in drinking water should be investigated meticulously when stipulating the water quality at WHO maximum recommended levels.

WHO water quality standards Vs Synergic effect(s) of fluoride, heavy metals and hardness in drinking water on kidney tissues

NASA Astrophysics Data System (ADS)

Wasana, Hewa M. S.; Perera, Gamage D. R. K.; Gunawardena, Panduka De S.; Fernando, Palika S.; Bandara, Jayasundera

2017-02-01

Despite WHO standards, waterborne diseases among the human being are rising alarmingly. It is known that the prolong exposure to contaminated water has major impact on public health. The effect of chemical contaminations in drinking water on human being is found to be chronic rather than acute and hence can be defined “consumption of contaminated drinking water could be a silent killer”. As the WHO recommended water quality standards are only for individual element and synergic effects of trace metals and anions have not been considered, investigation of synergic effects of trace metals and anions and their effect on human being is of prime important research. By an animal trial, we investigated the synergic effect(s) of heavy metals, aluminium, arsenic, fluoride and hardness in drinking water on kidney tissues of mice. Our investigation strongly suggests existing of a synergic effect especially among Cd, F and hardness of water which could lead to severe kidney damage in mice, even at WHO maximum recommended levels. Hence, the synergic effect(s) of trace metals, fluoride and hardness present in drinking water should be investigated meticulously when stipulating the water quality at WHO maximum recommended levels.

Method of manufacturing flexible metallic photonic band gap structures, and structures resulting therefrom

DOEpatents

Gupta, Sandhya; Tuttle, Gary L.; Sigalas, Mihail; McCalmont, Jonathan S.; Ho, Kai-Ming

2001-08-14

A method of manufacturing a flexible metallic photonic band gap structure operable in the infrared region, comprises the steps of spinning on a first layer of dielectric on a GaAs substrate, imidizing this first layer of dielectric, forming a first metal pattern on this first layer of dielectric, spinning on and imidizing a second layer of dielectric, and then removing the GaAs substrate. This method results in a flexible metallic photonic band gap structure operable with various filter characteristics in the infrared region. This method may be used to construct multi-layer flexible metallic photonic band gap structures. Metal grid defects and dielectric separation layer thicknesses are adjusted to control filter parameters.

Effect of manufacturing process sequence on the corrosion resistance characteristics of coated metallic bipolar plates

NASA Astrophysics Data System (ADS)

Dur, Ender; Cora, Ömer Necati; Koç, Muammer

2014-01-01

Metallic bipolar plate (BPP) with high corrosion and low contact resistance, durability, strength, low cost, volume, and weight requirements is one of the critical parts of the PEMFC. This study is dedicated to understand the effect of the process sequence (manufacturing then coating vs. coating then manufacturing) on the corrosion resistance of coated metallic bipolar plates. To this goal, three different PVD coatings (titanium nitride (TiN), chromium nitride (CrN), zirconium nitride (ZrN)), with three thicknesses, (0.1, 0.5, 1 μm) were applied on BPPs made of 316L stainless steel alloy before and after two types of manufacturing (i.e., stamping or hydroforming). Corrosion test results indicated that ZrN coating exhibited the best corrosion protection while the performance of TiN coating was the lowest among the tested coatings and thicknesses. For most of the cases tested, in which coating was applied before manufacturing, occurrence of corrosion was found to be more profound than the case where coating was applied after manufacturing. Increasing the coating thickness was found to improve the corrosion resistance. It was also revealed that hydroformed BPPs performed slightly better than stamped BPPs in terms of the corrosion behavior.

A Method for Fabricating Additive Manufactured Lightweight Metallic Mirrors

DTIC Science & Technology

2015-06-14

systems [3, 4].    The state of the art in this industry is the ULE™,  Zerodur ™, or beryllium isogrid  mirrors .  The isogrid design is a standard in...1    A Method for Fabricating Additive Manufactured Lightweight  Metallic  Mirrors   Michael Stern, Joseph Bari  This work  is  sponsored  by  the...methods for fabricating  low‐weight optics are in use today. We present a novel methodology for generating lightweight  metallic  mirrors  fabricated by

Additive Manufacturing and Casting Technology Comparison: Mechanical Properties, Productivity and Cost Benchmark

NASA Astrophysics Data System (ADS)

Vevers, A.; Kromanis, A.; Gerins, E.; Ozolins, J.

2018-04-01

The casting technology is one of the oldest production technologies in the world but in the recent years metal additive manufacturing also known as metal 3D printing has been evolving with huge steps. Both technologies have capabilities to produce parts with internal holes and at first glance surface roughness is similar for both technologies, which means that for precise dimensions parts have to be machined in places where precise fit is necessary. Benchmark tests have been made to find out if parts which are produced with metal additive manufacturing can be used to replace parts which are produced with casting technology. Most of the comparative tests have been made with GJS-400-15 grade which is one of the most popular cast iron grades. To compare mechanical properties samples have been produced using additive manufacturing and tested for tensile strength, hardness, surface roughness and microstructure and then the results have been compared with the samples produced with casting technology. In addition, both technologies have been compared in terms of the production time and production costs to see if additive manufacturing is competitive with the casting technology. The original paper has been written in the Latvian language as part of the Master Thesis within the framework of the production technology study programme at Riga Technical University.

Effect of layered manufacturing techniques, alloy powders, and layer thickness on metal-ceramic bond strength.

PubMed

Ekren, Orhun; Ozkomur, Ahmet; Ucar, Yurdanur

2018-03-01

Direct metal laser sintering (DMLS) and direct metal laser melting (DMLM) have become popular for fabricating the metal frameworks of metal-ceramic restorations. How the type of layered manufacturing device, layer thickness, and alloy powder may affect the bond strength of ceramic to metal substructure is unclear. The purpose of this in vitro study was to evaluate the bond strength of dental porcelain to metal frameworks fabricated using different layered manufacturing techniques (DMLS and DMLM), Co-Cr alloy powders, and layer thicknesses and to evaluate whether a correlation exists between the bond strength and the number of ceramic remnants on the metal surface. A total of 75 bar-shaped metal specimens (n=15) were fabricated using either DMLS or DMLM. The powder alloys used were Keramit NP-S and EOS-Cobalt-Chrome SP-2 with layer thicknesses of 20 μm and 30 μm. After ceramic application, the metal-ceramic bond strength was evaluated with a 3-point-bend test. Three-way ANOVA followed by the Tukey honest significance difference test were used for statistical analysis (α=.05). De-bonding surface microstructure was observed with scanning electron microscopy. Energy dispersive spectroscopy analysis was conducted to evaluate the correlation between ceramic remnants on the metal surface and bond strength values. The mean bond strength value of DMLS was significantly higher than that of DMLM. While no statistically significant difference was found between layer thicknesses, alloy powders closely affected bond strength. Statistical comparisons revealed that the highest bond strength could be achieved with DMLS-Cobalt-Chrome SP2-20μm, and the lowest bond strength was observed in DMLS-Keramit NP-S-20μm (P≤.05). No correlation was found between porcelain remnants on the metal surface and bond strength values. The layered manufacturing device and the alloy powders evaluated in the current study closely affected the bond strength of dental porcelain to a metal framework

Comparison of the metal-to-ceramic bond strengths of four noble alloys with press-on-metal and conventional porcelain layering techniques.

PubMed

Khmaj, Mofida R; Khmaj, Abdulfatah B; Brantley, William A; Johnston, William M; Dasgupta, Tridib

2014-11-01

New noble alloys for metal ceramic restorations introduced by manufacturers are generally lower-cost alternatives to traditional higher-gold alloys. Information about the metal-to-ceramic bond strength for these alloys, which is needed for rational clinical selection, is often lacking. The purpose of this study was to evaluate the bond strength of 4 recently introduced noble alloys by using 2 techniques for porcelain application. Aquarius Hard (high-gold: 86.1 gold, 8.5 platinum, 2.6 palladium, 1.4 indium; values in wt. %), Evolution Lite (reduced-gold: 40.3 gold, 39.3 palladium, 9.3 indium, 9.2 silver, 1.8 gallium), Callisto 75 Pd (palladium-silver containing gold: 75.2 palladium, 7.1 silver, 2.5 gold, 9.3 tin, 1.0 indium), and Aries, (conventional palladium-silver: 63.7 palladium, 26.0 silver, 7.0 tin, 1.8 gallium, 1.5 indium) were selected for bonding to leucite-containing veneering porcelains. Ten metal ceramic specimens that met dimensional requirements for International Organization for Standardization (ISO) Standard 9693 were prepared for each alloy by using conventional porcelain layering and press-on-metal methods. The 3-point bending test in ISO Standard 9693 was used to determine bond strength. Values were compared with 2-way ANOVA (maximum likelihood analysis, SAS Mixed Procedure) and the Tukey test (α=.05). Means (standard deviations) for bond strength with conventional porcelain layering were as follows: Aquarius Hard (50.7 ±5.5 MPa), Evolution Lite (40.2 ±3.3 MPa), Callisto 75 Pd (37.2 ±3.9 MPa), and Aries (34.0 ±4.9 MPa). For the press-on-metal technique, bond strength results were as follows: Aquarius Hard (33.7 ±11.5 MPa), Evolution Lite (34.9 ±4.5 MPa), Callisto 75 Pd (37.2 ±11.9 MPa), and Aries (30.7 ±10.8 MPa). From statistical analyses, the following 3 significant differences were found for metal-to-ceramic bond strength: the bond strength for Aquarius Hard was significantly higher for conventional porcelain layers compared with

Microstructural and hardness investigations on a dissimilar metal weld between low alloy steel and Alloy 82 weld metal

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Z.R., E-mail: raymix@aliyun.com

The investigation on microstructure and hardness at the fusion boundary (FB) region of a dissimilar metal weld (DMW) between low alloy steel (LAS) A508-III and Alloy 82 weld metal (WM) was carried out. The results indicated that there were two kinds of FBs, martensite FB and sharp FB, with obvious different microstructures, alternately distributed in the same FB. The martensite FB region had a gradual change of elemental concentration across FB, columnar WM grains with high length/width ratios, a thick martensite layer and a wide heat affected zone (HAZ) with large prior austenite grains. By comparison, the sharp FB regionmore » had a relatively sharp change of elemental concentration across the FB, WM grains with low length/width ratios and a narrow HAZ with smaller prior austenite grains. The martensite possessed a K-S orientation relationship with WM grains, while no orientation relationship was found between the HAZ grains and WM grains at the sharp FB. Compared with sharp FB there were much more Σ3 boundaries in the HAZ beside martensite FB. The hardness maximum of the martensite FB was much higher than that of the sharp FB, which was attributed to the martensite layer at the martensite FB. - Highlights: •Martensite and sharp FBs with different microstructures were found in the same FB. •There were high length/width-ratio WM grains and a wide HAZ beside martensite FB. •There were low length/width-ratio WM grains and a narrow HAZ beside sharp FB. •Compared with sharp FB, there were much more Σ3 boundaries in HAZ of martensite FB. •Hardness maximium of martensite FB was much higher than that of sharp FB.« less

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

NASA Technical Reports Server (NTRS)

Tylka, Jonathan; Cooper, Ken; Peralta, Stephen; Wilcutt, Terrence; Hughitt, Brian; Generazio, Edward

2016-01-01

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

Ti1-xAux Alloys: Hard Biocompatible Metals and Their Possible Applications

NASA Astrophysics Data System (ADS)

Svanidze, Eteri; Besara, Tiglet; Ozaydin, M. Fevzi; Xin, Yan; Han, Ke; Liang, Hong; Siegrist, Theo; Morosan, Emilia

2015-03-01

The search for new hard materials is often challenging from both theoretical and experimental points of view. Furthermore, using materials for biomedical applications calls for alloys with high biocompatibility which are even more sparse. The Ti1-xAux (0 . 22 <= x <= 0 . 8) exhibit extreme hardness and strength values, elevated melting temperatures (compared to those of constituent elements), reduced density compared to Au, high malleability, bulk metallicity, high biocompatibility, low wear, reduced friction, potentially high radio opacity, as well as osseointegration. All these properties render the Ti1-xAux alloys particularly useful for orthopedic, dental, and prosthetic applications, where they could be used as both permanent and temporary components. Additionally, the ability of Ti1-xAux alloys to adhere to ceramic parts could reduce the weight and cost of these components. The work at Rice was supported by NSF DMR 0847681 (E.M. and E.S.).

Manufacturing and Machining Challenges of Hybrid Aluminium Metal Matix Composites

NASA Astrophysics Data System (ADS)

Baburaja, Kammuluri; Sainadh Teja, S.; Karthik Sri, D.; Kuldeep, J.; Gowtham, V.

2017-08-01

Manufacturing which involves material removal processes or material addition processes or material transformation processes. One or all the processes to obtain the final desired properties for a material with desired shape which meets the required precision and accuracy values for the expected service life of a material in working conditions. Researchers found the utility of aluminium to be the second largest after steel. Aluminium and its metal matrix composite possess wide applications in various applications in aerospace industry, automobile industry, Constructions and even in kitchen utensils. Hybrid Al-MMCconsist of two different materials, and one will be from organic origin along with the base material. In this paper an attempt is made to bring out the importance of utilization of aluminium and the challenges concerned in manufacturing and machining of hybrid aluminium MMC.

Advanced optical modeling of TiN metal hard mask for scatterometric critical dimension metrology

NASA Astrophysics Data System (ADS)

Ebersbach, Peter; Urbanowicz, Adam M.; Likhachev, Dmitriy; Hartig, Carsten

2017-03-01

The majority of scatterometric production control models assume constant optical properties of the materials and only dimensional parameters are allowed to vary. However, this assumption, especially in case of thin-metal films, negatively impacts model precision and accuracy. In this work we focus on optical modeling of the TiN metal hardmask for scatterometry applications. Since the dielectric function of TiN exhibits thickness dependence, we had to take this fact into account. Moreover, presence of the highly absorbing films influences extracted thicknesses of dielectric layers underneath the metal films. The later phenomenon is often not reflected by goodness of fit. We show that accurate optical modeling of metal is essential to achieve desired scatterometric model quality for automatic process control in microelectronic production. Presented modeling methodology can be applied to other TiN applications such as diffusion barriers and metal gates as well as for other metals used in microelectronic manufacturing for all technology nodes.

Integrating Fiber Optic Strain Sensors into Metal Using Ultrasonic Additive Manufacturing

NASA Astrophysics Data System (ADS)

Hehr, Adam; Norfolk, Mark; Wenning, Justin; Sheridan, John; Leser, Paul; Leser, Patrick; Newman, John A.

2018-03-01

Ultrasonic additive manufacturing, a rather new three-dimensional (3D) printing technology, uses ultrasonic energy to produce metallurgical bonds between layers of metal foils near room temperature. This low temperature attribute of the process enables integration of temperature sensitive components, such as fiber optic strain sensors, directly into metal structures. This may be an enabling technology for Digital Twin applications, i.e., virtual model interaction and feedback with live load data. This study evaluates the consolidation quality, interface robustness, and load sensing limits of commercially available fiber optic strain sensors embedded into aluminum alloy 6061. Lastly, an outlook on the technology and its applications is described.

Integrated manufacturing flow for selective-etching SADP/SAQP

NASA Astrophysics Data System (ADS)

Ali, Rehab Kotb; Fatehy, Ahmed Hamed; Word, James

2018-03-01

Printing cut mask in SAMP (Self Aligned Multi Patterning) is very challenging at advanced nodes. One of the proposed solutions is to print the cut shapes selectively. Which means the design is decomposed into mandrel tracks, Mandrel cuts and non-Mandrel cuts. The mandrel and non-Mandrel cuts are mutually independent which results in relaxing spacing constrains and as a consequence more dense metal lines. In this paper, we proposed the manufacturing flow of selective etching process. The results are quantified in terms of measuring PVBand, EPE and the number of hard bridging and pinching across the layout.

Additive Manufacturing Infrared Inspection

NASA Technical Reports Server (NTRS)

Gaddy, Darrell

2014-01-01

Additive manufacturing is a rapid prototyping technology that allows parts to be built in a series of thin layers from plastic, ceramics, and metallics. Metallic additive manufacturing is an emerging form of rapid prototyping that allows complex structures to be built using various metallic powders. Significant time and cost savings have also been observed using the metallic additive manufacturing compared with traditional techniques. Development of the metallic additive manufacturing technology has advanced significantly over the last decade, although many of the techniques to inspect parts made from these processes have not advanced significantly or have limitations. Several external geometry inspection techniques exist such as Coordinate Measurement Machines (CMM), Laser Scanners, Structured Light Scanning Systems, or even traditional calipers and gages. All of the aforementioned techniques are limited to external geometry and contours or must use a contact probe to inspect limited internal dimensions. This presentation will document the development of a process for real-time dimensional inspection technique and digital quality record of the additive manufacturing process using Infrared camera imaging and processing techniques.

Structure changes in steels and hard metal induced by nanosecond and femtosecond laser processing

NASA Astrophysics Data System (ADS)

Dumitru, Gabriel; Romano, Valerio; Weber, Heinz P.; Haefke, Henry; Gerbig, Yvonne; Sentis, Marc L.; Hermann, Joerg; Bruneau, Sebastien

2003-11-01

Investigations on the occurrence of structure and hardness changes (for two sorts of steel and for a hard metal substrate) in the immediate vicinity of laser induced craters are presented in this work. Experiments with femtosecond pulses were performed in air with a Ti:sapphire laser (800 nm, 100 fs) at mean fluences of 2, 5 and 10 J/cm2. Series of microcraters were induced with 100 to 5,000 laser pulses per hole. Experiments with similar fluences, but 10 to 40 pules per hole, were performed on the same materials using a Nd:YAG delivering 100 ns pulese. After laser irradiation, cuts were made through the processed samples and the changes occurred in the crystalline structure of the target materials were evidenced by metallographical analysis of the resulting cross-sections. Hardness measurements were performed in points situated in the immediate vicinity of the laser-induced pores. Affected zones in the material surrounding laser induced pores were always found in the ns-regime, however with different properties for various laser parameters. In the fs-regime, zones of modified materials were also found and in such zones a significant hardness increasing was evidenced; the limit of the low fluences regime, where no structure changes occurred, was found to be slightly above 2 J/cm2.

Process combinations for the manufacturing of metal-plastic hybrid parts

NASA Astrophysics Data System (ADS)

Drossel, W.-G.; Lies, C.; Albert, A.; Haase, R.; Müller, R.; Scholz, P.

2016-03-01

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of “using the right material at the right place” is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

Systems and Methods for Fabricating Objects Including Amorphous Metal Using Techniques Akin to Additive Manufacturing

NASA Technical Reports Server (NTRS)

Hofmann, Douglas (Inventor)

2017-01-01

Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.

Manufacturing Techniques for Titanium Aluminide Based Alloys and Metal Matrix Composites

DTIC Science & Technology

2010-01-01

aluminides are being used in the low pressure turbine (LPT) blades . In addition, titanium aluminides were also investigated for use in High Speed Civil... Titanium aluminides are also being used in General Electric’s GEnex gas turbine engine for the 6th and the 7th stage of the low pressure turbine blades ...ABSTRACT Title of Dissertation: MANUFACTURING TECHNIQUES FOR TITANIUM ALUMINIDE BASED ALLOYS AND METAL MATRIX COMPOSITES

Quasi-static strength and fractography analysis of two dental implants manufactured by direct metal laser sintering.

PubMed

Gehrke, Sergio Alexandre; Pérez-Díaz, Leticia; Dedavid, Berenice Anina

2018-06-01

New manufacturing methods was developed to improve the tissues integration with the titanium alloy pieces. The present in vitro study was to assess the resistance and fracture mode after applied a quasi-static compressive force on the two dental implants manufactured by direct metal laser sintering. Twenty dental implants manufactured by direct metal laser sintering, using titanium alloy (Ti-6Al-4V) granules in two designs (n = 10 per group): Conventional dental implant (group Imp1) two-piece implant design, where the surgical implant and prosthetic abutment are two separate components and, the one-piece implant (group Imp2), where the surgical implant and prosthetic abutment are one integral piece. All samples were subjected to quasi-static loading at a 30° angle to the implant axis in a universal testing machine. The mean fracture strengths were 1269.2 ± 128.8 N for the group Imp1 and, 1259.5 ± 115.1 N for the group Imp2, without statistical differences (P = .8722). In both groups, the fracture surface does not present crack between the compact core and the superficial (less dense and porous) part of the implants. Based on the measured resistance data for the two implant models manufactured by direct metal laser sintering tested in the present study, we can suggest that they have adequate capacity to withstand the masticatory loads. © 2018 Wiley Periodicals, Inc.

3D Metal Printing - Additive Manufacturing Technologies for Frameworks of Implant-Borne Fixed Dental Prosthesis.

PubMed

Revilla León, M; Klemm, I M; García-Arranz, J; Özcan, M

2017-09-01

An edentulous patient was rehabilitated with maxillary metal-ceramic and mandibular metal-resin implant-supported fixed dental prosthesis (FDP). Metal frameworks of the FDPs were fabricated using 3D additive manufacturing technologies utilizing selective laser melting (SLM) and electron beam melting (EBM) processes. Both SLM and EBM technologies were employed in combination with computer numerical control (CNC) post-machining at the implant interface. This report highlights the technical and clinical protocol for fabrication of FDPs using SLM and EBM additive technologies. Copyright© 2017 Dennis Barber Ltd.

Effects of Computer-Aided Manufacturing Technology on Precision of Clinical Metal-Free Restorations.

PubMed

Lee, Ki-Hong; Yeo, In-Sung; Wu, Benjamin M; Yang, Jae-Ho; Han, Jung-Suk; Kim, Sung-Hun; Yi, Yang-Jin; Kwon, Taek-Ka

2015-01-01

The purpose of this study was to investigate the marginal fit of metal-free crowns made by three different computer-aided design/computer-aided manufacturing (CAD/CAM) systems. The maxillary left first premolar of a dentiform was prepared for all-ceramic crown restoration. Thirty all-ceramic premolar crowns were made, ten each manufactured by the Lava system, Cercon, and Cerec. Ten metal ceramic gold (MCG) crowns served as control. The marginal gap of each sample was measured under a stereoscopic microscope at 75x magnification after cementation. One-way ANOVA and the Duncan's post hoc test were used for data analysis at the significance level of 0.05. The mean (standard deviation) marginal gaps were 70.5 (34.4) μm for the MCG crowns, 87.2 (22.8) μm for Lava, 58.5 (17.6) μm for Cercon, and 72.3 (30.8) μm for Cerec. There were no significant differences in the marginal fit among the groups except that the Cercon crowns had significantly smaller marginal gaps than the Lava crowns (P < 0.001). Within the limitation of this study, all the metal-free restorations made by the digital CAD/CAM systems had clinically acceptable marginal accuracy.

Characterization of Ti and Co based biomaterials processed via laser based additive manufacturing

NASA Astrophysics Data System (ADS)

Sahasrabudhe, Himanshu

Titanium and Cobalt based metallic materials are currently the most ideal materials for load-bearing metallic bio medical applications. However, the long term tribological degradation of these materials still remains a problem that needs a solution. To improve the tribological performance of these two metallic systems, three different research approaches were adapted, stemming out four different research projects. First, the simplicity of laser gas nitriding was utilized with a modern LENS(TM) technology to form an in situ nitride rich later in titanium substrate material. This nitride rich composite coating improved the hardness by as much as fifteen times and reduced the wear rate by more than a magnitude. The leaching of metallic ions during wear was also reduced by four times. In the second research project, a mixture of titanium and silicon were processed on a titanium substrate in a nitrogen rich environment. The results of this reactive, in situ additive manufacturing process were Ti-Si-Nitride coatings that were harder than the titanium substrate by more than twenty times. These coatings also reduced the wear rate by more than two magnitudes. In the third research approach, composites of CoCrMo alloy and Calcium phosphate (CaP) bio ceramic were processed using LENS(TM) based additive manufacturing. These composites were effective in reducing the wear in the CoCrMo alloy by more than three times as well as reduce the leaching of cobalt and chromium ions during wear. The novel composite materials were found to develop a tribofilm during wear. In the final project, a combination of hard nitride coating and addition of CaP bioceramic was investigated by processing a mixture of Ti6Al4V alloy and CaP in a nitrogen rich environment using the LENS(TM) technology. The resultant Ti64-CaP-Nitride coatings significantly reduced the wear damage on the substrate. There was also a drastic reduction in the metal ions leached during wear. The results indicate that the three

Mechanical and Fatigue Properties of Additively Manufactured Metallic Materials

NASA Astrophysics Data System (ADS)

Yadollahi, Aref

This study aims to investigate the mechanical and fatigue behavior of additively manufactured metallic materials. Several challenges associated with different metal additive manufacturing (AM) techniques (i.e. laser-powder bed fusion and direct laser deposition) have been addressed experimentally and numerically. Experiments have been carried out to study the effects of process inter-layer time interval--i.e. either building the samples one-at-a-time or multi-at-a-time (in-parallel)--on the microstructural features and mechanical properties of 316L stainless steel samples, fabricated via a direct laser deposition (DLD). Next, the effect of building orientation--i.e. the orientation in which AM parts are built--on microstructure, tensile, and fatigue behaviors of 17-4 PH stainless steel, fabricated via a laser-powder bed fusion (L-PBF) method was investigated. Afterwards, the effect of surface finishing--here, as-built versus machined--on uniaxial fatigue behavior and failure mechanisms of Inconel 718 fabricated via a laser-powder bed fusion technique was sought. The numerical studies, as part of this dissertation, aimed to model the mechanical behavior of AM materials, under monotonic and cyclic loading, based on the observations and findings from the experiments. Despite significant research efforts for optimizing process parameters, achieving a homogenous, defect-free AM product--immediately after fabrication--has not yet been fully demonstrated. Thus, one solution for ensuring the adoption of AM materials for application should center on predicting the variations in mechanical behavior of AM parts based on their resultant microstructure. In this regard, an internal state variable (ISV) plasticity-damage model was employed to quantify the damage evolution in DLD 316L SS, under tensile loading, using the microstructural features associated with the manufacturing process. Finally, fatigue behavior of AM parts has been modeled based on the crack-growth concept

Relationships Between Abrasive Wear, Hardness, and Surface Grinding Characteristics of Titanium-Based Metal Matrix Composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blau, Peter Julian; Jolly, Brian C

2009-01-01

The objective of this work was to support the development of grinding models for titanium metal-matrix composites (MMCs) by investigating possible relationships between their indentation hardness, low-stress belt abrasion, high-stress belt abrasion, and the surface grinding characteristics. Three Ti-based particulate composites were tested and compared with the popular titanium alloy Ti-6Al-4V. The three composites were a Ti-6Al-4V-based MMC with 5% TiB{sub 2} particles, a Ti-6Al-4V MMC with 10% TiC particles, and a Ti-6Al-4V/Ti-7.5%W binary alloy matrix that contained 7.5% TiC particles. Two types of belt abrasion tests were used: (a) a modified ASTM G164 low-stress loop abrasion test, and (b)more » a higher-stress test developed to quantify the grindability of ceramics. Results were correlated with G-ratios (ratio of stock removed to abrasives consumed) obtained from an instrumented surface grinder. Brinell hardness correlated better with abrasion characteristics than microindentation or scratch hardness. Wear volumes from low-stress and high-stress abrasive belt tests were related by a second-degree polynomial. Grindability numbers correlated with hard particle content but were also matrix-dependent.« less

30 CFR 56.15002 - Hard hats.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Hard hats. 56.15002 Section 56.15002 Mineral... HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Personal Protection § 56.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant where falling objects...

30 CFR 56.15002 - Hard hats.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Hard hats. 56.15002 Section 56.15002 Mineral... HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Personal Protection § 56.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant where falling objects...

30 CFR 57.15002 - Hard hats.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Hard hats. 57.15002 Section 57.15002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND... Underground § 57.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant...

30 CFR 57.15002 - Hard hats.

Code of Federal Regulations, 2011 CFR

2011-07-01

... 30 Mineral Resources 1 2011-07-01 2011-07-01 false Hard hats. 57.15002 Section 57.15002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND... Underground § 57.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant...

30 CFR 56.15002 - Hard hats.

Code of Federal Regulations, 2010 CFR

2010-07-01

... 30 Mineral Resources 1 2010-07-01 2010-07-01 false Hard hats. 56.15002 Section 56.15002 Mineral... HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Personal Protection § 56.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant where falling objects...

30 CFR 56.15002 - Hard hats.

Code of Federal Regulations, 2014 CFR

2014-07-01

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30 CFR 56.15002 - Hard hats.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Hard hats. 56.15002 Section 56.15002 Mineral... HEALTH SAFETY AND HEALTH STANDARDS-SURFACE METAL AND NONMETAL MINES Personal Protection § 56.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant where falling objects...

30 CFR 57.15002 - Hard hats.

Code of Federal Regulations, 2013 CFR

2013-07-01

... 30 Mineral Resources 1 2013-07-01 2013-07-01 false Hard hats. 57.15002 Section 57.15002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND... Underground § 57.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant...

30 CFR 57.15002 - Hard hats.

Code of Federal Regulations, 2012 CFR

2012-07-01

... 30 Mineral Resources 1 2012-07-01 2012-07-01 false Hard hats. 57.15002 Section 57.15002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND... Underground § 57.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant...

30 CFR 57.15002 - Hard hats.

Code of Federal Regulations, 2014 CFR

2014-07-01

... 30 Mineral Resources 1 2014-07-01 2014-07-01 false Hard hats. 57.15002 Section 57.15002 Mineral Resources MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR METAL AND NONMETAL MINE SAFETY AND... Underground § 57.15002 Hard hats. All persons shall wear suitable hard hats when in or around a mine or plant...

Advanced Manufacturing Technologies

NASA Technical Reports Server (NTRS)

Fikes, John

2016-01-01

Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

Nanoindentation hardness and atomic force microscope imaging studies of pressure-quenched zirconium metal

NASA Astrophysics Data System (ADS)

Catledge, Shane A.; Spencer, Philemon T.; Vohra, Yogesh K.

2000-11-01

We have carried out mechanical property measurements on zirconium metal compressed in a diamond anvil cell to 19 GPa at room temperature with subsequent quenching to room pressure. The irreversible transformation from the ambient hexagonal-close-packed phase to the simple hexagonal ω phase (AlB2 structure) is confirmed by synchrotron energy dispersive x-ray diffraction followed by nanoindentation of the pressure-quenched sample. We document an 80% increase in hardness as a consequence of the pressure-induced transformation to the ω phase at room temperature. This is a large increase for a metallic phase transformation and can be attributed to the presence of sp2-hybrid bonds forming graphite-like nets in the (0001) plane of the AlB2 structure. Atomic force microscopy of the indents shows that a plastic deformation of 2 μm in depth was achieved with a force of 200 mN.

Anomalous metallic state with strong charge fluctuations in BaxTi8O16 +δ revealed by hard x-ray photoemission spectroscopy

NASA Astrophysics Data System (ADS)

Dash, S.; Kajita, T.; Okawa, M.; Saitoh, T.; Ikenaga, E.; Saini, N. L.; Katsufuji, T.; Mizokawa, T.

2018-04-01

We have studied a charge-orbital driven metal-insulator transition (MIT) in hollandite-type BaxTi8O16 +δ by means of hard x-ray photoemission spectroscopy (HAXPES). The Ti 2 p HAXPES indicates strong Ti3 +/Ti4 + charge fluctuation in the metallic phase above the MIT temperature. The metallic phase is characterized by a power-law spectral function near the Fermi level which would be a signature of bad metal with non-Drude polaronic behavior. The power-law spectral shape is associated with the large Seebeck coefficient of the metallic phase in BaxTi8O16 +δ .

Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

NASA Astrophysics Data System (ADS)

Williams, Christopher Bryant

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of

Manufacture and quality control of interconnecting wire hardnesses, Volume 1

NASA Technical Reports Server (NTRS)

1972-01-01

A standard is presented for manufacture, installation, and quality control of eight types of interconnecting wire harnesses. The processes, process controls, and inspection and test requirements reflected are based on acknowledgment of harness design requirements, acknowledgment of harness installation requirements, identification of the various parts, materials, etc., utilized in harness manufacture, and formulation of a typical manufacturing flow diagram for identification of each manufacturing and quality control process, operation, inspection, and test. The document covers interconnecting wire harnesses defined in the design standard, including type 1, enclosed in fluorocarbon elastomer convolute, tubing; type 2, enclosed in TFE convolute tubing lines with fiberglass braid; type 3, enclosed in TFE convolute tubing; and type 5, combination of types 3 and 4. Knowledge gained through experience on the Saturn 5 program coupled with recent advances in techniques, materials, and processes was incorporated.

Facilities | Advanced Manufacturing Research | NREL

Science.gov Websites

, and black building with two people walking in front of it. Energy Systems Integration Facility Its projects. Photo of a large, warehouse-like, lab space with several people in hard hats operating equipment with a few people and manufacturing equipment, including spools and web lines. Manufacturing Laboratory

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C.; Borgonia, John Paul C.; Dillon, Robert P.; Suh, Eric J.; Mulder, jerry L.; Gardner, Paul B.

2013-01-01

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an

Embedding Carbon Fibre Structures in Metal Matrixes for Additive Manufacturing

NASA Astrophysics Data System (ADS)

Frostevarg, Jan; Robertson, Stephanie; Benavides, Vicente; Soldatov, Alexander

It is possible to reinforce structures and components using carbon fibres for applications in electronics and medicine, but most commonly used in reinforcing resin fibre composites for personal protection equipment and light weight constructions. Carbon fibres act as stress redistributors while having increased electrical and thermal conductivities. These properties could also be utilized in metal matrixes, if the fibres are properly fused to the metal and the structure remains intact. Another recently developed high potential carbon structure, carbon nanotube- (CNT) yarns, has similar but even greater mechanical properties than common carbon fibres. Via laser cladding, these reinforcing materials could be used in a plethora of applications, either locally (or globally) as surface treatments or as structural reinforcements using multi-layer laser cladding (additive manufacturing). The challenges of embedding carbon fibres or CNT-yarns in a CuAl mixture and SnPb solder wire using lasers are here investigated using high speed imaging and SEM. It is revealed that the carbon fibres have very high buoyancy in the molten metal and quickly degrades when irradiated by the laser. Wetting of the fibres is shown to be improved by a Tungsten coating and embedding of the structures after processing are evaluated using SEM and Raman spectroscopy.

Effect of Manufacturing Process on the Biocompatibility and Mechanical Properties of Ti-30Ta Alloy

NASA Astrophysics Data System (ADS)

Gill, P.; Munroe, N.; Pulletikurthi, C.; Pandya, S.; Haider, W.

2011-07-01

Ti alloys have been widely used in the aerospace, chemical, and biomedical industries for their high strength/weight ratio and corrosion resistance. However, Nitinol's usage in the latter industry has been fraught with concerns of allergic and toxic effects of Ni released from implants. Recently, much attention has been placed on the development of Ni-free Ti-Ta alloys, which are considered prime candidates for applications such as metal-on-metal spinal disk replacements, orthopedic implants, cardiovascular stents, dental posts, and guide wires. In this research, the biocompatibility of Ti-30Ta alloys manufactured by powder metallurgy (PM) and arc melting (ARC) were investigated. The corrosion resistance of each alloy was determined in accordance with ASTM F 2129-08 in phosphate buffered saline (PBS) and PBS with amino acids at 37 °C. The concentration of metal ions released during corrosion was measured by Inductively Coupled Plasma Mass Spectroscopy (ICP-MS). Scanning Electron Microscopy (SEM) was used to assess the morphology of the alloys before and after corrosion. Vicker's hardness tests were performed to compare the hardness and tensile strength of the alloys. Human osteoblast cells were successfully grown on the surface of both alloys.

High-rate production of micro- and nanostructured surfaces: Injection molding and novel process for metal tooling manufacturing

NASA Astrophysics Data System (ADS)

De Jesus Vega, Marisely

Devices containing micro and nanostructured surfaces are developing and constantly finding new applications, especially for medical diagnostics, point-of-care applications, and microneedles. They are also employed in the functionalization of surfaces for superhydrophobicity, drag reduction, or reversible adhesion by mimicking bio-inspired surfaces. This research provides a thorough investigation on the effects of different polymeric materials and processing conditions on the replication of micro and nanostructured surfaces via injection molding. In addition, this dissertation also presents a novel approach for the production of durable microstructured metal tooling to be used for the production of surfaces with microchannels via injection molding. Materials such as thermoplastic vulcanizates are substituting regular thermoplastic materials and vulcanized elastomers in many applications due to their outstanding properties and ease of processability. These material properties broaden the scope of applications for microstructured surfaces. However, there is a need for understanding how these materials behave in microinjection molding since thermoplastic elastomers' behavior during injection molding have been shown to differ from that of the widely understood behavior of thermoplastics. Replication of microstructured surfaces using thermoplastic vulcanizates (TPV) was studied in the first part of this thesis. TPVs with different hardness's were molded using microinjection molding with various processing conditions and the replication and surface details of 20 microm pillars (aspect ratio of 1:1) were characterized. In the second part of this research liquid silicone rubber (LSR) was studied as a material for the production of micro and nanostructured surfaces. LSR is a silicone based material such as polydimethylsiloxane (PDMS), which is widely used for research and development of micro and nanostructured devices, and thus provides all the benefits of PDMS but can be

Femtosecond ablation applied to deep-drilling of hard metals

NASA Astrophysics Data System (ADS)

Bruneau, Sebastien; Hermann, Joerg; Dumitru, Gabriel; Sentis, Marc L.

2004-09-01

Mechanisms responsible for the limitation of the aspect ratio obtained by deep drilling of hard metals are investigated in the present work. Cemented carbide targets have been irradiated with laser pulses of 100 fs duration and 100 μJ maximum energy delivered by a Ti:sapphire laser system. The experiments are carried out in different gas environments (vacuum, air, helium up to atmospheric pressure) with incident laser fluences ranging from 1 to 20 Jcm-2. During deep drilling, the laser-induced ablation plume is characterized by means of in-situ plasma diagnostics. Fast imaging is used to observe the expansion behavior of the plasma plume whereas time- and space-resolved emission spectroscopy is employed to analyze the plasma composition. After irradiation, the laser-produced craters were examined by optical microscopy. A correlation between the ablation plume characteristics and the morphological changes of the mciro-holes is established. The results indicate that nanoclusters, that present a significant part of the ablated material, are responsbile for the alteration of the crater shape in the high laser fluence regime.

