Consolidation of materials by pulse-discharge processes

NASA Astrophysics Data System (ADS)

Strizhakov, E. L.; Nescoromniy, S. V.

2017-07-01

The article presents the research and the analysis of the pulse-discharge processes of capacitor discharge sintering: CD Stud Welding, capacitor discharge percussion welding (CDPW), high-voltage capacitor welding with an inductive-dynamic drive (HVCW with IDD), pulse electric current sintering (PECS) of powders. The comparative analysis of the impact parameter is presented.

Application of Box-Behnken Design and Response Surface Methodology for Surface Roughness Prediction Model of CP-Ti Powder Metallurgy Components Through WEDM

NASA Astrophysics Data System (ADS)

Das, Arunangsu; Sarkar, Susenjit; Karanjai, Malobika; Sutradhar, Goutam

2018-04-01

The present work was undertaken to investigate and characterize the machining parameters (such as surface roughness, etc.) of uni-axially pressed commercially pure titanium sintered powder metallurgy components. Powder was uni-axially pressed at designated pressure of 840 MPa to form cylindrical samples and the green compacts were sintered at 0.001 mbar for about 4 h with sintering temperature varying from 1350 to 1450 °C. The influence of the sintering temperature, pulse-on and pulse-off time at wire-EDM on the surface roughness of the preforms has been investigated thoroughly. Experiments were conducted under different machining parameters in a CNC operated wire-cut EDM. The surface roughness of the machined surface was measured and critically analysed. The optimum surface roughness was achieved under the conditions of 6 μs pulse-on time, 9 μs pulse-off time and at sintering temperature of 1450 °C.

40 CFR 63.1542 - Definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... materials are introduced into a sinter machine, blast furnace, or dross furnace. Dross furnace means any... which material is prepared for charging to a sinter machine or smelting furnace or other lead processing operation. Operating time means the period of time in hours that an affected source is in operation...

40 CFR 63.1542 - Definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... materials are introduced into a sinter machine, blast furnace, or dross furnace. Dross furnace means any... which material is prepared for charging to a sinter machine or smelting furnace or other lead processing operation. Operating time means the period of time in hours that an affected source is in operation...

40 CFR 63.1542 - Definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... materials are introduced into a sinter machine, blast furnace, or dross furnace. Dross furnace means any... which material is prepared for charging to a sinter machine or smelting furnace or other lead processing operation. Operating time means the period of time in hours that an affected source is in operation...

Electric Discharge Sintering and Joining of Tungsten Carbide—Cobalt Composite with High-Speed Steel Substrate

NASA Astrophysics Data System (ADS)

Grigoryev, Evgeny G.

2011-01-01

Simultaneous electro discharge sintering of high strength structure of tungsten carbide—cobalt composite and connection it with high-speed steel substrate is investigated and suitable operating parameters are defined. Tungsten carbide—cobalt and high-speed steel joining was produced by the method of high voltage electrical discharge together with application of mechanical pressure to powder compact. It was found that the density and hardness of composite material reach its maximum values at certain magnitudes of applied pressure and high voltage electrical discharge parameters. We show that there is an upper level for the discharge voltage beyond which the powder of composite material disintegrates like an exploding wire. Due to our results it is possible to determine optimal parameters for simultaneous electro discharge sintering of WC-Co and bonding it with high-speed steel substrate.

Quality prediction modeling for sintered ores based on mechanism models of sintering and extreme learning machine based error compensation

NASA Astrophysics Data System (ADS)

Tiebin, Wu; Yunlian, Liu; Xinjun, Li; Yi, Yu; Bin, Zhang

2018-06-01

Aiming at the difficulty in quality prediction of sintered ores, a hybrid prediction model is established based on mechanism models of sintering and time-weighted error compensation on the basis of the extreme learning machine (ELM). At first, mechanism models of drum index, total iron, and alkalinity are constructed according to the chemical reaction mechanism and conservation of matter in the sintering process. As the process is simplified in the mechanism models, these models are not able to describe high nonlinearity. Therefore, errors are inevitable. For this reason, the time-weighted ELM based error compensation model is established. Simulation results verify that the hybrid model has a high accuracy and can meet the requirement for industrial applications.

Machinability of Green Powder Metallurgy Components: Part I. Characterization of the Influence of Tool Wear

NASA Astrophysics Data System (ADS)

Robert-Perron, Etienne; Blais, Carl; Pelletier, Sylvain; Thomas, Yannig

2007-06-01

The green machining process is an interesting approach for solving the mediocre machining behavior of high-performance powder metallurgy (PM) steels. This process appears as a promising method for extending tool life and reducing machining costs. Recent improvements in binder/lubricant technologies have led to high green strength systems that enable green machining. So far, tool wear has been considered negligible when characterizing the machinability of green PM specimens. This inaccurate assumption may lead to the selection of suboptimum cutting conditions. The first part of this study involves the optimization of the machining parameters to minimize the effects of tool wear on the machinability in turning of green PM components. The second part of our work compares the sintered mechanical properties of components machined in green state with other machined after sintering.

Method to synthesize bulk iron nitride

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

Monson, Todd; Lavernia, Enrique J.; Zheng, Baolong

Bulk iron nitride can be synthesized from iron nitride powder by spark plasma sintering. The iron nitride can be spark plasma sintered at a temperature of less than 600°C. and a pressure of less than 600 MPa, with 400 MPa or less most often being sufficient. High pressure SPS can consolidate dense iron nitrides at a lower temperature to avoid decomposition. The higher pressure and lower temperature of spark discharge sintering avoids decomposition and limits grain growth, enabling enhanced magnetic properties. The method can further comprise synthesis of nanocrystalline iron nitride powders using two-step reactive milling prior to high-pressure sparkmore » discharge sintering.« less

Slip casting and extruding shapes of rhenium with metal oxide additives. 1: Feasibility demonstration

NASA Technical Reports Server (NTRS)

Barr, F. A.; Page, R. J.