Production of fiberglass/metal composite material suitable for building habitat and manufacturing facilities

NASA Technical Reports Server (NTRS)

1987-01-01

The production of a fiberglass/metal composite material suitable for building habitats and manufacturing facilities was the project for Clemson. The concept and development of the knowledge necessary to produce glass fibers originated in the spring semester. During the summer, while at Johnson Space Center, fiberglass from a rock composition similar to ones found at the Apollo 16 site on the moon was successfully produced. The project this year was a continuation of last year's studies. We addressed the following problems which emerged as the work progressed: (1) Methods for coating the fibers with a metal were explored. We manufactured composites in two stages: Glass fibers without any coating on them; and fibers coated with metals as they were made. This proved to be a difficult process. Future activities include using a chemical vapor deposition process on fibers which have been made. (2) A glass furnace was developed which relies primarily on solar energy for melting the glass. The temperature of the melted glass is maintained by electrical means. The design is for 250 kg of glass per day. An electrical engineering student developed a scheme for controlling the melting and manufacturing process from the earth. This was done to minimize the human risk. Graphite refractories are relied on to contain the melt. (3) The glass composition chosen for the project is a relatively pure anorthite which is available in the highland regions of the lunar surface. A major problems with this material is that it melts at a comparatively high temperature. This problem will be solved by using graphite refractory materials for the furnace. The advantage of this glass composition is that it is very stable and does not tend to crystallize. (4) We have also refined the experimental furnace and fiber making machinery which we will be using at Johnson Space Center this summer. We believe that we will be able to draw and coat glass fibers in a vacuum for use in composites. We intend to

Compressed Air System Overhaul Improves Production at a Powdered Metal Manufacturing Plant (GKN Sinter Metals in Salem, IN)

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

In 1998, GKN Sinter Metals completed a successful compressed air system improvement project at its Salem, Indiana manufacturing facility. The project was performed after GKN undertook a survey of its system in order to solve air quality problems and to evaluate whether the capacity of their compressed air system would meet their anticipated plant expansion. Once the project was implemented, the plant was able to increase production by 31% without having to add any additional compressor capacity.

Treatment of Wastewater from Electroplating, Metal Finishing and Printed Circuit Board Manufacturing. Operation of Wastewater Treatment Plants Volume 4.

ERIC Educational Resources Information Center

California State Univ., Sacramento. Dept. of Civil Engineering.

One of four manuals dealing with the operation of wastewater plants, this document was designed to address the treatment of wastewater from electroplating, metal finishing, and printed circuit board manufacturing. It emphasizes how to operate and maintain facilities which neutralize acidic and basic waters; treat waters containing metals; destroy…

Effective hard x-ray spectrum of a tabletop Mather-type plasma focus optimized for flash radiography of metallic objects

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raspa, V.; Moreno, C.; Sigaut, L.

The effective spectrum of the hard x-ray output of a Mather-type tabletop plasma focus device was determined from attenuation data on metallic samples using commercial radiographic film coupled to a Gd{sub 2}O{sub 2}S:Tb phosphor intensifier screen. It was found that the radiation has relevant spectral components in the 40-150 keV range, with a single maximum around 60-80 keV. The radiation output allows for 50 ns resolution, good contrast, and introspective imaging of metallic objects even through metallic walls. A numerical estimation of the induced voltage on the focus during the compressional stage is briefly discussed.

Depositing laser-generated nanoparticles on powders for additive manufacturing of oxide dispersed strengthened alloy parts via laser metal deposition

NASA Astrophysics Data System (ADS)

Streubel, René; Wilms, Markus B.; Doñate-Buendía, Carlos; Weisheit, Andreas; Barcikowski, Stephan; Henrich Schleifenbaum, Johannes; Gökce, Bilal

2018-04-01

We present a novel route for the adsorption of pulsed laser-dispersed nanoparticles onto metal powders in aqueous solution without using any binders or surfactants. By electrostatic interaction, we deposit Y2O3 nanoparticles onto iron-chromium based powders and obtain a high dispersion of nano-sized particles on the metallic powders. Within the additively manufactured component, we show that the particle spacing of the oxide inclusion can be adjusted by the initial mass fraction of the adsorbed Y2O3 particles on the micropowder. Thus, our procedure constitutes a robust route for additive manufacturing of oxide dispersion-strengthened alloys via oxide nanoparticles supported on steel micropowders.

Performance of Metal Cutting on Endmills Manufactured by Cooling-Air and Minimum Quantity Lubrication Grinding

NASA Astrophysics Data System (ADS)

Inoue, Shigeru; Aoyama, Tojiro

Grinding fluids have been commonly used during the grinding of tools for their cooling and lubricating effect since the hard, robust materials used for cutting tools are difficult to grind. Grinding fluids help prevent a drop in hardness due to burning of the cutting edge and keep chipping to an absolute minimum. However, there is a heightened awareness of the need to improve the work environment and protect the global environment. Thus, the present study is aimed at applying dry grinding, cooling-air grinding, cooling-air grinding with minimum quantity lubrication (MQL), and oil-based fluid grinding to manufacturing actual endmills (HSS-Co). Cutting tests were performed by a vertical machining center. The results indicated that the lowest surface inclination values and longest tool life were obtained by cooling-air grinding with MQL. Thus, cooling-air grinding with MQL has been demonstrated to be at least as effective as oil-based fluid grinding.

How to estimate hardness of crystals on a pocket calculator

NASA Astrophysics Data System (ADS)

Šimůnek, Antonín

2007-05-01

A generalization of the semiempirical microscopic model of hardness is presented and applied to currently studied borides, carbides, and nitrides of heavy transition metals. The hardness of OsB, OsC, OsN, PtN, RuC, RuB2 , ReB2 , OsB2 , IrN2 , PtN2 , and OsN2 crystals in various structural phases is predicted. It is found that none of the transition metal crystals is superhard, i.e., with hardness greater than 40GPa . The presented method provides materials researchers with a practical tool in the search for new hard materials.

Hard and low friction nitride coatings and methods for forming the same

DOEpatents

Erdemir, Ali; Urgen, Mustafa; Cakir, Ali Fuat; Eryilmaz, Osman Levent; Kazmanli, Kursat; Keles, Ozgul

2007-05-01

An improved coating material possessing super-hard and low friction properties and a method for forming the same. The improved coating material includes the use of a noble metal or soft metal homogeneously distributed within a hard nitride material. The addition of small amounts of such metals into nitrides such as molybdenum nitride, titanium nitride, and chromium nitride results in as much as increasing of the hardness of the material as well as decreasing the friction coefficient and increasing the oxidation resistance.

Economic Assessment for Recycling Critical Metals From Hard Disk Drives Using a Comprehensive Recovery Process

NASA Astrophysics Data System (ADS)

Nguyen, Ruby Thuy; Diaz, Luis A.; Imholte, D. Devin; Lister, Tedd E.

2017-09-01

Since the 2011 price spike of rare earth elements (REEs), research on permanent magnet recycling has blossomed globally in an attempt to reduce future REE criticality. Hard disk drives (HDDs) have emerged as one feasible feedstock for recovering valuable REEs such as praseodymium, neodymium, and dysprosium. Nevertheless, current processes for recycling electronic waste only focus on certain metals as a result of feedstock and metal price uncertainties. In addition, there is a perception that recycling REEs is unprofitable. To shed some light on the economic viability of REE recycling from U.S. HDDs, this article combines techno-economic information of an electro-hydrometallurgical process with end-of-life HDD availability in a simulation model. The results showed that adding REE recovery to an HDD base and precious metal recovery process was profitable given current prices. Recovered REEs from U.S. HDDs could meet up to 5.2% rest-of-world (excluding China) neodymium magnet demand. Feedstock, aluminum, and gold prices are key factors to recycling profitability. REEs contributed 13% to the co-recycling profit.

Radiation hardness of β-Ga2O3 metal-oxide-semiconductor field-effect transistors against gamma-ray irradiation

NASA Astrophysics Data System (ADS)

Wong, Man Hoi; Takeyama, Akinori; Makino, Takahiro; Ohshima, Takeshi; Sasaki, Kohei; Kuramata, Akito; Yamakoshi, Shigenobu; Higashiwaki, Masataka

2018-01-01

The effects of ionizing radiation on β-Ga2O3 metal-oxide-semiconductor field-effect transistors (MOSFETs) were investigated. A gamma-ray tolerance as high as 1.6 MGy(SiO2) was demonstrated for the bulk Ga2O3 channel by virtue of weak radiation effects on the MOSFETs' output current and threshold voltage. The MOSFETs remained functional with insignificant hysteresis in their transfer characteristics after exposure to the maximum cumulative dose. Despite the intrinsic radiation hardness of Ga2O3, radiation-induced gate leakage and drain current dispersion ascribed respectively to dielectric damage and interface charge trapping were found to limit the overall radiation hardness of these devices.

Innovations in Advanced Materials and Metals Manufacturing Project (IAM2)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Scott, Elizabeth

This project, under the Jobs and Innovation Accelerator Challenge, Innovations in Advanced Materials and Metals Manufacturing Project, contracted with Cascade Energy to provide a shared energy project manager engineer to work with five different companies throughout the Portland metro grant region to implement ten energy efficiency projects and develop a case study to analyze the project model. As a part of the project, the energy project manager also looked into specific new technologies and methodologies that could change the way energy is consumed by manufacturers—from game-changing equipment and technology to monitor energy use to methodologies that change the way companiesmore » interact and use their machines to reduce energy consumption.« less

New Insights into Hard Phases of CoCrMo Metal-on-Metal Hip Replacements

PubMed Central

Liao, Y.; Pourzal, R.; Stemmer, P.; Wimmer, M.A.; Jacobs, J.J.; Fischer, A.; Marks, L. D.

2012-01-01

The microstructural and mechanical properties of the hard phases in CoCrMo prosthetic alloys in both cast and wrought conditions were examined using transmission electron microscopy and nanoindentation. Besides the known carbides of M23C6-type (M=Cr, Mo, Co) and M6C-type which are formed by either eutectic solidification or precipitation, a new mixed-phase hard constituent has been found in the cast alloys, which is composed of ~100 nm fine grains. The nanosized grains were identified to be mostly of M23C6 type using nano-beam precession electron diffraction, and the chemical composition varied from grain to grain being either Cr- or Co-rich. In contrast, the carbides within the wrought alloy having the same M23C6 structure were homogeneous, which can be attributed to the repeated heating and deformation steps. Nanoindentation measurements showed that the hardness of the hard phase mixture in the cast specimen was ~15.7 GPa, while the M23C6 carbides in the wrought alloy were twice as hard (~30.7 GPa). The origin of the nanostructured hard phase mixture was found to be related to slow cooling during casting. Mixed hard phases were produced at a cooling rate of 0.2 °C/s, whereas single phase carbides were formed at a cooling rate of 50 °C/s. This is consistent with sluggish kinetics and rationalizes different and partly conflicting microstructural results in the literature, and could be a source of variations in the performance of prosthetic devices in-vivo. PMID:22659365

Manufacturing information system

NASA Astrophysics Data System (ADS)

Allen, D. K.; Smith, P. R.; Smart, M. J.

1983-12-01

The size and cost of manufacturing equipment has made it extremely difficult to perform realistic modeling and simulation of the manufacturing process in university research laboratories. Likewise the size and cost factors, coupled with many uncontrolled variables of the production situation has even made it difficult to perform adequate manufacturing research in the industrial setting. Only the largest companies can afford manufacturing research laboratories; research results are often held proprietary and seldom find their way into the university classroom to aid in education and training of new manufacturing engineers. It is the purpose for this research to continue the development of miniature prototype equipment suitable for use in an integrated CAD/CAM Laboratory. The equipment being developed is capable of actually performing production operations (e.g. drilling, milling, turning, punching, etc.) on metallic and non-metallic workpieces. The integrated CAD/CAM Mini-Lab is integrating high resolution, computer graphics, parametric design, parametric N/C parts programmings, CNC machine control, automated storage and retrieval, with robotics materials handling. The availability of miniature CAD/CAM laboratory equipment will provide the basis for intensive laboratory research on manufacturing information systems.

Manufacturing of GLARE Parts and Structures

NASA Astrophysics Data System (ADS)

Sinke, J.

2003-07-01

GLARE is a hybrid material consisting of alternating layers of metal sheets and composite layers, requiring special attention when manufacturing of parts and structures is concerned. On one hand the applicable manufacturing processes for GLARE are limited, on the other hand, due to the constituents and composition of the laminate, it offers new opportunities for production. One of the opportunities is the manufacture of very large skin panels by lay-up techniques. Lay-up techniques are common for full composites, but uncommon for metallic structures. Nevertheless, large GLARE skin panels are made by lay-up processes. In addition, the sequences of forming and laminating processes, that can be selected, offer manufacturing options that are not applicable to metals or full composites. With respect to conventional manufacturing processes, the possibilities for Fibre Metal Laminates in general, are limited. The limits are partly due to the different failure modes, partly due to the properties of the constituents in the laminate. For machining processes: the wear of the cutting tools during machining operations of GLARE stems from the abrasive nature of the glass fibres. For the forming processes: the limited formability, expressed by a small failure strain, is related to the glass fibres. However, although these manufacturing issues may restrict the use of manufacturing processes for FMLs, application of these laminates in aircraft is not hindered.

Experimental study on internal cooling system in hard turning of HCWCI using CBN tools

NASA Astrophysics Data System (ADS)

Ravi, A. M.; Murigendrappa, S. M.

2018-04-01

In recent times, hard turning became most emerging technique in manufacturing processes, especially to cut high hard materials like high chrome white cast iron (HCWCI). Use of Cubic boron nitride (CBN), pCBN and Carbide tools are most appropriate to shear the metals but are uneconomical. Since hard turning carried out in dry condition, lowering the tool wear by minimizing tool temperature is the only solution. Study reveals, no effective cooling systems are available so for in order to enhance the tool life of the cutting tools and to improve machinability characteristics. The detrimental effect of cutting parameters on cutting temperature is generally controlled by proper selections. The objective of this paper is to develop a new cooling system to control tool tip temperature, thereby minimizing the cutting forces and the tool wear rates. The materials chosen for this work was HCWCI and cutting tools are CBN inserts. Intricate cavities were made on the periphery of the tool holder for easy flow of cold water. Taguchi techniques were adopted to carry out the experimentations. The experimental results confirm considerable reduction in the cutting forces and tool wear rates.

A Sensory Material Approach for Reducing Variability in Additively Manufactured Metal Parts.

PubMed

Franco, B E; Ma, J; Loveall, B; Tapia, G A; Karayagiz, K; Liu, J; Elwany, A; Arroyave, R; Karaman, I

2017-06-15

Despite the recent growth in interest for metal additive manufacturing (AM) in the biomedical and aerospace industries, variability in the performance, composition, and microstructure of AM parts remains a major impediment to its widespread adoption. The underlying physical mechanisms, which cause variability, as well as the scale and nature of variability are not well understood, and current methods are ineffective at capturing these details. Here, a Nickel-Titanium alloy is used as a sensory material in order to quantitatively, and rather rapidly, observe compositional and/or microstructural variability in selective laser melting manufactured parts; thereby providing a means to evaluate the role of process parameters on the variability. We perform detailed microstructural investigations using transmission electron microscopy at various locations to reveal the origins of microstructural variability in this sensory material. This approach helped reveal how reducing the distance between adjacent laser scans below a critical value greatly reduces both the in-sample and sample-to-sample variability. Microstructural investigations revealed that when the laser scan distance is wide, there is an inhomogeneity in subgrain size, precipitate distribution, and dislocation density in the microstructure, responsible for the observed variability. These results provide an important first step towards understanding the nature of variability in additively manufactured parts.

Electrodeposition of Nanocrystalline Cobalt Phosphorous Coatings as a Hard Chrome Alternative

DTIC Science & Technology

2014-11-01

1 ASETSDefense 2014 Electrodeposition of Nanocrystalline Cobalt Phosphorous Coatings as a Hard Chrome Alternative Ruben A. Prado, CEF...COVERED 00-00-2014 to 00-00-2014 4. TITLE AND SUBTITLE Electrodeposition of Nanocrystalline Cobalt Phosphorous Coatings as a Hard Chrome Alternative...coatings as a Hard Chrome (EHC) electroplating alternative for DoD manufacturing and repair. – Fully define deposition parameters and properties

Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture

NASA Astrophysics Data System (ADS)

Hehr, Adam; Wenning, Justin; Terrani, Kurt; Babu, Sudarsanam Suresh; Norfolk, Mark

2017-03-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact with the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. It is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.

Five-axis ultrasonic additive manufacturing for nuclear component manufacture

DOE PAGES

Hehr, Adam; Wenning, Justin; Terrani, Kurt A.; ...

2016-01-01

Ultrasonic additive manufacturing (UAM) is a three-dimensional metal printing technology which uses high-frequency vibrations to scrub and weld together both similar and dissimilar metal foils. There is no melting in the process and no special atmosphere requirements are needed. Consequently, dissimilar metals can be joined with little to no intermetallic compound formation, and large components can be manufactured. These attributes have the potential to transform manufacturing of nuclear reactor core components such as control elements for the High Flux Isotope Reactor at Oak Ridge National Laboratory. These components are hybrid structures consisting of an outer cladding layer in contact withmore » the coolant with neutron-absorbing materials inside, such as neutron poisons for reactor control purposes. UAM systems are built into a computer numerical control (CNC) framework to utilize intermittent subtractive processes. These subtractive processes are used to introduce internal features as the component is being built and for net shaping. The CNC framework is also used for controlling the motion of the welding operation. Lastly, it is demonstrated here that curved components with embedded features can be produced using a five-axis code for the welder for the first time.« less

Correction of facial and mandibular asymmetry using a computer aided design/computer aided manufacturing prefabricated titanium implant.

PubMed

Watson, Jason; Hatamleh, Muhanad; Alwahadni, Ahed; Srinivasan, Dilip

2014-05-01

Patients with significant craniofacial asymmetry may have functional problems associated with their occlusion and aesthetic concerns related to the imbalance in soft and hard tissue profiles. This report details a case of facial asymmetry secondary to left mandible angle deficiency due to undergoing previous radiotherapy. We describe the correction of the bony deformity using computer aided design/computer aided manufacturing custom-made titanium onlay using novel direct metal laser sintering. The direct metal laser sintering onlay proved a very accurate operative fit and showed a good aesthetic correction of the bony defect with no reported complications postoperatively. It is a useful low-morbidity technique, and there is no resorption or associated donor-site complications.

Feasibility study of custom manufacturing methods of ionic polymer-metal composite sensors

NASA Astrophysics Data System (ADS)

Nelson, Shelby E.

The ability to create an ion exchange membrane with any shape or thickness through custom manufacturing techniques is highly desirable in ionic polymer-metal composite (IPMC) research. This is caused by the poor selection and limited availability of certain thicknesses of commercial ion exchange membranes. The objective of this study is to determine the feasibility of manufacturing custom ion exchange membranes for IPMC sensors. The manufacturing methods used in this study are extrusion, injection molding, and hot pressing. A commercial membrane from Golden Energy Fuel Cells (GEFC) is used as a comparison. After the membranes are fabricated, certain properties of the membranes are tested throughout each processing stage to determine if they are suitable to be developed into IPMCs. The three processing stages are pre-activation, activation (hydrated and dehydrated), and IPMC. It was observed that the stiffness of the membranes increased from pre-activation to activation and decreased from activation to IPMC. A more flexible membrane in an IPMC allows for larger cation displacement within the membrane. The extruded and injection molded membranes showed the most potential with having the lowest stiffness of all the samples; however, they were not able to be made into IPMCs due to repeated membrane failures in the primary plating process. Gas accumulated between the layers that formed in the membranes due to the extrusion and injection molding cooling process during manufacturing. The hot pressed membrane was the only custom manufactured membrane to be fully processed into an IPMC. The hot pressed and GEFC IPMC sensors were operated at 1 Hz, 5 Hz, and 10 Hz frequencies with the GEFC IPMC producing the strongest output voltage signal. While the extruded and injection molded membranes showed potential to become IPMCs with their high water uptake percentage, high ion exchange capacity, and low stiffness, more development is needed within the manufacturing process to make

A Crossover from High Stiffness to High Hardness: The Case of Osmium and Its Borides

NASA Astrophysics Data System (ADS)

Bian, Yongming; Liu, Xiaomei; Li, Anhu; Liang, Yongcheng

2016-09-01

Transition-metal light-element compounds are currently raising great expectations for hard and superhard materials. Using the widely attracting osmium (Os) and its borides (OsB, Os2B3 and OsB2) as prototypes, we demonstrate by first-principles calculations that heavy transition metals, which possess high stiffness but low hardness, can be converted into highly hard materials by incorporating of light elements to form compounds. Such a crossover is a manifestation that the underlying sources of high stiffness and high hardness are fundamentally different. The stiffness is related to elastic deformation that is closely associated with valence electron density, whereas the hardness depends strongly on plastic deformation that is determined by bonding nature. Therefore, the incorporation of light atoms into transition metal should be a valid pathway of designing hard and superhard materials. This strategy is in principle also applicable to other transition-metal borides, carbides, and nitrides.

Evolution of residual stress, free volume, and hardness in the laser shock peened Ti-based metallic glass

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Liang; Wang, Lu; Nie, Zhihua

Laser shock peening (LSP) with different cycles was performed on the Ti-based bulk metallic glasses (BMGs). The sub-surface residual stress of the LSPed specimens was measured by high-energy X-ray diffraction (HEXRD) and the near-surface residual stress was measured by scanning electron microscope/focused ion beam (SEM/FIB) instrument. The sub-surface residual stress in the LSP impact direction (about-170MPa) is much lower than that perpendicular to the impact direction (about -350 MPa), exhibiting anisotropy. The depth of the compressive stress zone increases from 400 mu m to 500 mu m with increasing LSP cycles. The highest near-surface residual stress is about -750 MPa.more » LSP caused the free volume to increase and the maximum increase appeared after the first LSP process. Compared with the hardness (567 +/- 7 HV) of the as-cast BMG, the hardness (590 +/- 9 HV) on the shocked surface shows a hardening effect due to the hardening mechanism of compressive residual stress; and the hardness (420 +/- 9 HV) on the longitudinal section shows a softening effect due to the softening mechanism of free volume.« less

Microchannel neural interface manufacture by stacking silicone and metal foil laminae

NASA Astrophysics Data System (ADS)

Lancashire, Henry T.; Vanhoestenberghe, Anne; Pendegrass, Catherine J.; Ajam, Yazan Al; Magee, Elliot; Donaldson, Nick; Blunn, Gordon W.

2016-06-01

Objective. Microchannel neural interfaces (MNIs) overcome problems with recording from peripheral nerves by amplifying signals independent of node of Ranvier position. Selective recording and stimulation using an MNI requires good insulation between microchannels and a high electrode density. We propose that stacking microchannel laminae will improve selectivity over single layer MNI designs due to the increase in electrode number and an improvement in microchannel sealing. Approach. This paper describes a manufacturing method for creating MNIs which overcomes limitations on electrode connectivity and microchannel sealing. Laser cut silicone—metal foil laminae were stacked using plasma bonding to create an array of microchannels containing tripolar electrodes. Electrodes were DC etched and electrode impedance and cyclic voltammetry were tested. Main results. MNIs with 100 μm and 200 μm diameter microchannels were manufactured. High electrode density MNIs are achievable with electrodes present in every microchannel. Electrode impedances of 27.2 ± 19.8 kΩ at 1 kHz were achieved. Following two months of implantation in Lewis rat sciatic nerve, micro-fascicles were observed regenerating through the MNI microchannels. Significance. Selective MNIs with the peripheral nervous system may allow upper limb amputees to control prostheses intuitively.

Quantitative Analysis of Electroplated Nickel Coating on Hard Metal

PubMed Central

Wahab, Hassan A.; Noordin, M. Y.; Izman, S.

2013-01-01

Electroplated nickel coating on cemented carbide is a potential pretreatment technique for providing an interlayer prior to diamond deposition on the hard metal substrate. The electroplated nickel coating is expected to be of high quality, for example, indicated by having adequate thickness and uniformity. Electroplating parameters should be set accordingly for this purpose. In this study, the gap distances between the electrodes and duration of electroplating process are the investigated variables. Their effect on the coating thickness and uniformity was analyzed and quantified using design of experiment. The nickel deposition was carried out by electroplating in a standard Watt's solution keeping other plating parameters (current: 0.1 Amp, electric potential: 1.0 V, and pH: 3.5) constant. The gap distance between anode and cathode varied at 5, 10, and 15 mm, while the plating time was 10, 20, and 30 minutes. Coating thickness was found to be proportional to the plating time and inversely proportional to the electrode gap distance, while the uniformity tends to improve at a large electrode gap. Empirical models of both coating thickness and uniformity were developed within the ranges of the gap distance and plating time settings, and an optimized solution was determined using these models. PMID:23997678

Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing.

PubMed

Ly, Sonny; Rubenchik, Alexander M; Khairallah, Saad A; Guss, Gabe; Matthews, Manyalibo J

2017-06-22

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results. Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.

Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A.

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results.more » Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.« less

Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

DOE PAGES

Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A.; ...

2017-06-22

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results.more » Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.« less

Structural characterization of biomedical Co-Cr-Mo components produced by direct metal laser sintering.

PubMed

Barucca, G; Santecchia, E; Majni, G; Girardin, E; Bassoli, E; Denti, L; Gatto, A; Iuliano, L; Moskalewicz, T; Mengucci, P

2015-03-01

Direct metal laser sintering (DMLS) is a technique to manufacture complex functional mechanical parts from a computer-aided design (CAD) model. Usually, the mechanical components produced by this procedure show higher residual porosity and poorer mechanical properties than those obtained by conventional manufacturing techniques. In this work, a Co-Cr-Mo alloy produced by DMLS with a composition suitable for biomedical applications was submitted to hardness measurements and structural characterization. The alloy showed a hardness value remarkably higher than those commonly obtained for the same cast or wrought alloys. In order to clarify the origin of this unexpected result, the sample microstructure was investigated by X-ray diffraction (XRD), electron microscopy (SEM and TEM) and energy dispersive microanalysis (EDX). For the first time, a homogeneous microstructure comprised of an intricate network of thin ε (hcp)-lamellae distributed inside a γ (fcc) phase was observed. The ε-lamellae grown on the {111}γ planes limit the dislocation slip inside the γ (fcc) phase, causing the measured hardness increase. The results suggest possible innovative applications of the DMLS technique to the production of mechanical parts in the medical and dental fields. Copyright © 2014 Elsevier B.V. All rights reserved.

A Novel Approach to Hardness Testing

NASA Technical Reports Server (NTRS)

Spiegel, F. Xavier; West, Harvey A.

1996-01-01

This paper gives a description of the application of a simple rebound time measuring device and relates the determination of relative hardness of a variety of common engineering metals. A relation between rebound time and hardness will be sought. The effect of geometry and surface condition will also be discussed in order to acquaint the student with the problems associated with this type of method.

Economic assessment for recycling critical metals from hard disk drives using a comprehensive recovery process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nguyen, Ruby Thuy; Diaz, Luis A.; Imholte, D. Devin

Since the 2011 price spike of rare earth elements (REEs), research on permanent magnet recycling has blossomed globally to reduce future REE criticality. Hard disk drives (HDDs) have emerged as one feasible feedstock for recovering valuable REEs such as praseodymium, neodymium, and dysprosium. However, current processes for recycling e-waste only focus on certain metals due to feedstock and metal price uncertainties. In addition, some believe that recycling REEs is unprofitable. To shed some light on the economic viability of REE recycling from HDDs, this paper combines techno-economic information of a hydrometallurgical process with end-of-life HDD availability in a simulation model.more » Results showed that adding REEs to HDD recycling was profitable given current prices. As a result, recovered REEs could meet up to 5.1% rest of world (excluding China) magnet demand. Aluminum, gold, copper scrap and REEs were the primary main revenue streams from HDD recycling.« less

Economic assessment for recycling critical metals from hard disk drives using a comprehensive recovery process

DOE PAGES

Nguyen, Ruby Thuy; Diaz, Luis A.; Imholte, D. Devin; ...

2017-06-05

Since the 2011 price spike of rare earth elements (REEs), research on permanent magnet recycling has blossomed globally to reduce future REE criticality. Hard disk drives (HDDs) have emerged as one feasible feedstock for recovering valuable REEs such as praseodymium, neodymium, and dysprosium. However, current processes for recycling e-waste only focus on certain metals due to feedstock and metal price uncertainties. In addition, some believe that recycling REEs is unprofitable. To shed some light on the economic viability of REE recycling from HDDs, this paper combines techno-economic information of a hydrometallurgical process with end-of-life HDD availability in a simulation model.more » Results showed that adding REEs to HDD recycling was profitable given current prices. As a result, recovered REEs could meet up to 5.1% rest of world (excluding China) magnet demand. Aluminum, gold, copper scrap and REEs were the primary main revenue streams from HDD recycling.« less

Ultrasonic material hardness depth measurement

DOEpatents

Good, M.S.; Schuster, G.J.; Skorpik, J.R.

1997-07-08

The invention is an ultrasonic surface hardness depth measurement apparatus and method permitting rapid determination of hardness depth of shafts, rods, tubes and other cylindrical parts. The apparatus of the invention has a part handler, sensor, ultrasonic electronics component, computer, computer instruction sets, and may include a display screen. The part handler has a vessel filled with a couplant, and a part rotator for rotating a cylindrical metal part with respect to the sensor. The part handler further has a surface follower upon which the sensor is mounted, thereby maintaining a constant distance between the sensor and the exterior surface of the cylindrical metal part. The sensor is mounted so that a front surface of the sensor is within the vessel with couplant between the front surface of the sensor and the part. 12 figs.

Correlation of impression removal force with elastomeric impression material rigidity and hardness.

PubMed

Walker, Mary P; Alderman, Nick; Petrie, Cynthia S; Melander, Jennifer; McGuire, Jacob

2013-07-01

Difficult impression removal has been linked to high rigidity and hardness of elastomeric impression materials. In response to this concern, manufacturers have reformulated their materials to reduce rigidity and hardness to decrease removal difficulty; however, the relationship between impression removal and rigidity or hardness has not been evaluated. The purpose of this study was to determine if there is a positive correlation between impression removal difficulty and rigidity or hardness of current elastomeric impression materials. Light- and medium-body polyether (PE), vinylpolysiloxane (VPS), and hybrid vinyl polyether siloxane (VPES) impression materials were tested (n = 5 for each material/consistency/test method). Rigidity (elastic modulus) was measured via tensile testing of dumbbell-shaped specimens (Die C, ASTM D412). Shore A hardness was measured using disc specimens according to ASTM D2240-05 test specifications. Impressions were also made of a custom stainless steel model using a custom metal tray that could be attached to a universal tester to measure associated removal force. Within each impression material consistency, one-factor ANOVA and Tukey's post hoc analyses (α = 0.05) were used to compare rigidity, hardness, and removal force of the three types of impression materials. A Pearson's correlation (α = 0.05) was used to evaluate the association between impression removal force and rigidity or hardness. With medium-body materials, VPS exhibited significantly higher (p ≤ 0.05) rigidity and hardness than VPES or PE, while PE impressions required significantly higher (p ≤ 0.05) removal force than VPS or VPES impressions. With light-body materials, VPS again demonstrated significantly higher (p ≤ 0.05) hardness than VPES or PE, while the rigidity of the light-body materials did not significantly differ between materials (p > 0.05); however, just as with the medium-body materials, light-body PE impressions required significantly higher (p �

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

NASA Astrophysics Data System (ADS)

Yang, Nancy; Yee, J.; Zheng, B.; Gaiser, K.; Reynolds, T.; Clemon, L.; Lu, W. Y.; Schoenung, J. M.; Lavernia, E. J.

2017-04-01

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. The study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. The study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. The current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

Bond-orientational analysis of hard-disk and hard-sphere structures.

PubMed

Senthil Kumar, V; Kumaran, V

2006-05-28

We report the bond-orientational analysis results for the thermodynamic, random, and homogeneously sheared inelastic structures of hard-disks and hard-spheres. The thermodynamic structures show a sharp rise in the order across the freezing transition. The random structures show the absence of crystallization. The homogeneously sheared structures get ordered at a packing fraction higher than the thermodynamic freezing packing fraction, due to the suppression of crystal nucleation. On shear ordering, strings of close-packed hard-disks in two dimensions and close-packed layers of hard-spheres in three dimensions, oriented along the velocity direction, slide past each other. Such a flow creates a considerable amount of fourfold order in two dimensions and body-centered-tetragonal (bct) structure in three dimensions. These transitions are the flow analogs of the martensitic transformations occurring in metals due to the stresses induced by a rapid quench. In hard-disk structures, using the bond-orientational analysis we show the presence of fourfold order. In sheared inelastic hard-sphere structures, even though the global bond-orientational analysis shows that the system is highly ordered, a third-order rotational invariant analysis shows that only about 40% of the spheres have face-centered-cubic (fcc) order, even in the dense and near-elastic limits, clearly indicating the coexistence of multiple crystalline orders. When layers of close-packed spheres slide past each other, in addition to the bct structure, the hexagonal-close-packed (hcp) structure is formed due to the random stacking faults. Using the Honeycutt-Andersen pair analysis and an analysis based on the 14-faceted polyhedra having six quadrilateral and eight hexagonal faces, we show the presence of bct and hcp signatures in shear ordered inelastic hard-spheres. Thus, our analysis shows that the dense sheared inelastic hard-spheres have a mixture of fcc, bct, and hcp structures.

Additive Manufacturing and Characterization of Polylactic Acid (PLA) Composites Containing Metal Reinforcements

NASA Technical Reports Server (NTRS)

Kuentz, Lily; Salem, Anton; Singh, M.; Halbig, M. C.; Salem, J. A.

2016-01-01

Additive manufacturing of polymeric systems using 3D printing has become quite popular recently due to rapid growth and availability of low cost and open source 3D printers. Two widely used 3D printing filaments are based on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) systems. PLA is much more environmentally friendly in comparison to ABS since it is made from renewable resources such as corn, sugarcane, and other starches as precursors. Recently, polylactic acid-based metal powder containing composite filaments have emerged which could be utilized for multifunctional applications. The composite filaments have higher density than pure PLA, and the majority of the materials volume is made up of polylactic acid. In order to utilize functionalities of composite filaments, printing behavior and properties of 3-D printed composites need to be characterized and compared with the pure PLA materials. In this study, pure PLA and composite specimens with different metallic reinforcements (Copper, Bronze, Tungsten, Iron, etc) were 3D printed at various layer heights and resulting microstructures and properties were characterized. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) behavior of filaments with different reinforcements were studied. The microscopy results show an increase in porosity between 3-D printed regular PLA and the metal composite PLA samples, which could produce weaker mechanical properties in the metal composite materials. Tensile strength and fracture toughness behavior of specimens as a function of print layer height will be presented.

Study of metallic powder behavior in very low pressure plasma spraying (VLPPS) — Application to the manufacturing of titanium–aluminum coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vautherin, B.; Planche, M.-P.; Montavon, G.

2015-08-28

In this study, metallic materials made of aluminum and titanium were manufactured implementing very low pressure plasma spraying (VLPPS). Aluminum was selected at first as a demonstrative material due to its rather low vaporization enthalpy ( i.e., 381.9 kJ·mol⁻¹). Developments were then carried out with titanium which exhibits a higher vaporization enthalpy ( i.e., 563.6 kJ·mol⁻¹). Optical emission spectroscopy (OES) was implemented to analyze the behavior of each solid precursor (metallic powders) when it is injected into the plasma jet under very low pressure ( i.e., in the 150 Pa range). Besides, aluminum, titanium and titanium–aluminum coatings were deposited inmore » the same conditions implementing a stick-cathode plasma torch operated at 50 kW, maximum power. Coating phase compositions were identified by X-Ray Diffraction (XRD). Coating elementary compositions were quantified by Glow Discharge Optical Emission Spectroscopy (GDOES) and Energy Dispersive Spectroscopy (EDS) analyses. The coating structures were observed by Scanning Electron Microscopy (SEM). The coating void content was determined by Ultra-Small Angle X-ray Scattering (USAXS). The coatings exhibit a two-scale structure corresponding to condensed vapors (smaller scale) and solidified areas (larger scale). Titanium–aluminum sprayed coatings, with various Ti/Al atomic ratios, are constituted of three phases: metastable α-Ti, Al and metastable α₂-Ti₃Al. This latter is formed at elevated temperature in the plasma flow, before being condensed. Its rather small fraction, impeded by the rather small amount of vaporized Ti, does not allow modifying however the coating hardness.« less

Scalable Manufacturing of Metal Micro/Nanowires and Applications by Thermal Fiber Drawing Method

NASA Astrophysics Data System (ADS)

Hwang, Injoo

The objective of this study is to better understand the fundamental principal of the thermal fiber drawing process with metal-core preforms. This would enable us to overcome the fundamental limits of current thermal drawing techniques by tuning material properties of core metals and interactions between core and cladding materials using nanoparticles. Metal micro/nanowires with controlled size, aspect ratio and spatial configurations of core and cladding materials exhibit extraordinary mechanical, thermal, electrical and optical properties. These metal micro/nanowires can be utilized for widespread applications such as: thermoelectric, conductive electrode and plasmonic photonic crystal fibers. Thermal fiber drawing method has emerged as an advanced scalable manufacturing technique for micro/nanowires production due to its unique characteristics that allow mass production of continuous and arbitrary designed wires. It is of tremendous scientific and technical interests to conduct a fundamental study on thermal fiber drawing methods and to break the current limits of the crystalline metal core thermal fiber drawing process. In this study, metal core was fabricated by cold compaction of the Zinc (Zn)-Tungsten Carbide (WC) nanopowders. Our characterizations through scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) showed that WC nanoparticle are uniformly dispersed in Zn matrix. The effects of WC nanoparticles on the mechanical properties and degradation rate in Zn-WC nanocomposites were carefully analyzed by tensile, compressive, hardness, degradation and viscosity tests. Metallic stents are commonly used to expand blood vessels that have been narrowed by plaque buildup (atherosclerosis). Fabrication difficulty and other constrains of metallic stents result in high cost. Zn-WC nanocomposite microwires were controllably drawn for stent struts with a diameter of 200 ?m. Characterizations by the tensile and degradation tests of Zn

Development of in-Situ Al-Si/CuAl₂ Metal Matrix Composites: Microstructure, Hardness, and Wear Behavior.

PubMed

Tash, Mahmoud M; Mahmoud, Essam R I

2016-06-02

In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15%) into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD) pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl₂, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl₂ at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature.

Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts.

PubMed

Alfieri, Vittorio; Argenio, Paolo; Caiazzo, Fabrizia; Sergi, Vincenzo

2016-12-31

Optimization of processing parameters and exposure strategies is usually performed in additive manufacturing to set up the process; nevertheless, standards for roughness may not be evenly matched on a single complex part, since surface features depend on the building direction of the part. This paper aims to evaluate post processing treating via laser surface modification by means of scanning optics and beam wobbling to process metal parts resulting from selective laser melting of stainless steel in order to improve surface topography. The results are discussed in terms of roughness, geometry of the fusion zone in the cross-section, microstructural modification, and microhardness so as to assess the effects of laser post processing. The benefits of beam wobbling over linear scanning processing are shown, as heat effects in the base metal are proven to be lower.

In vitro expression of hard metal dust (WC-Co) - responsive genes in human peripheral blood mononucleated cells

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lombaert, Nooemi; Lison, Dominique; Van Hummelen, Paul

Hard metals consist of tungsten carbide (WC) and metallic cobalt (Co) particles and are important industrial materials produced for their extreme hardness and high wear resistance properties. While occupational exposure to metallic Co alone is apparently not associated with an increased risk of cancer, the WC-Co particle mixture was shown to be carcinogenic in exposed workers. The in vitro mutagenic/apoptogenic potential of WC-Co in human peripheral blood mononucleated cells was previously demonstrated by us. This study aimed at obtaining a broader view of the pathways responsible for WC-Co induced carcinogenicity, and in particular genotoxicity and apoptosis. We analyzed the profilemore » of gene expression induced in vitro by WC-Co versus control (24 h treatment) in human PBMC and monocytes using microarrays. The most significantly up-regulated pathways for WC-Co treated PBMC were apoptosis and stress/defense response; the most down-regulated was immune response. For WC-Co treated monocytes the most significantly up- and down-regulated pathways were nucleosome/chromatin assembly and immune response respectively. Quantitative RT-PCR data for a selection of the most strongly modulated genes (HMOX1, HSPA1A, HSPA1L, BNIP3, BNIP3L, ADORA2B, MT3, PLA2G7, TNFAIP6), and some additionally chosen apoptosis related genes (BCL2, BAX, FAS, FASL, TNF{alpha}), confirmed the microarray data after WC-Co exposure and demonstrated limited differences between the Co-containing compounds. Overall, this study provides the first analysis of gene expression induced by the WC-Co mixture showing a large profile of gene modulation and giving a preliminary indication for a hypoxia mimicking environment induced by WC-Co exposure.« less

Further studies on gold alloys used in fabrication of porcelain-fused-to-metal restorations.

PubMed

Civjan, S; Huget, E F; Dvivedi, N; Cosner, H J

1975-03-01

Composition, microstructure, castability, mechanical properties, and heat treatment characteristics of two gold-palladium-silver-based alloys were studied. The materials exhibited compositional as well as microstructural differences. Clinically acceptable castings could not be obtained when manufacturers' recommended casting temperatures were used. Ultimate tensile strength, yield strength, modulus of elasticity, and Brinell hardness values for the alloys were comparable. The elastic limit of Cameo, however, was significantly higher than that of vivo-star. Maximum rehardening of annealed castings occurred on reheat treatment at temperatures between 1,200 and 1,300 F. As-cast specimens, however, were not heat hardenable. The sequence of heat treatments used in the application of porcelain reduced slightly the hardness of both alloys. Hardness of the metal substructures was not increased by return of porcelain-coated specimens to a 1,250 F oven for final heat treatment.

Fully Disposable Manufacturing Concepts for Clinical and Commercial Manufacturing and Ballroom Concepts.

PubMed

Boedeker, Berthold; Goldstein, Adam; Mahajan, Ekta

2017-11-04

The availability and use of pre-sterilized disposables has greatly changed the methods used in biopharmaceuticals development and production, particularly from mammalian cell culture. Nowadays, almost all process steps from cell expansion, fermentation, cell removal, and purification to formulation and storage of drug substances can be carried out in disposables, although there are still limitations with single-use technologies, particularly in the areas of pretesting and quality control of disposables, bag and connections standardization and qualification, extractables and leachables (E/L) validation, and dependency on individual vendors. The current status of single-use technologies is summarized for all process unit operations using a standard mAb process as an example. In addition, current pros and cons of using disposables are addressed in a comparative way, including quality control and E/L validation.The continuing progress in developing single-use technologies has an important impact on manufacturing facilities, resulting in much faster, less expensive and simpler plant design, start-up, and operation, because cell culture process steps are no longer performed in hard-piped unit operations. This leads to simpler operations in a lab-like environment. Overall it enriches the current landscape of available facilities from standard hard-piped to hard-piped/disposables hybrid to completely single-use-based production plants using the current segregation and containment concept. At the top, disposables in combination with completely and functionally closed systems facilitate a new, revolutionary design of ballroom facilities without or with much less segregation, which enables us to perform good manufacturing practice manufacturing of different products simultaneously in unclassified but controlled areas.Finally, single-use processing in lab-like shell facilities is a big enabler of transferring and establishing production in emergent countries, and this is

ADVANCED MANUFACTURING TEAM

NASA Image and Video Library

2016-03-17

JOHNNIE CLARK, BRIAN WEST, AND ZACK JONES OF MSFC’S ADVANCED MANUFACTURING TEAM, WITH MSFC’S XLINE SELECTIVE LASER MELTING SYSTEM. CURRENTLY ONE OF THE LARGEST METAL 3D PRINTERS, THE XLINE AT MARSHALL IS BEING USED TO DEVELOP AND CERTIFY NICKEL ALLOY 718 MATERIAL PROPERTIES AND LARGE MANUFACTURING TECH DEMOS FOR THE RS25 ENGINE AND THE COMMERCIAL CREWED VEHICLE PROJECTS.

Plasma Processing Systems for the Manufacture of Refractory Metals and their Alloys for Military Needs

DTIC Science & Technology

1978-10-09

melting point is around 4000*K. An exceedingly interesting feature of these solidification composites is the formation of fibrous MC type carbide ...the matrix could be refractory metal binary alloys with copper or uranium and the eutectic phase could be carbide of tungsten, * molybdenum, tantalum or...42 Accs -n or - *DTTI Tf Avn ! -7ll ’ i CrDi t , l’’*i,;. LIST OF FIGURES FIG. 1 Flow Diagram of Cemented Carbide Manufacture

Rad-Hard/HI-REL FPGA

NASA Technical Reports Server (NTRS)

Wang, Jih-Jong; Cronquist, Brian E.; McGowan, John E.; Katz, Richard B.

1997-01-01

The goals for a radiation hardened (RAD-HARD) and high reliability (HI-REL) field programmable gate array (FPGA) are described. The first qualified manufacturer list (QML) radiation hardened RH1280 and RH1020 were developed. The total radiation dose and single event effects observed on the antifuse FPGA RH1280 are reported on. Tradeoffs and the limitations in the single event upset hardening are discussed.

Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Roehling, Tien T.; Wu, Sheldon S. Q.; Khairallah, Saad A.

Additively manufactured (AM) metals are often highly textured, containing large columnar grains that initiate epitaxially under steep temperature gradients and rapid solidification conditions. These unique microstructures partially account for the massive property disparity existing between AM and conventionally processed alloys. Although equiaxed grains are desirable for isotropic mechanical behavior, the columnar-to-equiaxed transition remains difficult to predict for conventional solidification processes, and much more so for AM. In this study, the effects of laser intensity profile ellipticity on melt track macrostructures and microstructures were studied in 316L stainless steel. Experimental results were supported by temperature gradients and melt velocities simulated usingmore » the ALE3D multi-physics code. As a general trend, columnar grains preferentially formed with increasing laser power and scan speed for all beam profiles. However, when conduction mode laser heating occurs, scan parameters that result in coarse columnar microstructures using Gaussian profiles produce equiaxed or mixed equiaxed-columnar microstructures using elliptical profiles. Furthermore, by modulating spatial laser intensity profiles on the fly, site-specific microstructures and properties can be directly engineered into additively manufactured parts.« less

Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

DOE PAGES

Roehling, Tien T.; Wu, Sheldon S. Q.; Khairallah, Saad A.; ...

2017-02-12

Additively manufactured (AM) metals are often highly textured, containing large columnar grains that initiate epitaxially under steep temperature gradients and rapid solidification conditions. These unique microstructures partially account for the massive property disparity existing between AM and conventionally processed alloys. Although equiaxed grains are desirable for isotropic mechanical behavior, the columnar-to-equiaxed transition remains difficult to predict for conventional solidification processes, and much more so for AM. In this study, the effects of laser intensity profile ellipticity on melt track macrostructures and microstructures were studied in 316L stainless steel. Experimental results were supported by temperature gradients and melt velocities simulated usingmore » the ALE3D multi-physics code. As a general trend, columnar grains preferentially formed with increasing laser power and scan speed for all beam profiles. However, when conduction mode laser heating occurs, scan parameters that result in coarse columnar microstructures using Gaussian profiles produce equiaxed or mixed equiaxed-columnar microstructures using elliptical profiles. Furthermore, by modulating spatial laser intensity profiles on the fly, site-specific microstructures and properties can be directly engineered into additively manufactured parts.« less

Reduction of Surface Roughness by Means of Laser Processing over Additive Manufacturing Metal Parts

PubMed Central

Alfieri, Vittorio; Argenio, Paolo; Caiazzo, Fabrizia; Sergi, Vincenzo

2016-01-01

Optimization of processing parameters and exposure strategies is usually performed in additive manufacturing to set up the process; nevertheless, standards for roughness may not be evenly matched on a single complex part, since surface features depend on the building direction of the part. This paper aims to evaluate post processing treating via laser surface modification by means of scanning optics and beam wobbling to process metal parts resulting from selective laser melting of stainless steel in order to improve surface topography. The results are discussed in terms of roughness, geometry of the fusion zone in the cross-section, microstructural modification, and microhardness so as to assess the effects of laser post processing. The benefits of beam wobbling over linear scanning processing are shown, as heat effects in the base metal are proven to be lower. PMID:28772380

Correlation between the sub-structure parameters and the manufacturing technologies of metal threads in historical textiles using X-ray line profile analysis

NASA Astrophysics Data System (ADS)

Csiszár, Gábor; Ungár, Tamás; Járó, Márta

2013-06-01

Micro-structure can talk when documentation is missing. In ancient Roman or medieval periods, kings, queens, or just rich people decorated their clothes or even their horse covers richly with miniature jewels or metal threads. The origin or the fabrication techniques of these ancient threads is often unknown. Thirteen thread samples made of gold or gilt silver manufactured during the last sixteen hundred years are investigated for the micro-structure in terms of dislocation density, crystallite size, and planar defects. In a few cases, these features are compared with sub-structure of similar metallic threads prepared in modern, twentieth century workshops. The sub-structure is determined by X-ray line profile analysis, using high resolution diffractograms with negligible instrumental broadening. On the basis of the sub-structure parameters, we attempt to assess the metal-threads manufacturing procedures on samples stemming from the fourth century A.D. until now.

Short-term acute hypercapnia affects cellular responses to trace metals in the hard clams Mercenaria mercenaria.

PubMed

Ivanina, Anna V; Beniash, Elia; Etzkorn, Markus; Meyers, Tiffany B; Ringwood, Amy H; Sokolova, Inna M

2013-09-15

Estuarine and coastal habitats experience large fluctuations of environmental factors such as temperature, salinity, partial pressure of CO2 ( [Formula: see text] ) and pH; they also serve as the natural sinks for trace metals. Benthic filter-feeding organisms such as bivalves are exposed to the elevated concentrations of metals in estuarine water and sediments that can strongly affect their physiology. The effects of metals on estuarine organisms may be exacerbated by other environmental factors. Thus, a decrease in pH caused by high [Formula: see text] (hypercapnia) can modulate the effects of trace metals by affecting metal bioavailability, accumulation or binding. To better understand the cellular mechanisms of interactions between [Formula: see text] and trace metals in marine bivalves, we exposed isolated mantle cells of the hard clams (Mercenaria mercenaria) to different levels of [Formula: see text] (0.05, 1.52 and 3.01 kPa) and two major trace metal pollutants - cadmium (Cd) and copper (Cu). Elevated [Formula: see text] resulted in a decrease in intracellular pH (pHi) of the isolated mantle cells from 7.8 to 7.4. Elevated [Formula: see text] significantly but differently affected the trace metal accumulation by the cells. Cd uptake was suppressed at elevated [Formula: see text] levels while Cu accumulation has greatly accelerated under hypercapnic conditions. Interestingly, at higher extracellular Cd levels, labile intracellular Cd(2+) concentration remained the same, while intracellular levels of free Zn(2+) increased suggesting that Cd(2+) substitutes bound Zn(2+) in these cells. In contrast, Cu exposure did not affect intracellular Zn(2+) but led to a profound increase in the intracellular levels of labile Cu(2+) and Fe(2+). An increase in the extracellular concentrations of Cd and Cu led to the elevated production of reactive oxygen species under the normocapnic conditions (0.05 kPa [Formula: see text] ); surprisingly, this effect was mitigated in

Optimization of heat treatment parameters for additive manufacturing and gravity casting AlSi10Mg alloy

NASA Astrophysics Data System (ADS)

Girelli, L.; Tocci, M.; Montesano, L.; Gelfi, M.; Pola, A.

2017-11-01

Additive manufacturing of metals is a production process developed in the last few years to realize net shape components with complex geometry and high performance. AlSi10Mg is one of the most widely used aluminium alloys, both in this field and in conventional foundry processes, for its significant mechanical properties combined with good corrosion resistance. In this paper the effect of heat treatment on AlSi10Mg alloy was investigated. Solution and ageing treatments were carried out with different temperatures and times on samples obtained by direct metal laser sintering and gravity casting in order to compare their performance. Microstructural analyses and hardness tests were performed to investigate the effectiveness of the heat treatment. The results were correlated to the sample microstructure and porosity, analysed by means of optical microscopy and density measurements. It was found that, in the additive manufactured samples, the heat treatment can reduce significantly the performance of the alloy also because of the increase of porosity due to entrapped gas during the deposition technique and that the higher the solution temperature the higher the increase of such defects. A so remarkable effect was not found in the conventional cast alloy.

The effect of three whitening oral rinses on enamel micro-hardness.

PubMed

Potgieter, E; Osman, Y; Grobler, S R

2014-05-01

The purpose of this study was to determine the effect on human enamel micro-hardness of three over-the-counter whitening oral rinses available in South Africa. Enamel fragments were gathered into three groups of 15 each. One group was exposed to Colgate Plax Whitening Blancheur, the second group to White Glo 2 in 1 and the third to Plus White, in each case for periods recommended by the respective manufacturers. Surface micro-hardness of all groups was measured before and after a 14 day treatment period. pH levels of the oral rinses were also determined with a combination pH electrode. Pre- and post- treatment data were analysed by the Wilcoxon Signed Rank Sum Test. According to the micro-hardness values no significant (p > 0.05) enamel damage was found as a result of treatment. However, it was observed that Colgate Pax and White Glo decreased the enamel hardness, an early sign of enamel damage, while Plus White showed a small increase in hardness. The three whitening oral rinses on the South African market do not damage the tooth enamel significantly when used as recommended by the manufacturers. However, extending the contact period and increasing the frequency of application might lead to damage of enamel.

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives

PubMed Central

Cano, Santiago

2018-01-01

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented. PMID:29783705

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives.

PubMed

Gonzalez-Gutierrez, Joamin; Cano, Santiago; Schuschnigg, Stephan; Kukla, Christian; Sapkota, Janak; Holzer, Clemens

2018-05-18

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

Improvement of hot-carrier and radiation hardnesses in metal-oxide-nitride-oxide semiconductor devices by irradiation-then-anneal treatments

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chang-Liao, K.S.; Hwu, J.G.

The hardnesses of hot-carrier and radiation of metal-oxide nitride-oxide semiconductor (MONOS) devices can be improved by the irradiation-then-anneal (ITA) treatments. Each treatment includes an irradiation of Co-60 with a total dose of 1M rads(SiO[sub 2]) and an anneal in N[sub 2] at 400 C for 10 min successively. This improvement can be explained by the release of SiO[sub 2]/Si interfacial strain.

Effect of magneto rheological damper on tool vibration during hard turning

NASA Astrophysics Data System (ADS)

Paul, P. Sam; Varadarajan, A. S.

2012-12-01

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yang, Nancy; Yee, J.; Zheng, B.

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE PAGES

Yang, Nancy; Yee, J.; Zheng, B.; ...

2016-12-08

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Experimental Investigation of White Layer formation in Hard Turning

NASA Astrophysics Data System (ADS)

Umbrello, D.; Rotella, G.; Crea, F.

2011-05-01

Hard turning with super hard cutting tools, like PCBN or Ceramics inserts, represents an interesting advance in the manufacturing industry, regarding the finishing of hardened steels. This innovative machining technique is considered an attractive alternative to traditional finish grinding operations because of the high flexibility, the ability to achieve higher metal removal rates, the possibility to operate without the use of coolants, and the capability to achieve comparable workpiece quality. However, the surface integrity effects of hard machining need to be taken into account due to their influence on the life of machined components. In particular, the formation of a usually undesirable white layer at the surface needs further investigation. Three different mechanisms have been proposed as main responsible of the white layer genesis: (i) microstructural phase transformation due to a rapid heating and quenching, (ii) severe plastic deformation resulting in a homogenous structure and/or a very fine grain size microstructure; (iii) surface reaction with the environment. In this research, an experimental campaign was carried out and several experimental techniques were used in order to analyzed the machined surface and to understand which of the above mentioned theories is the main cause of the white layer formation when AISI 52100 hardened steel is machined by PCBN inserts. In particular, the topography characterization has obtained by means of optical and scanning electron microscope (SEM) while microstructural phase composition and chemical characterization have been respectively detected using X-ray Diffraction (XRD) and Energy-dispersive X-ray spectroscopy (EDS) techniques. The results prove that the white layer is the result of microstructural alteration, i.e. the generation of a martensitic structure.

3D FE simulation of semi-finishing machining of Ti6Al4V additively manufactured by direct metal laser sintering

NASA Astrophysics Data System (ADS)

Imbrogno, Stano; Rinaldi, Sergio; Raso, Antonio; Bordin, Alberto; Bruschi, Stefania; Umbrello, Domenico

2018-05-01

The Additive Manufacturing techniques are gaining more and more interest in various industrial fields due to the possibility of drastically reduce the material waste during the production processes, revolutionizing the standard scheme and strategies of the manufacturing processes. However, the metal parts shape produced, frequently do not satisfy the tolerances as well as the surface quality requirements. During the design phase, the finite element simulation results a fundamental tool to help the engineers in the correct decision of the most suitable process parameters, especially in manufacturing processes, in order to produce products of high quality. The aim of this work is to develop a 3D finite element model of semi-finishing turning operation of Ti6Al4V, produced via Direct Metal Laser Sintering (DMLS). A customized user sub-routine was built-up in order to model the mechanical behavior of the material under machining operations to predict the main fundamental variables as cutting forces and temperature. Moreover, the machining induced alterations are also studied by the finite element model developed.

Measurement of electromagnetic properties of powder and solid metal materials for additive manufacturing

NASA Astrophysics Data System (ADS)

Todorov, Evgueni Iordanov

2017-04-01

The lack of validated nondestructive evaluation (NDE) techniques for examination during and after additive manufacturing (AM) component fabrication is one of the obstacles in the way of broadening use of AM for critical applications. Knowledge of electromagnetic properties of powder (e.g. feedstock) and solid AM metal components is necessary to evaluate and deploy electromagnetic NDE modalities for examination of AM components. The objective of this research study was to develop and implement techniques for measurement of powder and solid metal electromagnetic properties. Three materials were selected - Inconel 625, duplex stainless steel 2205, and carbon steel 4140. The powder properties were measured with alternate current (AC) model based eddy current technique and direct current (DC) resistivity measurements. The solid metal properties were measured with DC resistivity measurements, DC magnetic techniques, and AC model based eddy current technique. Initial magnetic permeability and electrical conductivity were acquired for both powder and solid metal. Additional magnetic properties such as maximum permeability, coercivity, retentivity, and others were acquired for 2205 and 4140. Two groups of specimens were tested along the build length and width respectively to investigate for possible anisotropy. There was no significant difference or anisotropy when comparing measurements acquired along build length to those along the width. A trend in AC measurements might be associated with build geometry. Powder electrical conductivity was very low and difficult to estimate reliably with techniques used in the study. The agreement between various techniques was very good where adequate comparison was possible.

Biocompatibility of Advanced Manufactured Titanium Implants-A Review.

PubMed

Sidambe, Alfred T

2014-12-19

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

PubMed Central

Sidambe, Alfred T.

2014-01-01

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy. PMID:28788296

Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays.

PubMed

Murr, L E; Gaytan, S M; Medina, F; Lopez, H; Martinez, E; Machado, B I; Hernandez, D H; Martinez, L; Lopez, M I; Wicker, R B; Bracke, J

2010-04-28

In this paper, we examine prospects for the manufacture of patient-specific biomedical implants replacing hard tissues (bone), particularly knee and hip stems and large bone (femoral) intramedullary rods, using additive manufacturing (AM) by electron beam melting (EBM). Of particular interest is the fabrication of complex functional (biocompatible) mesh arrays. Mesh elements or unit cells can be divided into different regions in order to use different cell designs in different areas of the component to produce various or continually varying (functionally graded) mesh densities. Numerous design elements have been used to fabricate prototypes by AM using EBM of Ti-6Al-4V powders, where the densities have been compared with the elastic (Young) moduli determined by resonant frequency and damping analysis. Density optimization at the bone-implant interface can allow for bone ingrowth and cementless implant components. Computerized tomography (CT) scans of metal (aluminium alloy) foam have also allowed for the building of Ti-6Al-4V foams by embedding the digital-layered scans in computer-aided design or software models for EBM. Variations in mesh complexity and especially strut (or truss) dimensions alter the cooling and solidification rate, which alters the alpha-phase (hexagonal close-packed) microstructure by creating mixtures of alpha/alpha' (martensite) observed by optical and electron metallography. Microindentation hardness measurements are characteristic of these microstructures and microstructure mixtures (alpha/alpha') and sizes.

Integration of Heat Treatment with Shot Peening of 17-4 Stainless Steel Fabricated by Direct Metal Laser Sintering

NASA Astrophysics Data System (ADS)

AlMangour, Bandar; Yang, Jenn-Ming

2017-11-01

Direct metal laser sintering (DMLS) is a promising powder-based additive manufacturing process for fabrication of near-net-shape parts. However, the typically poor fatigue performance of DMLS parts must be addressed for use in demanding industrial applications. Post-treatment can be applied to enhance the performance of such components. Earlier attempts at inducing grain refinement through severe plastic deformation of part surfaces using shot peening improved the physical and mechanical properties of metals without chemical alteration. However, heat treatment can modify the surface-hardening effects attained by shot peening. Hence, we examined the feasibility of applying shot peening combined with heat treatment to improve the performance of DMLS-fabricated 17-4 stainless steel parts through microstructural evolution studies and hardness measurements. Compared to a specimen treated only by shot peening, the sample exposed to additional heat treatment showed increased hardness due to aging of the dominant phase.

Electronic transport properties of 4f shell elements of liquid metal using hard sphere Yukawa system

NASA Astrophysics Data System (ADS)

Patel, H. P.; Sonvane, Y. A.; Thakor, P. B.

2018-04-01

The electronic transport properties are analyzed for 4f shell elements of liquid metals. To examine the electronic transport properties like electrical resistivity (ρ), thermal conductivity (σ) and thermo electrical power (Q), we used our own parameter free model potential with the Hard Sphere Yukawa (HSY) reference system. The screening effect on aforesaid properties has been examined by using different screening functions like Hartree (H), Taylor (T) and Sarkar (S). The correlations of our resultsand other data with available experimental values are intensely promising. Also, we conclude that our newly constructed parameter free model potential is capable of explaining the above mentioned electronic transport properties.

Manufacturing techniques for titanium aluminide based alloys and metal matrix composites

NASA Astrophysics Data System (ADS)

Kothari, Kunal B.

Dual phase titanium aluminides composed vastly of gamma phase (TiAl) with moderate amount of alpha2 phase (Ti3Al) have been considered for several high temperature aerospace and automobile applications. High specific strength coupled with good high temperature performance in the areas of creep and oxidation resistance makes titanium aluminides "materials of choice" for next generation propulsion systems. Titanium alumnides are primarily being considered as potential replacements for Ni-based superalloys in gas turbine engine components with aim of developing more efficient and leaner engines exhibiting high thrust-to-weight ratio. Thermo-mechanical treatments have shown to enhance the mechanical performance of titanium aluminides. Additionally, small additions of interstitial elements have shown further and significant improvement in the mechanical performance of titanium alumnide alloys. However, titanium aluminides lack considerably in room temperature ductility and as a result manufacturing processes of these aluminides have greatly suffered. Traditional ingot metallurgy and investment casting based methods to produce titanium aluminide parts in addition to being expensive, have also been unsuccessful in producing titanium aluminides with the desired mechanical properties. Hence, the manufacturing costs associated with these methods have completely outweighed the benefits offered by titanium aluminides. Over the last two decades, several powder metallurgy based manufacturing techniques have been studied to produce titanium aluminide parts. These techniques have been successful in producing titanium aluminide parts with a homogeneous and refined microstructure. These powder metallurgy techniques also hold the potential of significant cost reduction depending on the wide market acceptance of titanium aluminides. In the present study, a powder metallurgy based rapid consolidation technique has been used to produce near-net shape parts of titanium aluminides. Micron

Building a Competitive Edge with Additive Manufacturing

DTIC Science & Technology

2013-02-14

construct ceramic molds for complex metal parts using a 3D printing technique. They estimate the new 6 technique could eliminate all of the...processes. They include 3D printing and Additive Beam Techniques.15 Most Additive Manufacturing techniques are specific to certain classes of materials...9 Example Additive Manufacturing Techniques16 3D Printing Additive Beam Stereolithography (SLA) Direct Metal Laser Sintering (DMLS

Development of High Strength Ni-Cu-Zr-Ti-Si-Sn In-Situ Bulk Metallic Glass Composites Reinforced by Hard B2 Phase

NASA Astrophysics Data System (ADS)

Park, Hyo Jin; Hong, Sung Hwan; Park, Hae Jin; Kim, Young Seok; Kim, Jeong Tae; Na, Young Sang; Lim, Ka Ram; Wang, Wei-Min; Kim, Ki Buem

2018-03-01

In the present study, the influence of atomic ratio of Zr to Ti on the microstructure and mechanical properties of Ni-Cu-Zr-Ti-Si-Sn alloys is investigated. The alloys were designed by fine replacement of Ti for Zr from Ni39Cu20Zr36-xTixSi2Sn3. The increase of Ti content enhances glass forming ability of the alloy by suppression of formation of (Ni, Cu)10(Zr, Ti)7 phase during solidification. With further increasing Ti content up to 24 at.%, the B2 phase is introduced in the amorphous matrix with a small amount of B19' phase from alloy melt. The bulk metallic glass composite containing B2 phase with a volume fraction of 10 vol% exhibits higher fracture strength ( 2.5 GPa) than that of monolithic bulk metallic glass ( 2.3 GPa). This improvement is associated to the individual mechanical characteristics of the B2 phase and amorphous matrix. The B2 phase exhibits higher hardness and modulus than those of amorphous matrix as well as effective stress accommodation up to the higher stress level than the yield strength of amorphous matrix. The large stress accommodation capacity of the hard B2 phase plays an important factor to improve the mechanical properties of in situ Ni-based bulk metallic glass composites.

Surface modification of additive manufactured metal products by an intense electron beam

NASA Astrophysics Data System (ADS)

Teresov, A. D.; Koval, N. N.; Ivanov, Yu F.; Petrikova, E. A.; Krysina, O. V.

2017-11-01

On the example of VT6 titanium alloy it is shown that successive surface modification of additive manufactured metal specimens in vacuum at an argon pressure of 3.5·10-2 by ten pulses with 200 μs, 45 J/cm2 and then by three pulses with 50 μm, 20 J/cm2 provides a considerable decrease in their porosity and surface roughness (20 times for Ra) while their surface microhardness, friction coefficient, and wear level remain almost unchanged. After electron beam irradiation, the ultimate tensile strength of the material increases 1.33 times, and its tensile strain 1.18 times. For specimens obtained by conventional metallurgy and irradiated in the same modes, no such effects are observed.

Microgravity Manufacturing: Extending Rapid Prototyping Past the Horizon

NASA Technical Reports Server (NTRS)

Cooper, Ken

2003-01-01

Over the last decade, rapid prototyping (RP) technologies have continued to advance in all aspects of operation and application. From continuously advanced materials and processes development to more hard-core manufacturing uses, the RP realm has stretched considerably past its original expectations as a prototyping capability. This paper discusses the unique applications for which NASA has chosen these manufacturing techniques to be utilized in outer space.

Analyses of heavy metals in mineral trioxide aggregate and Portland cement.

PubMed

Schembri, Matthew; Peplow, George; Camilleri, Josette

2010-07-01

Portland cement is used in the construction industry as a binder in concrete. It is manufactured from chalk, limestone, and clay, which are clinkered at very high temperatures and ground with gypsum to form Portland cement. The raw materials and the manufacturing process can result in the inclusion of heavy metals in Portland cement. Portland cement with a four to one addition of bismuth oxide is marketed as mineral trioxide aggregate (MTA), which is used mainly as a dental material. Heavy metal inclusion can be of concern because MTA is in contact with hard and soft tissues. Measurements of arsenic, lead, and chromium in hydrated gray and white Portland cement, ProRoot MTA, and MTA Angelus were conducted with graphite furnace atomic absorption spectrophotometry after acid digestion on the hydrated material. The leaching of the metal ions from the solid material in water and simulated body fluid (SBF) was also determined. All cement types showed high relative values of leached chromium compared with arsenic and lead in both the total metal content and leached species. The gray Portland cement showed the highest total amount of metal. The white Portland and both MTAs had lower values for all the leached metal ions. Both MTAs released more arsenic than the amount specified in ISO 9917-1 (2007). Portland cements and MTAs showed evidence of heavy metals in the acid-soluble form as well as leaching in deionized water and SBF. MTA contained levels of arsenic higher than the safe limit specified by the ISO 9917-1 (2007). Copyright 2010 American Association of Endodontists. Published by Elsevier Inc. All rights reserved.

Occupational Exposure to Cobalt and Tungsten in the Swedish Hard Metal Industry: Air Concentrations of Particle Mass, Number, and Surface Area

PubMed Central

Bryngelsson, Ing-Liss; Pettersson, Carin; Husby, Bente; Arvidsson, Helena; Westberg, Håkan

2016-01-01

Exposure to cobalt in the hard metal industry entails severe adverse health effects, including lung cancer and hard metal fibrosis. The main aim of this study was to determine exposure air concentration levels of cobalt and tungsten for risk assessment and dose–response analysis in our medical investigations in a Swedish hard metal plant. We also present mass-based, particle surface area, and particle number air concentrations from stationary sampling and investigate the possibility of using these data as proxies for exposure measures in our study. Personal exposure full-shift measurements were performed for inhalable and total dust, cobalt, and tungsten, including personal real-time continuous monitoring of dust. Stationary measurements of inhalable and total dust, PM2.5, and PM10 was also performed and cobalt and tungsten levels were determined, as were air concentration of particle number and particle surface area of fine particles. The personal exposure levels of inhalable dust were consistently low (AM 0.15mg m−3, range <0.023–3.0mg m−3) and below the present Swedish occupational exposure limit (OEL) of 10mg m−3. The cobalt levels were low as well (AM 0.0030mg m−3, range 0.000028–0.056mg m−3) and only 6% of the samples exceeded the Swedish OEL of 0.02mg m−3. For continuous personal monitoring of dust exposure, the peaks ranged from 0.001 to 83mg m−3 by work task. Stationary measurements showed lower average levels both for inhalable and total dust and cobalt. The particle number concentration of fine particles (AM 3000 p·cm−3) showed the highest levels at the departments of powder production, pressing and storage, and for the particle surface area concentrations (AM 7.6 µm2·cm−3) similar results were found. Correlating cobalt mass-based exposure measurements to cobalt stationary mass-based, particle area, and particle number concentrations by rank and department showed significant correlations for all measures except for particle

Determination of pollutants in foundry during the manufacture of metal constructions for high buildings

NASA Astrophysics Data System (ADS)

Ivanova, Irina; Sushko, Elena; Lyshnikova, Anna; Prykina, Larisa

2018-03-01

Current developments are devoted to the environmental safety of the foundry. There is a significant amount of pollutants, according to dust, which is released in the working area, during the manufacture of metal structures for high buildings. From the point of dust extraction, the most unfavorable areas are shot blasting, sand-blasting chambers and knockout grills. The weight fraction of dust composition with diameters up to 20 μm reaches 43,8% by mass, according to experimental analysis. This kind of dust is the most dangerous to employees and also it creates problems for dust-cleaning in the air.

Development of in-Situ Al-Si/CuAl2 Metal Matrix Composites: Microstructure, Hardness, and Wear Behavior

PubMed Central

Tash, Mahmoud M.; Mahmoud, Essam R. I.

2016-01-01

In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15%) into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD) pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl2, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl2 at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature. PMID:28773564

Solid-State Additive Manufacturing for Heat Exchangers

NASA Astrophysics Data System (ADS)

Norfolk, Mark; Johnson, Hilary

2015-03-01

Energy densities in devices are increasing across many industries including power generation, high power electronics, manufacturing, and automotive. Increasingly, there is a need for very high efficiency thermal management devices that can pull heat out of a small area at higher and higher rates. Metal additive manufacturing (AM) technologies have the promise of creating parts with complex internal geometries required for integral thermal management. However, this goal has not been met due to constraints in fusion-based metal 3D printers. This work presents a new strategy for metal AM of heat exchangers using an ultrasonic sheet lamination approach.

TRANSFORMATION AND FATE OF MANUFACTURED METAL OXIDE AND METAL NANOPARTICLES IN AQUEOUS ENVIRONMENTS

EPA Science Inventory

As commercial manufactured nanomaterials become more commonplace, we can expect that these manufactured materials have the potential to get into the environment sometime during production, distribution, use or disposal, i.e. sometime during the lifecycle of these materials. In...

Glyphosate, Hard Water and Nephrotoxic Metals: Are They the Culprits Behind the Epidemic of Chronic Kidney Disease of Unknown Etiology in Sri Lanka?

PubMed Central

Jayasumana, Channa; Gunatilake, Sarath; Senanayake, Priyantha

2014-01-01

The current chronic kidney disease epidemic, the major health issue in the rice paddy farming areas in Sri Lanka has been the subject of many scientific and political debates over the last decade. Although there is no agreement among scientists about the etiology of the disease, a majority of them has concluded that this is a toxic nephropathy. None of the hypotheses put forward so far could explain coherently the totality of clinical, biochemical, histopathological findings, and the unique geographical distribution of the disease and its appearance in the mid-1990s. A strong association between the consumption of hard water and the occurrence of this special kidney disease has been observed, but the relationship has not been explained consistently. Here, we have hypothesized the association of using glyphosate, the most widely used herbicide in the disease endemic area and its unique metal chelating properties. The possible role played by glyphosate-metal complexes in this epidemic has not been given any serious consideration by investigators for the last two decades. Furthermore, it may explain similar kidney disease epidemics observed in Andra Pradesh (India) and Central America. Although glyphosate alone does not cause an epidemic of chronic kidney disease, it seems to have acquired the ability to destroy the renal tissues of thousands of farmers when it forms complexes with a localized geo environmental factor (hardness) and nephrotoxic metals. PMID:24562182

Identification of metal s states in Sn-doped anatase by polarisation dependent hard X-ray photoelectron spectroscopy

NASA Astrophysics Data System (ADS)

Regoutz, A.; Oropeza, F. E.; Poll, C. G.; Payne, D. J.; Palgrave, R. G.; Panaccione, G.; Borgatti, F.; Agrestini, S.; Utsumi, Y.; Tsuei, K. D.; Liao, Y. F.; Watson, G. W.; Egdell, R. G.

2016-03-01

The contributions of Sn 5s and Ti 4s states to the valence band electronic structure of Sn-doped anatase have been identified by hard X-ray photoelectron spectroscopy. The metal s state intensity is strongly enhanced relative to that of O 2p states at high photon energies due to matrix element effects when electrons are detected parallel to the direction of the polarisation vector of the synchrotron beam, but becomes negligible in the perpendicular direction. The experimental spectra in both polarisations are in good agreement with cross section and asymmetry parameter weighted partial densities of states derived from density functional theory calculations.

Study of metal whiskers growth and mitigation technique using additive manufacturing

NASA Astrophysics Data System (ADS)

Gullapalli, Vikranth

For years, the alloy of choice for electroplating electronic components has been tin-lead (Sn-Pb) alloy. However, the legislation established in Europe on July 1, 2006, required significant lead (Pb) content reductions from electronic hardware due to its toxic nature. A popular alternative for coating electronic components is pure tin (Sn). However, pure tin has the tendency to spontaneously grow electrically conductive Sn whisker during storage. Sn whisker is usually a pure single crystal tin with filament or hair-like structures grown directly from the electroplated surfaces. Sn whisker is highly conductive, and can cause short circuits in electronic components, which is a very significant reliability problem. The damages caused by Sn whisker growth are reported in very critical applications such as aircraft, spacecraft, satellites, and military weapons systems. They are also naturally very strong and are believed to grow from compressive stresses developed in the Sn coating during deposition or over time. The new directive, even though environmentally friendly, has placed all lead-free electronic devices at risk because of whisker growth in pure tin. Additionally, interest has occurred about studying the nature of other metal whiskers such as zinc (Zn) whiskers and comparing their behavior to that of Sn whiskers. Zn whiskers can be found in flooring of data centers which can get inside electronic systems during equipment reorganization and movement and can also cause systems failure. Even though the topic of metal whiskers as reliability failure has been around for several decades to date, there is no successful method that can eliminate their growth. This thesis will give further insights towards the nature and behavior of Sn and Zn whiskers growth, and recommend a novel manufacturing technique that has potential to mitigate metal whiskers growth and extend life of many electronic devices.

Microstructures, mechanical properties, and fracture behaviors of metal-injection molded 17-4PH stainless steel

NASA Astrophysics Data System (ADS)

Wu, Ming-Wei; Huang, Zeng-Kai; Tseng, Chun-Feng; Hwang, Kuen-Shyang

2015-05-01

Metal injection molding (MIM) is a versatile technique for economically manufacturing various metal parts with complicated shapes and excellent properties. The objective of this study was to clarify the effects of powder type (water-atomized and gas-atomized powders) and various heat treatments (sintering, solutioning, H900, and H1100) on the microstructures, mechanical properties, and fracture behaviors of MIM 17-4PH stainless steels. The results showed that better mechanical properties of MIM 17-4PH can be achieved with gas-atomized powder than with water-atomized powder due mainly to the lower silicon and oxygen contents and fewer SiO2 inclusions in the steels. The presence of 10 vol% δ ferrite does not impair the UTS or elongation of MIM 17-4PH stainless steels. The δ ferrite did not fracture, even though the neighboring martensitic matrix was severely cracked. Moreover, H900 treatment produces the highest hardness and UTS, along with moderate elongation. H1100 treatment produces the best elongation, along with moderate hardness and UTS.