1986-01-01

The feasibility of fabricating small rhenium parts with metal oxide additives by means of slip casting and extrusion techniques is described. The metal oxides, ZrO2 and HfO2 were stabilized into the cubic phase with Y2O3. Additions of metal oxide to the rhenium of up to 15 weight percent were used. Tubes of 17 mm diameter with 0.5 mm walls were slip cast by adapting current ceramic oxide techniques. A complete cast double conical nozzle demonstrated the ability to meet shapes and tolerances. Extrusion of meter long tubing lengths of 3.9 mm o.d. x 2.3 mm i.d. final dimension is documented. Sintering schedules are presented to produce better than 95% of theoretical density parts. Finished machining was found possible were requried by electric discharge machining and diamond grinding.

Hardness and wear analysis of Cu/Al2O3 composite for application in EDM electrode

NASA Astrophysics Data System (ADS)

Hussain, M. Z.; Khan, U.; Jangid, R.; Khan, S.

2018-02-01

Ceramic materials, like Aluminium Oxide (Al2O3), have high mechanical strength, high wear resistance, high temperature resistance and good chemical durability. Powder metallurgy processing is an adaptable method commonly used to fabricate composites because it is a simple method of composite preparation and has high efficiency in dispersing fine ceramic particles. In this research copper and novel material aluminium oxide/copper (Al2O3/Cu) composite has been fabricated for the application of electrode in Electro-Discharge Machine (EDM) using powder metallurgy technique. Al2O3 particles with different weight percentages (0, 1%, 3% and 5%) were reinforced into copper matrix using powder metallurgy technique. The powders were blended and compacted at a load of 100MPa to produce green compacts and sintered at a temperature of 574 °C. The effect of aluminium oxide content on mass density, Rockwell hardness and wear behaviour were investigated. Wear behaviour of the composites was investigated on Die-Sink EDM (Electro-Discharge Machine). It was found that wear rate is highly depending on hardness, mass density and green protective carbonate layer formation at the surface of the composite.

Effect of Ceramic Surface Treatments After Machine Grinding on the Biaxial Flexural Strength of Different CAD/CAM Dental Ceramics.

PubMed

Bagheri, Hossein; Hooshmand, Tabassom; Aghajani, Farzaneh

2015-09-01

This study aimed to evaluate the effect of different ceramic surface treatments after machining grinding on the biaxial flexural strength (BFS) of machinable dental ceramics with different crystalline phases. Disk-shape specimens (10mm in diameter and 1.3mm in thickness) of machinable ceramic cores (two silica-based and one zirconia-based ceramics) were prepared. Each type of the ceramic surfaces was then randomly treated (n=15) with different treatments as follows: 1) machined finish as control, 2) machined finish and sandblasting with alumina, and 3) machined finish and hydrofluoric acid etching for the leucite and lithium disilicate-based ceramics, and for the zirconia; 1) machined finish and post-sintered as control, 2) machined finish, post-sintered, and sandblasting, and 3) machined finish, post-sintered, and Nd;YAG laser irradiation. The BFS were measured in a universal testing machine. Data based were analyzed by ANOVA and Tukey's multiple comparisons post-hoc test (α=0.05). The mean BFS of machined finish only surfaces for leucite ceramic was significantly higher than that of sandblasted (P=0.001) and acid etched surfaces (P=0.005). A significantly lower BFS was found after sandblasting for lithium disilicate compared with that of other groups (P<0.05). Sandblasting significantly increased the BFS for the zirconia (P<0.05), but the BFS was significantly decreased after laser irradiation (P<0.05). The BFS of the machinable ceramics was affected by the type of ceramic material and surface treatment method. Sandblasting with alumina was detrimental to the strength of only silica-based ceramics. Nd:YAG laser irradiation may lead to substantial strength degradation of zirconia.

Effect of Ceramic Surface Treatments After Machine Grinding on the Biaxial Flexural Strength of Different CAD/CAM Dental Ceramics

PubMed Central

Bagheri, Hossein; Aghajani, Farzaneh

2015-01-01

Objectives: This study aimed to evaluate the effect of different ceramic surface treatments after machining grinding on the biaxial flexural strength (BFS) of machinable dental ceramics with different crystalline phases. Materials and Methods: Disk-shape specimens (10mm in diameter and 1.3mm in thickness) of machinable ceramic cores (two silica-based and one zirconia-based ceramics) were prepared. Each type of the ceramic surfaces was then randomly treated (n=15) with different treatments as follows: 1) machined finish as control, 2) machined finish and sandblasting with alumina, and 3) machined finish and hydrofluoric acid etching for the leucite and lithium disilicate-based ceramics, and for the zirconia; 1) machined finish and post-sintered as control, 2) machined finish, post-sintered, and sandblasting, and 3) machined finish, post-sintered, and Nd;YAG laser irradiation. The BFS were measured in a universal testing machine. Data based were analyzed by ANOVA and Tukey’s multiple comparisons post-hoc test (α=0.05). Results: The mean BFS of machined finish only surfaces for leucite ceramic was significantly higher than that of sandblasted (P=0.001) and acid etched surfaces (P=0.005). A significantly lower BFS was found after sandblasting for lithium disilicate compared with that of other groups (P<0.05). Sandblasting significantly increased the BFS for the zirconia (P<0.05), but the BFS was significantly decreased after laser irradiation (P<0.05). Conclusions: The BFS of the machinable ceramics was affected by the type of ceramic material and surface treatment method. Sandblasting with alumina was detrimental to the strength of only silica-based ceramics. Nd:YAG laser irradiation may lead to substantial strength degradation of zirconia. PMID:27148372

40 CFR 57.301 - General requirements.

Code of Federal Regulations, 2012 CFR

2012-07-01

... maintained at all times. The NSO shall require the following gas streams to be treated by interim constant... sintering machine and any other sinter gases which are recirculated; (c) In zinc smelters, off-gases from...

40 CFR 57.301 - General requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

..., electric furnaces and copper converters; (b) In lead smelters, off-gases from the front end of the sintering machine and any other sinter gases which are recirculated; (c) In zinc smelters, off-gases from...

Contributions a la caracterisation et a l'amelioration de l'usinabilite de pieces d'acier elaborees par metallurgie des poudres

NASA Astrophysics Data System (ADS)

Boilard, Patrick

Even though powder metallurgy (P/M) is a near net shape process, a large number of parts still require one or more machining operations during the course of their elaboration and/or their finishing. The main objectives of the work presented in this thesis are centered on the elaboration of blends with enhanced machinability, as well as helping with the definition and in the characterization of the machinability of P/M parts. Enhancing machinability can be done in various ways, through the use of machinability additives and by decreasing the amount of porosity of the parts. These different ways of enhancing machinability have been investigated thoroughly, by systematically planning and preparing series of samples in order to obtain valid and repeatable results leading to meaningful conclusions relevant to the P/M domain. Results obtained during the course of the work are divided into three main chapters: (1) the effect of machining parameters on machinability, (2) the effect of additives on machinability, and (3) the development and the characterization of high density parts obtained by liquid phase sintering. Regarding the effect of machining parameters on machinability, studies were performed on parameters such as rotating speed, feed, tool position and diameter of the tool. Optimal cutting parameters are found for drilling operations performed on a standard FC-0208 blend, for different machinability criteria. Moreover, study of material removal rates shows the sensitivity of the machinability criteria for different machining parameters and indicates that thrust force is more regular than tool wear and slope of the drillability curve in the characterization of machinability. The chapter discussing the effect of various additives on machinability reveals many interesting results. First, work carried out on MoS2 additions reveals the dissociation of this additive and the creation of metallic sulphides (namely CuxS sulphides) when copper is present. Results also show that it is possible to reduce the amount of MoS2 in the blend so as to lower the dimensional change and the cost (blend Mo8A), while enhancing machinability and keeping hardness values within the same range (70 HRB). Second, adding enstatite (MgO·SiO2) permits the observation of the mechanisms occurring with the use of this additive. It is found that the stability of enstatite limits the diffusion of graphite during sintering, leading to the presence of free graphite in the pores, thus enhancing machinability. Furthermore, a lower amount of graphite in the matrix leads to a lower hardness, which is also beneficial to machinability. It is also found that the presence of copper enhances the diffusion of graphite, through the formation of a liquid phase during sintering. With the objective of improving machinability by reaching higher densities, blends were developed for densification through liquid phase sintering. High density samples are obtained (>7.5 g/cm3) for blends prepared with Fe-C-P constituents, namely with 0.5%P and 2.4%C. By systematically studying the effect of different parameters, the importance of the chemical composition (mainly the carbon content) and the importance of the sintering cycle (particularly the cooling rate) are demonstrated. Moreover, various heat treatments studied illustrate the different microstructures achievable for this system, showing various amounts of cementite, pearlite and free graphite. Although the machinability is limited for samples containing large amounts of cementite, it can be greatly improved with very slow cooling, leading to graphitization of the carbon in presence of phosphorus. Adequate control of the sintering cycle on samples made from FGS1625 powder leads to the obtention of high density (≥7.0 g/cm 3) microstructures containing various amounts of pearlite, ferrite and free graphite. Obtaining ferritic microstructures with free graphite designed for very high machinability (tool wear <1.0%) or fine pearlitic microstructures with excellent mechanical properties (transverse rupture strength >1600 MPa) is therefore possible. These results show that improvement of machinability through higher densities is limited by microstructure. Indeed, for the studied samples, microstructure is dominant in the determination of machinability, far more important than density, judging by the influence of cementite or of the volume fraction of free graphite on machinability for example. (Abstract shortened by UMI.)

Scanning Electron Microscopy Analysis of the Adaptation of Single-Unit Screw-Retained Computer-Aided Design/Computer-Aided Manufacture Abutments After Mechanical Cycling.

PubMed

Markarian, Roberto Adrian; Galles, Deborah Pedroso; Gomes França, Fabiana Mantovani

To measure the microgap between dental implants and custom abutments fabricated using different computer-aided design/computer-aided manufacture (CAD/CAM) methods before and after mechanical cycling. CAD software (Dental System, 3Shape) was used to design a custom abutment for a single-unit, screw-retained crown compatible with a 4.1-mm external hexagon dental implant. The resulting stereolithography file was sent for manufacturing using four CAD/CAM methods (n = 40): milling and sintering of zirconium dioxide (ZO group), cobalt-chromium (Co-Cr) sintered via selective laser melting (SLM group), fully sintered machined Co-Cr alloy (MM group), and machined and sintered agglutinated Co-Cr alloy powder (AM group). Prefabricated titanium abutments (TI group) were used as controls. Each abutment was placed on a dental implant measuring 4.1× 11 mm (SA411, SIN) inserted into an aluminum block. Measurements were taken using scanning electron microscopy (SEM) (×4,000) on four regions of the implant-abutment interface (IAI) and at a relative distance of 90 degrees from each other. The specimens were mechanically aged (1 million cycles, 2 Hz, 100 N, 37°C) and the IAI width was measured again using the same approach. Data were analyzed using two-way analysis of variance, followed by the Tukey test. After mechanical cycling, the best adaptation results were obtained from the TI (2.29 ± 1.13 μm), AM (3.58 ± 1.80 μm), and MM (1.89 ± 0.98 μm) groups. A significantly worse adaptation outcome was observed for the SLM (18.40 ± 20.78 μm) and ZO (10.42 ± 0.80 μm) groups. Mechanical cycling had a marked effect only on the AM specimens, which significantly increased the microgap at the IAI. Custom abutments fabricated using fully sintered machined Co-Cr alloy and machined and sintered agglutinated Co-Cr alloy powder demonstrated the best adaptation results at the IAI, similar to those obtained with commercial prefabricated titanium abutments after mechanical cycling. The adaptation of custom abutments made by means of SLM or milling and sintering of zirconium dioxide were worse both before and after mechanical cycling.