Lead, mercury, and arsenic in US- and Indian-manufactured Ayurvedic medicines sold via the Internet.

PubMed

Saper, Robert B; Phillips, Russell S; Sehgal, Anusha; Khouri, Nadia; Davis, Roger B; Paquin, Janet; Thuppil, Venkatesh; Kales, Stefanos N

2008-08-27

Lead, mercury, and arsenic have been detected in a substantial proportion of Indian-manufactured traditional Ayurvedic medicines. Metals may be present due to the practice of rasa shastra (combining herbs with metals, minerals, and gems). Whether toxic metals are present in both US- and Indian-manufactured Ayurvedic medicines is unknown. To determine the prevalence of Ayurvedic medicines available via the Internet containing detectable lead, mercury, or arsenic and to compare the prevalence of toxic metals in US- vs Indian-manufactured medicines and between rasa shastra and non-rasa shastra medicines. A search using 5 Internet search engines and the search terms Ayurveda and Ayurvedic medicine identified 25 Web sites offering traditional Ayurvedic herbs, formulas, or ingredients commonly used in Ayurveda, indicated for oral use, and available for sale. From 673 identified products, 230 Ayurvedic medicines were randomly selected for purchase in August-October 2005. Country of manufacturer/Web site supplier, rasa shastra status, and claims of Good Manufacturing Practices were recorded. Metal concentrations were measured using x-ray fluorescence spectroscopy. Prevalence of medicines with detectable toxic metals in the entire sample and stratified by country of manufacture and rasa shastra status. One hundred ninety-three of the 230 requested medicines were received and analyzed. The prevalence of metal-containing products was 20.7% (95% confidence interval [CI], 15.2%-27.1%). The prevalence of metals in US-manufactured products was 21.7% (95% CI, 14.6%-30.4%) compared with 19.5% (95% CI, 11.3%-30.1%) in Indian products (P = .86). Rasa shastra compared with non-rasa shastra medicines had a greater prevalence of metals (40.6% vs 17.1%; P = .007) and higher median concentrations of lead (11.5 microg/g vs 7.0 microg/g; P = .03) and mercury (20,800 microg/g vs 34.5 microg/g; P = .04). Among the metal-containing products, 95% were sold by US Web sites and 75% claimed Good

Use of a hard mask for formation of gate and dielectric via nanofilament field emission devices

DOEpatents

Morse, Jeffrey D.; Contolini, Robert J.

2001-01-01

A process for fabricating a nanofilament field emission device in which a via in a dielectric layer is self-aligned to gate metal via structure located on top of the dielectric layer. By the use of a hard mask layer located on top of the gate metal layer, inert to the etch chemistry for the gate metal layer, and in which a via is formed by the pattern from etched nuclear tracks in a trackable material, a via is formed by the hard mask will eliminate any erosion of the gate metal layer during the dielectric via etch. Also, the hard mask layer will protect the gate metal layer while the gate structure is etched back from the edge of the dielectric via, if such is desired. This method provides more tolerance for the electroplating of a nanofilament in the dielectric via and sharpening of the nanofilament.

Additive Manufacturing/Diagnostics via the High Frequency Induction Heating of Metal Powders: The Determination of the Power Transfer Factor for Fine Metallic Spheres

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rios, Orlando; Radhakrishnan, Balasubramaniam; Caravias, George

2015-03-11

Grid Logic Inc. is developing a method for sintering and melting fine metallic powders for additive manufacturing using spatially-compact, high-frequency magnetic fields called Micro-Induction Sintering (MIS). One of the challenges in advancing MIS technology for additive manufacturing is in understanding the power transfer to the particles in a powder bed. This knowledge is important to achieving efficient power transfer, control, and selective particle heating during the MIS process needed for commercialization of the technology. The project s work provided a rigorous physics-based model for induction heating of fine spherical particles as a function of frequency and particle size. This simulationmore » improved upon Grid Logic s earlier models and provides guidance that will make the MIS technology more effective. The project model will be incorporated into Grid Logic s power control circuit of the MIS 3D printer product and its diagnostics technology to optimize the sintering process for part quality and energy efficiency.« less

LC and ferromagnetic resonance in soft/hard magnetic microwires

NASA Astrophysics Data System (ADS)

Tian, Bin; Vazquez, Manuel

2015-12-01

The magnetic behavior of soft/hard biphase microwires is introduced here. The microwires consist of a Co59.1Fe14.8Si10.2B15.9 soft magnetic nucleus and a Co90Ni10 hard outer shell separated by an intermediate insulating Pyrex glass microtube. By comparing the resistance spectrums of welding the ends of metallic core (CC) or welding the metallic core and outer shell (CS) to the connector, it is found that one of the two peaks in the resistance spectrum is because the LC resonance depends on the inductor and capacitors in which one is the capacitor between the metallic core and outer shell, and the other is between the outer shell and connector. Correspondingly, another peak is for the ferromagnetic resonance of metallic core. After changing the capacitance of the capacitors, the frequency of LC resonance moves to high frequency band, and furthermore, the peak of LC resonance in the resistance spectrum disappeared. These magnetostatically coupled biphase systems are thought to be of large potential interest as sensing elements in sensor devices.

"Designer" Metals as a Manufacturing Unit.

ERIC Educational Resources Information Center

Stier, Kenneth W.

1996-01-01

Technology educators have an obligation to keep pace with the changes taking place in materials science by changing their instructional content to provide students with the knowledge and skills in materials and processing methods that will be used in manufacturing for the 21st century. (JOW)

Rapid manufacturing of metallic Molds for parts in Automobile

NASA Astrophysics Data System (ADS)

Zhang, Renji; Xu, Da; Liu, Yuan; Yan, Xudong; Yan, Yongnian

1998-03-01

The recent research of RPM (Rapid Prototyping Manufacturing) in our lab has been focused on the rapid creation of alloyed cast iron (ACI) molds. There are a lot of machinery parts in an automobile, so a lot of mettallic molds are needed in automobile industry. A new mold manufacturing technology has been proposed. A new large scale RP machine has been set up in our lab now. Then rapid prototypes could be manufactured by means of laminated object manufacturing (LOM) technology. The molds for parts in automobile have been produced by ceramic shell precision casting. An example is a drawing mold for cover parts in automobile. Sufficient precision and surface roughness have been obtained. Itis proved that this is a vew kind of technology. Work supported by the Mational Science Foundation of China.

Influence of photoactivation method and mold for restoration on the Knoop hardness of resin composite restorations.

PubMed

Brandt, William Cunha; Silva-Concilio, Lais Regiane; Neves, Ana Christina Claro; de Souza-Junior, Eduardo Jose Carvalho; Sinhoreti, Mario Alexandre Coelho

2013-09-01

The aim of this study was to evaluate in vitro the Knoop hardness in the top and bottom of composite photo activated by different methods when different mold materials were used. Z250 (3M ESPE) and XL2500 halogen unit (3M ESPE) were used. For hardness test, conical restorations were made in extracted bovine incisors (tooth mold) and also metal mold (approximately 2 mm top diameter × 1.5 mm bottom diameter × 2 mm in height). Different photoactivation methods were tested: high-intensity continuous (HIC), low-intensity continuous (LIC), soft-start, or pulse-delay (PD), with constant radiant exposure. Knoop readings were performed on top and bottom restoration surfaces. Data were submitted to two-way ANOVA and Tukey's test (p = 0.05). On the top, regardless of the mold used, no significant difference in the Knoop hardness (Knoop hardness number, in kilograms-force per square millimeter) was observed between the photoactivation methods. On the bottom surface, the photoactivation method HIC shows higher means of hardness than LIC when tooth and metal were used. Significant differences of hardness on the top and in the bottom were detected between tooth and metal. The photoactivation method LIC and the material mold can interfere in the hardness values of composite restorations.

Submicron cubic boron nitride as hard as diamond

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liu, Guoduan; Kou, Zili, E-mail: kouzili@scu.edu.cn, E-mail: yanxz@hpstar.ac.cn; Lei, Li

Here, we report the sintering of aggregated submicron cubic boron nitride (sm-cBN) at a pressure of 8 GPa. The sintered cBN compacts exhibit hardness values comparable to that of single crystal diamond, fracture toughness about 5-fold that of cBN single crystal, in combination with a high oxidization temperature. Thus, another way has been demonstrated to improve the mechanical properties of cBN besides reducing the grain size to nano scale. In contrast to other ultrahard compacts with similar hardness, the sm-cBN aggregates are better placed for potential industrial application, as their relative low pressure manufacturing perhaps be easier and cheaper.

Photon Doppler Velocimeter to Measure Entrained Additive Manufactured Bulk Metal Powders in Hot Subsonic and Supersonic Oxygen Gas

NASA Technical Reports Server (NTRS)

Tylka, Jonathan

2016-01-01

Parts produced by additive manufacturing, particularly selective laser melting (SLM), have been shown to silt metal particulate even after undergoing stringent precision aerospace cleaning processes (Lowrey 2016). As printed parts are used in oxygen systems with increased pressures, temperatures, and gas velocity, the risk of ignition by particle impact, the most common direct ignition source of metals in oxygen, substantially increases. The White Sands Test Facility (WSTF), in collaboration with Marshall Space Flight Center (MSFC), desires to test the ignitability of SLM metals by particle impact in heated oxygen. The existing test systems rely on gas velocity calculations to infer particle velocity in both subsonic and supersonic particle impact systems. Until now, it was not possible to directly measure particle velocity. To increase the fidelity of planned SLM ignition studies, it is necessary to validate that the Photon Doppler Velocimetry(PDV) test system can accurately measure particle velocity.

Incremental electrohydraulic forming - A new approach for the manufacture of structured multifunctional sheet metal blanks

NASA Astrophysics Data System (ADS)

Djakow, Eugen; Springer, Robert; Homberg, Werner; Piper, Mark; Tran, Julian; Zibart, Alexander; Kenig, Eugeny

2017-10-01

Electrohydraulic Forming (EHF) processes permit the production of complex, sharp-edged geometries even when high-strength materials are used. Unfortunately, the forming zone is often limited as compared to other sheet metal forming processes. The use of a special industrial-robot-based tool setup and an incremental process strategy could provide a promising solution for this problem. This paper describes such an innovative approach using an electrohydraulic incremental forming machine, which can be employed to manufacture the large multifunctional and complex part geometries in steel, aluminium, magnesium and reinforced plastic that are employed in lightweight constructions or heating elements.

Potential of direct metal deposition technology for manufacturing thick functionally graded coatings and parts for reactors components

NASA Astrophysics Data System (ADS)

Thivillon, L.; Bertrand, Ph.; Laget, B.; Smurov, I.

2009-03-01

Direct metal deposition (DMD) is an automated 3D deposition process arising from laser cladding technology with co-axial powder injection to refine or refurbish parts. Recently DMD has been extended to manufacture large-size near-net-shape components. When applied for manufacturing new parts (or their refinement), DMD can provide tailored thermal properties, high corrosion resistance, tailored tribology, multifunctional performance and cost savings due to smart material combinations. In repair (refurbishment) operations, DMD can be applied for parts with a wide variety of geometries and sizes. In contrast to the current tool repair techniques such as tungsten inert gas (TIG), metal inert gas (MIG) and plasma welding, laser cladding technology by DMD offers a well-controlled heat-treated zone due to the high energy density of the laser beam. In addition, this technology may be used for preventative maintenance and design changes/up-grading. One of the advantages of DMD is the possibility to build functionally graded coatings (from 1 mm thickness and higher) and 3D multi-material objects (for example, 100 mm-sized monolithic rectangular) in a single-step manufacturing cycle by using up to 4-channel powder feeder. Approved materials are: Fe (including stainless steel), Ni and Co alloys, (Cu,Ni 10%), WC compounds, TiC compounds. The developed coatings/parts are characterized by low porosity (<1%), fine microstructure, and their microhardness is close to the benchmark value of wrought alloys after thermal treatment (Co-based alloy Stellite, Inox 316L, stainless steel 17-4PH). The intended applications concern cooling elements with complex geometry, friction joints under high temperature and load, light-weight mechanical support structures, hermetic joints, tubes with complex geometry, and tailored inside and outside surface properties, etc.

Metallic powder-bed based 3D printing of cellular scaffolds for orthopaedic implants: A state-of-the-art review on manufacturing, topological design, mechanical properties and biocompatibility.

PubMed

Tan, X P; Tan, Y J; Chow, C S L; Tor, S B; Yeong, W Y

2017-07-01

Metallic cellular scaffold is one of the best choices for orthopaedic implants as a replacement of human body parts, which could improve life quality and increase longevity for the people needed. Unlike conventional methods of making cellular scaffolds, three-dimensional (3D) printing or additive manufacturing opens up new possibilities to fabricate those customisable intricate designs with highly interconnected pores. In the past decade, metallic powder-bed based 3D printing methods emerged and the techniques are becoming increasingly mature recently, where selective laser melting (SLM) and selective electron beam melting (SEBM) are the two representatives. Due to the advantages of good dimensional accuracy, high build resolution, clean build environment, saving materials, high customisability, etc., SLM and SEBM show huge potential in direct customisable manufacturing of metallic cellular scaffolds for orthopaedic implants. Ti-6Al-4V to date is still considered to be the optimal materials for producing orthopaedic implants due to its best combination of biocompatibility, corrosion resistance and mechanical properties. This paper presents a state-of-the-art overview mainly on manufacturing, topological design, mechanical properties and biocompatibility of cellular Ti-6Al-4V scaffolds via SLM and SEBM methods. Current manufacturing limitations, topological shortcomings, uncertainty of biocompatible test were sufficiently discussed herein. Future perspectives and recommendations were given at the end. Copyright © 2017 Elsevier B.V. All rights reserved.

Process for manufacturing multilayer capacitors

DOEpatents

Lauf, R.J.; Holcombe, C.E.; Dykes, N.L.

1996-01-02

The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation. 4 figs.

Process for manufacturing multilayer capacitors

DOEpatents

Lauf, Robert J.; Holcombe, Cressie E.; Dykes, Norman L.

1996-01-01

The invention is directed to a method of manufacture of multilayer electrical components, especially capacitors, and components made by such a method. High capacitance dielectric materials and low cost metallizations layered with such dielectrics may be fabricated as multilayer electrical components by sintering the metallizations and the dielectrics during the fabrication process by application of microwave radiation.

OsB 2 and RuB 2, ultra-incompressible, hard materials: First-principles electronic structure calculations

NASA Astrophysics Data System (ADS)

Chiodo, S.; Gotsis, H. J.; Russo, N.; Sicilia, E.

2006-07-01

Recently it has been reported that osmium diboride has an unusually large bulk modulus combined with high hardness, and consequently is a most interesting candidate as an ultra-incompressible and hard material. The electronic and structural properties of the transition metal diborides OsB 2 and RuB 2 have been calculated within the local density approximation (LDA). It is shown that the high hardness is the result of covalent bonding between transition metal d states and boron p states in the orthorhombic structure.

Multivariate analysis of mixed contaminants (PAHs and heavy metals) at manufactured gas plant site soils.

PubMed

Thavamani, Palanisami; Megharaj, Mallavarapu; Naidu, Ravi

2012-06-01

Principal component analysis (PCA) was used to provide an overview of the distribution pattern of polycyclic aromatic hydrocarbons (PAHs) and heavy metals in former manufactured gas plant (MGP) site soils. PCA is the powerful multivariate method to identify the patterns in data and expressing their similarities and differences. Ten PAHs (naphthalene, acenapthylene, acenaphthene, fluorene, phenanthrene, anthracene, fluoranthene, pyrene, chrysene, benzo[a]pyrene) and four toxic heavy metals - lead (Pb), cadmium (Cd), chromium (Cr) and zinc (Zn) - were detected in the site soils. PAH contamination was contributed equally by both low and high molecular weight PAHs. PCA was performed using the varimax rotation method in SPSS, 17.0. Two principal components accounting for 91.7% of the total variance was retained using scree test. Principle component 1 (PC1) substantially explained the dominance of PAH contamination in the MGP site soils. All PAHs, except anthracene, were positively correlated in PC1. There was a common thread in high molecular weight PAHs loadings, where the loadings were inversely proportional to the hydrophobicity and molecular weight of individual PAHs. Anthracene, which was less correlated with other individual PAHs, deviated well from the origin which can be ascribed to its lower toxicity and different origin than its isomer phenanthrene. Among the four major heavy metals studied in MGP sites, Pb, Cd and Cr were negatively correlated in PC1 but showed strong positive correlation in principle component 2 (PC2). Although metals may not have originated directly from gaswork processes, the correlation between PAHs and metals suggests that the materials used in these sites may have contributed to high concentrations of Pb, Cd, Cr and Zn. Thus, multivariate analysis helped to identify the sources of PAHs, heavy metals and their association in MGP site, and thereby better characterise the site risk, which would not be possible if one uses chemical analysis

Superhard composite materials including compounds of carbon and nitrogen deposited on metal and metal nitride carbide and carbonitride

DOEpatents

Wong, M.S.; Li, D.; Chung, Y.W.; Sproul, W.D.; Xi Chu; Barnett, S.A.

1998-03-10

A composite material having high hardness comprises a carbon nitrogen compound, such as CN{sub x} where x is greater than 0.1 and up to 1.33, deposited on a metal or metal compound selected to promote deposition of substantially crystalline CN{sub x}. The carbon nitrogen compound is deposited on a crystal plane of the metal or metal compound sufficiently lattice-matched with a crystal plane of the carbon nitrogen compound that the carbon nitrogen compound is substantially crystalline. A plurality of layers of the compounds can be formed in alternating sequence to provide a multi-layered, superlattice coating having a coating hardness in the range of 45--55 GPa, which corresponds to the hardness of a BN coating and approaches that of a diamond coating. 10 figs.

Superhard composite materials including compounds of carbon and nitrogen deposited on metal and metal nitride, carbide and carbonitride

DOEpatents

Wong, M.S.; Li, D.; Chung, Y.W.; Sproul, W.D.; Chu, X.; Barnett, S.A.

1998-07-07

A composite material having high hardness comprises a carbon nitrogen compound, such as CN{sub x} where x is greater than 0.1 and up to 1.33, deposited on a metal or metal compound selected to promote deposition of substantially crystalline CN{sub x}. The carbon nitrogen compound is deposited on a crystal plane of the metal or metal compound sufficiently lattice-matched with a crystal plane of the carbon nitrogen compound that the carbon nitrogen compound is substantially crystalline. A plurality of layers of the compounds can be formed in alternating sequence to provide a multi-layered, superlattice coating having a coating hardness in the range of 45--55 GPa, which corresponds to the hardness of a BN coating and approaches that of a diamond coating. 10 figs.

Superhard composite materials including compounds of carbon and nitrogen deposited on metal and metal nitride, carbide and carbonitride

DOEpatents

Wong, Ming-Show; Li, Dong; Chung, Yip-Wah; Sproul, William D.; Chu, Xi; Barnett, Scott A.

1998-01-01

A composite material having high hardness comprises a carbon nitrogen compound, such as CN.sub.x where x is greater than 0.1 and up to 1.33, deposited on a metal or metal compound selected to promote deposition of substantially crystalline CN.sub.x. The carbon nitrogen compound is deposited on a crystal plane of the metal or metal compound sufficiently lattice-matched with a crystal plane of the carbon nitrogen compound that the carbon nitrogen compound is substantially crystalline. A plurality of layers of the compounds can be formed in alternating sequence to provide a multi-layered, superlattice coating having a coating hardness in the range of 45-55 GPa, which corresponds to the hardness of a BN coating and approaches that of a diamond coating.

Superhard composite materials including compounds of carbon and nitrogen deposited on metal and metal nitride carbide and carbonitride

DOEpatents

Wong, Ming-Show; Li, Dong; Chung, Yin-Wah; Sproul, William D.; Chu, Xi; Barnett, Scott A.

1998-01-01

A composite material having high hardness comprises a carbon nitrogen compound, such as CN.sub.x where x is greater than 0.1 and up to 1.33, deposited on a metal or metal compound selected to promote deposition of substantially crystalline CN.sub.x. The carbon nitrogen compound is deposited on a crystal plane of the metal or metal compound sufficiently lattice-matched with a crystal plane of the carbon nitrogen compound that the carbon nitrogen compound is substantially crystalline. A plurality of layers of the compounds can be formed in alternating sequence to provide a multi-layered, superlattice coating having a coating hardness in the range of 45-55 GPa, which corresponds to the hardness of a BN coating and approaches that of a diamond coating.

Lead, Mercury, and Arsenic in US- and Indian-Manufactured Ayurvedic Medicines Sold via the Internet

PubMed Central

Saper, Robert B.; Phillips, Russell S.; Sehgal, Anusha; Khouri, Nadia; Davis, Roger B.; Paquin, Janet; Thuppil, Venkatesh; Kales, Stefanos N.

2009-01-01

Context Lead, mercury, and arsenic have been detected in a substantial proportion of Indian-manufactured traditional Ayurvedic medicines. Metals may be present due to the practice of rasa shastra (combining herbs with metals, minerals, and gems). Whether toxic metals are present in both US- and Indian-manufactured Ayurvedic medicines is unknown. Objectives To determine the prevalence of Ayurvedic medicines available via the Internet containing detectable lead, mercury, or arsenic and to compare the prevalence of toxic metals in US- vs Indian-manufactured medicines and between rasa shastra and non–rasa shastra medicines. Design A search using 5 Internet search engines and the search terms Ayurveda and Ayurvedic medicine identified 25 Web sites offering traditional Ayurvedic herbs, formulas, or ingredients commonly used in Ayurveda, indicated for oral use, and available for sale. From 673 identified products, 230 Ayurvedic medicines were randomly selected for purchase in August–October 2005. Country of manufacturer/Web site supplier, rasa shastra status, and claims of Good Manufacturing Practices were recorded. Metal concentrations were measured using x-ray fluorescence spectroscopy. Main Outcome Measures Prevalence of medicines with detectable toxic metals in the entire sample and stratified by country of manufacture and rasa shastra status. Results One hundred ninety-three of the 230 requested medicines were received and analyzed. The prevalence of metal-containing products was 20.7% (95% confidence interval [CI], 15.2%–27.1%). The prevalence of metals in US-manufactured products was 21.7% (95% CI, 14.6%–30.4%) compared with 19.5% (95% CI, 11.3%–30.1%) in Indian products (P=.86). Rasa shastra compared with non–rasa shastra medicines had a greater prevalence of metals (40.6% vs 17.1%; P=.007) and higher median concentrations of lead (11.5 μg/g vs 7.0 μg/g; P=.03) and mercury (20 800 μg/g vs 34.5 μg/g; P=.04). Among the metal-containing products, 95

Additive Manufacturing of AlSi10Mg Alloy Using Direct Energy Deposition: Microstructure and Hardness Characterization

NASA Astrophysics Data System (ADS)

Javidani, M.; Arreguin-Zavala, J.; Danovitch, J.; Tian, Y.; Brochu, M.

2017-04-01

This paper aims to study the manufacturing of the AlSi10Mg alloy with direct energy deposition (DED) process. Following fabrication, the macro- and microstructural evolution of the as-processed specimens was initially investigated using optical microscopy and scanning electron microscopy. Columnar dendritic structure was the dominant solidification feature of the deposit; nevertheless, detailed microstructural analysis revealed cellular morphology near the substrate and equiaxed dendrites at the top end of the deposit. Moreover, the microstructural morphology in the melt pool boundary of the deposit differed from the one in the core of the layers. The remaining porosity of the deposit was evaluated by Archimedes' principle and by image analysis of the polished surface. Crystallographic texture in the deposit was also assessed using electron backscatter diffraction and x-ray diffraction analysis. The dendrites were unidirectionally oriented at an angle of 80° to the substrate. EPMA line scans were performed to evaluate the compositional variation and elemental segregation in different locations. Eventually, microhardness (HV) tests were conducted in order to study the hardness gradient in the as-DED-processed specimen along the deposition direction. The presented results, which exhibited a deposit with an almost defect free structure, indicate that the DED process can suitable for the deposition of Al-Si-based alloys with a highly consolidated structure.

Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs.

PubMed

Sing, Swee Leong; An, Jia; Yeong, Wai Yee; Wiria, Florencia Edith

2016-03-01

Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two AM processes suitable for metallic orthopaedic implant applications, namely selective laser melting (SLM) and electron beam melting (EBM) are presented. Several critical design factors such as the need for data acquisition for patient-specific design, design dependent porosity for osteo-inductive implants, surface topology of the implants and design for reduction of stress-shielding in implants are discussed. Additive manufactured biomaterials such as 316L stainless steel, titanium-6aluminium-4vanadium (Ti6Al4V) and cobalt-chromium (CoCr) are highlighted. Limitations and future potential of such technologies are also explored. © 2015 Orthopaedic Research Society. Published by Wiley Periodicals, Inc.

Hardness Assurance Techniques for New Generation COTS Devices

NASA Technical Reports Server (NTRS)

Lee, C. I.; Rax, B. G.; Johnston, A. H.

1996-01-01

Hardness Assurance (HA) techniques and total dose radiation characterization data for new generation linear and COTS devices from various manufacturers are presented. A bipolar op amp showed significant degradation at HDR, not at low dose rate environment. New generation low-power op amps showed more degradation at low voltage applications. HA test techniques for COTS devices are presented in this paper.

Focusing hard X-rays with old LPs

NASA Astrophysics Data System (ADS)

Cederström, Björn; Cahn, Robert N.; Danielsson, Mats; Lundqvist, Mats; Nygren, David R.

2000-04-01

We have found that two sections cut from a vinyl long-playing record can form a spherical aberration-free refractive lens for hard X-rays. Our manufactured saw-tooth refractive lens has a focal length of 22 cm for 23-keV X-rays. The low cost and short focal length of this lens make it feasible for use in small-scale experiments with conventional X-ray tubes.

Computed Tomography Inspection and Analysis for Additive Manufacturing Components

NASA Technical Reports Server (NTRS)

Beshears, Ronald D.

2017-01-01

Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws and geometric features were inspected using a 2-megavolt linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

Designing superhard metals: The case of low borides

NASA Astrophysics Data System (ADS)

Liang, Yongcheng; Qin, Ping; Jiang, Haitao; Zhang, Lizhen; Zhang, Jing; Tang, Chun

2018-04-01

The search for new superhard materials has usually focused on strong covalent solids. It is, however, a huge challenge to design superhard metals because of the low resistance of metallic bonds against the formation and movement of dislocations. Here, we report a microscopic mechanism of enhancing hardness by identifying highly stable thermodynamic phases and strengthening weak slip planes. Using the well-known transition-metal borides as prototypes, we demonstrate that several low borides possess unexpectedly high hardness whereas high borides exhibit an anomalous hardness reduction. Such an unusual phenomenon originates from the peculiar bonding mechanisms in these compounds. Furthermore, the low borides have close compositions, similar structures, and degenerate formation energies. This enables facile synthesis of a multiphase material that includes a large number of interfaces among different borides, and these interfaces form nanoscale interlocks that strongly suppress the glide dislocations within the metal bilayers, thereby drastically enhancing extrinsic hardness and achieving true superhard metals. Therefore, this study not only elucidates the unique mechanism responsible for the anomalous hardening in this class of borides but also offers a valid alchemy to design novel superhard metals with multiple functionalities.

Method for manufacturing magnetohydrodynamic electrodes

DOEpatents

Killpatrick, D.H.; Thresh, H.R.

1980-06-24

A method of manufacturing electrodes for use in a magnetohydrodynamic (MHD) generator is described comprising the steps of preparing a billet having a core of a first metal, a tubular sleeve of a second metal, and an outer sheath of an extrusile metal; evacuating the space between the parts of the assembled billet; extruding the billet; and removing the outer jacket. The extruded bar may be made into electrodes by cutting and bending to the shape required for an MHD channel frame. The method forms a bond between the first metal of the core and the second metal of the sleeve strong enough to withstand a hot and corrosive environment.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

NASA Astrophysics Data System (ADS)

King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubenchik, A. M.

2015-12-01

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

DOE PAGES

King, W. E.; Anderson, A. T.; Ferencz, R. M.; ...

2015-12-29

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In thismore » study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.« less

Manufacturing and actuation characterization of ionic polymer metal composites with silver as electrodes

NASA Astrophysics Data System (ADS)

Pandita, Surya D.; Lim, Hyoung Tae; Yoo, Youngtai; Park, Hoon Cheol

2006-03-01

Manufacturing and characterization of ionic polymer metal composites (IPMCs) with silver as electrodes have been investigated. Tollen's reagent that contains ion Ag(NH 3) II + was used as a raw material for silver deposition on the surfaces of the polymer membrane Nafion"R". Two types of inner solvents, namely common water based electrolyte solution (LiOH 1N) and ionic liquid were used and investigated. Compared to IPMCs with platinum electrodes, silver-plated IPMCs with water electrolyte showed higher conductivity. The actuation response of silver-plated IPMCs with the water based electrolyte was faster than that of platinum IPMCs. However, the silver electrode was too brittle and severely damaged during the solvent exchange process from water to ionic liquid, resulted in high resistance and hence very low actuation behavior.

The Role of Laser Additive Manufacturing Methods of Metals in Repair, Refurbishment and Remanufacturing - Enabling Circular Economy

NASA Astrophysics Data System (ADS)

Leino, Maija; Pekkarinen, Joonas; Soukka, Risto

Circular economy is an economy model where products, components, and materials are aimed to be kept at their highest utility and value at all times. Repair, refurbishment and remanufacturing processes are procedures aiming at returning the value of the product during its life cycle. Additive manufacturing (AM) is expected to be an enabling technology in circular economy based business models. One of AM process that enables repair, refurbishment and remanufacturing is Directed Energy Deposition. Respectively Powder Bed Fusion enables manufacturing of replacement components on demand. The aim of this study is to identify the current research findings and state of art of utilizing AM in repair, refurbishment and remanufacturing processes of metallic products. The focus is in identifying possibilities of AM in promotion of circular economy and expected environmental benefits based on the found literature. Results of the study indicate significant potential in utilizing AM in repair, refurbishment and remanufacturing activities.

Occurrence of cohesion of metals during combined plastic deformation

NASA Technical Reports Server (NTRS)

Aynbinder, S. G.; Klokova, E. F.

1980-01-01

Experiments were conducted to study the cohesion of metals with surface films of varying thickness and hardness. It was established that the deformation necessary for the occurrence of cohesion is determined by the correlation of mechanical properties of the films and the base metal. The greater the relative hardness of the film the lower the deformation necessary for the occurrence of cohesion. The films are as plastic as the base metal prevent cohesion, since in this case it is impossible for sections of metal to appear that are free of contaminants. The physical perculiarities of metals that determine their capability for coalescence under conditions of dry friction are the relative hardness and plasticity of the oxide films formed on their surface under atmospheric conditions.

Metal-on-metal hip joint tribology.

PubMed

Dowson, D; Jin, Z M

2006-02-01

The basic tribological features of metal-on-metal total hip replacements have been reviewed to facilitate an understanding of the engineering science underpinning the renaissance of these hard-on-hard joints. Metal-on-polymer hip replacements operate in the boundary lubrication regime, thus leading to the design guidance to reduce the femoral head diameter as much as is feasible to minimize frictional torque and volumetric wear. This explains why the gold-standard implant of this form from the past half-century had a diameter of only 22.225 mm (7/8 in). Metal-on-metal implants can operate in the mild mixed lubrication regime in which much of the applied load is supported by elastohydrodynamic films. Correct tribological design leads to remarkably low steady state wear rates. Promotion of the most effective elastohydrodynamic films calls for the largest possible head diameters and the smallest clearances that can reasonably be adopted, consistent with fine surface finishes, good sphericity and minimal structural elastic deformation of the cup on its foundations. This guidance, which is opposite in form to that developed for metal-on-polymer joints, is equally valid for solid (monolithic) metallic heads on metallic femoral stems and surface replacement femoral shells. Laboratory measurements of friction and wear in metal-on-metal joints have confirmed their potential to achieve a very mild form of mixed lubrication. The key lies in the generation of effective elastohydrodynamic lubricating films of adequate thickness compared with the composite roughness of the head and cup. The calculation of the film thickness is by no means easy, but the full procedure is outlined and the use of an empirical formula that displays good agreement with calculations based upon the full numerical solutions is explained. The representation of the lambda ratio, lambda, embracing both film thickness and composite roughness, is described.

Additive Manufacturing of Fuel Injectors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sadek Tadros, Dr. Alber Alphonse; Ritter, Dr. George W.; Drews, Charles Donald

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventionalmore » manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the

Optimization of Design and Manufacturing Process of Metal Foam Filled Anti-Intrusion Bars

NASA Astrophysics Data System (ADS)

Villa, Andrea; Strano, Matteo; Mussi, Valerio

2011-05-01

The role of an anti-intrusion bar for automotive use is to absorb the kinetic energy of the colliding bodies that is partially converted into internal work of the bodies involved in the crash. The aim of this paper is to investigate the performances of a new kind of anti-intrusion bars for automotive use, filled with metallic foams. The reason for using a cellular material as a filler deals with its capacity to absorb energy during plastic deformation, while being lightweight. The study is the evolution of a previous paper presented by the authors at Esaform 2010 and will present new results and findings. It is conducted by evaluating some key technical issues of the manufacturing problem and by conducting experimental and numerical analyses. The evaluation of materials and shapes of the closed sections to be filled is made in the perspective of a car manufacturer (production costs, weight reduction, space availability in a car door, etc.). Experimentally, foams are produced starting from an industrial aluminium precursor with a TiH2 blowing agent. Bars are tested in three point bending, in order to evaluate their performances in terms of force-displacement response and other specific performance parameters. In order to understand the role of interface between the inner surface of the tube and the external surface of the foam, different kinds of interface are tested.

In-situ acoustic signature monitoring in additive manufacturing processes

NASA Astrophysics Data System (ADS)

Koester, Lucas W.; Taheri, Hossein; Bigelow, Timothy A.; Bond, Leonard J.; Faierson, Eric J.

2018-04-01

Additive manufacturing is a rapidly maturing process for the production of complex metallic, ceramic, polymeric, and composite components. The processes used are numerous, and with the complex geometries involved this can make quality control and standardization of the process and inspection difficult. Acoustic emission measurements have been used previously to monitor a number of processes including machining and welding. The authors have identified acoustic signature measurement as a potential means of monitoring metal additive manufacturing processes using process noise characteristics and those discrete acoustic emission events characteristic of defect growth, including cracks and delamination. Results of acoustic monitoring for a metal additive manufacturing process (directed energy deposition) are reported. The work investigated correlations between acoustic emissions and process noise with variations in machine state and deposition parameters, and provided proof of concept data that such correlations do exist.

In Situ Production of Hard Metal Matrix Composite Coating on Engineered Surfaces Using Laser Cladding Technique

NASA Astrophysics Data System (ADS)

Raza, Mohammad Shahid; Hussain, Manowar; Kumar, Vikash; Das, Alok Kumar

2017-01-01

The growing need for high wear-resistant surface with enhanced physical properties has led to extensive researches in the field of surface engineering. Laser cladding emerged to be a promising method to achieve these objectives in a cost-effective way. The present paper studies the viability of cladding of tungsten disulfide (WS2) powder by using 400 W continuous-wave fiber laser. WS2 was used as a coating material, which was decomposed at higher temperature and underwent several chemical reactions. By this process, in situ formation of metal matrix composites and hard face coating on the substrate surface were attained. The characterization of laser cladded surface was done to study its morphological, microstructural, mechanical and tribological properties. It was observed that cladding of WS2 powder on 304 SS resulted in the formation of Cr-W-C-Fe metal matrix composite having improved mechanical and tribological properties. The value of microhardness of the coated surface was found to increase three to four times in comparison with the parent material surface. Wear test results indicated a decrease in wear by 1/9th (maximum) as compared to the parent 304 SS surface. The volume fractions of tungsten particles on the cladded surface were also investigated through EDS analysis.

Copper Disk Manufactured at the Space Optics Manufacturing and Technology Center

NASA Technical Reports Server (NTRS)

2001-01-01

This photograph shows Wes Brown, Marshall Space Flight Center's (MSFC's) lead diamond tuner, an expert in the science of using diamond-tipped tools to cut metal, inspecting the mold's physical characteristics to ensure the uniformity of its more than 6,000 grooves. This king-size copper disk, manufactured at the Space Optics Manufacturing and Technology Center (SOMTC) at MSFC, is a special mold for making high resolution monitor screens. This master mold will be used to make several other molds, each capable of forming hundreds of screens that have a type of lens called a fresnel lens. Weighing much less than conventional optics, fresnel lenses have multiple concentric grooves, each formed to a precise angle, that together create the curvature needed to focus and project images. The MSFC leads NASA's space optics manufacturing technology development as a technology leader for diamond turning. The machine used to manufacture this mold is among many one-of-a-kind pieces of equipment of MSFC's SOMTC.

Computed Tomography Inspection and Analysis for Additive Manufacturing Components

NASA Technical Reports Server (NTRS)

Beshears, Ronald D.

2016-01-01

Computed tomography (CT) inspection was performed on test articles additively manufactured from metallic materials. Metallic AM and machined wrought alloy test articles with programmed flaws were inspected using a 2MeV linear accelerator based CT system. Performance of CT inspection on identically configured wrought and AM components and programmed flaws was assessed using standard image analysis techniques to determine the impact of additive manufacturing on inspectability of objects with complex geometries.

Progress in cold roll bonding of metals

PubMed Central

Li, Long; Nagai, Kotobu; Yin, Fuxing

2008-01-01

Layered composite materials have become an increasingly interesting topic in industrial development. Cold roll bonding (CRB), as a solid phase method of bonding same or different metals by rolling at room temperature, has been widely used in manufacturing large layered composite sheets and foils. In this paper, we provide a brief overview of a technology using layered composite materials produced by CRB and discuss the suitability of this technology in the fabrication of layered composite materials. The effects of process parameters on bonding, mainly including process and surface preparation conditions, have been analyzed. Bonding between two sheets can be realized when deformation reduction reaches a threshold value. However, it is essential to remove surface contamination layers to produce a satisfactory bond in CRB. It has been suggested that the degreasing and then scratch brushing of surfaces create a strong bonding between the layers. Bonding mechanisms, in which the film theory is expressed as the major mechanism in CRB, as well as bonding theoretical models, have also been reviewed. It has also been showed that it is easy for bcc structure metals to bond compared with fcc and hcp structure metals. In addition, hardness on bonding same metals plays an important part in CRB. Applications of composites produced by CRB in industrial fields are briefly reviewed and possible developments of CRB in the future are also described. PMID:27877949

Optical fibre sensing in metals by embedment in 3D printed metallic structures

NASA Astrophysics Data System (ADS)

Maier, R. R. J.; Havermann, D.; Schneller, O.; Mathew, J.; Polyzos, D.; MacPherson, W. N.; Hand, D. P.