Development of Processing Parameters for Organic Binders Using Selective Laser Sintering

NASA Technical Reports Server (NTRS)

Mobasher, Amir A.

2003-01-01

This document describes rapid prototyping, its relation to Computer Aided Design (CAD), and the application of these techniques to choosing parameters for Selective Laser Sintering (SLS). The document reviews the parameters selected by its author for his project, the SLS machine used, and its software.

Selective laser sintering: A qualitative and objective approach

NASA Astrophysics Data System (ADS)

Kumar, Sanjay

2003-10-01

This article presents an overview of selective laser sintering (SLS) work as reported in various journals and proceedings. Selective laser sintering was first done mainly on polymers and nylon to create prototypes for audio-visual help and fit-to-form tests. Gradually it was expanded to include metals and alloys to manufacture functional prototypes and develop rapid tooling. The growth gained momentum with the entry of commercial entities such as DTM Corporation and EOS GmbH Electro Optical Systems. Computational modeling has been used to understand the SLS process, optimize the process parameters, and enhance the efficiency of the sintering machine.

Effects of particle size and forming pressure on pore properties of Fe-Cr-Al porous metal by pressureless sintering

NASA Astrophysics Data System (ADS)

Koo, Bon-Uk; Yi, Yujeong; Lee, Minjeong; Kim, Byoung-Kee

2017-03-01

With increased hydrogen consumption in ammonia production, refining and synthesis, fuel cells and vehicle industries, development of the material components related to hydrogen production is becoming an important factor in industry growth. Porous metals for fabrication of hydrogen are commonly known for their relative excellence in terms of large area, lightness, lower heat capacity, high toughness, and permeability. Fe-Cr-Al alloys not only have high corrosion resistance, heat resistance, and chemical stability but also ductility, excellent mechanical properties. In order to control powder size and sintering temperature effects of Fe-Cr-Al porous metal fabrication, Fe-Cr-Al powder was classified into 25-35 μm, 35-45 μm, 45-75 μm using an auto shaking sieve machine and then classified Fe-Cr-Al powders were pressed into disk shapes using a uniaxial press machine and CIP. The pelletized Fe-Cr-Al specimens were sintered at various temperatures in high vacuum. Properties such as pore size, porosity, and air permeability were evaluated using perm-porosimetry. Microstructure and phase changes were observed with SEM and XRD. Porosity and relative density were proportionated to increasing sintering temperature. With sufficient sintering at increasing temperatures, the pore size is expected to be gradually reduced. Porosity decreased with increasing sintering temperature and gradually increased necking of the powder.

Surface structure and electrochemical characteristics of Ti-V-Cr bcc-type solid solution alloys sintered with Ni

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

Tsuji, Yoichiro; Yamamoto, Osamu; Matsuda, Hiromu

2000-07-01

Ti-V-Cr bcc-type solid solution alloys can absorb a large amount of hydrogen and be applied to active materials of the negative electrode in Ni-MH batteries. However, because of the insolubility of Ni into these alloys, the electrochemical characteristics like discharge capacity and cycle life were poor. In order to increase the discharge capacity of hydrogen absorbing alloy electrodes, Ti-V-Cr bcc-type alloy powders were sintered with Ni in order to form Ni contained surface layer on the alloy surface. As sintering temperature rose up, the surface composition changed from TiNi to Ti{sub 2}Ni. TiNi surface layer showed better electrochemical characteristics. Formore » the Ni adding method, Ni electroless plating was preferred because of good adhesion. As a result of optimized conditions, a discharge capacity of 570 mAh/g and an improvement of cycle life were achieved.« less

Osteoblast adhesion on novel machinable calcium phosphate/lanthanum phosphate composites for orthopedic applications.

PubMed

Ergun, Celaletdin; Liu, Huinan; Webster, Thomas J

2009-06-01

Lanthanum phosphate (LaPO(4), LP) was combined with either hydroxyapatite (HA) or tricalcium phosphate (TCP) to form novel composites for orthopedic applications. In this study, these composites were prepared by wet chemistry synthesis and subsequent powder mixing. These HA/LP and TCP/LP composites were characterized in terms of phase stability and microstructure evolution during sintering using X-ray diffraction (XRD) and scanning electron microscopy (SEM). Their machinability was evaluated using a direct drilling test. For HA/LP composites, LP reacted with HA during sintering and formed a new phase, Ca(8)La(2)(PO(4))(6)O(2), as a reaction by-product. However, TCP/LP composites showed phase stability and the formation of a weak interface between TCP and LP machinability when sintered at 1100 degrees C, which is crucial for achieving desirable properties. Thus, these novel TCP/LP composites fulfilled the requirements for machinability, a key consideration for manufacturing orthopedic implants. Moreover, the biocompatibility of these novel LP composites was studied, for the first time, in this paper. In vitro cell culture tests demonstrated that the LP and its composites supported osteoblast (bone-forming cell) adhesion similar to natural bioceramics (such as HA and TCP). In conclusion, these novel LP composites should be further studied and developed for more effectively treating bone related diseases or injuries. 2008 Wiley Periodicals, Inc.

[Influence of multiple sintering on wear behavior of Cercon veneering ceramic].