2014-05-01

Additive manufacturing or 3D printing of structural components in metals has potential to revolutionise the manufacturing industry. Embedded sensing in such structures opens a route towards SMART metals, providing added functionality, intelligence and enhanced performance in many components. Such embedded sensors would be capable of operating at extremely high temperatures by utilizing regenerated fibre Bragg gratings and in-fibre Fabry-Perot cavities.

Laser polishing of additive manufactured Ti alloys

NASA Astrophysics Data System (ADS)

Ma, C. P.; Guan, Y. C.; Zhou, W.

2017-06-01

Laser-based additive manufacturing has attracted much attention as a promising 3D printing method for metallic components in recent years. However, surface roughness of additive manufactured components has been considered as a challenge to achieve high performance. In this work, we demonstrate the capability of fiber laser in polishing rough surface of additive manufactured Ti-based alloys as Ti-6Al-4V and TC11. Both as-received surface and laser-polished surfaces as well as cross-section subsurfaces were analyzed carefully by White-Light Interference, Confocal Microscope, Focus Ion Beam, Scanning Electron Microscopy, Energy Dispersive Spectrometer, and X-ray Diffraction. Results revealed that as-received Ti-based alloys with surface roughness more than 5 μm could be reduce to less than 1 μm through laser polishing process. Moreover, microstructure, microhardness and wear resistance of laser-polished zone was investigated in order to examine the thermal effect of laser polishing processing on the substrate of additive manufactured Ti alloys. This proof-of-concept process has the potential to effectively improve the surface roughness of additive manufactured metallic alloy by local polishing method without damage to the substrate.

Multi-methodological investigation of the variability of the microstructure of HPMC hard capsules.

PubMed

Faulhammer, E; Kovalcik, A; Wahl, V; Markl, D; Stelzer, F; Lawrence, S; Khinast, J G; Paudel, A

2016-09-25

The objective of this study was to analyze differences in the subtle microstructure of three different grades of HMPC hard capsule shells using mechanical, spectroscopic, microscopic and tomographic approaches. Dynamic mechanical analysis (DMA), thermogravimetric analysis (TGA), vibrational spectroscopic, X-Ray scattering techniques as well as environmental scanning electron microscopy (ESEM) and optical coherence tomography (OCT) were used. Two HPMC capsules manufactured via chemical gelling, one capsule shell manufactured via thermal gelling and one thermally gelled transparent capsule were included. Characteristic micro-structural alterations (associated manufacturing processes) such as mechanical and physical properties relevant to capsule performance and processability were thoroughly elucidated with the integration of data obtained from multi-methodological investigations. The physico-chemical and physico-mechanical data obtained from a gamut of techniques implied that thermally gelled HPMC hard capsule shells could offer an advantage in terms of machinability during capsule filling, owing to their superior micro- and macroscopic structure as well as specifically the mechanical stability under dry or humid conditions. Copyright © 2016 Elsevier B.V. All rights reserved.

Precision replenishable grinding tool and manufacturing process

DOEpatents

Makowiecki, D.M.; Kerns, J.A.; Blaedel, K.L.; Colella, N.J.; Davis, P.J.; Juntz, R.S.

1998-06-09

A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool are disclosed. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools. 11 figs.

Precision replenishable grinding tool and manufacturing process

DOEpatents

Makowiecki, Daniel M.; Kerns, John A.; Blaedel, Kenneth L.; Colella, Nicholas J.; Davis, Pete J.; Juntz, Robert S.

1998-01-01

A reusable grinding tool consisting of a replaceable single layer of abrasive particles intimately bonded to a precisely configured tool substrate, and a process for manufacturing the grinding tool. The tool substrate may be ceramic or metal and the abrasive particles are preferably diamond, but may be cubic boron nitride. The manufacturing process involves: coating a configured tool substrate with layers of metals, such as titanium, copper and titanium, by physical vapor deposition (PVD); applying the abrasive particles to the coated surface by a slurry technique; and brazing the abrasive particles to the tool substrate by alloying the metal layers. The precision control of the composition and thickness of the metal layers enables the bonding of a single layer or several layers of micron size abrasive particles to the tool surface. By the incorporation of an easily dissolved metal layer in the composition such allows the removal and replacement of the abrasive particles, thereby providing a process for replenishing a precisely machined grinding tool with fine abrasive particles, thus greatly reducing costs as compared to replacing expensive grinding tools.

Method for manufacturing magnetohydrodynamic electrodes

DOEpatents

Killpatrick, Don H.; Thresh, Henry R.

1982-01-01

A method of manufacturing electrodes for use in a magnetohydrodynamic (MHD) generator comprising the steps of preparing a billet having a core 10 of a first metal, a tubular sleeve 12 of a second metal, and an outer sheath 14, 16, 18 of an extrusile metal; evacuating the space between the parts of the assembled billet; extruding the billet; and removing the outer jacket 14. The extruded bar may be made into electrodes by cutting and bending to the shape required for an MDH channel frame. The method forms a bond between the first metal of the core 10 and the second metal of the sleeve 12 strong enough to withstand a hot and corrosive environment.

Additive Manufacturing of Porous Metal

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dehoff, Ryan R.; Kirka, Michael M.

2017-06-01

Currently, helium is obtained through separation from natural gas. The current industrial process incurs significant costs and requires large energy resources to successfully achieve separation. Through utilizing Additive Manufacturing (AM) technologies it is possible to reduce both of these burdens when refining helium gas. The ability to engineer porosity levels within Inconel 718 discs for controlled separation of helium from natural gas was investigated. Arrays of samples fabricated using the electron beam melting process were analyzed for their relative porosity density. Based upon the measurements, full scale discs were fabricated, and subsequently tested to determine their effectiveness in separating heliummore » from liquefied natural gas.« less

Manufacturing and integration of the SOFIA suspension assembly

NASA Astrophysics Data System (ADS)

Sust, Eberhard; Weis, Ulrich; Bremers, Eckhard; Schubbach, Walter

2003-02-01

The Suspension Assembly is the most complex mechanical subsystem of the SOFIA telescope, responsible for suspending and positioning the telescope in the aircraft on the sky. It is a highly integrated system comprising of a vibration isolating system, a spherical hydraulic bearing, a spherical torque motor, a coarse drive and airworthiness relevant components like brakes, hard-stops etc. The components were manufactured under airworthiness standards by dedicated suppliers and integrated and commissioned in 2001/2002 at MAN Technologie in Augsburg. The paper describes the experience gotten during the manufacturing and integration process.

The development of additive manufacturing technique for nickel-base alloys: A review

NASA Astrophysics Data System (ADS)

Zadi-Maad, Ahmad; Basuki, Arif

2018-04-01

Nickel-base alloys are an attractive alloy due to its excellent mechanical properties, a high resistance to creep deformation, corrosion, and oxidation. However, it is a hard task to control performance when casting or forging for this material. In recent years, additive manufacturing (AM) process has been implemented to replace the conventional directional solidification process for the production of nickel-base alloys. Due to its potentially lower cost and flexibility manufacturing process, AM is considered as a substitute technique for the existing. This paper provides a comprehensive review of the previous work related to the AM techniques for Ni-base alloys while highlighting current challenges and methods to solving them. The properties of conventionally manufactured Ni-base alloys are also compared with the AM fabricated alloys. The mechanical properties obtained from tension, hardness and fatigue test are included, along with discussions of the effect of post-treatment process. Recommendations for further work are also provided.

Collaborative Manufacturing for Small-Medium Enterprises

NASA Astrophysics Data System (ADS)

Irianto, D.

2016-02-01

Manufacturing systems involve decisions concerning production processes, capacity, planning, and control. In a MTO manufacturing systems, strategic decisions concerning fulfilment of customer requirement, manufacturing cost, and due date of delivery are the most important. In order to accelerate the decision making process, research on decision making structure when receiving order and sequencing activities under limited capacity is required. An effective decision making process is typically required by small-medium components and tools maker as supporting industries to large industries. On one side, metal small-medium enterprises are expected to produce parts, components or tools (i.e. jigs, fixture, mold, and dies) with high precision, low cost, and exact delivery time. On the other side, a metal small- medium enterprise may have weak bargaining position due to aspects such as low production capacity, limited budget for material procurement, and limited high precision machine and equipment. Instead of receiving order exclusively, a small-medium enterprise can collaborate with other small-medium enterprise in order to fulfill requirements high quality, low manufacturing cost, and just in time delivery. Small-medium enterprises can share their best capabilities to form effective supporting industries. Independent body such as community service at university can take a role as a collaboration manager. The Laboratory of Production Systems at Bandung Institute of Technology has implemented shared manufacturing systems for small-medium enterprise collaboration.

Extreme-value statistics reveal rare failure-critical defects in additive manufacturing

DOE PAGES

Boyce, Brad L.; Salzbrenner, Bradley C.; Rodelas, Jeffrey M.; ...

2017-04-21

Additive manufacturing enables the rapid, cost effective production of large populations of material test coupons such as tensile bars. By adopting streamlined test methods including ‘drop-in’ grips and non-contact extensometry, testing these large populations becomes more efficient. Unlike hardness tests, the tensile test provides a direct measure of yield strength, flow properties, and ductility, which can be directly incorporated into solid mechanics simulations. In the present work, over 1000 nominally identical tensile tests were used to explore the effect of process variability on the mechanical property distributions of a precipitation hardened stainless steel, 17-4PH, produced by a laser powder bedmore » fusion process, also known as direct metal laser sintering. With this large dataset, rare defects are revealed that affect only ~2% of the population, stemming from a single build lot of material. Lastly, the rare defects caused a substantial loss in ductility and were associated with an interconnected network of porosity.« less

Producing Hybrid Metal Composites by Combining Additive Manufacturing and Casting

DOE PAGES

Pawlowski, Alex E.; Splitter, Derek A.; Muth, Thomas R.; ...

2017-10-01

Additive manufacturing by itself provides many benefits, but by combining different materials processing techniques like traditional casting with additive manufacturing to create hybrid processes, custom materials can be tailor-made and mass produced for applications with specific performance needs.

A comparison of the wear resistance and hardness of indirect composite resins.

PubMed

Mandikos, M N; McGivney, G P; Davis, E; Bush, P J; Carter, J M

2001-04-01

Various new, second-generation indirect composites have been developed with claimed advantages over existing tooth-colored restorative materials. To date, little independent research has been published on these materials, and the properties specified in the advertising materials are largely derived from in-house or contracted testing. Four second-generation indirect composites (Artglass, belleGlass, Sculpture, and Targis) were tested for wear resistance and hardness against 2 control materials with well-documented clinical application. Human enamel was also tested for comparison. Twelve specimens of each material were fabricated according to the manufacturers' directions and subjected to accelerated wear in a 3-body abrasion, toothbrushing apparatus. Vickers hardness was measured for each of the tested materials, and energy dispersive x-ray (EDX) spectroscopy was performed to determine the elemental composition of the composite fillers. The statistical tests used for wear and hardness were the Kruskal-Wallis 1-way ANOVA test with Mann-Whitney tests and 1-way ANOVA with multiple comparisons (Tukey HSD). The Pearson correlation coefficient was used to determine the existence of a relationship between the hardness of the materials and the degree to which they had worn. The level of statistical significance chosen was alpha=.05. The control material Concept was superior to the other composites in wear resistance and hardness and had the lowest surface roughness. Significant relationships were observed between depth of wear and hardness and between depth of wear and average surface roughness. Enamel specimens were harder and more wear resistant than any of the composites. EDX spectroscopy revealed that the elemental composition of the fillers of the 4 new composites was almost identical, as was the composition of the 2 control composites. The differences in wear, hardness, and average surface roughness may have been due to differences in the chemistry or method of

Cobalt deposition in mineralized bone tissue after metal-on-metal hip resurfacing: Quantitative μ-X-ray-fluorescence analysis of implant material incorporation in periprosthetic tissue.

PubMed

Hahn, Michael; Busse, Björn; Procop, Mathias; Zustin, Jozef; Amling, Michael; Katzer, Alexander

2017-10-01

Most resurfacing systems are manufactured from cobalt-chromium alloys with metal-on-metal (MoM) bearing couples. Because the quantity of particulate metal and corrosion products which can be released into the periprosthetic milieu is greater in MoM bearings than in metal-on-polyethylene (MoP) bearings, it is hypothesized that the quantity and distribution of debris released by the MoM components induce a compositional change in the periprosthetic bone. To determine the validity of this claim, nondestructive µ-X-ray fluorescence analysis was carried out on undecalcified histological samples from 13 femoral heads which had undergone surface replacement. These samples were extracted from the patients after gradient time points due to required revision surgery. Samples from nonintervened femoral heads as well as from a MoP resurfaced implant served as controls. Light microscopy and µ-X-ray fluorescence analyses revealed that cobalt debris was found not only in the soft tissue around the prosthesis and the bone marrow, but also in the mineralized bone tissue. Mineralized bone exposed to surface replacements showed significant increases in cobalt concentrations in comparison with control specimens without an implant. A maximum cobalt concentration in mineralized hard tissue of up to 380 ppm was detected as early as 2 years after implantation. Values of this magnitude are not found in implants with a MoP surface bearing until a lifetime of more than 20 years. This study demonstrates that hip resurfacing implants with MoM bearings present a potential long-term health risk due to rapid cobalt ion accumulation in periprosthetic hard tissue. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 1855-1862, 2017. © 2016 Wiley Periodicals, Inc.

A new, bright and hard aluminum surface produced by anodization

NASA Astrophysics Data System (ADS)

Hou, Fengyan; Hu, Bo; Tay, See Leng; Wang, Yuxin; Xiong, Chao; Gao, Wei

2017-07-01

Anodized aluminum (Al) and Al alloys have a wide range of applications. However, certain anodized finishings have relatively low hardness, dull appearance and/or poor corrosion resistance, which limited their applications. In this research, Al was first electropolished in a phosphoric acid-based solution, then anodized in a sulfuric acid-based solution under controlled processing parameters. The anodized specimen was then sealed by two-step sealing method. A systematic study including microstructure, surface morphology, hardness and corrosion resistance of these anodized films has been conducted. Results show that the hardness of this new anodized film was increased by a factor of 10 compared with the pure Al metal. Salt spray corrosion testing also demonstrated the greatly improved corrosion resistance. Unlike the traditional hard anodized Al which presents a dull-colored surface, this newly developed anodized Al alloy possesses a very bright and shiny surface with good hardness and corrosion resistance.

Mechanics of hard films on soft substrates

NASA Astrophysics Data System (ADS)

Lu, Nanshu

2009-12-01

Flexible electronics have been developed for various applications, including paper-like electronic readers, rollable solar cells, electronic skins etc., with the merits of light weight, low cost, large area, and ruggedness. The systems may be subject to one-time or repeated large deformation during manufacturing and application. Although organic materials can be highly deformable, currently they are not able to fulfill every electronic function. Therefore flexible electronic devices are usually made as organic/inorganic hybrids, with diverse materials, complex architecture, and micro features. While the polymer substrates can recover from large deformations, thin films of electronic materials such as metals, silicon, oxides, and nitrides fracture at small strains, usually less than a few percent. Mechanics of hard films on soft substrates hence holds the key to build high-performance and highly reliable flex circuits. This thesis investigates the deformability and failure mechanisms of thin films of metallic and ceramic materials supported by soft polymeric substrates through combined experimental, theoretical, and numerical methods. When subject to tension, micron-thick metal films with stable microstructure and strong interfacial adhesion to the substrate can be stretched beyond 50% without forming cracks. They eventually rupture by a ductile transgranular fracture which involves simultaneous necking and debonding. When metal films become nanometer-thick, intergranular fracture dominates the failure mode at elongations of only a few percent. Unannealed films show unstable microstructure at room temperature when subject to mechanical loading. In this case, films also rupture at small strains but by three concurrent mechanisms: deformation-induced grain growth, strain localization at large grains, and simultaneous debonding. In contrast to metal films, ceramic films rupture by brittle mechanisms. The only way to prevent rupture of ceramic films is to reduce the

New insights on the hard-to-boil massecuite phenomenon in raw sugar manufacture

USDA-ARS?s Scientific Manuscript database

Hard-to-boil (HTB) massecuites (mixture of sucrose crystals in molasses) with markedly low heat transfer properties are a sporadic but continuing problem in sugarcane factories, which causes raw sugar and molasses production to decrease and increase, respectively. It usually occurs after severely d...

Qualitative Assessment of Wear Resistance and Surface Hardness of Different Commercially Available Dental Porcelain: An in vitro Study.

PubMed

Singh, Abhishek; Nagpal, Abhishek; Pawah, Salil; Pathak, Chetan; Issar, Gaurav; Sharma, Pankaj

2016-09-01

In an attempt to minimize wear damage to the enamel of antagonist teeth, new low and medium fusing ceramic materials have been developed. Manufacturers usually claim that these ceramics are wear-friendly because of their lower hardness, lower concentrations of crystal phase, and smaller crystal sizes. This study aimed to quantitatively analyze the wear strength of various commercially available dental porcelain with tooth enamel as well as the surface hardness of these dental porcelain. The basic model was designed as a pin on plate arrangement. The tooth specimens were mounted on the stylus which was centered on the ceramic specimen in a wear testing machine. The dental ceramic specimen was centered in the metal die. A load of 40 N was applied at a rate of 80 cycles/minute for 15 minutes. In the current study, mean wear depth (Ra) value, volumetric loss, and surface hardness were obtained by standard quantification method and were statistically evaluated. Ceramco-3 was reported to be most abrasive for enamel; however, Duceram love significantly more abraded itself than the other two, Ceramco-3 and Vita Alpha, and generated the lowest loss of enamel. Also, same abrasive type of wear was revealed for all three variants of tested ceramics. Ceramco-3 was the most abrasive for enamel, while surface roughness (mean wear depth) of Duceram love was maximum and for Ceramco-3 it was minimum. The value of surface roughness for Vita Alpha was in between Duceram love and Ceramco-3. Nonetheless, the mean surface hardness of Duceram love was found to be least and maximum for Vita Alpha. In situations of dental wear and wasting tooth disease (Attrition/Abrasion), Duceram can be applied in lieu of Ceramco-3 so as to prevent worsening of existing dentition. However, in younger patients Vita Alpha would offer maximum durability due to its greater surface hardness.

Friction and hardness of gold films deposited by ion plating and evaporation

NASA Technical Reports Server (NTRS)

Miyoshi, K.; Spalvins, T.; Buckley, D. H.

1983-01-01

Sliding friction experiments were conducted with ion-plated and vapor-deposited gold films on various substrates in contact with a 0.025-mm-radius spherical silicon carbide rider in mineral oil. Hardness measurements were also made to examine the hardness depth profile of the coated gold on the substrate. The results indicate that the hardness is influenced by the depth of the gold coating from the surface. The hardness increases with an increase in the depth. The hardness is also related to the composition gradient in the graded interface between the gold coating and the substrate. The graded interface exhibited the highest hardness resulting from an alloy hardening effect. The coefficient of friction is inversely related to the hardness, namely, the load carrying capacity of the surface. The greater the hardness that the metal surface possesses, the lower is the coefficient of friction. The graded interface exhibited the lowest coefficient of friction.

Microjet formation and hard x-ray production from a liquid metal target irradiated by intense femtosecond laser pulses

NASA Astrophysics Data System (ADS)

Lar'kin, A.; Uryupina, D.; Ivanov, K.; Savel'ev, A.; Bonnet, T.; Gobet, F.; Hannachi, F.; Tarisien, M.; Versteegen, M.; Spohr, K.; Breil, J.; Chimier, B.; Dorchies, F.; Fourment, C.; Leguay, P.-M.; Tikhonchuk, V. T.

2014-09-01

By using a liquid metal as a target one may significantly enhance the yield of hard x-rays with a sequence of two intense femtosecond laser pulses. The influence of the time delay between the two pulses is studied experimentally and interpreted with numerical simulations. It was suggested that the first arbitrary weak pulse produces microjets from the target surface, while the second intense pulse provides an efficient electron heating and acceleration along the jet surface. These energetic electrons are the source of x-ray emission while striking the target surface. The microjet formation is explained based on the results given by both optical diagnostics and hydrodynamic modeling by a collision of shocks originated from two distinct zones of laser energy deposition.

Numerical simulation of metallic wire arc additive manufacturing (WAAM)

NASA Astrophysics Data System (ADS)

Graf, M.; Pradjadhiana, K. P.; Hälsig, A.; Manurung, Y. H. P.; Awiszus, B.

2018-05-01

Additive-manufacturing technologies have been gaining tremendously in popularity for some years in the production of single-part series with complex, close-to-final-contour geometries and the processing of special or hybrid materials. In principle, the processes can be subdivided into wire-based and powder-based processes in accordance with the Association of German Engineers (VDI) Guideline 3405. A further subdivision is made with respect to the smelting technology. In all of the processes, the base material is applied in layers at the points where it is needed in accordance with the final contour. The process that was investigated was wire-based, multi-pass welding by means of gas-metal arc welding. This was accomplished in the present study by determining the material parameters (thermo-mechanical and thermo-physical characteristics) of the welding filler G3Si1 (material number: 1.5125) that were necessary for the numerical simulation and implementing them in a commercial FE program (MSC Marc Mentat). The focus of this paper was on simulation and validation with respect to geometry and microstructural development in the welding passes. The resulting minimal deviation between reality and simulation was a result of the measurement inertia of the thermocouples. In general, however, the FE model can be used to make a very good predetermination of the cooling behaviour, which affects the microstructural development and thus the mechanical properties of the joining zone, as well as the geometric design of the component (distortion, etc.).

Influence of design variables on radiation hardness of silicon MINP solar cells

NASA Technical Reports Server (NTRS)

Anderson, W. A.; Solaun, S.; Rao, B. B.; Banerjee, S.

1985-01-01

Metal-insulator-N/P silicon (MINP) solar cells were fabricated using different substrate resistivity values, different N-layer designs, and different I-layer designs. A shallow junction into an 0.3 ohm-cm substrate gave best efficiency whereas a deeper junction into a 1 to 4 ohm-cm substrate gave improved radiation hardness. I-layer design variation did little to influence radiation hardness.

Synthesis and Characterization of Low-Cost Superhard Transition-Metal Borides

NASA Astrophysics Data System (ADS)

Kaner, Richard

2013-06-01

The increasing demand for high-performance cutting and forming tools, along with the shortcomings of traditional tool materials such as diamond (unable to cut ferrous materials), cubic boron nitride (expensive) and tungsten carbide (relatively-low hardness), has motivated the search for new superhard materials for these applications. This has led us to a new class of superhard materials, dense refractory transition-metal borides, which promise to address some of the existing problems of conventional superhard materials. For example, we have synthesized rhenium diboride (ReB2) using arc melting at ambient pressure. This superhard material has demonstrated an excellent electrical conductivity and superior mechanical properties, including a Vickers hardness of 48.0 GPa (under an applied load of 0.49 N). To further increase the hardness and lower the materials costs, we have begun exploring high boron content metal borides including tungsten tetraboride (WB4) . We have synthesized WB4 by arc melting and studied its hardness and high-pressure behavior. With a similar Vickers hardness (43.3 GPa under a load of 0.49 N) and bulk modulus (326-339 GPa) to ReB2, WB4 offers a lower cost alternative and has the potential to be used in cutting tools. To further enhance the hardness of this superhard metal, we have created the binary and ternary solid solutions of WB4 with Cr, Mn and Ta, the results of which show a hardness increase of up to 20 percent. As with other metals, these metallic borides can be readily cut and shaped using electric discharge machining (EDM).

Using Innovative Techniques for Manufacturing Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, Erin M.; Reynolds, David C.; Eddleman, David E.; Hardin, Andy

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using the Workhorse Gas Generator (WHGG) test setup at MSFC?s East Test Area test stand 116, the duct was subject to extreme J-2X gas generator environments and endured a total of 538 seconds of hot-fire time. The duct survived the testing and was inspected after the test. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

WASTE MINIMIZATION ASSESSMENT FOR A MANUFACTURER OF SHEET METAL COMPONENTS

EPA Science Inventory

The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. n an effort to assist these manufacturers Waste Minimization ssessment Cente...

Response of benthic invertebrate assemblages to metal exposure and bioaccumulation associated with hard-rock mining in northwestern streams, USA

USGS Publications Warehouse

Maret, T.R.; Cain, D.J.; MacCoy, D.E.; Short, T.M.

2003-01-01

Benthic macroinvertebrate assemblages, environmental variables, and associated mine density were evaluated during the summer of 2000 at 18 reference and test sites in the Coeur d'Alene and St. Regis River basins, northwestern USA as part of the US Geological Survey's National Water-Quality Assessment Program. Concentrations of Cd, Pb, and Zn in water and (or) streambed sediment at test sites in basins where production mine density was ???0.2 mines/km2 (in a 500-m stream buffer) were significantly higher than concentrations at reference sites. Zn and Pb were identified as the primary contaminants in water and streambed sediment, respectively. These metal concentrations often exceeded acute Ambient Water Quality Criteria for aquatic life and the National Oceanic and Atmospheric Administration Probable Effect Level for streambed sediment. Regression analysis identified significant correlations between production mine density in each basin and Zn concentrations in water and Pb in streambed sediment (r2 = 0.69 and 0.65, p < 0.01). Metal concentrations in caddisfly tissue, used to verify site-specific exposures of benthos, also were highest at sites downstream from intensive mining. Benthic invertebrate taxa richness and densities were lower at sites downstream than upstream of areas of intensive hard-rock mining and associated metal enrichment. Benthic invertebrate metrics that were most effective in discriminating changes in assemblage structure between reference and mining sites were total number of taxa, number of Ephemeroptera, Plecoptera, and Trichoptera (EPT) taxa, and densities of total individuals, EPT individuals, and metal-sensitive Ephemeroptera individuals.

Space Manufacturing: The Next Great Challenge

NASA Technical Reports Server (NTRS)

Whitaker, Ann F.; Curreri, Peter; Sharpe, Jonathan B.; Colberg, Wendell R.; Vickers, John H.

1998-01-01

Space manufacturing encompasses the research, development and manufacture necessary for the production of any product to be used in near zero gravity, and the production of spacecraft required for transporting research or production devices to space. Manufacturing for space, and manufacturing in space will require significant breakthroughs in materials and manufacturing technology, as well as in equipment designs. This report reviews some of the current initiatives in achieving space manufacturing. The first initiative deals with materials processing in space, e.g., processing non-terrestrial and terrestrial materials, especially metals. Some of the ramifications of the United States Microgravity Payloads fourth (USMP-4) mission are discussed. Some problems in non-terrestrial materials processing are mentioned. The second initiative is structures processing in space. In order to accomplish this, the International Space Welding Experiment was designed to demonstrate welding technology in near-zero gravity. The third initiative is advancements in earth-based manufacturing technologies necessary to achieve low cost access to space. The advancements discussed include development of lightweight material having high specific strength, and automated fabrication and manufacturing methods for these materials.

Electro-optic product design for manufacture: where next?

NASA Astrophysics Data System (ADS)

Barr, John R. M.; MacDonald, M.; Jeffery, G.; Troughton, M.

2016-10-01

Manufacturing of electro-optic products for military environments poses a large number of apparently intractable and mutually contradictory problems. The ability to successfully engage in this area presents an intellectual challenge of a high order. The Advanced Targeting Sector of Leonardo's Airborne and Space Systems Division, based in Edinburgh, has developed a successful range of electro-optic products and transitioned these into a volume, and high value, manufacturing environment. As products cycle through the design process, there has been strong feedback from users, suppliers, and most importantly from our manufacturing organization, that has driven evolution of our design practices. It is fair to say that recent pointer trackers and lasers bear little resemblance to those designed and built 10 years ago. Looking ahead, this process will only continue. There are interesting technologies that will drive improvements in manufacturability, reliability and usability of electro-optic products. Examples might include freeform optics, additive manufacture of metal components, and laser welding of optics to metals, to name but a few. These have uses across our product portfolio and, when sufficiently matured, will have a major impact on the product quality and reliability

Microstructure and High Temperature Oxidation Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Powder Injection Molding Process

NASA Astrophysics Data System (ADS)

Joo, Yeun-Ah; Kim, Young-Kyun; Yoon, Tae-Sik; Lee, Kee-Ahn

2018-03-01

This study investigated the microstructure and high temperature oxidation property of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding process. Observations of initial microstructure showed a unique structure where α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performed at 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84 and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented parabolic curves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identified Cr2O3 and SiO2 at 900 and 1000 °C. In addition to Cr2O3 and SiO2, CrBO3 and FeCr2O4 formed due to phase decomposition of boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidation mechanism of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding, and the possibility of its application as a high temperature component material was also discussed.

Novel Structured Metal Bipolar Plates for Low Cost Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Conghua

Bipolar plates are an important component in fuel cell stacks and accounts for more than 75% of stack weight and volume, and 20% of the stack cost. The technology development of metal bipolar plates can effectively reduce the fuel cells stack weight and volume over 50%. The challenge is to protect metal plate from corrosion at low cost for the broad commercial applications. While most of today’s PEM fuel cell metallic bipolar plate technologies use some precious metal, the focus of this SBIR project is to develop a low cost, novel nano-structured metal bipolar plate coating technology without using anymore » precious metal. The technology must meet the performance and cost requirements for automobile applications.« less

Technique for microswitch manufacture

NASA Technical Reports Server (NTRS)

Kitamura, T.; Kiyoyama, S.

1983-01-01

A five-step technique for microswitch manufacture is described: (1) A clad board is inlaid with a precious metal and the board is pressed. (2) One end of the fixed contact containing a precious metal inlay section is curved, and this edge of the precious metal inlay section becomes a fixed contact. (3) Inserts are formed in the unit body and terminal strips are placed through the top and bottom of the base and held. (4) The unit body is held by the base and the sequential contact strips are cut off. (5) Movable stripes are attached to the support of the terminal strips on the movable side and movable contacts are placed opposite the fixed contacts.

New Nomenclatures for Heat Treatments of Additively Manufactured Titanium Alloys

NASA Astrophysics Data System (ADS)

Baker, Andrew H.; Collins, Peter C.; Williams, James C.

2017-07-01

The heat-treatment designations and microstructure nomenclatures for many structural metallic alloys were established for traditional metals processing, such as casting, hot rolling or forging. These terms do not necessarily apply for additively manufactured (i.e., three-dimensionally printed or "3D printed") metallic structures. The heat-treatment terminology for titanium alloys generally implies the heat-treatment temperatures and their sequence relative to a thermomechanical processing step (e.g., forging, rolling). These designations include: β-processing, α + β-processing, β-annealing, duplex annealing and mill annealing. Owing to the absence of a thermomechanical processing step, these traditional designations can pose a problem when titanium alloys are first produced via additive manufacturing, and then heat-treated. This communication proposes new nomenclatures for heat treatments of additively manufactured titanium alloys, and uses the distinct microstructural features to provide a correlation between traditional nomenclature and the proposed nomenclature.

Current use and potential of additive manufacturing for optical applications

NASA Astrophysics Data System (ADS)

Brunelle, Matthew; Ferralli, Ian; Whitsitt, Rebecca; Medicus, Kate

2017-10-01

Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. Because the parts are created in a layer-by-layer manner, the flexibility of additive manufacturing is unparalleled and has opened the design space to enable features like undercuts and internal channels which cannot exist on traditional, subtractively manufactured parts. This flexibility can also be leveraged for optical applications. This paper outlines some of the current uses of 3D printing in the optical manufacturing process at Optimax. Several materials and additive technologies are utilized, including polymer printing through fused deposition modeling, which creates parts by depositing a softened thermoplastic filament in a layerwise fashion. Stereolithography, which uses light to cure layers of a photopolymer resin, will also be discussed. These technologies are used to manufacture functional prototypes, fixtures, sealed housings, and other components. Additionally, metal printing through selective laser melting, which uses a laser to melt metal powder layers into a dense solid, will be discussed due to the potential to manufacture thermally stable opticalmechanical assembly frameworks and functional optics. Examples of several additively manufactured optical components will be shown.

The Influence of Wheel/Rail Contact Conditions on the Microstructure and Hardness of Railway Wheels

PubMed Central

Davis, Claire

2014-01-01

The susceptibility of railway wheels to wear and rolling contact fatigue damage is influenced by the properties of the wheel material. These are influenced by the steel composition, wheel manufacturing process, and thermal and mechanical loading during operation. The in-service properties therefore vary with depth below the surface and with position across the wheel tread. This paper discusses the stress history at the wheel/rail contact (derived from dynamic simulations) and observed variations in hardness and microstructure. It is shown that the hardness of an “in-service” wheel rim varies significantly, with three distinct effects. The underlying hardness trend with depth can be related to microstructural changes during manufacturing (proeutectoid ferrite fraction and pearlite lamellae spacing). The near-surface layer exhibits plastic flow and microstructural shear, especially in regions which experience high tangential forces when curving, with consequentially higher hardness values. Between 1 mm and 7 mm depth, the wheel/rail contacts cause stresses exceeding the material yield stress, leading to work hardening, without a macroscopic change in microstructure. These changes in material properties through the depth of the wheel rim would tend to increase the likelihood of crack initiation on wheels toward the end of their life. This correlates with observations from several train fleets. PMID:24526883

Investigations on the corrosion resistance of metallic bipolar plates (BPP) in proton exchange membrane fuel cells (PEMFC) - understanding the effects of material, coating and manufacturing

NASA Astrophysics Data System (ADS)

Dur, Ender

Polymer Electrolyte Membrane Fuel Cell (PEMFC) systems are promising technology for contributing to meet the deficiency of world`s clean and sustainable energy requirements in the near future. Metallic bipolar plate (BPP) as one of the most significant components of PEMFC device accounts for the largest part of the fuel cell`s stack. Corrosion for metallic bipolar plates is a critical issue, which influences the performance and durability of PEMFC. Corrosion causes adverse impacts on the PEMFC`s performance jeopardizing commercialization. This research is aimed at determining the corrosion resistance of metallic BPPs, particularly stainless steels, used in PEMFC from different aspects. Material selection, coating selection, manufacturing process development and cost considerations need to be addressed in terms of the corrosion behavior to justify the use of stainless steels as a BPP material in PEMFC and to make them commercially feasible in industrial applications. In this study, Ti, Ni, SS304, SS316L, and SS 430 blanks, and BPPs comprised of SS304 and SS316L were examined in terms of the corrosion behavior. SS316L plates were coated to investigate the effect of coatings on the corrosion resistance performance. Stamping and hydroforming as manufacturing processes, and three different coatings (TiN, CrN, ZrN) applied via the Physical Vapor Deposition (PVD) method in three different thicknesses were selected to observe the effects of manufacturing processes, coating types and coating thicknesses on the corrosion resistance of BPP, respectively. Uncoated-coated blank and formed BPP were subjected to two different corrosion tests: potentiostatic and potentiodynamic. Some of the substantial results: 1- Manufacturing processes have an adverse impact on the corrosion resistance. 2- Hydroformed plates have slightly higher corrosion resistance than stamped samples. 3- BPPs with higher channel size showed better corrosion resistance. 4- Since none of the uncoated samples

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian

2003-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA.s Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aide in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing

Metallization of bacterial cellulose for electrical and electronic device manufacture

DOEpatents

Evans, Barbara R [Oak Ridge, TN; O'Neill, Hugh M [Knoxville, TN; Jansen, Valerie Malyvanh [Memphis, TN; Woodward, Jonathan [Knoxville, TN

2011-06-07

A method for the deposition of metals in bacterial cellulose and for the employment of the metallized bacterial cellulose in the construction of fuel cells and other electronic devices is disclosed. The method for impregnating bacterial cellulose with a metal comprises placing a bacterial cellulose matrix in a solution of a metal salt such that the metal salt is reduced to metallic form and the metal precipitates in or on the matrix. The method for the construction of a fuel cell comprises placing a hydrated bacterial cellulose support structure in a solution of a metal salt such that the metal precipitates in or on the support structure, inserting contact wires into two pieces of the metal impregnated support structure, placing the two pieces of metal impregnated support structure on opposite sides of a layer of hydrated bacterial cellulose, and dehydrating the three layer structure to create a fuel cell.

Metallization of bacterial cellulose for electrical and electronic device manufacture

DOEpatents

Evans, Barbara R [Oak Ridge, TN; O'Neill, Hugh M [Knoxville, TN; Jansen, Valerie Malyvanh [Memphis, TN; Woodward, Jonathan [Knoxville, TN

2010-09-28

A method for the deposition of metals in bacterial cellulose and for the employment of the metallized bacterial cellulose in the construction of fuel cells and other electronic devices is disclosed. The method for impregnating bacterial cellulose with a metal comprises placing a bacterial cellulose matrix in a solution of a metal salt such that the metal salt is reduced to metallic form and the metal precipitates in or on the matrix. The method for the construction of a fuel cell comprises placing a hydrated bacterial cellulose support structure in a solution of a metal salt such that the metal precipitates in or on the support structure, inserting contact wires into two pieces of the metal impregnated support structure, placing the two pieces of metal impregnated support structure on opposite sides of a layer of hydrated bacterial cellulose, and dehydrating the three layer structure to create a fuel cell.

Cleaner Technology in the Hard Disk Drive Manufacturing Industry: A Case Study

NASA Astrophysics Data System (ADS)

Moolla, Premchai; Chompu-inwai, Rungchat

2010-10-01

The objectives of this research are to improve raw material and energy consumption efficiency, as well as reduce defects and the use of chemicals in the arm coil assembly process of hard disk drive manufacturing in the case study company by applying the Cleaner Technology concepts. The four main sequential steps used in this research were: (1) pre-assessment, (2) assessment, (3) feasibility study, and (4) implementation. In the first step, raw data, such as process flows, raw material usage and defects data were collected. In the second step, the loss during production and causes of loss were analyzed. Opportunities to reduce raw material, chemical and energy wastage could then be recommended. The next step was to evaluate the feasibility and potential benefits of a particular Cleaner Technology opportunity. Finally, in the last step, after a thorough evaluation and implementation of the opportunities to apply Cleaner Technology, the results showed that arm coil defects could be reduced by improving the production process using the ECRS technique. ECRS stands for Eliminate, Combine, Rearrange and Simplify. This improvement reduced arm coil defect rates from 0.48% to 0.15%, thus saving approximately 139,638 Thai Baht per month. In addition, production stoppage decision made by workers was used to increase employee involvement in defect detection. Allowing workers to participate in such a decision was an effective way to reduce defect rate and could motivate workers to produce a better quality job. This resulted in arm coil defects reducing from 0.41% to 0.025%, with about 74,562 Thai Baht per month saving. Additionally, an increase in the efficiency of electricity consumption occurred, by increasing the speed of the infrared oven conveyor belt, improving average productivity from 533 pieces/hour to 560 pieces/hour, without adversely affecting product costs and quality, thus producing products of up to the value of 206,242 Thai Baht per month. Furthermore, the new

Additive Manufacturing of Al-12Si Alloy Via Pulsed Selective Laser Melting

NASA Astrophysics Data System (ADS)

Chou, R.; Milligan, J.; Paliwal, M.; Brochu, M.