PubMed

Gao, Qing-ping; Chao, Yong-lie; Jian, Xin-chun; Guo, Feng

2010-04-01

To investigate the influence of multiple sintering on wear behavior of Cercon veneering ceramic. Samples were fabricated according to the manufacture's requirement for different sintering times (1, 3, 5, 7 times). The wear test was operated with a modified MM-200 friction and wear machine in vitro. The wear scars were characterized by scanning electron microscope (SEM) and atomic force microscopy (AFM). With the sintering times increasing, the wear scar width became larger. The correlation was significant at the 0.01 level. Significant difference was observed in wear scar width among different samples (P < 0.05). SEM and AFM results showed that veneering ceramic wear facets demonstrated grooves characteristic of abrasive wear. Multiple sintering can decrease the wear ability of Cercon veneer, and the wear pattern has the tendency to severe wear.

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.

40 CFR 63.7790 - What emission limitations must I meet?

Code of Federal Regulations, 2013 CFR

2013-07-01

... plant discharge end or blast furnace casthouse or to secondary emissions from a BOPF at or above the... Administrator. (d) For each sinter plant, you must either: (1) Maintain the 30-day rolling average oil content... organic compound emissions from the windbox exhaust stream at or below 0.2 lb/ton of sinter. [68 FR 27663...

40 CFR 63.7790 - What emission limitations must I meet?

Code of Federal Regulations, 2014 CFR

2014-07-01

... plant discharge end or blast furnace casthouse or to secondary emissions from a BOPF at or above the... Administrator. (d) For each sinter plant, you must either: (1) Maintain the 30-day rolling average oil content... organic compound emissions from the windbox exhaust stream at or below 0.2 lb/ton of sinter. [68 FR 27663...

40 CFR 63.7790 - What emission limitations must I meet?

Code of Federal Regulations, 2012 CFR

2012-07-01

... plant discharge end or blast furnace casthouse or to secondary emissions from a BOPF at or above the... Administrator. (d) For each sinter plant, you must either: (1) Maintain the 30-day rolling average oil content... organic compound emissions from the windbox exhaust stream at or below 0.2 lb/ton of sinter. [68 FR 27663...

Lightweight Aluminum/Nano composites for Automotive Drive Train Applications

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

Chelluri, Bhanumathi; Knoth, Edward A.; Schumaker, Edward J.

2012-12-14

During Phase I, we successfully processed air atomized aluminum powders via Dynamic Magnetic Compaction (DMC) pressing and subsequent sintering to produce parts with properties similar to wrought aluminum. We have also showed for the first time that aluminum powders can be processed without lubes via press and sintering to 100 % density. This will preclude a delube cycle in sintering and promote environmentally friendly P/M processing. Processing aluminum powders via press and sintering with minimum shrinkage will enable net shape fabrication. Aluminum powders processed via a conventional powder metallurgy process produce too large a shrinkage. Because of this, sinter partsmore » have to be machined into specific net shape. This results in increased scrap and cost. Fully sintered aluminum alloy under this Phase I project has shown good particle-to-particle bonding and mechanical properties. We have also shown the feasibility of preparing nano composite powders and processing via pressing and sintering. This was accomplished by dispersing nano silicon carbide (SiC) powders into aluminum matrix comprising micron-sized powders (<100 microns) using a proprietary process. These composite powders of Al with nano SiC were processed using DMC press and sinter process to sinter density of 85-90%. The process optimization along with sintering needs to be carried out to produce full density composites.« less

Evaluation of Fatigue Behavior and Surface Characteristics of Aluminum Alloy 2024 T6 After Electric Discharge Machining

NASA Astrophysics Data System (ADS)

Mehmood, Shahid; Shah, Masood; Pasha, Riffat Asim; Sultan, Amir

2017-10-01

The effect of electric discharge machining (EDM) on surface quality and consequently on the fatigue performance of Al 2024 T6 is investigated. Five levels of discharge current are analyzed, while all other electrical and nonelectrical parameters are kept constant. At each discharge current level, dog-bone specimens are machined by generating a peripheral notch at the center. The fatigue tests are performed on four-point rotating bending machine at room temperature. For comparison purposes, fatigue tests are also performed on the conventionally machined specimens. Linearized SN curves for 95% failure probability and with four different confidence levels (75, 90, 95 and 99%) are plotted for each discharge current level as well as for conventionally machined specimens. These plots show that the electric discharge machined (EDMed) specimens give inferior fatigue behavior as compared to conventionally machined specimen. Moreover, discharge current inversely affects the fatigue life, and this influence is highly pronounced at lower stresses. The EDMed surfaces are characterized by surface properties that could be responsible for change in fatigue life such as surface morphology, surface roughness, white layer thickness, microhardness and residual stresses. It is found that all these surface properties are affected by changing discharge current level. However, change in fatigue life by discharge current could not be associated independently to any single surface property.

Micro electrical discharge milling using deionized water as a dielectric fluid

NASA Astrophysics Data System (ADS)

Chung, Do Kwan; Kim, Bo Hyun; Chu, Chong Nam

2007-05-01

In electrical discharge machining, dielectric fluid is an important factor affecting machining characteristics. Generally, kerosene and deionized water have been used as dielectric fluids. In micro electrical discharge milling, which uses a micro electrode as a tool, the wear of the tool electrode decreases the machining accuracy. However, the use of deionized water instead of kerosene can reduce the tool wear and increase the machining speed. This paper investigates micro electrical discharge milling using deionized water. Deionized water with high resistivity was used to minimize the machining gap. Machining characteristics such as the tool wear, machining gap and machining rate were investigated according to resistivity of deionized water. As the resistivity of deionized water decreased, the tool wear was reduced, but the machining gap increased due to electrochemical dissolution. Micro hemispheres were machined for the purpose of investigating machining efficiency between dielectric fluids, kerosene and deionized water.