2015-03-01

Additive manufacturing (AM) of metallic materials is experiencing a research and commercialization craze in almost all industrial sectors. However, to date, AM has been limited to a small numbers of alloys. With respect to aluminum, two alloys received some attention: Al-12Si and Al-10Si-1Mg. In both cases, fully dense components have been achieved using a continuous-wave selective laser melting system. In this article, a new approach of selective laser melting using a pulsed-laser source as opposed to a continuous-wave laser is proposed. Pulse selective laser melting (P-SLM) would allow for greater control over the heat input and thus further optimization possibilities of the microstructure. P-SLM was demonstrated using the Al-12Si system. Si refinement below 200 nm was achieved throughout the component. Density up to 95% and high hardness of above 135 HV were obtained. The solidification mechanism is also explained.

Metallurgical characterization of orthodontic brackets produced by Metal Injection Molding (MIM).

PubMed

Zinelis, Spiros; Annousaki, Olga; Makou, Margarita; Eliades, Theodore

2005-11-01

The aim of this study was to investigate the bonding base surface morphology, alloy type, microstructure, and hardness of four types of orthodontic brackets produced by Metal Injection Molding technology (Discovery, Extremo, Freedom, and Topic). The bonding base morphology of the brackets was evaluated by scanning electron microscopy (SEM). Brackets from each manufacturer were embedded in epoxy resin, and after metallographic grinding, polishing and coating were analyzed by x-ray energy-dispersive spectroscopic (EDS) microanalysis to assess their elemental composition. Then, the brackets were subjected to metallographic etching to reveal their metallurgical structure. The same specimen surfaces were repolished and used for Vickers microhardness measurements. The results were statistically analyzed with one-way analysis of variance and Student-Newman-Keuls multiple comparison test at the 0.05 level of significance. The findings of SEM observations showed a great variability in the base morphology design among the brackets tested. The x-ray EDS analysis demonstrated that each bracket was manufactured from different ferrous or Co-based alloys. Metallographic analysis showed the presence of a large grain size for the Discovery, Freedom, and Topic brackets and a much finer grain size for the Extremo bracket. Vickers hardness showed great variations among the brackets (Topic: 287 +/- 16, Freedom: 248 +/- 13, Discovery: 214 +/- 12, and Extremo: 154 +/- 9). The results of this study showed that there are significant differences in the base morphology, composition, microstructure, and microhardness among the brackets tested, which may anticipate significant clinical implications.

Automated measurement system employing eddy currents to adjust probe position and determine metal hardness

DOEpatents

Prince, James M.; Dodson, Michael G.; Lechelt, Wayne M.

1989-01-01

A system for measuring the hardness of cartridge cases employs an eddy current probe for inducing and sensing eddy currents in each cartridge case. A first component of the sensed signal is utilized in a closed loop system for accurately positioning the probe relative to the cartridge case both in the lift off direction and in the tangential direction, and a second component of the sensed signal is employed as a measure of the hardness. The positioning and measurement are carried out under closed loop microprocessor control facilitating hardness testing on a production line basis.

Cyclic Hardness Test PHYBALCHT: A New Short-Time Procedure to Estimate Fatigue Properties of Metallic Materials

NASA Astrophysics Data System (ADS)

Kramer, Hendrik; Klein, Marcus; Eifler, Dietmar

Conventional methods to characterize the fatigue behavior of metallic materials are very time and cost consuming. That is why the new short-time procedure PHYBALCHT was developed at the Institute of Materials Science and Engineering at the University of Kaiserslautern. This innovative method requires only a planar material surface to perform cyclic force-controlled hardness indentation tests. To characterize the cyclic elastic-plastic behavior of the test material the change of the force-indentation-depth-hysteresis is plotted versus the number of indentation cycles. In accordance to the plastic strain amplitude the indentation-depth width of the hysteresis loop is measured at half minimum force and is called plastic indentation-depth amplitude. Its change as a function of the number of cycles of indentation can be described by power-laws. One of these power-laws contains the hardening-exponentCHT e II , which correlates very well with the amount of cyclic hardening in conventional constant amplitude fatigue tests.

Hardness and adhesion performances of nanocoating on carbon steel

NASA Astrophysics Data System (ADS)

Hasnidawani, J. N.; Azlina, H. N.; Norita, H.; Bonnia, N. N.

2018-01-01

Nanocoatings industry has been aggressive in searching for cost-effective alternatives and environmental friendly approaches to manufacture products. Nanocoatings represent an engineering solution to prevent corrosion of the structural parts of ships, insulation and pipelines industries. The adhesion and hardness properties of coating affect material properties. This paper reviews ZnO-SiO2 as nanopowder in nano coating formulation as the agent for new and improved coating performances. Carbon steel on type S50C used as common substrate in nanocoating industry. 3wt% ZnO and 2wt% SiO2 addition of nanoparticles into nanocoating showed the best formulation since hardness and adhesion of nanocoating was good on carbon steel substrate. Incorporation of nanoparticles into coating increased the performances of coating.

Hardness and microstructure analysis of damaged gear caused by adhesive wear

NASA Astrophysics Data System (ADS)

Mahendra, Rizky Budi; Nugroho, Sri; Ismail, Rifky

2018-03-01

This study was a result from research on repairing project of damaged elevator gear box. The objective of this research is to analyze the failure part on elevator gearbox at flourmill factory. The equipment was damaged after one year installed and running on factory. Severe wear was occurred on high speed helical gear. These helical gear was one of main part of elevator gearbox in flour mill manufacture. Visually, plastic deformation didn't occurred and not visible on the failure helical gear shaft. Some test would be performed to check the chemical composition, microstructure and hardness of failure helical gear. The material of failure helical gear shaft was a medium carbon steel alloy. The microstructure was showed a martensitic phase formed on the surface to the center area of gear shaft. Otherwise, the depth of hardness layer slight formed on surface and lack depth of hardness layer was a main trigger of severe wear. It was not enough to resist wear due to friction caused by rolling and sliding on surface between high speed gear and low speed gear. Enhancement of hardness layer on surface and depth of hardness layer will make the component has more long life time. Furthermore, to perform next research is needed to analyze the reliability of enhanced hardness on layer and depth of hardness layer on helical gear shaft.

Halogen and LED light curing of composite: temperature increase and Knoop hardness.

PubMed

Schneider, L F; Consani, S; Correr-Sobrinho, L; Correr, A B; Sinhoreti, M A

2006-03-01

This study assessed the Knoop hardness and temperature increase provided by three light curing units when using (1) the manufacturers' recommended times of photo-activation and (2) standardizing total energy density. One halogen--XL2500 (3M/ESPE)--and two light-emitting diode (LED) curing units--Freelight (3M/ESPE) and Ultrablue IS (DMC)--were used. A type-K thermocouple registered the temperature change produced by the composite photo-activation in a mold. Twenty-four hours after the photo-activation procedures, the composite specimens were submitted to a hardness test. Both temperature increase and hardness data were submitted to ANOVA and Tukey's test (5% significance). Using the first set of photo-activation conditions, the halogen unit produced a statistically higher temperature increase than did both LED units, and the Freelight LED resulted in a lower hardness than did the other curing units. When applying the second set of photo-activation conditions, the two LED units produced statistically greater temperature increase than did the halogen unit, whereas there were no statistical differences in hardness among the curing units.

Beyond the bed: effects of metal contamination on recruitment to bedded sediments and overlying substrata.

PubMed

Hill, Nicole A; Simpson, Stuart L; Johnston, Emma L

2013-02-01

Metal-contaminated sediments pose a recognised threat to sediment-dwelling fauna. Re-mobilisation of contaminated sediments however, may impact more broadly on benthic ecosystems, including on diverse assemblages living on hard substrata patches immediately above sediments. We used manipulative field experiments to simultaneously test for the effects of metal contamination on recruitment to marine sediments and overlying hard substrata. Recruitment to sediments was strongly and negatively affected by metal contamination. However, while assemblage-level effects on hard-substratum fauna and flora were observed, most functional groups were unaffected or slightly enhanced by exposure to contaminated sediments. Diversity of hard-substratum fauna was also enhanced by metal contamination at one site. Metal-contaminated sediments appear to pose less of a hazard to hard-substratum than sediment-dwelling assemblages, perhaps due to a lower direct contaminant exposure or to indirect effects mediated by contaminant impacts on sediment fauna. Our results indicate that current sediment quality guidelines are protective of hard-substrata organisms. Crown Copyright © 2012. Published by Elsevier Ltd. All rights reserved.

Using Innovative Technologies for Manufacturing Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, E. M.; Eddleman, D. E.; Reynolds, D. C.; Hardin, N. A.

2011-01-01

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As the United States enters into the next space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, rapid manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on NASA s Space Launch System (SLS) upper stage engine, J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator (GG) discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using a workhorse gas generator (WHGG) test fixture at MSFC's East Test Area, the duct was subjected to extreme J-2X hot gas environments during 7 tests for a total of 537 seconds of hot-fire time. The duct underwent extensive post-test evaluation and showed no signs of degradation. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Personal electronics printing via tapping mode composite liquid metal ink delivery and adhesion mechanism

NASA Astrophysics Data System (ADS)

Zheng, Yi; He, Zhi-Zhu; Yang, Jun; Liu, Jing

2014-04-01

Printed electronics is becoming increasingly important in a variety of newly emerging areas. However, restricted to the rather limited conductive inks and available printing strategies, the current electronics manufacture is usually confined to industry level. Here, we show a highly cost-effective and entirely automatic printing way towards personal electronics making, through introducing a tapping-mode composite fluid delivery system. Fundamental mechanisms regarding the reliable printing, transfer and adhesion of the liquid metal inks on the substrate were disclosed through systematic theoretical interpretation and experimental measurements. With this liquid metal printer, a series of representative electronic patterns spanning from single wires to desired complex configurations such as integrated circuit (IC), printed-circuits-on-board (PCB), electronic paintings, or more do-it-yourself (DIY) devices, were demonstrated to be printed out with high precision in a moment. And the total machine cost already reached personally affordable price. This is hard to achieve by a conventional PCB technology which generally takes long time and is material, water and energy consuming, while the existing printed electronics is still far away from the real direct printing goal. The present work opens the way for large scale personal electronics manufacture and is expected to generate important value for the coming society.

Personal electronics printing via tapping mode composite liquid metal ink delivery and adhesion mechanism.

PubMed

Zheng, Yi; He, Zhi-Zhu; Yang, Jun; Liu, Jing

2014-04-04

Printed electronics is becoming increasingly important in a variety of newly emerging areas. However, restricted to the rather limited conductive inks and available printing strategies, the current electronics manufacture is usually confined to industry level. Here, we show a highly cost-effective and entirely automatic printing way towards personal electronics making, through introducing a tapping-mode composite fluid delivery system. Fundamental mechanisms regarding the reliable printing, transfer and adhesion of the liquid metal inks on the substrate were disclosed through systematic theoretical interpretation and experimental measurements. With this liquid metal printer, a series of representative electronic patterns spanning from single wires to desired complex configurations such as integrated circuit (IC), printed-circuits-on-board (PCB), electronic paintings, or more do-it-yourself (DIY) devices, were demonstrated to be printed out with high precision in a moment. And the total machine cost already reached personally affordable price. This is hard to achieve by a conventional PCB technology which generally takes long time and is material, water and energy consuming, while the existing printed electronics is still far away from the real direct printing goal. The present work opens the way for large scale personal electronics manufacture and is expected to generate important value for the coming society.

Personal electronics printing via tapping mode composite liquid metal ink delivery and adhesion mechanism

PubMed Central

Zheng, Yi; He, Zhi-Zhu; Yang, Jun; Liu, Jing

2014-01-01

Printed electronics is becoming increasingly important in a variety of newly emerging areas. However, restricted to the rather limited conductive inks and available printing strategies, the current electronics manufacture is usually confined to industry level. Here, we show a highly cost-effective and entirely automatic printing way towards personal electronics making, through introducing a tapping-mode composite fluid delivery system. Fundamental mechanisms regarding the reliable printing, transfer and adhesion of the liquid metal inks on the substrate were disclosed through systematic theoretical interpretation and experimental measurements. With this liquid metal printer, a series of representative electronic patterns spanning from single wires to desired complex configurations such as integrated circuit (IC), printed-circuits-on-board (PCB), electronic paintings, or more do-it-yourself (DIY) devices, were demonstrated to be printed out with high precision in a moment. And the total machine cost already reached personally affordable price. This is hard to achieve by a conventional PCB technology which generally takes long time and is material, water and energy consuming, while the existing printed electronics is still far away from the real direct printing goal. The present work opens the way for large scale personal electronics manufacture and is expected to generate important value for the coming society. PMID:24699375

Automated measurement system employing eddy currents to adjust probe position and determine metal hardness

DOEpatents

Prince, J.M.; Dodson, M.G.; Lechelt, W.M.

1989-07-18

A system for measuring the hardness of cartridge cases employs an eddy current probe for inducing and sensing eddy currents in each cartridge case. A first component of the sensed signal is utilized in a closed loop system for accurately positioning the probe relative to the cartridge case both in the lift off direction and in the tangential direction, and a second component of the sensed signal is employed as a measure of the hardness. The positioning and measurement are carried out under closed loop microprocessor control facilitating hardness testing on a production line basis. 14 figs.

Direct Numerical Simulations of Microstructure Effects During High-Rate Loading of Additively Manufactured Metals

NASA Astrophysics Data System (ADS)

Battaile, Corbett; Owen, Steven; Moore, Nathan

2017-06-01

The properties of most engineering materials depend on the characteristics of internal microstructures and defects. In additively manufactured (AM) metals, these can include polycrystalline grains, impurities, phases, and significant porosity that qualitatively differ from conventional engineering materials. The microscopic details of the interactions between these internal defects, and the propagation of applied loads through the body, act in concert to dictate macro-observable properties like strength and compressibility. In this work, we used Sandia's ALEGRA finite element software to simulate the high-strain-rate loading of AM metals from laser engineered net shaping (LENS) and thermal spraying. The microstructural details of the material were represented explicitly, such that internal features like second phases and pores are captured and meshed as individual entities in the computational domain. We will discuss the dependence of the high-strain-rate mechanical properties on microstructural characteristics such as the shapes, sizes, and volume fractions of second phases and pores. In addition, we will examine how the details of the microstructural representation affect the microscopic material response to dynamic loads, and the effects of using ``stair-step'' versus conformal interfaces smoothed via the SCULPT tool in Sandia's CUBIT software. Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the US DOE NNSA under contract DE-AC04-94AL85000.

Using Innovative Technologies for Manufacturing and Evaluating Rocket Engine Hardware

NASA Technical Reports Server (NTRS)

Betts, Erin M.; Hardin, Andy

2011-01-01

Many of the manufacturing and evaluation techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing and evaluating hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) and white light scanning are being adopted and evaluated for their use on J-2X, with hopes of employing both technologies on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powdered metal manufacturing process in order to produce complex part geometries. The white light technique is a non-invasive method that can be used to inspect for geometric feature alignment. Both the DMLS manufacturing method and the white light scanning technique have proven to be viable options for manufacturing and evaluating rocket engine hardware, and further development and use of these techniques is recommended.

Additively manufactured porous tantalum implants.

PubMed

Wauthle, Ruben; van der Stok, Johan; Amin Yavari, Saber; Van Humbeeck, Jan; Kruth, Jean-Pierre; Zadpoor, Amir Abbas; Weinans, Harrie; Mulier, Michiel; Schrooten, Jan

2015-03-01

The medical device industry's interest in open porous, metallic biomaterials has increased in response to additive manufacturing techniques enabling the production of complex shapes that cannot be produced with conventional techniques. Tantalum is an important metal for medical devices because of its good biocompatibility. In this study selective laser melting technology was used for the first time to manufacture highly porous pure tantalum implants with fully interconnected open pores. The architecture of the porous structure in combination with the material properties of tantalum result in mechanical properties close to those of human bone and allow for bone ingrowth. The bone regeneration performance of the porous tantalum was evaluated in vivo using an orthotopic load-bearing bone defect model in the rat femur. After 12 weeks, substantial bone ingrowth, good quality of the regenerated bone and a strong, functional implant-bone interface connection were observed. Compared to identical porous Ti-6Al-4V structures, laser-melted tantalum shows excellent osteoconductive properties, has a higher normalized fatigue strength and allows for more plastic deformation due to its high ductility. It is therefore concluded that this is a first step towards a new generation of open porous tantalum implants manufactured using selective laser melting. Copyright © 2014 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Manufacturing Methods and Technology Project Summary Reports

DTIC Science & Technology

1985-06-01

Computer -Aided Design (CAD)/ Computer -Aided Manufacturing (CAM) Process for the Production of Cold Forged Gears Project 483 6121 - Robotic Welding and...Caliber Projectile Bodies Project 682 8370 - Automatic Inspection and 1-I1 Process Control of Weapons Parts Manufacturing METALS Project 181 7285 - Cast...designed for use on each project. Experience suggested that a general purpose computer interface might be designed that could be used on any project

Hollow microspheres of silica glass and method of manufacture

DOEpatents

Downs, Raymond L.; Miller, Wayne J.

1982-01-01

A method of manufacturing gel powder suitable for use as a starting material in the manufacture of hollow glass microspheres having a high concentration of silica. The powder is manufactured from a gel containing boron in the amount of about 1% to 20% (oxide equivalent mole percent), alkali metals, specifically potassium and sodium, in an amount exceeding 8% total, and the remainder silicon. Preferably, the ratio of potassium to sodium is greater than 1.5.

Microstructure and High Temperature Mechanical Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Metal Injection Molding Process

NASA Astrophysics Data System (ADS)

Lee, Kee-Ahn; Gwon, Jin-Han; Yoon, Tae-Sik

2018-03-01

This study investigated the microstructure and the room and high temperature mechanical properties of Fe-Cr-B alloy manufactured by metal injection molding. In addition, hot isostatic pressing was performed to increase the density of the material, and a comparison of properties was made. Microstructural observation confirmed a bi-continuous structure composed of a three-dimensional network of α-Fe phase and (Cr,Fe)2B phase. The HIPed specimen featured a well-formed adhesion between the α-Fe phase and boride, and the number of fine pores was significantly reduced. The tensile results confirmed that the HIPed specimen (RT to 900 °C) had higher strengths compared to the as-sintered specimen, and the change of elongation starting from 700 °C was significantly greater in the HIPed specimen. Fractography suggested that cracks propagated mostly along the interface between the α-Fe matrix and boride in the as-sintered specimen, while direct fracture of boride was observed in addition to interface separation in the HIPed specimen.

Spin-on metal oxide materials with high etch selectivity and wet strippability

NASA Astrophysics Data System (ADS)

Yao, Huirong; Mullen, Salem; Wolfer, Elizabeth; McKenzie, Douglas; Rahman, Dalil; Cho, JoonYeon; Padmanaban, Munirathna; Petermann, Claire; Hong, SungEun; Her, YoungJun

2016-03-01

Metal oxide or metal nitride films are used as hard mask materials in semiconductor industry for patterning purposes due to their excellent etch resistances against the plasma etches. Chemical vapor deposition (CVD) or atomic layer deposition (ALD) techniques are usually used to deposit the metal containing materials on substrates or underlying films, which uses specialized equipment and can lead to high cost-of-ownership and low throughput. We have reported novel spin-on coatings that provide simple and cost effective method to generate metal oxide films possessing good etch selectivity and can be removed by chemical agents. In this paper, new spin-on Al oxide and Zr oxide hard mask formulations are reported. The new metal oxide formulations provide higher metal content compared to previously reported material of specific metal oxides under similar processing conditions. These metal oxide films demonstrate ultra-high etch selectivity and good pattern transfer capability. The cured films can be removed by various chemical agents such as developer, solvents or wet etchants/strippers commonly used in the fab environment. With high metal MHM material as an underlayer, the pattern transfer process is simplified by reducing the number of layers in the stack and the size of the nano structure is minimized by replacement of a thicker film ACL. Therefore, these novel AZ® spinon metal oxide hard mask materials can potentially be used to replace any CVD or ALD metal, metal oxide, metal nitride or spin-on silicon-containing hard mask films in 193 nm or EUV process.

Additive manufacturing of hybrid circuits

DOE PAGES

Bell, Nelson S.; Sarobol, Pylin; Cook, Adam; ...

2016-03-26

There is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects.more » Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. As a result, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.« less

Synthesis, Hardness, and Electronic Properties of Stoichiometric VN and CrN

DOE PAGES

Wang, Shanmin; Yu, Xiaohui; Zhang, Jianzhong; ...

2015-11-09

Here, we report synthesis of single-crystal VN and CrN through high-pressure ionexchange reaction routes. The final products are stoichiometric and have crystallite sizes in the range of 50-120 mu m. We also prepared VN and TiN crystals using high-pressure sintering of nitride powders. On the basis of single-crystal indentation testing, the determined asymptotic Vickers hardness for TiN, VN, and CrN is 18 (1), 10 (1), and 16 (1) GPa, respectively. Moreover, the relatively low hardness in VN indicates that the metallic bonding prevails due to the overfilled metallic a bonds, although the cation-anion covalent hybridization in this compound is muchmore » stronger than that in TiN and CrN. All three nitrides are intrinsically excellent metals at ambient pressure. In particular, VN exhibits superconducting transition at T-c approximate to 7.8 K, which is slightly lower than the reported values for nitrogen-deficient or crystallinedisordered samples due to unsuppressed "spin fluctuation" in the well-crystallized stoichiometric VN. The magnetostructural transition in CrN correlates with a metal metal transition at T-N = 240(5) K and is accompanied by a similar to 40% drop in electrical resistivity. Additionally, more detailed electronic properties are presented with new insights into these nitrides.« less

Economic manufacturing of bulk metallic glass compositions by microalloying

DOEpatents

Liu, Chain T.

2003-05-13

A method of making a bulk metallic glass composition includes the steps of:a. providing a starting material suitable for making a bulk metallic glass composition, for example, BAM-11; b. adding at least one impurity-mitigating dopant, for example, Pb, Si, B, Sn, P, to the starting material to form a doped starting material; and c. converting the doped starting material to a bulk metallic glass composition so that the impurity-mitigating dopant reacts with impurities in the starting material to neutralize deleterious effects of the impurities on the formation of the bulk metallic glass composition.

Beyond packing of hard spheres: The effects of core softness, non-additivity, intermediate-range repulsion, and many-body interactions on the glass-forming ability of bulk metallic glasses

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Kai; Fan, Meng; Liu, Yanhui

When a liquid is cooled well below its melting temperature at a rate that exceeds the critical cooling rate R{sub c}, the crystalline state is bypassed and a metastable, amorphous glassy state forms instead. R{sub c} (or the corresponding critical casting thickness d{sub c}) characterizes the glass-forming ability (GFA) of each material. While silica is an excellent glass-former with small R{sub c} < 10{sup −2} K/s, pure metals and most alloys are typically poor glass-formers with large R{sub c} > 10{sup 10} K/s. Only in the past thirty years have bulk metallic glasses (BMGs) been identified with R{sub c} approachingmore » that for silica. Recent simulations have shown that simple, hard-sphere models are able to identify the atomic size ratio and number fraction regime where BMGs exist with critical cooling rates more than 13 orders of magnitude smaller than those for pure metals. However, there are a number of other features of interatomic potentials beyond hard-core interactions. How do these other features affect the glass-forming ability of BMGs? In this manuscript, we perform molecular dynamics simulations to determine how variations in the softness and non-additivity of the repulsive core and form of the interatomic pair potential at intermediate distances affect the GFA of binary alloys. These variations in the interatomic pair potential allow us to introduce geometric frustration and change the crystal phases that compete with glass formation. We also investigate the effect of tuning the strength of the many-body interactions from zero to the full embedded atom model on the GFA for pure metals. We then employ the full embedded atom model for binary BMGs and show that hard-core interactions play the dominant role in setting the GFA of alloys, while other features of the interatomic potential only change the GFA by one to two orders of magnitude. Despite their perturbative effect, understanding the detailed form of the intermetallic potential is important

SQUID sensor application for small metallic particle detection

NASA Astrophysics Data System (ADS)

Tanaka, Saburo; Hatsukade, Yoshimi; Ohtani, Takeyoshi; Suzuki, Shuichi

2009-04-01

High-Tc superconducting quantum interference device (SQUID) is an ultra-sensitive magnetic sensor. Since the performance of the SQUID is improved and stabilized, now it is ready for application. One strong candidate for application is a detection system of magnetic foreign matters in industrial products or beverages. There is a possibility that ultra-small metallic foreign matter has been accidentally mixed with industrial products such as lithium ion batteries. If this happens, the manufacturer of the product suffers a great loss recalling products. The outer dimension of metallic particles less than 100 μm cannot be detected by an X-ray imaging, which is commonly used for the inspection. Ionization of the material is also a big issue for beverages in the case of the X-ray imaging. Therefore a highly sensitive and safety detection system for small foreign matters is required. We developed detection systems based on high-Tc SQUID with a high-performance magnetic shield. We could successfully measure small iron particles of 100 μm on a belt conveyer and stainless steel balls of 300 μm in water. These detection levels were hard to be achieved by a conventional X-ray detection or other methods.

Rubber pad forming - Efficient approach for the manufacturing of complex structured sheet metal blanks for food industry

NASA Astrophysics Data System (ADS)

Spoelstra, Paul; Djakow, Eugen; Homberg, Werner

2017-10-01

The production of complex organic shapes in sheet metals is gaining more importance in the food industry due to increasing functional and hygienic demands. Hence it is necessary to produce parts with complex geometries promoting cleanability and general sanitation leading to improvement of food safety. In this context, and especially when stainless steel has to be formed into highly complex geometries while maintaining desired surface properties, it is inevitable that alternative manufacturing processes will need to be used which meet these requirements. Rubber pad forming offers high potential when it comes to shaping complex parts with excellent surface quality, with virtually no tool marks and scratches. Especially in cases where only small series are to be produced, rubber pad forming processes offers both technological and economic advantages. Due to the flexible punch, variation in metal thickness can be used with the same forming tool. The investments to set-up Rubber pad forming is low in comparison to conventional sheet metal forming processes. The process facilitates production of shallow sheet metal parts with complex contours and bends. Different bending sequences in a multiple tool set-up can also be conducted. The planned contribution thus describes a brief overview of the rubber pad technology. It shows the prototype rubber pad forming machine which can be used to perform complex part geometries made from stainless steel (1.4301). Based on an analysis of the already existing systems and new machines for rubber pad forming processes, together with their process properties, influencing variables and areas of application, some relevant parts for the food industry are presented.

Bite force measurements with hard and soft bite surfaces.

PubMed

Serra, C M; Manns, A E

2013-08-01

Bite force has been measured by different methods and over a wide variety of designs. In several instruments, the fact that bite surface has been manufactured with stiff materials might interfere in obtaining reliable data, by a more prompt activation of inhibitory reflex mechanisms. The purpose of this study was to compare the maximum voluntary bite force measured by a digital occlusal force gauge (GM10 Nagano Keiki, Japan) between different opponent teeth, employing semi-hard or soft bite surfaces. A sample of 34 young adults with complete natural dentition was studied. The original semi-hard bite surface was exchanged by a soft one, made of leather and rubber. Maximum voluntary bite force recordings were made for each tooth group and for both bite surfaces. Statistical analyses (Student's t-test) revealed significant differences, with higher scores while using the soft surface across sexes and tooth groups (P < 0·05). Differential activation of periodontal mechanoreceptors of a specific tooth group is mainly conditioned by the hardness of the bite surface; a soft surface induces greater activation of elevator musculature, while a hard one induces inhibition more promptly. Thus, soft bite surfaces are recommended for higher reliability in maximum voluntary bite force recordings. © 2013 John Wiley & Sons Ltd.

Influence of Ni-P Coated SiC and Laser Scan Speed on the Microstructure and Mechanical Properties of IN625 Metal Matrix Composites

NASA Astrophysics Data System (ADS)

Sateesh, N. H.; Kumar, G. C. Mohan; Krishna, Prasad

2015-12-01

Nickel based Inconel-625 (IN625) metal matrix composites (MMCs) were prepared using pre-heated nickel phosphide (Ni-P) coated silicon carbide (SiC) reinforcement particles by Direct Metal Laser Sintering (DMLS) additive manufacturing process under inert nitrogen atmosphere to obtain interface influences on MMCs. The distribution of SiC particles and microstructures were characterized using optical and scanning electron micrographs, and the mechanical behaviours were thoroughly examined. The results clearly reveal that the interface integrity between the SiC particles and the IN625 matrix, the mixed powders flowability, the SiC ceramic particles and laser beam interaction, and the hardness, and tensile characteristics of the DMLS processed MMCs were improved effectively by the use of Ni-P coated SiC particles.

Strain hardening behavior during manufacturing of tube shapes by hydroforming

NASA Astrophysics Data System (ADS)

Park, Hyun Kyu; Yi, Hyae Kyung; Van Tyne, Chester J.; Moon, Young Hoon

2009-12-01

Safe and robust process design relies on knowledge of the evolution of the mechanical properties in a tube during hydroforming. The manufacturing of tubular shapes generally consists of three main stages: bending, preforming, and expansion. The latter is usually called hydroforming. As a result of these three steps, the final product's strain hardening history is nonlinear. In the present study, the strain hardening behavior during hydroforming was experimentally investigated. The variation of local flow stress and/or local hardness was used as an index of the strain hardening during the various steps and the local flow stress and/or local hardness were used with respective correlations to determine the effective strain. The strain hardening behavior during hydroforming after preforming has been successfully analyzed by using the relationships between hardness, flow stress, and effective strain for variable pre-strains prior to hydroforming. The comparison of predicted hardness with measured hardness confirms that the methodology used in this study is feasible, and that the strain hardening behavior can be quantitatively estimated with good accuracy.

Spin-on metal oxide materials for N7 and beyond patterning applications

NASA Astrophysics Data System (ADS)

Mannaert, G.; Altamirano-Sanchez, E.; Hopf, T.; Sebaai, F.; Lorant, C.; Petermann, C.; Hong, S.-E.; Mullen, S.; Wolfer, E.; Mckenzie, D.; Yao, H.; Rahman, D.; Cho, J.-Y.; Padmanaban, M.; Piumi, D.

2017-04-01

There is a growing interest in new spin on metal oxide hard mask materials for advanced patterning solutions both in BEOL and FEOL processing. Understanding how these materials respond to plasma conditions may create a competitive advantage. In this study patterning development was done for two challenging FEOL applications where the traditional Si based films were replaced by EMD spin on metal oxides, which acted as highly selective hard masks. The biggest advantage of metal oxide hard masks for advanced patterning lays in the process window improvement at lower or similar cost compared to other existing solutions.

Thermoplastic composite parts manufacture at Du Pont

NASA Astrophysics Data System (ADS)

Medwin, Steven J.; Coyle, Edward J.

1993-01-01

Low-cost routes to the manufacture of complex shaped composite parts have been defined using metal forming techniques and Du Pont's long discontinuous fiber (LDF) Technology. These manufacturing techniques include roll forming, stretch forming, and press forming. Near equivalence between the static, dynamic, and damage tolerance properties of LDF and continuous fiber composites have been demonstrated. Several examples are cited which demonstrate the potential for this technology to significantly reduce the cost of aerospace components.

ENVIRONMENTAL RESEARCH BRIEF: POLLUTION PREVENTION FOR A MANUFACTURER OF METAL FASTENERS

EPA Science Inventory

The U.S. Environmental Protection Agency (EPA) has funded a pilot project to assist small and medium-size manufacturers who want to minimize their generation of waste but who lack the expertise to do so. n an effort to assist these manufacturers Waste Minimization Assessment Cent...

Refractory metals for ARPS AMTEC cells

DOE Office of Scientific and Technical Information (OSTI.GOV)

Svedberg, R.C.; Sievers, R.C.

1998-07-01

Alkali Metal Thermal-to-Electric Converter (AMTEC) cells for the Advanced Radioisotope Power Systems (ARPS) program are being developed with refractory metals and alloys as the basic structural materials. AMTEC cell efficiency increases with cell operating temperature. For space applications, long term reliability and high efficiency are essential and refractory metals were selected because of their high temperature strength, low vapor pressure, and compatibility with sodium. However, refractory metals are sensitive to oxygen, nitrogen and hydrogen contamination and refractory metal cells cannot be processed in air. Because of this sensitivity, new manufacturing and processing techniques are being developed. In addition to structuralmore » elements, development of other refractory metal components for the AMTEC cells, such as the artery and evaporator wicks, pinchoff tubes and feedthroughs are required. Changes in cell fabrication techniques and processing procedures being implemented to manufacture refractory metal cells are discussed.« less

Sustainable Manufacturing framework from Islamic Perspective

NASA Astrophysics Data System (ADS)

Zain, S.; Adesta, E. Y. T.; Ismail, A. F.; Ahmad, Z.

2017-03-01

Islam is a complete way of life and offers holistic and comprehensive solutions to the human life. Manufacturing is one of the fields in which the voice of Islam is hardly heard. The efforts to relate and integrate manufacturing practices with Islamic principles and to eventually create a holistic solution is still lacking. This study is an attempt to develop a framework of sustainable manufacturing practices from the Islamic perspective. This framework may offer optional solutions to the current problems faced by the world such as global warming, climate change, pollutions, diseases etc. due to human ignorance. The framework was developed based on a preliminary research on the recent study of Maqasid Shari’ah, which is used as the main foundation. The developed framework comprises of three main domains, namely social, economic and environment. The framework is hoped to offer alternative solutions in producing high quality products, whilst taking into consideration the society, economy and environment, in line with the teachings of Islam and in accordance to our subservience to Allah SWT.

ION EXCHANGE SOFTENING: EFFECTS ON METAL CONCENTRATIONS

EPA Science Inventory

A corrosion control pipe loop study to evaluate the effect of ion exchange water softening on metal leaching from household plumbing materials was conducted on two different water qualities having different pH's and hardness levels. The results showed that removing hardness ions ...

Printability of alloys for additive manufacturing

DOE PAGES

Mukherjee, T.; Zuback, J. S.; De, A.; ...

2016-01-22

Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is usedmore » to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. Here, the findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts.« less

Printability of alloys for additive manufacturing

PubMed Central

Mukherjee, T.; Zuback, J. S.; De, A.; DebRoy, T.

2016-01-01

Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts. PMID:26796864

Highly crystalline inverse opal transition metal oxides via a combined assembly of soft and hard chemistries.

PubMed

Orilall, M Christopher; Abrams, Neal M; Lee, Jinwoo; DiSalvo, Francis J; Wiesner, Ulrich

2008-07-16

A combined assembly of soft and hard chemistries is employed to generate highly crystalline three-dimensionally ordered macroporous (3DOM) niobia (Nb2O5) and titania (TiO2) structures by colloidal crystal templating. Polystyrene spheres with sp2 hybridized carbon are used in a reverse-template infiltration technique based on the aqueous liquid phase deposition of the metal oxide in the interstitial spaces of a colloidal assembly. Heating under inert atmosphere as high as 900 degrees C converts the polymer into sturdy carbon that acts as a scaffold and keeps the macropores open while the oxides crystallize. Using X-ray diffraction it is demonstrated that for both oxides this approach leads to highly crystalline materials while heat treatments to lower temperatures commonly used for polymer colloidal templating, in particular for niobia, results in only weakly crystallized materials. Furthermore it is demonstrated that heat treatment directly to higher temperatures without generating the carbon scaffold leads to a collapse of the macrostructure. The approach should in principle be applicable to other 3DOM materials that require heat treatments to higher temperatures.

Implementing QML for radiation hardness assurance

NASA Astrophysics Data System (ADS)

Winokur, P. S.; Sexton, F. W.; Fleetwood, D. M.; Terry, M. D.; Shaneyfelt, M. R.

1990-12-01

The US government has proposed a qualified manufacturers list (QML) methodology to qualify integrated circuits for high reliability and radiation hardness. An approach to implementing QML for single-event upset (SEU) immunity on 16k SRAMs that involves relating values of feedback resistance to system error rates is demonstrated. It is seen that the process capability indices, Cp and Cpk, for the manufacture of 400-k-ohm feedback resistors required to provide SEU tolerance do not conform to 6 sigma quality standards. For total-dose, interface trap charge, Delta Vit, shifts measured on transistors are correlated with circuit response in the space environment. Statistical process control (SPC) is illustrated for Delta Vit, and violations of SPC rules are interpreted in terms of continuous improvement. Design validation for SEU and quality conformance inspections for total-dose are identified as major obstacles to cost-effective QML implementation. Techniques and tools that will help QML provide real cost savings are identified as physical models, 3-D device-plus-circuit codes, and improved design simulators.

Driving forces of heavy metal changes in agricultural soils in a typical manufacturing center.

PubMed

Qiu, Menglong; Li, Fangbai; Wang, Qi; Chen, Junjian; Yang, Guoyi; Liu, Liming

2015-05-01

Heavy metal concentrations in 2002 and 2012 in agricultural soils in Dongguan, a manufacturing center in southern China, were analyzed to determine the impact of rapid economic development on soil pollution. The level of pollution was assessed using the Nemerow synthetic pollution index (NPI), and its changing characteristics and driving forces were analyzed using multivariate statistical and geostatistical methods. The results indicate that the mean NPI was 0.79 in 2002 and 0.84 in 2012, which indicates aggravated heavy metal contamination in the agricultural soils. The concentrations of Cd and Zn increased 54.7 and 20.8 %, respectively, whereas Hg and Pb decreased 35.3 and 24.5 %, respectively. Cr, As, Cu, and Ni remained relatively stable. The Hg and Cd concentrations were highly correlated with soil types (P < 0.01), the secondary industrial output per unit of land (P < 0.01), proportion of cereal fields (P < 0.01), proportion of vegetable fields (P < 0.01), population density (P < 0.05), and road density (P < 0.05). The Pb and As concentrations were greatly influenced by soil types (P < 0.01), river density (P < 0.01), fertilizer rate (P < 0.01), and road density (P < 0.05). Cr, Zn, Cu, and Ni concentrations were primarily driven by soil types (P < 0.01), river density (P < 0.01), and fertilizer rate (P < 0.05).

Nano-Magnets and Additive Manufacturing for Electric Motors

NASA Technical Reports Server (NTRS)

Misra, Ajay K.

2014-01-01

High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.

Scale-up of 2G wire manufacturing at American Superconductor Corporation

NASA Astrophysics Data System (ADS)

Fleshler, S.; Buczek, D.; Carter, B.; Cedrone, P.; DeMoranville, K.; Gannon, J.; Inch, J.; Li, X.; Lynch, J.; Otto, A.; Podtburg, E.; Roy, D.; Rupich, M.; Sathyamurthy, S.; Schreiber, J.; Thieme, C.; Thompson, E.; Tucker, D.; Nagashima, K.; Ogata, M.