New Polymer Materials for the Laser Sintering Process: Polypropylene and Others

NASA Astrophysics Data System (ADS)

Wegner, Andreas

Laser sintering of polymers gets more and more importance for small series production. However, there is only a little number of materials available for the process. In most cases parts are build up using polyamide 12 or polyamide 11. Reasons for that are high prices, a restricted availability, poor mechanical part properties or an insufficient understanding of the processing of other materials. These problems result from the complex processing conditions in laser sintering with high requirements on the material's characteristics. Within this area, at the chair for manufacturing technology fundamental knowledge was established. Aim of the presented study was to qualify different polymers for the laser sintering process. Polyethylene, polypropylene, polyamide 6, polyoxymethylene as well as polybutylene terephthalate were analyzed. Within the study problems of qualifying new materials are discussed using some examples. Furthermore, the processing conditions as well as mechanical properties of a new polypropylene compound are shown considering also different laser sintering machines.

Beryllium fabrication/cost assessment for ITER (International Thermonuclear Experimental Reactor)

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

Beeston, J.M.; Longhurst, G.R.; Parsonage, T.

1990-06-01

A fabrication and cost estimate of three possible beryllium shapes for the International Thermonuclear Experimental Reactor (ITER) blanket is presented. The fabrication method by hot pressing (HP), cold isostatic pressing plus sintering (CIP+S), cold isostatic pressing plus sintering plus hot isostatic pressing (CIP+S+HIP), and sphere production by atomization or rotary electrode will be discussed. Conventional hot pressing blocks of beryllium with subsequent machining to finished shapes can be more expensive than production of a net shape by cold isostatic pressing and sintering. The three beryllium shapes to be considered here and proposed for ITER are: (1) cubic blocks (3 tomore » 17 cm on an edge), (2) tubular cylinders (33 to 50 mm i.d. by 62 mm o.d. by 8 m long), and (3) spheres (1--5 mm dia.). A rough cost estimate of the basic shape is presented which would need to be refined if the surface finish and tolerances required are better than the sintering process produces. The final cost of the beryllium in the blanket will depend largely on the machining and recycling of beryllium required to produce the finished product. The powder preparation will be discussed before shape fabrication. 10 refs., 6 figs.« less

Machining of AISI D2 Tool Steel with Multiple Hole Electrodes by EDM Process

NASA Astrophysics Data System (ADS)

Prasad Prathipati, R.; Devuri, Venkateswarlu; Cheepu, Muralimohan; Gudimetla, Kondaiah; Uzwal Kiran, R.

2018-03-01

In recent years, with the increasing of technology the demand for machining processes is increasing for the newly developed materials. The conventional machining processes are not adequate to meet the accuracy of the machining of these materials. The non-conventional machining processes of electrical discharge machining is one of the most efficient machining processes is being widely used to machining of high accuracy products of various industries. The optimum selection of process parameters is very important in machining processes as that of an electrical discharge machining as they determine surface quality and dimensional precision of the obtained parts, even though time consumption rate is higher for machining of large dimension features. In this work, D2 high carbon and chromium tool steel has been machined using electrical discharge machining with the multiple hole electrode technique. The D2 steel has several applications such as forming dies, extrusion dies and thread rolling. But the machining of this tool steel is very hard because of it shard alloyed elements of V, Cr and Mo which enhance its strength and wear properties. However, the machining is possible by using electrical discharge machining process and the present study implemented a new technique to reduce the machining time using a multiple hole copper electrode. In this technique, while machining with multiple holes electrode, fin like projections are obtained, which can be removed easily by chipping. Then the finishing is done by using solid electrode. The machining time is reduced to around 50% while using multiple hole electrode technique for electrical discharge machining.

40 CFR 63.1541 - Applicability.

Code of Federal Regulations, 2011 CFR

2011-07-01

... subpart apply to the following affected sources at primary lead smelters: sinter machine, blast furnace... (Incorporations by reference), and § 63.15 (Availability of information confidentiality). The following sections...

The effect of abrading and cutting instruments on machinability of dental ceramics.

PubMed

Sakoda, Satoshi; Nakao, Noriko; Watanabe, Ikuya

2018-03-16

The aim was to investigate the effect of machining instruments on machinability of dental ceramics. Four dental ceramics, including two zirconia ceramics were machined by three types (SiC, diamond vitrified, and diamond sintered) of wheels with a hand-piece engine and two types (diamond and carbide) of burs with a high-speed air turbine. The machining conditions used were abrading speeds of 10,000 and 15,000 r.p.m. with abrading force of 100 gf for the hand-piece engine, and a pressure of 200 kPa and a cutting force of 80 gf for the air-turbine hand-piece. The machinability efficiency was evaluated by volume losses after machining the ceramics. A high-abrading speed had high-abrading efficiency (high-volume loss) compared to low-abrading speed in all abrading instruments used. The diamond vitrified wheels demonstrated higher volume loss for two zirconia ceramics than those of SiC and diamond sintered wheels. When the high-speed air-turbine instruments were used, the diamond points showed higher volume losses compared to the carbide burs for one ceramic and two zirconia ceramics with high-mechanical properties. The results of this study indicated that the machinability of dental ceramics depends on the mechanical and physical properties of dental ceramics and machining instruments. The abrading wheels show autogenous action of abrasive grains, in which ground abrasive grains drop out from the binder during abrasion, then the binder follow to wear out, subsequently new abrasive grains come out onto the instrument surface (autogenous action) and increase the grinding amount (volume loss) of grinding materials.

Development of high toughness, high strength aluminide-bonded carbide ceramics

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

Becher, P.F.; Plucknett, K.P.; Tiegs, T.N.

1997-04-01

Cemented carbides are widely used in applications where resistance to abrasion and wear are important, particularly in combination with high strength and stiffness. In the present case, ductile aluminides have been used as a binder phase to fabricate dense carbide cermets by either sintering of mixed powders or a melt-infiltration sintering process. The choice of an aluminide binder was based on the exceptional high temperature strength and chemical stability exhibited by these alloys. For example, TiC-based composites with a Ni{sub 3}Al binder phase exhibit improved oxidation resistance, Young`s moduli > 375 GPa, high fracture strengths (> 1 GPa) that aremore » retained to {ge} 900{degrees}C, and fracture toughness values of 10 to 15 MPa{radical}m, identical to that measured in commercial cobalt-bonded WC with the same test method. The thermal diffusivity values at 200{degrees}C for these composites are {approximately} 0.070 to 0.075 cm{sup 2}/s while the thermal expansion coefficients rise with Ni3Al content from {approximately} 8 to {approximately}11 x 10{sup {minus}6}/{degrees}C over the range of 8 to 40 vol. % Ni{sub 3}Al. The oxidation and acidic corrosion resistances are quite promising as well. Finally, these materials also exhibit good electrical conductivity allowing them to be sectioned and shaped by electrical discharge machining (EDM) processes.« less

Comparative investigation of smooth polycrystalline diamond films on dental burs by chemical vapor deposition

NASA Astrophysics Data System (ADS)

Sein, Htet; Ahmed, Waqar; Rego, Christopher; Jackson, Mark; Polini, Riccardo

2006-04-01

Depositions of hot filament chemical vapor-deposited diamond on cobalt-cemented tungsten carbide (WC-Co) rotary cutting dental burs are presented. Conventional dental tools made of sintered polycrystalline diamond have a number of problems associated with the heterogeneity of the crystallite, decreased cutting efficiency, and short life. A preferential (111) faceted diamond was obtained after 15 h of deposition at a growth rate of 1.1 µm/h. Diamond-coated WC-Co dental burs and conventional sintered burs are mainly used in turning, milling, and drilling operations for machining metal ceramic hard alloys such as CoCr, composite teeth, and aluminum alloy in the dental laboratory. The influence of structure, the mechanical characteristics of both diamond grains and hard alloys on the wear behavior, as well as the regimen of grinding on diamond wear are considered. Erosion wear properties are also investigated under air-sand erosion testing. After machining with excessive cutting performance, calculations can be made on flank and crater wear areas. Diamond-coated WC-Co dental burs offered significantly better erosion and wear resistance compared with uncoated WC-Co tools and sintered burs.

Fast femtosecond laser ablation for efficient cutting of sintered alumina substrates

NASA Astrophysics Data System (ADS)

Oosterbeek, Reece N.; Ward, Thomas; Ashforth, Simon; Bodley, Owen; Rodda, Andrew E.; Simpson, M. Cather

2016-09-01

Fast, accurate cutting of technical ceramics is a significant technological challenge because of these materials' typical high mechanical strength and thermal resistance. Femtosecond pulsed lasers offer significant promise for meeting this challenge. Femtosecond pulses can machine nearly any material with small kerf and little to no collateral damage to the surrounding material. The main drawback to femtosecond laser machining of ceramics is slow processing speed. In this work we report on the improvement of femtosecond laser cutting of sintered alumina substrates through optimisation of laser processing parameters. The femtosecond laser ablation thresholds for sintered alumina were measured using the diagonal scan method. Incubation effects were found to fit a defect accumulation model, with Fth,1=6.0 J/cm2 (±0.3) and Fth,∞=2.5 J/cm2 (±0.2). The focal length and depth, laser power, number of passes, and material translation speed were optimised for ablation speed and high quality. Optimal conditions of 500 mW power, 100 mm focal length, 2000 μm/s material translation speed, with 14 passes, produced complete cutting of the alumina substrate at an overall processing speed of 143 μm/s - more than 4 times faster than the maximum reported overall processing speed previously achieved by Wang et al. [1]. This process significantly increases processing speeds of alumina substrates, thereby reducing costs, making femtosecond laser machining a more viable option for industrial users.

Optimization of Gas Composition Used in Plasma Chemical Vaporization Machining for Figuring of Reaction-Sintered Silicon Carbide with Low Surface Roughness.

PubMed

Sun, Rongyan; Yang, Xu; Ohkubo, Yuji; Endo, Katsuyoshi; Yamamura, Kazuya

2018-02-05

In recent years, reaction-sintered silicon carbide (RS-SiC) has been of interest in many engineering fields because of its excellent properties, such as its light weight, high rigidity, high heat conductance and low coefficient of thermal expansion. However, RS-SiC is difficult to machine owing to its high hardness and chemical inertness and because it contains multiple components. To overcome the problem of the poor machinability of RS-SiC in conventional machining, the application of atmospheric-pressure plasma chemical vaporization machining (AP-PCVM) to RS-SiC was proposed. As a highly efficient and damage-free figuring technique, AP-PCVM has been widely applied for the figuring of single-component materials, such as Si, SiC, quartz crystal wafers, and so forth. However, it has not been applied to RS-SiC since it is composed of multiple components. In this study, we investigated the AP-PCVM etching characteristics for RS-SiC by optimizing the gas composition. It was found that the different etching rates of the different components led to a large surface roughness. A smooth surface was obtained by applying the optimum gas composition, for which the etching rate of the Si component was equal to that of the SiC component.

[Effect of sintering temperature on mechanical properties of dental zirconia toughened alumina ceramics].

PubMed

Fan, Jiang-Yuan; Lin, Ting-Ting; Hu, Fang-Xuan; Zheng, Rui-Bin; Fan, Fan; Ma, Jian-Feng

2017-04-01

To investigate the effect of sintering temperature on mechanical properties of dental zirconia toughened alumina (ZTA) ceramics prepared by gel-casting technique. The samples prepared by gel-casting were sintered at 1100, 1200, 1250, 1300 and 1400degrees centigrade for each group. The flexural strength, fracture toughness, Vickers hardness and brittleness index were obtained and microscopic morphology of each group was observed under scanning electron microscope (SEM). The data were statistically analyzed using SPSS 19.0 software package. The flexural strength, fracture toughness and Vickers hardness increased with the increasing sintering temperature during 1100~1400degrees centigrade. The lowest brittleness index (0.74±0.16) μm -1/2 was observed in group sintered at 1200degrees centigrade and the highest (2.76±0.14) μm -1/2 was at 1400degrees centigrade (P<0.05), while the flexural strength of these two groups was (46.89±3.24) MPa and (349.64±54.72) MPa, respectively. The ZTA dental ceramics exhibit good machinability with proper sintering temperature (1200degrees centigrade) and the strength meets the requirement of clinical application.