2009-10-01

American Superconductor Corporation (AMSC) has developed the base technology and a manufacturing line for initial volume production of low-cost second generation high temperature superconductor (2G HTS) wire for commercial and military applications. The manufacturing line is based on reel-to-reel processing of wide HTS strips using rolling assisted bi-axially textured substrate (RABiTS™) for the template and Metal Organic Deposition (MOD) for the HTS layer. AMSC’s wide strip process is a low cost manufacturing technology since multiple wires are produced in a single manufacturing pass by slitting the wide strip to narrower width in the last stage of the manufacturing process. Industry standard 4.4 mm wide wires are produced by laminating metallic foils, such as copper, stainless steel or any other material, to the HTS insert wire, and are chosen to tailor the electrical, thermal and mechanical properties of the wire for specific applications. The laminated, 4.4 mm wide wires are known as “344 superconductors.” In this paper, we summarize the status of AMSC’s manufacturing capability, the performance of the wire presently being produced, as well as the cost and technical advantages of AMSC’s manufacturing approach. In addition, future direction for research and development to improve electrical performance is presented.

High capacity hard carbon derived from lotus stem as anode for sodium ion batteries

NASA Astrophysics Data System (ADS)

Zhang, Nan; Liu, Qing; Chen, Weilun; Wan, Min; Li, Xiaocheng; Wang, Lili; Xue, Lihong; Zhang, Wuxing

2018-02-01

Porous hard carbons are synthesized via carbonizing lotus stems with naturally hierarchical structures. The hard carbon carbonized at 1400 °C (LS1400) delivers a total capacity 350 mAh g-1 in the current density of 100 mA g-1 and a plateau capacity of 250 mAh g-1. Even cycled at 100 mA g-1 after 450 cycles, the capacity still retains 94%. Further investigation shows that the sodium storage of LS carbons involves Na+ adsorption in the defect sites, Na+ insertion and Na metal deposition in the closed pores. However, the Na metal deposition in closed pores mainly contribute to the plateau capacity, leading to the excellent sodium storage performance of LS1400 with a large closed pore ratio of 66%. The results show that the intrinsic structure of natural biomass can inspire us to design hard carbon with large closed pore ratio as excellent anode for sodium ion batteries.

Clean Metal Finishing Alternatives

DTIC Science & Technology

2006-05-01

Cr, must heat treat for hardness 4 4 Trivalent chrome Trivalent plating chemistry Varying success, some must be brush plate 3 3 Alloy plating...metals. Hard coating deposition unproven. 3 N/A Weld coating Electrospark Deposition/ Alloying (ESD/ ESA) Microarc welding Localized repair of non...Alternatives to chromate conversion coatings Al TriChrome Pretreatment (TCP)* – AnoChem TCP, Aluminescent, TCP-HF Trivalent Cr3+ conversion with Zr

EVALUATING THE ROLE OF ION COMPOSITION ON THE TOXICITY OF COPPER TO CERIODAPHNIA DUBIA IN VERY HARD WATERS

EPA Science Inventory

The mitigating effect of increasing hardness on metal toxicity is reflected in water quality criteria in the United States. - - - Copper toxicity did not consistently vary as a function of hardness, but likely as a function of other water quality characteristics (e.g. alkalinity ...

Quality of Metal Deposited Flux Cored Wire With the System Fe-C-Si-Mn-Cr-Mo-Ni-V-Co

NASA Astrophysics Data System (ADS)

Gusev, Aleksander I.; Kozyrev, Nikolay A.; Osetkovskiy, Ivan V.; Kryukov, Roman E.; Kozyreva, Olga A.

2017-10-01

Studied the effect of the introduction of vanadium and cobalt into the charge powder fused wire system Fe-C-Si-Mn-Cr-Ni-Mo-V, used in cladding assemblies and equipment parts and mechanisms operating under abrasive and abrasive shock loads. the cored wires samples were manufactured in the laboratory conditions and using appropriate powder materials and as a carbonfluoride contained material were used the dust from gas purification of aluminum production, with the following components composition, %: Al2O3 = 21-46.23; F = 18-27; Na2O = 8-15; K2O = 0.4-6; CaO = 0.7-2.3; Si2O = 0.5-2.48; Fe2O3 = 2.1-3.27; C = 12.5-30.2; MnO = 0.07-0.9; MgO = 0.06-0.9; S = 0.09-0.19; P = 0.1-0.18. Surfacing was produced on the St3 metal plates in 6 layers under the AN-26C flux by welding truck ASAW-1250. Cutting and preparation of samples for research had been implemented. The chemical composition and the hydrogen content of the weld metal were determined by modern methods. The hardness and abrasion rate of weld metal had been measured. Conducted metallographic studies of weld metal: estimated microstructure, grain size, contamination of oxide non-metallic inclusions. Metallographic studies showed that the microstructure of the surfaced layer by cored wire system Fe-C-Si-Mn-Cr-Mo-Ni-V-Co is uniform, thin dendrite branches are observed. The microstructure consists of martensite, which is formed inside the borders of the former austenite grain retained austenite present in small amounts in the form of separate islands, and thin layers of δ-ferrite, which is located on the borders of the former austenite grains. Carried out an assessment the effect of the chemical composition of the deposited metal on the hardness and wear and hydrogen content. In consequence of multivariate correlation analysis, it was determined dependence to the hardness of the deposited layer and the wear resistance of the mass fraction of the elements included in the flux-cored wires of the system Fe

Method for forming metal contacts

DOEpatents

Reddington, Erik; Sutter, Thomas C; Bu, Lujia; Cannon, Alexandra; Habas, Susan E; Curtis, Calvin J; Miedaner, Alexander; Ginley, David S; Van Hest, Marinus Franciscus Antonius Maria

2013-09-17

Methods of forming metal contacts with metal inks in the manufacture of photovoltaic devices are disclosed. The metal inks are selectively deposited on semiconductor coatings by inkjet and aerosol apparatus. The composite is heated to selective temperatures where the metal inks burn through the coating to form an electrical contact with the semiconductor. Metal layers are then deposited on the electrical contacts by light induced or light assisted plating.

Comparison of Maraging Steel Micro- and Nanostructure Produced Conventionally and by Laser Additive Manufacturing.

PubMed

Jägle, Eric A; Sheng, Zhendong; Kürnsteiner, Philipp; Ocylok, Sörn; Weisheit, Andreas; Raabe, Dierk

2016-12-24

Maraging steels are used to produce tools by Additive Manufacturing (AM) methods such as Laser Metal Deposition (LMD) and Selective Laser Melting (SLM). Although it is well established that dense parts can be produced by AM, the influence of the AM process on the microstructure-in particular the content of retained and reversed austenite as well as the nanostructure, especially the precipitate density and chemistry, are not yet explored. Here, we study these features using microhardness measurements, Optical Microscopy, Electron Backscatter Diffraction (EBSD), Energy Dispersive Spectroscopy (EDS), and Atom Probe Tomography (APT) in the as-produced state and during ageing heat treatment. We find that due to microsegregation, retained austenite exists in the as-LMD- and as-SLM-produced states but not in the conventionally-produced material. The hardness in the as-LMD-produced state is higher than in the conventionally and SLM-produced materials, however, not in the uppermost layers. By APT, it is confirmed that this is due to early stages of precipitation induced by the cyclic re-heating upon further deposition-i.e., the intrinsic heat treatment associated with LMD. In the peak-aged state, which is reached after a similar time in all materials, the hardness of SLM- and LMD-produced material is slightly lower than in conventionally-produced material due to the presence of retained austenite and reversed austenite formed during ageing.

Comparison of Maraging Steel Micro- and Nanostructure Produced Conventionally and by Laser Additive Manufacturing

PubMed Central

Jägle, Eric A.; Sheng, Zhendong; Kürnsteiner, Philipp; Ocylok, Sörn; Weisheit, Andreas; Raabe, Dierk

2016-01-01

Maraging steels are used to produce tools by Additive Manufacturing (AM) methods such as Laser Metal Deposition (LMD) and Selective Laser Melting (SLM). Although it is well established that dense parts can be produced by AM, the influence of the AM process on the microstructure—in particular the content of retained and reversed austenite as well as the nanostructure, especially the precipitate density and chemistry, are not yet explored. Here, we study these features using microhardness measurements, Optical Microscopy, Electron Backscatter Diffraction (EBSD), Energy Dispersive Spectroscopy (EDS), and Atom Probe Tomography (APT) in the as-produced state and during ageing heat treatment. We find that due to microsegregation, retained austenite exists in the as-LMD- and as-SLM-produced states but not in the conventionally-produced material. The hardness in the as-LMD-produced state is higher than in the conventionally and SLM-produced materials, however, not in the uppermost layers. By APT, it is confirmed that this is due to early stages of precipitation induced by the cyclic re-heating upon further deposition—i.e., the intrinsic heat treatment associated with LMD. In the peak-aged state, which is reached after a similar time in all materials, the hardness of SLM- and LMD-produced material is slightly lower than in conventionally-produced material due to the presence of retained austenite and reversed austenite formed during ageing. PMID:28772369

Systems and Methods for Designing and Fabricating Contact-Free Support Structures for Overhang Geometries of Parts in Powder-Bed Metal Additive Manufacturing

NASA Technical Reports Server (NTRS)

Cooper, Kenneth (Inventor); Chou, Yuag-Shan (Inventor)

2017-01-01

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step.

Hardness variation of welded boron steel using continuous wave (CW) and pulse wave (PW) mode of fiber laser

NASA Astrophysics Data System (ADS)

Yaakob, K. I.; Ishak, M.; Idris, S. R. A.; Aiman, M. H.; Khalil, N. Z.

2017-09-01

Recent car manufacturer requirement in lightweight and optimum safety lead to utilization of boron steel with tailor welded blank approach. Laser welding process in tailor welded blank (TWB) production can be applied in continuous wave (CW) of pulse wave (PW) which produce different thermal experience in welded area. Instead of microstructure identification, hardness properties also can determine the behavior of weld area. In this paper, hardness variation of welded boron steel using PW and CW mode is investigated. Welding process is conducted using similar average power for both welding mode. Hardness variation across weld area is observed. The result shows similar hardness pattern across weld area for both welding mode. Hardness degradation at fusion zone (FZ) is due to ferrite formation existence from high heat input applied. With additional slower cooling rate for CW mode, the hardness degradation is become obvious. The normal variation of hardness behavior with PW mode might lead to good strength.

Advances in Additive Manufacturing

DTIC Science & Technology

2016-07-14

of 3D - printed structures. Analysis examples will include quantification of tolerance differences between the designed and manufactured parts, void...15. SUBJECT TERMS 3-D printing , validation and verification, nondestructive inspection, print -on-the-move, prototyping 16. SECURITY CLASSIFICATION...researching the formation of AM-grade metal powder from battlefield scrap and operating base waste, 2) potential of 3-D printing with sand to make

Alternative Manufacturing Concepts for Solid Oral Dosage Forms From Drug Nanosuspensions Using Fluid Dispensing and Forced Drying Technology.

PubMed

Bonhoeffer, Bastian; Kwade, Arno; Juhnke, Michael

2018-03-01

Flexible manufacturing technologies for solid oral dosage forms with a continuous adjustability of the manufactured dose strength are of interest for applications in personalized medicine. This study explored the feasibility of using microvalve technology for the manufacturing of different solid oral dosage form concepts. Hard gelatin capsules filled with excipients, placebo tablets, and polymer films, placed in hard gelatin capsules after drying, were considered as substrates. For each concept, a basic understanding of relevant formulation parameters and their impact on dissolution behavior has been established. Suitable matrix formers, present either on the substrate or directly in the drug nanosuspension, proved to be essential to prevent nanoparticle agglomeration of the drug nanoparticles and to ensure a fast dissolution behavior. Furthermore, convection and radiation drying methods were investigated for the fast drying of drug nanosuspensions dispensed onto polymer films, which were then placed in hard gelatin capsules. Changes in morphology and in drug and matrix former distribution were observed for increasing drying intensity. However, even fast drying times below 1 min could be realized, while maintaining the nanoparticulate drug structure and a good dissolution behavior. Copyright © 2018 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.

Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing.

PubMed

Luecke, William E; Slotwinski, John A

2014-01-01

Using uniaxial tensile and hardness testing, we evaluated the variability and anisotropy of the mechanical properties of an austenitic stainless steel, UNS S17400, manufactured by an additive process, selective laser melting. Like wrought materials, the mechanical properties depend on the orientation introduced by the processing. The recommended stress-relief heat treatment increases the tensile strength, reduces the yield strength, and decreases the extent of the discontinuous yielding. The mechanical properties, assessed by hardness, are very uniform across the build plate, but the stress-relief heat treatment introduced a small non-uniformity that had no correlation to position on the build plate. Analysis of the mechanical property behavior resulted in four conclusions. (1) The within-build and build-to-build tensile properties of the UNS S17400 stainless steel are less repeatable than mature engineering structural alloys, but similar to other structural alloys made by additive manufacturing. (2) The anisotropy of the mechanical properties of the UNS S17400 material of this study is larger than that of mature structural alloys, but is similar to other structural alloys made by additive manufacturing. (3) The tensile mechanical properties of the UNS S17400 material fabricated by selective laser melting are very different from those of wrought, heat-treated 17-4PH stainless steel. (4) The large discontinuous yielding strain in all tests resulted from the formation and propagation of Lüders bands.

First-principles modeling of hardness in transition-metal diborides

NASA Astrophysics Data System (ADS)

Lazar, Petr; Chen, Xing-Qiu; Podloucky, Raimund

2009-07-01

Based on recent experiments, the diborides OsB2 and ReB2 were proposed to be ultraincompressible and superhard materials. By application of an ab initio density-functional theory approach we investigate the elastic and cleavage fracture properties of the borides MB2 ( M=Hf , Ta, W, Re, Os, and Ir). We derive a direct correlation between the lowest calculated critical cleavage stress and the experimental (micro)hardness. By calculating the critical shear stress and estimating the possibility of dislocation emission we can justify the prediction that ReB2 is indeed a superhard material.

Internal fit of three-unit fixed dental prostheses produced by computer-aided design/computer-aided manufacturing and the lost-wax metal casting technique assessed using the triple-scan protocol.

PubMed

Dahl, Bjørn E; Dahl, Jon E; Rønold, Hans J

2018-02-01

Suboptimal adaptation of fixed dental prostheses (FDPs) can lead to technical and biological complications. It is unclear if the computer-aided design/computer-aided manufacturing (CAD/CAM) technique improves adaptation of FDPs compared with FDPs made using the lost-wax and metal casting technique. Three-unit FDPs were manufactured by CAD/CAM based on digital impression of a typodont model. The FDPs were made from one of five materials: pre-sintered zirconium dioxide; hot isostatic pressed zirconium dioxide; lithium disilicate glass-ceramic; milled cobalt-chromium; and laser-sintered cobalt-chromium. The FDPs made using the lost-wax and metal casting technique were used as reference. The fit of the FDPs was analysed using the triple-scan method. The fit was evaluated for both single abutments and three-unit FDPs. The average cement space varied between 50 μm and 300 μm. Insignificant differences in internal fit were observed between the CAD/CAM-manufactured FDPs, and none of the FPDs had cement spaces that were statistically significantly different from those of the reference FDP. For all FDPs, the cement space at a marginal band 0.5-1.0 mm from the preparation margin was less than 100 μm. The milled cobalt-chromium FDP had the closest fit. The cement space of FDPs produced using the CAD/CAM technique was similar to that of FDPs produced using the conventional lost-wax and metal casting technique. © 2017 Eur J Oral Sci.

Designing Superhard Materials by Incorporating Boron Into Heavy Transition Metals

NASA Astrophysics Data System (ADS)

Liang, Yongcheng; Li, Anhu; Zhao, Jianzhi; Zhang, Wenqing

First-principles calculations on the incompressibility, elasticity and hardness of the Os, OsB2, Re, and ReB2 materials have systematically been performed by the plane-wave basis pseudopotential method. Transition metals Os and Re, which have high bulk modulus but low hardness, can be converted into hard materials by combining them with small B atoms. Moreover, electronic and structural mechanisms of ReB2 and OsB2 are analyzed in detail and compared. It is shown that incorporating small B atoms into heavy transition metals should be a valid pathway to obtain new superhard materials.

Computer Modeling of Direct Metal Laser Sintering

NASA Technical Reports Server (NTRS)

Cross, Matthew

2014-01-01

A computational approach to modeling direct metal laser sintering (DMLS) additive manufacturing process is presented. The primary application of the model is for determining the temperature history of parts fabricated using DMLS to evaluate residual stresses found in finished pieces and to assess manufacturing process strategies to reduce part slumping. The model utilizes MSC SINDA as a heat transfer solver with imbedded FORTRAN computer code to direct laser motion, apply laser heating as a boundary condition, and simulate the addition of metal powder layers during part fabrication. Model results are compared to available data collected during in situ DMLS part manufacture.

Ceramic TBS/porous metal compliant layer

NASA Technical Reports Server (NTRS)

Tolokan, Robert P.; Jarrabet, G. P.

1992-01-01

Technetics Corporation manufactures metal fiber materials and components used in aerospace applications. Our technology base is fiber metal porous sheet material made from sinter bonded metal fibers. Fiber metals have percent densities (metal content by volume) from 10 to 65 percent. Various topics are covered and include the following: fiber metal materials, compliant layer thermal bayer coatings (TBC's), pad properties, ceramic/pad TBC design, thermal shock rig, fabrication, and applications.

Substantiation of the ratio of the sample thickness to the indentation depth in hardness measurements

NASA Astrophysics Data System (ADS)

Matyunin, V. M.; Marchenkov, A. Yu.; Terent'ev, E. V.; Demidov, A. N.

2016-12-01

The depths to which plastic deformation occurs under ball indentation of a steel plate at various loads is determined. It is established that the ratio of the depth that plastic deformation reaches to the indentation depth is constant (approximately 15) independently of the indentation load. This finding allows us to conclude that this ratio should be held no less than 15 in hardness measurements. Experiments demonstrate that the lower the hardness of the metal substrate, the larger the decrease in the measured hardness when the ratio is lower than 15.

Evaluation of the Various Drying Methods on Surface Hardness of Type IV Dental Stone

PubMed Central

Sudhakar, A; Srivatsa, G; Shetty, Rohit; Rajeswari, C L; Manvi, Supriya

2015-01-01

Background: Studies regarding the effect of various methods to increase the surface hardness of Type IV dental stone are not conclusive. Therefore, this study was carried out to evaluate the effect of air drying, micro oven drying and die hardener on surface hardness of Type IV dental stone. Materials and Methods: A standard metal die was fabricated; polyvinyl siloxane impression material was used to make the molds of metal die. A total of 120 specimens were obtained from two different die stones and were grouped as Group A (kalrock) and Group B (pearl stone), and were subjected to air drying for 24 h, micro oven drying and application of die hardener. These models were then subjected to surface hardness testing using the knoop hardness instrument. The obtained data were subjected to statistical analysis. Results: The hardness of Group A specimens was 64 ± 0.54 Knoop hardness number (KHN) after application of die hardener, 60.47 ± 0.41 KHN after 24 h air drying, 58.2 ± 0.88 after microwave oven drying and 24.6 ± 0.4 after 1 h air drying. The hardness of Group B specimens was 45.59 ± 0.63 KHN after application of die hardener, 40.2 ± 0.63 KHN after 24 h air drying, 38.28 ± 0.55 KHN after microwave oven drying and 19.91 ± 0.64 KHN after 1 h air drying. Conclusion: Group A showed better results than Group B at all times. Application of the die hardener showed highest hardness values followed in the order by 24 h air drying, microwave oven drying and 1 h air drying in both groups. The study showed that air drying the dies for 24 h followed by application of a single layer of the die hardener produced the best surface hardness and is recommended to be followed in practice. PMID:26124610

A framework for development of an intelligent system for design and manufacturing of stamping dies

NASA Astrophysics Data System (ADS)

Hussein, H. M. A.; Kumar, S.

2014-07-01

An integration of computer aided design (CAD), computer aided process planning (CAPP) and computer aided manufacturing (CAM) is required for development of an intelligent system to design and manufacture stamping dies in sheet metal industries. In this paper, a framework for development of an intelligent system for design and manufacturing of stamping dies is proposed. In the proposed framework, the intelligent system is structured in form of various expert system modules for different activities of design and manufacturing of dies. All system modules are integrated with each other. The proposed system takes its input in form of a CAD file of sheet metal part, and then system modules automate all tasks related to design and manufacturing of stamping dies. Modules are coded using Visual Basic (VB) and developed on the platform of AutoCAD software.

Impact of effluents from a car battery manufacturing plant in Nigeria on water, soil, and food qualities.

PubMed

Orisakwe, Orish Ebere; Asomugha, Rose; Afonne, Onyenmechi Johnson; Anisi, C N; Obi, Ejeatuluchukwualo; Dioka, Chudi Emma

2004-01-01

The authors investigated the impact of effluents from a car battery manufacturing plant in Nnewi, Nigeria, on water, soil, and food qualities. The authors analyzed heavy metals mercury, arsenic, lead, cadmium and nickel in tap and cassava waters, soil, dried cassava tuber, and edible fruit samples from the company, using an atomic absorption spectrophotometer. Other parameters the authors analyzed include pH, electrical conductivity (EC), salinity (SAL), total hardness (TH), biological oxygen demand (BOD), volatile and non-volatile solids, and bacterial and fungal loads of the soil samples. Results show that lead had the highest concentration in all the samples, with the soil samples having the highest lead concentration (38-12 ppm, 102 ppm) and the water samples having the lowest (0.02-0.20 ppm). Mercury had the lowest concentration (<0.0002 ppm) in all the samples. Soil sample B had the highest concentration of all the metals tested. Cassava water had higher levels of EC, SAL, TH, BOD, and volatile and nonvolatile solids, but lower pH than tap water. Bacterial loads were higher than fungal loads in all the soil samples. Because there was moderate contamination of the environment by some of the metals studied, with lead being exceptionally high and above the specified international standards, the authors recommend control measures to reduce lead exposure to the local populace within and around this industry.

Manufacturing, Marketing and Distribution, Business and Office Occupations: Grade 8. Cluster III.

ERIC Educational Resources Information Center

Calhoun, Olivia H.

A curriculum guide for grade 8, the document is divided into eleven units: marketing and distribution; food manufacturing; data processing and automation; administration, management, and labor; secretarial and clerical services; office machines; equipment; metal manufacturing and processing; prefabrication and prepackaging; textile and clothing…

The MSFC complementary metal oxide semiconductor (including multilevel interconnect metallization) process handbook

NASA Technical Reports Server (NTRS)

Bouldin, D. L.; Eastes, R. W.; Feltner, W. R.; Hollis, B. R.; Routh, D. E.

1979-01-01

The fabrication techniques for creation of complementary metal oxide semiconductor integrated circuits at George C. Marshall Space Flight Center are described. Examples of C-MOS integrated circuits manufactured at MSFC are presented with functional descriptions of each. Typical electrical characteristics of both p-channel metal oxide semiconductor and n-channel metal oxide semiconductor discrete devices under given conditions are provided. Procedures design, mask making, packaging, and testing are included.

Developing and Characterizing Bulk Metallic Glasses for Extreme Applications

NASA Astrophysics Data System (ADS)

Roberts, Scott Nolan

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 Cu43Zr 43Al7Be7). 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

Simulation of the infiltration process of a ceramic open-pore body with a metal alloy in semi-solid state to design the manufacturing of interpenetrating phase composites

NASA Astrophysics Data System (ADS)

Schomer, Laura; Liewald, Mathias; Riedmüller, Kim Rouven

2018-05-01

Metal-ceramic Interpenetrating Phase Composites (IPC) belong to a special subcategory of composite materials and reveal enhanced properties compared to conventional composite materials. Currently, IPC are produced by infiltration of a ceramic open-pore body with liquid metal applying high pressure and I or high temperature to avoid residual porosity. However, these IPC are not able to gain their complete potential, because of structural damages and interface reactions occurring during the manufacturing process. Compared to this, the manufacturing of IPC using the semi-solid forming technology offers great perspectives due to relative low processing temperatures and reduced mechanical pressure. In this context, this paper is focusing on numerical investigations conducted by using the FLOW-3D software for gaining a deeper understanding of the infiltration of open-pore bodies with semi-solid materials. For flow simulation analysis, a geometric model and different porous media drag models have been used. They have been adjusted and compared to get a precise description of the infiltration process. Based on these fundamental numerical investigations, this paper also shows numerical investigations that were used for basically designing a semi-solid forming tool. Thereby, the development of the flow front and the pressure during the infiltration represent the basis of the evaluation. The use of an open and closed tool cavity combined with various geometries of the upper die shows different results relating to these evaluation arguments. Furthermore, different overflows were designed and its effects on the pressure at the end of the infiltration process were investigated. Thus, this paper provides a general guideline for a tool design for manufacturing of metal-ceramic IPC using semi-solid forming.

Biorefining of precious metals from wastes: an answer to manufacturing of cheap nanocatalysts for fuel cells and power generation via an integrated biorefinery?

PubMed

Yong, Ping; Mikheenko, Iryna P; Deplanche, Kevin; Redwood, Mark D; Macaskie, Lynne E

2010-12-01

Bio-manufacturing of nano-scale palladium was achieved via enzymatically-mediated deposition of Pd from solution using Desulfovibrio desulfuricans, Escherichia coli and Cupriavidus metallidurans. Dried 'Bio-Pd' materials were sintered, applied onto carbon papers and tested as anodes in a proton exchange membrane (PEM) fuel cell for power production. At a Pd(0) loading of 25% by mass the fuel cell power using Bio-Pd( D. desulfuricans ) (positive control) and Bio-Pd( E. coli ) (negative control) was ~140 and ~30 mW respectively. Bio-Pd( C. metallidurans ) was intermediate between these with a power output of ~60 mW. An engineered strain of E. coli (IC007) was previously reported to give a Bio-Pd that was >3-fold more active than Bio-Pd of the parent E. coli MC4100 (i.e. a power output of >110 mW). Using this strain, a mixed metallic catalyst was manufactured from an industrial processing waste. This 'Bio-precious metal' ('Bio-PM') gave ~68% of the power output as commercial Pd(0) and ~50% of that of Bio-Pd( D. desulfuricans ) when used as fuel cell anodic material. The results are discussed in relation to integrated bioprocessing for clean energy.

Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors

NASA Technical Reports Server (NTRS)

Vudler, Vladimir

2012-01-01

High-precision mirrors for space applications are traditionally manufactured from one piece of material, such as lightweight glass sandwich or beryllium. The purpose of this project was to develop and test the feasibility of a manufacturing process capable of producing mirrors out of welded segments of AlBeMet(Registered Trademark) (AM162H). AlBeMet(Registered Trademark) is a HIP'd (hot isostatic pressed) material containing approximately 62% beryllium and 38% aluminum. As a result, AlBeMet shares many of the benefits of both of those materials for use in high performance mirrors, while minimizing many of their weaknesses.

Application of hard coatings to substrates at low temperatures

NASA Technical Reports Server (NTRS)

Sproul, William D.

1993-01-01

BIRL, the industrial research laboratory of Northwestern University, has conducted unique and innovative research, under sponsorship from the NASA Marshall Space Flight Center (MSFC), in the application of hard, wear resistant coatings to bearing steels using the high-rate reactive sputtering (HRRS) process that was pioneered by Dr. William Sproul, the principal investigator on this program. Prior to this program, Dr. Sproul had demonstrated that it is possible to apply hard coatings such as titanium nitride (TiN) to alloy steels at low temperatures via the HRRS process without changing the metallurgical properties of the steel. The NASA MSFC program at BIRL had the specific objectives to: apply TiN to 440C stainless steel without changing the metallurgical properties of the steel; prepare rolling contact fatigue (RCF) test samples coated with binary hard coatings of TiN, zirconium nitride (ZrN), hafnium nitride (HfN), chromium nitride (CrN), and molybdenum nitride (MoN), and metal coatings of copper (Cu) and gold (Au); and develop new alloyed hard coatings of titanium aluminum nitride (Ti(0.5)Al(0.5)N), titanium zirconium nitride (Ti(0.5)Zr(0.5)N), and titanium aluminum vanadium nitride.

On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process.

PubMed

Ahmad, Azlan; Lajis, Mohd Amri; Yusuf, Nur Kamilah

2017-09-19

Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 °C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future.

On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process

PubMed Central

Ahmad, Azlan; Lajis, Mohd Amri

2017-01-01

Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 °C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future. PMID:28925963

In situ absorptivity measurements of metallic powders during laser powder-bed fusion additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Trapp, Johannes; Rubenchik, Alexander M.; Guss, Gabe

Here, the effective absorptivity of continuous wave 1070 nm laser light has been studied for bare and metal powder-coated discs of 316L stainless steel as well as for aluminum alloy 1100 and tungsten by use of direct calorimetric measurements. After carefully validating the applicability of the method, the effective absorptivity is plotted as a function of incident laser power from 30 up to ≈540 W for scanning speeds of 100, 500 and 1500 mm s –1. The effective absorptivity versus power curves of the bulk materials typically show a slight change in effective absorptivity from 30 W until the onsetmore » of the formation of a recoil pressure-induced surface depression. As observed using high-speed video, this change in surface morphology leads to an increase in absorption of the laser light. At the higher powers beyond the keyhole transition, a saturation value is reached for both bare discs and powder-coated disks. For ≈100 μm thick powder layers, the measured absorptivity was found to be two times that of the bare polished discs for low-laser power. There is a sharp decrease when full melting of the powder tracks is achieved, followed by a keyhole-driven increase at higher powers, similar to the bare disc case. It is shown that, under conditions associated with laser powder-bed fusion additive manufacturing, absorptivity values can vary greatly, and differ from both powder-layer measurements and liquid metal estimates from the literature.« less

In situ absorptivity measurements of metallic powders during laser powder-bed fusion additive manufacturing

DOE PAGES

Trapp, Johannes; Rubenchik, Alexander M.; Guss, Gabe; ...

2017-09-17

Here, the effective absorptivity of continuous wave 1070 nm laser light has been studied for bare and metal powder-coated discs of 316L stainless steel as well as for aluminum alloy 1100 and tungsten by use of direct calorimetric measurements. After carefully validating the applicability of the method, the effective absorptivity is plotted as a function of incident laser power from 30 up to ≈540 W for scanning speeds of 100, 500 and 1500 mm s –1. The effective absorptivity versus power curves of the bulk materials typically show a slight change in effective absorptivity from 30 W until the onsetmore » of the formation of a recoil pressure-induced surface depression. As observed using high-speed video, this change in surface morphology leads to an increase in absorption of the laser light. At the higher powers beyond the keyhole transition, a saturation value is reached for both bare discs and powder-coated disks. For ≈100 μm thick powder layers, the measured absorptivity was found to be two times that of the bare polished discs for low-laser power. There is a sharp decrease when full melting of the powder tracks is achieved, followed by a keyhole-driven increase at higher powers, similar to the bare disc case. It is shown that, under conditions associated with laser powder-bed fusion additive manufacturing, absorptivity values can vary greatly, and differ from both powder-layer measurements and liquid metal estimates from the literature.« less

Additive and Photochemical Manufacturing of Copper

PubMed Central

Yung, Winco K. C.; Sun, Bo; Meng, Zhengong; Huang, Junfeng; Jin, Yingdi; Choy, Hang Shan; Cai, Zhixiang; Li, Guijun; Ho, Cheuk Lam; Yang, Jinlong; Wong, Wai Yeung

2016-01-01

In recent years, 3D printing technologies have been extensively developed, enabling rapid prototyping from a conceptual design to an actual product. However, additive manufacturing of metals in the existing technologies is still cost-intensive and time-consuming. Herein a novel platform for low-cost additive manufacturing is introduced by simultaneously combining the laser-induced forward transfer (LIFT) method with photochemical reaction. Using acrylonitrile butadiene styrene (ABS) polymer as the sacrificial layer, sufficient ejection momentum can be generated in the LIFT method. A low-cost continuous wave (CW) laser diode at 405 nm was utilized and proved to be able to transfer the photochemically synthesized copper onto the target substrate. The wavelength-dependent photochemical behaviour in the LIFT method was verified and characterized by both theoretical and experimental studies compared to 1064 nm fiber laser. The conductivity of the synthesized copper patterns could be enhanced using post electroless plating while retaining the designed pattern shapes. Prototypes of electronic circuits were accordingly built and demonstrated for powering up LEDs. Apart from pristine PDMS materials with low surface energies, the proposed method can simultaneously perform laser-induced forward transfer and photochemical synthesis of metals, starting from their metal oxide forms, onto various target substrates such as polyimide, glass and thermoplastics. PMID:28000733

Additive and Photochemical Manufacturing of Copper

NASA Astrophysics Data System (ADS)

Yung, Winco K. C.; Sun, Bo; Meng, Zhengong; Huang, Junfeng; Jin, Yingdi; Choy, Hang Shan; Cai, Zhixiang; Li, Guijun; Ho, Cheuk Lam; Yang, Jinlong; Wong, Wai Yeung

2016-12-01

In recent years, 3D printing technologies have been extensively developed, enabling rapid prototyping from a conceptual design to an actual product. However, additive manufacturing of metals in the existing technologies is still cost-intensive and time-consuming. Herein a novel platform for low-cost additive manufacturing is introduced by simultaneously combining the laser-induced forward transfer (LIFT) method with photochemical reaction. Using acrylonitrile butadiene styrene (ABS) polymer as the sacrificial layer, sufficient ejection momentum can be generated in the LIFT method. A low-cost continuous wave (CW) laser diode at 405 nm was utilized and proved to be able to transfer the photochemically synthesized copper onto the target substrate. The wavelength-dependent photochemical behaviour in the LIFT method was verified and characterized by both theoretical and experimental studies compared to 1064 nm fiber laser. The conductivity of the synthesized copper patterns could be enhanced using post electroless plating while retaining the designed pattern shapes. Prototypes of electronic circuits were accordingly built and demonstrated for powering up LEDs. Apart from pristine PDMS materials with low surface energies, the proposed method can simultaneously perform laser-induced forward transfer and photochemical synthesis of metals, starting from their metal oxide forms, onto various target substrates such as polyimide, glass and thermoplastics.

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

NASA Technical Reports Server (NTRS)

Prater, Tracie; Bean, Quincy; Werkheiser, Niki; Ledbetter, Frank

2017-01-01

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

Preparation of magnesium metal matrix composites by powder metallurgy process

NASA Astrophysics Data System (ADS)

Satish, J.; Satish, K. G., Dr.

2018-02-01

Magnesium is the lightest metal used as the source for constructional alloys. Today Magnesium based metal matrix composites are widely used in aerospace, structural, oceanic and automobile applications for its light weight, low density(two thirds that of aluminium), good high temperature mechanical properties and good to excellent corrosion resistance. The reason of designing metal matrix composite is to put in the attractive attributes of metals and ceramics to the base metal. In this study magnesium metal matrix hybrid composite are developed by reinforcing pure magnesium with silicon carbide (SiC) and aluminium oxide by method of powder metallurgy. This method is less expensive and very efficient. The Hardness test was performed on the specimens prepared by powder metallurgy method. The results revealed that the micro hardness of composites was increased with the addition of silicon carbide and alumina particles in magnesium metal matrix composites.

Adhesion and friction of transition metals in contact with nonmetallic hard materials

NASA Technical Reports Server (NTRS)

Miyoshi, K.; Buckley, D. H.

1981-01-01

Sliding friction experiments were conducted with the metals yttrium, titanium, tantalum, zirconium, vanadium, neodymium, iron, cobalt, nickel, tungsten, platinum, rhenium, ruthenium, and rhodium in sliding contact with single crystal diamond, silicon carbide, pyrolytic boron nitride, and ferrite. Auger electron spectroscopy analysis was conducted with the metals and nonmetals to determine the surface chemistry and the degree of surface cleanliness. The results of the investigation indicate the adhesion and friction of the transition metals in contact with diamond, silicon carbide, boron nitride, and ferrite are related to the relative chemical activity of the metals. The more chemically active the metal, the higher the coefficient of friction and the greater amount of transfer to the nonmetals.

Titanium orthodontic brackets: structure, composition, hardness and ionic release.

PubMed

Gioka, Christiana; Bourauel, Christoph; Zinelis, Spiros; Eliades, Theodore; Silikas, Nikolaos; Eliades, George

2004-09-01

The aim of the present study was to investigate the composition, morphology, bulk structure and ionic release of two brands of titanium orthodontic brackets: Orthos2 (Ormco, USA) and Rematitan (Dentaurum, Germany). Five specimens of each group were examined with computerized X-ray microtomography, to reveal the morphology and structure of brackets, whilst resin-embedded and metallographically polished specimens were subjected to SEM/EDS analysis and Vickers microhardness measurements. Brackets were also maintained in 0.9% saline for 2 months and the ionic release in the immersion medium was determined with Inductively Coupled Plasma Atomic Emission Spectroscopy. The results of the hardness and ionic release measurements were statistically analyzed with two-way ANOVA and Tukey's test (alpha = 0.05). Orthos2 brackets consisted of two parts, the base (commercially pure Ti grade II) and the wing (Ti-6Al-4V alloy), joined together by laser welding, producing large gaps along the base-wing interface. The base was of lower hardness (Hv = 145), than the wing (Hv = 392) and incorporated a standard foil base-mesh pad. Rematitan brackets consisted of commercially pure Ti grade IV, with a single-piece manufacturing pattern of virtually identical hardness (p > 0.05) at the base and wings, featuring a laser-etched base-mesh pad. The hardness of the Rematitan brackets was significantly lower than the hardness of the Orthos2 wings, but double the hardness of the Orthos2 base. Released Ti levels were below the threshold level (1 ng/ml) of analysis for both materials, whilst traces of Al (3 ppm) and V (2 ppm) were found in the immersion media for Ti-6Al-4V alloy. The structural and hardness differences found may influence the torque transfer characteristics from activated archwires to the brackets and the crevice corrosion potential at the base-wing interface (Orthos2). The detection of Al and V in the immersion medium (Orthos2) may imply a different biological response from the two

Nanostructural Evolution of Hard Turning Layers in Carburized Steel

NASA Astrophysics Data System (ADS)

Bedekar, Vikram

The mechanisms of failure for components subjected to contact fatigue are sensitive to the structure and properties of the material surface. Although, the bulk material properties are determined by the steel making, forming and the heat treatment; the near surface material properties are altered during final material removal processes such as hard turning or grinding. Therefore, the ability to optimize, modulate and predict the near surface properties during final metal removal operations would be extremely useful in the enhancement of service life of a component. Hard machining is known to induce severely deformed layers causing dramatic microstructural transformations. These transformations occur via grain refinement or thermal phenomena depending upon cutting conditions. The aim of this work is to engineer the near surface nanoscale structure and properties during hard turning by altering strain, strain rate, temperature and incoming microstructure. The near surface material transformations due to hard turning were studied on carburized SAE 8620 bearing steel. Variations in parent material microstructures were introduced by altering the retained austenite content. The strain, strain rate and temperature achieved during final metal cutting were altered by varying insert geometry, insert wear and cutting speed. The subsurface evolution was quantified by a series of advanced characterization techniques such as transmission electron microscopy (TEM), glancing angle X-ray diffraction (GAXRD), X-ray stress evaluation and nanoindentation which were coupled with numerical modeling. Results showed that the grain size of the nanocrystalline near surface microstructure can be effectively controlled by altering the insert geometry, insert wear, cutting speed and the incoming microstructure. It was also evident that the near surface retained austenite decreased at lower cutting speed indicating transformation due to plastic deformation, while it increased at higher cutting

GaN-Based High Temperature and Radiation-Hard Electronics for Harsh Environments

NASA Technical Reports Server (NTRS)

Son, Kyung-ah; Liao, Anna; Lung, Gerald; Gallegos, Manuel; Hatakeh, Toshiro; Harris, Richard D.; Scheick, Leif Z.; Smythe, William D.

2010-01-01

We develop novel GaN-based high temperature and radiation-hard electronics to realize data acquisition electronics and transmitters suitable for operations in harsh planetary environments. In this paper, we discuss our research on metal-oxide-semiconductor (MOS) transistors that are targeted for 500 (sup o)C operation and >2 Mrad radiation hardness. For the target device performance, we develop Schottky-free AlGaN/GaN MOS transistors, where a gate electrode is processed in a MOS layout using an Al2O3 gate dielectric layer....

CHARACTERIZATION OF METAL BENZOTRIAZOLES AND RELATED POLYMERS

EPA Science Inventory

Benzotriazole (bta-H) is a well-known corrosion inhibitor for copper, copper-alloy, and other metal surfaces. Typical uses are to deactivate surfaces of computer hard drives and other internal metal computer parts, and for treatment of apparel hardware such as zippers and buttons...

Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

NASA Astrophysics Data System (ADS)

Hehr, Adam J.

Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

Research on width control of Metal Fused-coating Additive Manufacturing based on active control

NASA Astrophysics Data System (ADS)

Ren, Chuan qi; Wei, Zheng ying; Wang, Xin; Du, Jun; Zhang, Shan; Zhang, Zhitong; Bai, Hao

2017-12-01

Given the stability of the shape of the forming layer is one of the key problems that affect the final quality of the sample morphology, taking a study on the forming process and the control method of morphology make a significant difference to metal fused-coating additive manufacturing (MFCAM) in achieving the efficient and stable forming. To improve the quality and precision of the samples of single-layer single pass, a control method of morphology based on active control was established by this paper. The real-time acquisition of image was realized by CCD and the characteristics of morphology of the forming process were simultaneously extracted. Making analysis of the characteristics of the width during the process, the relationship between the relative difference of different frames and moving speed was given. A large number of experiments are used to verify the response speed and accuracy of the system. The results show that the active system can improve the morphology of the sample and the smoothness of the width of the single channel, and increase the uniformity of width by 55.16%.

Transverse excitations in liquid metals

NASA Astrophysics Data System (ADS)

Hosokawa, S.; Munejiri, S.; Inui, M.; Kajihara, Y.; Pilgrim, W.-C.; Baron, A. Q. R.; Shimojo, F.; Hoshino, K.

2013-02-01

The transverse acoustic excitation modes were detected by inelastic x-ray scattering in liquid Ga, Cu and Fe in the Q range around 10 nm-1 using a third-generation synchrotron radiation facility, SPring-8, although these liquid metals are mostly described by a simple hard-sphere liquid. Ab initio molecular dynamics simulations clearly support this finding for liquid Ga. From the detailed analyses for the S(Q,ω) spectra with good statistic qualities, the lifetime of less than 1 ps and the propagating length of less than 1 nm can be estimated for the transverse acoustic phonon modes, which correspond to the lifetime and size of cages formed instantaneously in these liquid metals. The microscopic Poisson's ratio estimated from the dynamic velocities of sound is 0.42 for liquid Ga and about -0.2 for liquid transition metals, indicating a rubber-like soft and extremely hard elastic properties of the cage clusters, respectively. The origin of these microscopic elastic properties is discussed in detail.

Environmentally friendly preparation of metal nanoparticles

EPA Science Inventory

The book chapter summarizes the “state of the art” in the exploitation of various environmentally-friendly synthesis approaches, reaction precursors and conditions to manufacture metal and metal oxide nanoparticles for a vast variety of purposes.

METAL COMPOSITIONS

DOEpatents

Seybolt, A.U.

1959-02-01

Alloys of uranium which are strong, hard, and machinable are presented, These alloys of uranium contain bctween 0.1 to 5.0% by weight of at least one noble metal such as rhodium, palladium, and gold. The alloys may be heat treated to obtain a product with iniproved tensile and compression strengths,

Shear bond strength comparison between conventional porcelain fused to metal and new functionally graded dental restorations after thermal-mechanical cycling.

PubMed

Henriques, B; Gonçalves, S; Soares, D; Silva, F S

2012-09-01

The aim of this study was to evaluate the effect of thermo-mechanical cycling on the metal-ceramic bond strength of conventional porcelain fused to metal restorations (PFM) and new functionally graded metal-ceramic dental restorations (FGMR). Two types of specimens were produced: PFM and FGMR specimens. PFM specimens were produced by conventional PFM technique. FGMR specimens were hot pressed and prepared with a metal/ceramic composite interlayer (50 M, vol%) at the metal-ceramic interface. They were manufactured and standardized in cylindrical format and then submitted to thermal (3000, 6000 and 12,000 cycles; between 5 °C and 60 °C; dwell time: 30s) and mechanical (25,000, 50,000 and 100,000 cycles under a load of 50 N; 1.6 Hz) cycling. The shear bond strength tests were performed in a universal testing machine (crosshead speed: 0.5mm/min), using a special device to concentrate the tension at the metal-ceramic interface and the load was applied until fracture. The metal-ceramic interfaces were examined with SEM/EDS prior to and after shear tests. The Young's modulus and hardness were measured across the interfaces of both types of specimens using nanoindentation tests. Data was analyzed with Shapiro-Wilk test to test the assumption of normality. The 2-way ANOVA was used to compare shear bond strength results (p<0.05). FGMR specimens showed significantly (p<0.001) higher shear bond strength results than PFM specimens, irrespective of fatigue conditions. Fatigue conditions significantly (p<0.05) affected the shear bond strength results. The analysis of surface fracture revealed adhesive fracture type for PFM specimens and mixed fracture type for FGMR specimens. Nanoindentation tests showed differences in mechanical properties measured across the metal-ceramic interface for the two types of specimens, namely Young's Modulus and hardness. This study showed significantly better performance of the new functionally graded restorations relative to conventional PFM

Non-noble metal based metallization systems

NASA Technical Reports Server (NTRS)

Garcia, A., III

1983-01-01

The results of efforts to produce a nonsilver metallization system for silicon photovoltaic cells are given. The system uses a metallization system based on molybdenum, tin, and titanium hydride. The initial work in this system was done using the MIDFILM process. The MIDFILM process attains a line resolution comparable to photoresist methods with a process related to screen printing. The surface to be processed is first coated with a thin layer of photopolymer material. Upon exposure to ultraviolet light through a suitable mask, the polymer in the non-pattern area crosslinks and becomes hard. The unexposed pattern areas remain tacky. The conductor material is then applied in the form of a dry mixture of metal which adheres to the tacky pattern area. The assemblage is then fired to ash the photopolymer and sinter the conductor powder.

Evaluation of the performance during hard turning of OHNS steel with minimal cutting fluid application and its comparison with minimum quantity lubrication

NASA Astrophysics Data System (ADS)

Raj, Anil; Wins, K. Leo Dev; Varadarajan, A. S.

2016-09-01

Cutting fluid application plays a significant role in the manufacturing industries that acts as a coolant as well as a lubricant. The conventional flood cooling application of cutting fluids not only increases the production cost on account of the expenses involved in procurement, storage and disposal but also creates serious environmental and health hazards. In order to overcome these negative effects, techniques like Minimum quantity lubrication (MQL) and Minimal Cutting fluid application (MCFA) have increasingly found their way into the area of metal cutting and have already been established as an alternative to conventional wet machining. This paper investigates the effect of minimal Cutting fluid application (MCFA) which involves application of high velocity pulsing jet of proprietary cutting fluids at the contact zones using a special fluid application system. During hard turning of oil hardened non shrinkable steel (OHNS) on cutting temperature and tool wear and to compare the performance with Minimum quantity lubrication (MQL) assisted hard turning in which cutting fluid is carried in a high velocity stream of air. An attempt was also made to compare the performance during Turning with MCFA and MQL application with conventional wet and dry turning by analysing the tool wear pattern using SEM images.

The Hardest Superconducting Metal Nitride

NASA Astrophysics Data System (ADS)

Wang, Shanmin; Antonio, Daniel; Yu, Xiaohui; Zhang, Jianzhong; Cornelius, Andrew L.; He, Duanwei; Zhao, Yusheng

2015-09-01

Transition-metal (TM) nitrides are a class of compounds with a wide range of properties and applications. Hard superconducting nitrides are of particular interest for electronic applications under working conditions such as coating and high stress (e.g., electromechanical systems). However, most of the known TM nitrides crystallize in the rock-salt structure, a structure that is unfavorable to resist shear strain, and they exhibit relatively low indentation hardness, typically in the range of 10-20 GPa. Here, we report high-pressure synthesis of hexagonal δ-MoN and cubic γ-MoN through an ion-exchange reaction at 3.5 GPa. The final products are in the bulk form with crystallite sizes of 50 - 80 μm. Based on indentation testing on single crystals, hexagonal δ-MoN exhibits excellent hardness of ~30 GPa, which is 30% higher than cubic γ-MoN (~23 GPa) and is so far the hardest among the known metal nitrides. The hardness enhancement in hexagonal phase is attributed to extended covalently bonded Mo-N network than that in cubic phase. The measured superconducting transition temperatures for δ-MoN and cubic γ-MoN are 13.8 and 5.5 K, respectively, in good agreement with previous measurements.

Manufacture and application of RuO2 solid-state metal-oxide pH sensor to common beverages.

PubMed

Lonsdale, W; Wajrak, M; Alameh, K

2018-04-01

A new reproducible solid-state metal-oxide pH sensor for beverage quality monitoring is developed and characterised. The working electrode of the developed pH sensor is based on the use of laser-etched sputter-deposited RuO 2 on Al 2 O 3 substrate, modified with thin layers of sputter-deposited Ta 2 O 5 and drop-cast Nafion for minimisation of redox interference. The reference electrode is manufactured by further modifying a working electrode with a porous polyvinyl butyral layer loaded with fumed SiO 2 . The developed pH sensor shows excellent performance when applied to a selection of beverage samples, with a measured accuracy within 0.08 pH of a commercial glass pH sensor. Copyright © 2017 Elsevier B.V. All rights reserved.

Mechanical Properties of Austenitic Stainless Steel Made by Additive Manufacturing

PubMed Central

Luecke, William E; Slotwinski, John A

2014-01-01

Using uniaxial tensile and hardness testing, we evaluated the variability and anisotropy of the mechanical properties of an austenitic stainless steel, UNS S17400, manufactured by an additive process, selective laser melting. Like wrought materials, the mechanical properties depend on the orientation introduced by the processing. The recommended stress-relief heat treatment increases the tensile strength, reduces the yield strength, and decreases the extent of the discontinuous yielding. The mechanical properties, assessed by hardness, are very uniform across the build plate, but the stress-relief heat treatment introduced a small non-uniformity that had no correlation to position on the build plate. Analysis of the mechanical property behavior resulted in four conclusions. (1) The within-build and build-to-build tensile properties of the UNS S17400 stainless steel are less repeatable than mature engineering structural alloys, but similar to other structural alloys made by additive manufacturing. (2) The anisotropy of the mechanical properties of the UNS S17400 material of this study is larger than that of mature structural alloys, but is similar to other structural alloys made by additive manufacturing. (3) The tensile mechanical properties of the UNS S17400 material fabricated by selective laser melting are very different from those of wrought, heat-treated 17-4PH stainless steel. (4) The large discontinuous yielding strain in all tests resulted from the formation and propagation of Lüders bands. PMID:26601037

The Application of Metal Matrix Composite Materials in Propulsion System Valves

NASA Technical Reports Server (NTRS)

Laszar, John; Shah, Sandeep; Kashalikar, Uday; Rozenoyer, Boris

2003-01-01

Metal Matrix Composite (MMC) materials have been developed and used in many applications to reduce the weight of components where weight and deflection are the driving design requirement. MMC materials are being developed for use in some propulsion system components, such as turbo-pumps and thrust chambers. However, to date, no propulsion system valves have been developed that take advantage of the materials unique properties. The stiffness of MMC's could help keep valves light or improve life where deflection is the design constraint (such as seal and bearing locations). The low CTE of the materials might allow the designer to reduce tolerances and clearances producing better performance and lighter weight valves. Using unique manufacturing processes allow parts to be plated/coated for longer life and allow joining either by welding or threading/bolting. Additionally, casting of multi part pre-forms to form a single part can lead to designs that would be hard or impossible to manufacture with other methods. Therefore, NASA's Marshall Space Flight Center (MSFC) has developed and tested a prototype propulsion system valve that utilizes these materials to demonstrate these advantages. Through design and testing, this effort will determine the best use of these materials in valves designed to achieve the goal of a highly reliable and lightweight propulsion system. This paper is a continuation of the paper, The Application of Metal Matrix Composite Materials In Propulsion System Valves, presented at the JANNAF Conference held in April, 2002. Fabrication techniques employed, valve development, and valve test results will be discussed in this paper.

Diamond Composite Films for Protective Coatings on Metals and Method of Formation

NASA Technical Reports Server (NTRS)

Ong, Tiong P. (Inventor); Shing, Yuh-Han (Inventor)

1997-01-01

Composite films consisting of diamond crystallites and hard amorphous films such as diamond-like carbon, titanium nitride, and titanium oxide are provided as protective coatings for metal substrates against extremely harsh environments. A composite layer having diamond crystallites and a hard amorphous film is affixed to a metal substrate via an interlayer including a bottom metal silicide film and a top silicon carbide film. The interlayer is formed either by depositing metal silicide and silicon carbide directly onto the metal substrate, or by first depositing an amorphous silicon film, then allowing top and bottom portions of the amorphous silicon to react during deposition of the diamond crystallites, to yield the desired interlayer structure.

Manufacturing and metrology for IR conformal windows and domes

NASA Astrophysics Data System (ADS)

Ferralli, Ian; Blalock, Todd; Brunelle, Matt; Lynch, Timothy; Myer, Brian; Medicus, Kate

2017-05-01

Freeform and conformal optics have the potential to dramatically improve optical systems by enabling systems with fewer optical components, reduced aberrations, and improved aerodynamic performance. These optical components differ from standard components in their surface shape, typically a non-symmetric equation based definition, and material properties. Traditional grinding and polishing tools are unable to handle these freeform shapes. Additionally, standard metrology tools cannot measure these surfaces. Desired substrates are typically hard ceramics, including poly-crystalline alumina or aluminum oxynitride. Notwithstanding the challenges that the hardness provides to manufacturing, these crystalline materials can be highly susceptible to grain decoration creating unacceptable scatter in optical systems. In this presentation, we will show progress towards addressing the unique challenges of manufacturing conformal windows and domes. Particular attention is given to our robotic polishing platform. This platform is based on an industrial robot adapted to accept a wide range of tooling and parts. The robot's flexibility has provided us an opportunity to address the unique challenges of conformal windows. Slurries and polishing active layers can easily be changed to adapt to varying materials and address grain decoration. We have the flexibility to change tool size and shape to address the varying sizes and shapes of conformal optics. In addition, the robotic platform can be a base for a deflectometry-based metrology tool to measure surface form error. This system, whose precision is independent of the robot's positioning accuracy, will allow us to measure optics in-situ saving time and reducing part risk. In conclusion, we will show examples of the conformal windows manufactured using our developed processes.

A hard X-ray nanoprobe beamline for nanoscale microscopy

PubMed Central

Winarski, Robert P.; Holt, Martin V.; Rose, Volker; Fuesz, Peter; Carbaugh, Dean; Benson, Christa; Shu, Deming; Kline, David; Stephenson, G. Brian; McNulty, Ian; Maser, Jörg

2012-01-01

The Hard X-ray Nanoprobe Beamline (or Nanoprobe Beamline) is an X-ray microscopy facility incorporating diffraction, fluorescence and full-field imaging capabilities designed and operated by the Center for Nanoscale Materials and the Advanced Photon Source at Sector 26 of the Advanced Photon Source at Argonne National Laboratory. This facility was constructed to probe the nanoscale structure of biological, environmental and material sciences samples. The beamline provides intense focused X-rays to the Hard X-ray Nanoprobe (or Nanoprobe) which incorporates Fresnel zone plate optics and a precision laser sensing and control system. The beamline operates over X-ray energies from 3 to 30 keV, enabling studies of most elements in the periodic table, with a particular emphasis on imaging transition metals. PMID:23093770

A hard X-ray nanoprobe beamline for nanoscale microscopy.

PubMed

Winarski, Robert P; Holt, Martin V; Rose, Volker; Fuesz, Peter; Carbaugh, Dean; Benson, Christa; Shu, Deming; Kline, David; Stephenson, G Brian; McNulty, Ian; Maser, Jörg

2012-11-01

The Hard X-ray Nanoprobe Beamline (or Nanoprobe Beamline) is an X-ray microscopy facility incorporating diffraction, fluorescence and full-field imaging capabilities designed and operated by the Center for Nanoscale Materials and the Advanced Photon Source at Sector 26 of the Advanced Photon Source at Argonne National Laboratory. This facility was constructed to probe the nanoscale structure of biological, environmental and material sciences samples. The beamline provides intense focused X-rays to the Hard X-ray Nanoprobe (or Nanoprobe) which incorporates Fresnel zone plate optics and a precision laser sensing and control system. The beamline operates over X-ray energies from 3 to 30 keV, enabling studies of most elements in the periodic table, with a particular emphasis on imaging transition metals.

Mechanical and Acoustic Characteristics of the Weld and the Base Metal Machine Part of Career Transport

NASA Astrophysics Data System (ADS)

Smirnov, Alexander N.; Knjaz'kov, Victor L.; Levashova, Elena E.; Ababkov, Nikolay V.; Pimonov, Maksim V.

2018-01-01

Currently, many industries use foreign-made machinery. There is no opportunity to purchase quality original spare parts for which machinery. Therefore, enterprises operating this equipment are looking for producers of analogues of various parts and assemblies. Quite often, the metal of such analog components turns out to be substandard, which leads to their breakdown at a much earlier date and the enterprises incur material losses. Due to the fact that the complex of performance characteristics and the resource of products are laid at the stage of their production, it is extremely important to control the quality of the raw materials. The structure, mechanical, acoustic and magnetic characteristics of metal samples of such destroyed details of quarry transport as hydraulic cylinders and detail “axis” of an excavator are investigated. A significant spread of data on the chemical composition of metal, hardness and characteristics of non-destructive testing is established, which gives grounds to recommend to manufacturers and suppliers of parts is more responsible to approach the incoming quality control. The results of the investigation of metal samples by destructive and non-destructive methods of control are compared, which showed that the spectral-acoustic method of nondestructive testing can be used to control the quality of the responsible machine parts under conditions of import substitution.

Mechanics of additively manufactured biomaterials.

PubMed

Zadpoor, Amir A

2017-06-01

Additive manufacturing (3D printing) has found many applications in healthcare including fabrication of biomaterials as well as bioprinting of tissues and organs. Additively manufactured (AM) biomaterials may possess arbitrarily complex micro-architectures that give rise to novel mechanical, physical, and biological properties. The mechanical behavior of such porous biomaterials including their quasi-static mechanical properties and fatigue resistance is not yet well understood. It is particularly important to understand the relationship between the designed micro-architecture (topology) and the resulting mechanical properties. The current special issue is dedicated to understanding the mechanical behavior of AM biomaterials. Although various types of AM biomaterials are represented in the special issue, the primary focus is on AM porous metallic biomaterials. As a prelude to this special issue, this editorial reviews some of the latest findings in the mechanical behavior of AM porous metallic biomaterials so as to describe the current state-of-the-art and set the stage for the other studies appearing in the issue. Some areas that are important for future research are also briefly mentioned. Copyright © 2017 Elsevier Ltd. All rights reserved.

Analysis of residual stress and hardness in regions of pre-manufactured and manual bends in fixation plates for maxillary advancement.

PubMed

Araújo, Marcelo Marotta; Lauria, Andrezza; Mendes, Marcelo Breno Meneses; Claro, Ana Paula Rosifini Alves; Claro, Cristiane Aparecida de Assis; Moreira, Roger William Fernandes

2015-12-01

The aim of this study was to analyze, through Vickers hardness test and photoelasticity analysis, pre-bent areas, manually bent areas, and areas without bends of 10-mm advancement pre-bent titanium plates (Leibinger system). The work was divided into three groups: group I-region without bend, group II-region of 90° manual bend, and group III-region of 90° pre-fabricated bends. All the materials were evaluated through hardness analysis by the Vickers hardness test, stress analysis by residual images obtained in a polariscope, and photoelastic analysis by reflection during the manual bending. The data obtained from the hardness tests were statistically analyzed using ANOVA and Tukey's tests at a significance level of 5 %. The pre-bent plate (group III) showed hardness means statistically significantly higher (P < 0.05) than those of the other groups (I-region without bends, II-90° manually bent region). Through the study of photoelastic reflection, it was possible to identify that the stress gradually increased, reaching a pink color (1.81 δ / λ), as the bending was performed. A general analysis of the results showed that the bent plate region of pre-bent titanium presented the best results.

High speed metal removal

NASA Astrophysics Data System (ADS)

Pugh, R. F.; Pohl, R. F.

1982-10-01

Four types of steel (AISI 1340, 4140, 4340, and HF-1) which are commonly used in large caliber projectile manufacture were machined at different hardness ranges representing the as-forged and the heat treated condition with various ceramic tools using ceramic coated tungsten carbide as a reference. Results show that machining speeds can be increased significantly using present available tooling.

Single crystalline hollow metal-organic frameworks: a metal-organic polyhedron single crystal as a sacrificial template.

PubMed

Kim, Hyehyun; Oh, Minhak; Kim, Dongwook; Park, Jeongin; Seong, Junmo; Kwak, Sang Kyu; Lah, Myoung Soo

2015-02-28

Single crystalline hollow metal-organic frameworks (MOFs) with cavity dimensions on the order of several micrometers and hundreds of micrometers were prepared using a metal-organic polyhedron single crystal as a sacrificial hard template. The hollow nature of the MOF crystal was confirmed by scanning electron microscopy of the crystal sliced using a focused ion beam.

Modelling of Mechanical Behavior at High Strain Rate of Ti-6al-4v Manufactured By Means of Direct Metal Laser Sintering Technique

NASA Astrophysics Data System (ADS)

Iannitti, Gianluca; Bonora, Nicola; Gentile, Domenico; Ruggiero, Andrew; Testa, Gabriel; Gubbioni, Simone

2017-06-01

In this work, the mechanical behavior of Ti-6Al-4V obtained by additive manufacturing technique was investigated, also considering the build direction. Dog-bone shaped specimens and Taylor cylinders were machined from rods manufactured by means of the EOSSINT M2 80 machine, based on Direct Metal Laser Sintering technique. Tensile tests were performed at strain rate ranging from 5E-4 s-1 to 1000 s-1 using an Instron electromechanical machine for quasistatic tests and a Direct-Tension Split Hopkinson Bar for dynamic tests. The mechanical strength of the material was described by a Johnson-Cook model modified to account for stress saturation occurring at high strain. Taylor cylinder tests and their corresponding numerical simulations were carried out in order to validate the constitutive model under a complex deformation path, high strain rates, and high temperatures.

Manufacturing Feasibility and Forming Properties of Cu-4Sn in Selective Laser Melting.

PubMed

Mao, Zhongfa; Zhang, David Z; Wei, Peitang; Zhang, Kaifei

2017-03-24

Copper alloys, combined with selective laser melting (SLM) technology, have attracted increasing attention in aerospace engineering, automobile, and medical fields. However, there are some difficulties in SLM forming owing to low laser absorption and excellent thermal conductivity. It is, therefore, necessary to explore a copper alloy in SLM. In this research, manufacturing feasibility and forming properties of Cu-4Sn in SLM were investigated through a systematic experimental approach. Single-track experiments were used to narrow down processing parameter windows. A Greco-Latin square design with orthogonal parameter arrays was employed to control forming qualities of specimens. Analysis of variance was applied to establish statistical relationships, which described the effects of different processing parameters (i.e., laser power, scanning speed, and hatch space) on relative density (RD) and Vickers hardness of specimens. It was found that Cu-4Sn specimens were successfully manufactured by SLM for the first time and both its RD and Vickers hardness were mainly determined by the laser power. The maximum value of RD exceeded 93% theoretical density and the maximum value of Vickers hardness reached 118 HV 0.3/5. The best tensile strength of 316-320 MPa is inferior to that of pressure-processed Cu-4Sn and can be improved further by reducing defects.

[Computer aided design and rapid manufacturing of removable partial denture frameworks].

PubMed

Han, Jing; Lü, Pei-jun; Wang, Yong

2010-08-01

To introduce a method of digital modeling and fabricating removable partial denture (RPD) frameworks using self-developed software for RPD design and rapid manufacturing system. The three-dimensional data of two partially dentate dental casts were obtained using a three-dimensional crossing section scanner. Self-developed software package for RPD design was used to decide the path of insertion and to design different components of RPD frameworks. The components included occlusal rest, clasp, lingual bar, polymeric retention framework and maxillary major connector. The design procedure for the components was as following: first, determine the outline of the component. Second, build the tissue surface of the component using the scanned data within the outline. Third, preset cross section was used to produce the polished surface. Finally, different RPD components were modeled respectively and connected by minor connectors to form an integrated RPD framework. The finished data were imported into a self-developed selective laser melting (SLM) machine and metal frameworks were fabricated directly. RPD frameworks for the two scanned dental casts were modeled with this self-developed program and metal RPD frameworks were successfully fabricated using SLM method. The finished metal frameworks fit well on the plaster models. The self-developed computer aided design and computer aided manufacture (CAD-CAM) system for RPD design and fabrication has completely independent intellectual property rights. It provides a new method of manufacturing metal RPD frameworks.

Feedstock powder processing research needs for additive manufacturing development

DOE PAGES

Anderson, Iver E.; White, Emma M. H.; Dehoff, Ryan

2018-02-01

Additive manufacturing (AM) promises to redesign traditional manufacturing by enabling the ultimate in agility for rapid component design changes in commercial products and for fabricating complex integrated parts. Here, by significantly increasing quality and yield of metallic alloy powders, the pace for design, development, and deployment of the most promising AM approaches can be greatly accelerated, resulting in rapid commercialization of these advanced manufacturing methods. By successful completion of a critical suite of processing research tasks that are intended to greatly enhance gas atomized powder quality and the precision and efficiency of powder production, researchers can help promote continued rapidmore » growth of AM. Finally, other powder-based or spray-based advanced manufacturing methods could also benefit from these research outcomes, promoting the next wave of sustainable manufacturing technologies for conventional and advanced materials.« less

Feedstock powder processing research needs for additive manufacturing development

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anderson, Iver E.; White, Emma M. H.; Dehoff, Ryan

Additive manufacturing (AM) promises to redesign traditional manufacturing by enabling the ultimate in agility for rapid component design changes in commercial products and for fabricating complex integrated parts. Here, by significantly increasing quality and yield of metallic alloy powders, the pace for design, development, and deployment of the most promising AM approaches can be greatly accelerated, resulting in rapid commercialization of these advanced manufacturing methods. By successful completion of a critical suite of processing research tasks that are intended to greatly enhance gas atomized powder quality and the precision and efficiency of powder production, researchers can help promote continued rapidmore » growth of AM. Finally, other powder-based or spray-based advanced manufacturing methods could also benefit from these research outcomes, promoting the next wave of sustainable manufacturing technologies for conventional and advanced materials.« less

Gas metal arc welding in refurbishment of cobalt base superalloys

NASA Astrophysics Data System (ADS)

Shahriary, M. S.; Miladi Gorji, Y.; Kolagar, A. M.

2017-01-01

Refurbishments of superalloys which are used in manufacturing gas turbine hot components usually consists of removing cracks and other defects by blending and then repair welding in order to reconstruct damaged area. In this study, the effects of welding parameters on repair of FSX-414 superalloy, as the most applicable cobalt base superalloy in order to manufacture gas turbine nozzles, by use of Gas Metal Arc Welding (GMAW) technic were investigated. Results then were compared by Gas Tungsten Arc Welding (GTAW). Metallographic and SEM studies of the microstructure of the weld and HAZ showed that there are no noticeable defects in the microstructure by use of GMAW. Also, chemical analysis and morphologies of carbide in both methods are similar. Hardness profile of the GM AW structure then also compared with GTAW and no noticeable difference was observed between the profiles. Also, proper tensile properties, compared with GTAW, can be achieved by use of optimum parameters that can be obtained by examining the current and welding speed. Tensile properties of optimized condition of the GMAW then were compared with GTAW. It was seen that the room and high temperature tensile properties of the GMAW structure is very similar and results confirmed that changing the technic did not have any significant influence on the properties.

Tribological Behavior of Aluminum Alloy AlSi10Mg-TiB2 Composites Produced by Direct Metal Laser Sintering (DMLS)

NASA Astrophysics Data System (ADS)

Lorusso, Massimo; Aversa, Alberta; Manfredi, Diego; Calignano, Flaviana; Ambrosio, Elisa Paola; Ugues, Daniele; Pavese, Matteo

2016-08-01

Direct metal laser sintering (DMLS) is an additive manufacturing technique for the production of parts with complex geometry and it is especially appropriate for structural applications in aircraft and automotive industries. Aluminum-based metal matrix composites (MMCs) are promising materials for these applications because they are lightweight, ductile, and have a good strength-to-weight ratio This paper presents an investigation of microstructure, hardness, and tribological properties of AlSi10Mg alloy and AlSi10Mg alloy/TiB2 composites prepared by DMLS. MMCs were realized with two different compositions: 10% wt. of microsize TiB2, 1% wt. of nanosize TiB2. Wear tests were performed using a pin-on-disk apparatus on the prepared samples. Performances of AlSi10Mg samples manufactured by DMLS were also compared with the results obtained on AlSi10Mg alloy samples made by casting. It was found that the composites displayed a lower coefficient of friction (COF), but in the case of microsize TiB2 reinforcement the wear rate was higher than with nanosize reinforcements and aluminum alloy without reinforcement. AlSi10Mg obtained by DMLS showed a higher COF than AlSi10Mg obtained by casting, but the wear rate was higher in the latter case.

Manufacture of sintered silicon nitrides

NASA Technical Reports Server (NTRS)

Iwai, T.

1985-01-01

Sintered silicon nitrides are manufactured by sintering Si3N powder containing 2 to 15% in wt of a powder mixture composed of nitride powder of lanthanide or Y 100 parts and AIN powder less than 100 parts at 1500 to 1900 deg. temperature under a pressure of less than 200 Kg/sq. cm. The sintered Si3N has high mechanical strength in high temperature. Thus, Si3N4 93.0, Y 5.0 and AlN 2.0% in weight were wet mixed in acetone in N atom, molded and sintered at 1750 deg. and 1000 Kg/sq. cm. to give a sintered body having high hardness.

Applied Physics Modules Selected for Manufacturing and Metal Technologies.

ERIC Educational Resources Information Center

Waring, Gene

Designed for individualized use in an applied physics course in postsecondary vocational-technical education, this series of eighteen learning modules is equivalent to the content of two quarters of a five-credit hour class in manufacturing engineering technology, machine tool and design technology, welding technology, and industrial plastics…

Metal Matrix Composite Material by Direct Metal Deposition

NASA Astrophysics Data System (ADS)

Novichenko, D.; Marants, A.; Thivillon, L.; Bertrand, P. H.; Smurov, I.

Direct Metal Deposition (DMD) is a laser cladding process for producing a protective coating on the surface of a metallic part or manufacturing layer-by-layer parts in a single-step process. The objective of this work is to demonstrate the possibility to create carbide-reinforced metal matrix composite objects. Powders of steel 16NCD13 with different volume contents of titanium carbide are tested. On the base of statistical analysis, a laser cladding processing map is constructed. Relationships between the different content of titanium carbide in a powder mixture and the material microstructure are found. Mechanism of formation of various precipitated titanium carbides is investigated.

A Review of Methods for the Manufacture of Residential Roofing Materials

DOE Office of Scientific and Technical Information (OSTI.GOV)

Akbari, Hashem; Levinson, Ronnen; Berdahl, Paul

2003-06-01

Shingles, tiles, and metal products comprise over 80% (by roof area) of the California roofing market (54-58% fiberglass shingle, 8-10% concrete tile, 8-10% clay tile, 7% metal, 3% wood shake, and 3% slate). In climates with significant demand for cooling energy, increasing roof solar reflectance reduces energy consumption in mechanically cooled buildings, and improves occupant comfort in non-conditioned buildings. This report examines methods for manufacturing fiberglass shingles, concrete tiles, clay tiles, and metal roofing. The report also discusses innovative methods for increasing the solar reflectance of these roofing materials. We have focused on these four roofing products because they aremore » typically colored with pigmented coatings or additives. A better understanding of the current practices for manufacturing colored roofing materials would allow us to develop cool colored materials creatively and more effectively.« less

Lead, Mercury, and Arsenic in US- and Indian-Manufactured Ayurvedic Medicines Sold via the Internet

EPA Science Inventory

Lead, mercury, and arsenic have been detected in a subsantial portion of Indian-manufactured traditional Ayurvedic medicines. Metals may be present due to the parctice of rasa shastra (combining herbs with metals, minerals and gems). Whether toxic metals are present in both US-...

[Analysis of 2 patients with occupational hard mental lung disease].

PubMed

Ding, Bangmei; Ding, Lu; Yu, Bin; Fan, Cunhua; Han, Lei; Hu, Jinmei; Zhu, Baoli

2015-01-01

We sought to master the clinical characteristics and prognosis of hard mental lung disease, improving this disease's diagnosis and treatment quality. We recruited two suspected patients with hard mental lung disease and collected their occupational history, examination results of occupational health, and past medical records. By virtue of laboratory tests, high Kv chest radiography, CT and HRCT of chest, fiberoptic bronchoscopy and ECG examination, diagnostic report was synthesized respectively by respiratory physicians and pathologist from three different agencies. Then the report was submitted to diagnosis organizations of occupational disease, and diagnostic conclusion of occupational disease was drawn after discussion by at least three diagnosticians of occupational disease. We found that both of the two suspected patients were exposed to dusts of hard metal, and length of exposure service ranged from 8 to 9 years. Clinical manifestations were dominated by dry cough, wheezing after activities, and pathological manifestation was characteristic giant cell interstitial pneumonia. The prognosis and outcome of the disease were different. According to exact occupational exposure history, clinical manifestations, combined with the results of high Kv chest radiography, CT of chest and pathological manifestation, it can be diagnosed with hard mental lung disease.

Motor vehicle manufacturing and prostate cancer.

PubMed

Brown, D A; Delzell, E

2000-07-01

The purpose of this investigation was to evaluate the relation between employment in motor vehicle manufacturing (MVM) and fatal prostate cancer. The study included 322 prostate cancer deaths occurring in 1973 through 1987 and 1,285 controls, selected from a cohort of 126,100 male MVM workers. Men employed in casting operations had an odds ratio of 1.5 (95% CI = 1. 1-2.0). The association was consistent across casting facilities and was attributable primarily to work in core and mold making (OR = 1.5, 95% CI = 1.1-2.2) and metal melting and pouring jobs (OR = 1.9, 95% CI = 1.0-3.6). Other results included ORs of 1.9 (95% CI = 1.0-3.7) for warehousing and distribution operations and 2.1 (95% CI = 1.2-3. 7) for electric and electronic equipment manufacturing. The latter two associations exhibited little internal consistency. The relationships seen in this study were weak and may have been due to chance. Core and mold making and metal melting and pouring foundry operations entail potential exposure to metal dusts and fumes, to polycyclic aromatic hydrocarbons (PAHs), and to other chemicals. However, associations between these exposures and prostate cancer have not been reported consistently, nor have other studies of foundry workers consistently noted an excess of prostate cancer. Copyright 2000 Wiley-Liss, Inc.

“Additive Manufacturing: Building the Pathway Towards Process and Material Qualification”

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2016-06-14

The potential benefits of metal additive manufacturing, as compared with more traditional, subtractive-only approaches, has created excitement within design circles seeking to take advantage of the ability to build and repair complex shapes, to integrate or consolidate multiple parts and minimize joining concerns, and to locally tailor material properties to increase functionality. Tempering the excitement of designers, however, has been concerns with the material deposited by the process. It is not enough for a part to ‘look’ right from a geometric perspective. Rather, the metallurgical aspects associated with the material being deposited must ‘look’ and ‘behave’ correctly along with themore » aforementioned geometric accuracy. Finally, without elucidation of the connections between processing, microstructure, properties, and performance from a materials science perspective, metal additive manufacturing will not realize its potential to change the manufacturing world for property and performance-critical engineering applications.« less

Toward predicting tensile strength of pharmaceutical tablets by ultrasound measurement in continuous manufacturing.

PubMed

Razavi, Sonia M; Callegari, Gerardo; Drazer, German; Cuitiño, Alberto M

2016-06-30

An ultrasound measurement system was employed as a non-destructive method to evaluate its reliability in predicting the tensile strength of tablets and investigate the benefits of incorporating it in a continuous line, manufacturing solid dosage forms. Tablets containing lactose, acetaminophen, and magnesium stearate were manufactured continuously and in batches. The effect of two processing parameters, compaction force and level of shear strain were examined. Young's modulus and tensile strength of tablets were obtained by ultrasound and diametrical mechanical testing, respectively. It was found that as the blend was exposed to increasing levels of shear strain, the speed of sound in the tablets decreased and the tablets became both softer and mechanically weaker. Moreover, the results indicate that two separate tablet material properties (e.g., relative density and Young's modulus) are necessary in order to predict tensile strength. A strategy for hardness prediction is proposed that uses the existing models for Young's modulus and tensile strength of porous materials. Ultrasound testing was found to be very sensitive in differentiating tablets with similar formulation but produced under different processing conditions (e.g., different level of shear strain), thus, providing a fast, and non-destructive method for hardness prediction that could be incorporated to a continuous manufacturing process. Copyright © 2016 Elsevier B.V. All rights reserved.