A High-Performance Sintered Iron Electrode for Rechargeable Alkaline Batteries to Enable Large-Scale Energy Storage

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

Yang, Chenguang; Manohar, Aswin K.; Narayanan, S. R.

Iron-based alkaline rechargeable batteries such as iron-air and nickel-iron batteries are particularly attractive for large-scale energy storage because these batteries can be relatively inexpensive, environment- friendly, and also safe. Therefore, our study has focused on achieving the essential electrical performance and cycling properties needed for the widespread use of iron-based alkaline batteries in stationary and distributed energy storage applications.We have demonstrated for the first time, an advanced sintered iron electrode capable of 3500 cycles of repeated charge and discharge at the 1-hour rate and 100% depth of discharge in each cycle, and an average Coulombic efficiency of over 97%. Suchmore » a robust and efficient rechargeable iron electrode is also capable of continuous discharge at rates as high as 3C with no noticeable loss in utilization. We have shown that the porosity, pore size and thickness of the sintered electrode can be selected rationally to optimize specific capacity, rate capability and robustness. As a result, these advances in the electrical performance and durability of the iron electrode enables iron-based alkaline batteries to be a viable technology solution for meeting the dire need for large-scale electrical energy storage.« less

A High-Performance Sintered Iron Electrode for Rechargeable Alkaline Batteries to Enable Large-Scale Energy Storage

DOE PAGES

Yang, Chenguang; Manohar, Aswin K.; Narayanan, S. R.

2017-01-07

Iron-based alkaline rechargeable batteries such as iron-air and nickel-iron batteries are particularly attractive for large-scale energy storage because these batteries can be relatively inexpensive, environment- friendly, and also safe. Therefore, our study has focused on achieving the essential electrical performance and cycling properties needed for the widespread use of iron-based alkaline batteries in stationary and distributed energy storage applications.We have demonstrated for the first time, an advanced sintered iron electrode capable of 3500 cycles of repeated charge and discharge at the 1-hour rate and 100% depth of discharge in each cycle, and an average Coulombic efficiency of over 97%. Suchmore » a robust and efficient rechargeable iron electrode is also capable of continuous discharge at rates as high as 3C with no noticeable loss in utilization. We have shown that the porosity, pore size and thickness of the sintered electrode can be selected rationally to optimize specific capacity, rate capability and robustness. As a result, these advances in the electrical performance and durability of the iron electrode enables iron-based alkaline batteries to be a viable technology solution for meeting the dire need for large-scale electrical energy storage.« less

Hot-spring sinter deposits in the Alvord-Pueblo Valley, Harney County, Oregon

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

Cummings, M.L.; St. John, A.M.

1993-04-01

Silica sinter deposits occur at Borax Lake, Alvord Hot Springs, and Mickey Springs in the Alvord-Pueblo Valley. Although the sinter deposits occur in areas of active hot springs, sinter is not being deposited. Hot springs are localized along faults that have been active since the Pleistocene. The sinter deposits formed after the drying of glacial Lake Alvord, but before and during extensive wind deflation of glacial-lacustrine sediments. At Mickey Springs, sinter rests directly on unaltered, unconsolidated lithic-rich sand. At Borax Lake, sinter overlies unaltered diatomite, but some armoring, presumably by silica, of the 30 m vent has developed. Field relationsmore » suggest rapid dumping of silica from solution without alteration of the country rock at the vent. Discharge of thermal fluids and cold groundwater along the same structure may have produced colloidal silica carried in a solution stripped of dissolved silica. Sinter is composed of opal-a, traces of detrital feldspar and quartz, and evaporation-related boracite. The concentration of Sb is similar among the three sinter deposits (20 to 70 ppm); however, As, Cs, and Br are highest at Borax Lake (5 to 560 ppm; 26 to 118 ppm; 5 to 1,040 ppm) while Hg is highest at Mickey Springs (1.0 to 5.2 ppm).« less

Experimental analysis on semi-finishing machining of Ti6Al4V additively manufactured by direct melting laser sintering

NASA Astrophysics Data System (ADS)

Imbrogno, Stano; Bordin, Alberto; Bruschi, Stefania; Umbrello, Domenico

2016-10-01

The Additive Manufacturing (AM) techniques are particularly appealing especially for titanium aerospace and biomedical components because they permit to achieve a strong reduction of the buy-to-fly ratio. However, finishing machining operations are often necessary to reduce the uneven surface roughness and geometrics because of local missing accuracy. This work shows the influence of the cutting parameters, cutting speed and feed rate, on the cutting forces as well as on the thermal field observed in the cutting zone, during a turning operation carried out on bars made of Ti6Al4V obtained by the AM process called Direct Metal Laser Sintering (DMLS). Moreover, the sub-surface microstructure alterations due to the process are also showed and commented.

Emerging Ceramic-based Materials for Dentistry

PubMed Central

Denry, I.; Kelly, J.R.

2014-01-01

Our goal is to give an overview of a selection of emerging ceramics and issues for dental or biomedical applications, with emphasis on specific challenges associated with full-contour zirconia ceramics, and a brief synopsis on new machinable glass-ceramics and ceramic-based interpenetrating phase composites. Selected fabrication techniques relevant to dental or biomedical applications such as microwave sintering, spark plasma sintering, and additive manufacturing are also reviewed. Where appropriate, the authors have added their opinions and guidance. PMID:25274751

Titanium dental copings prepared by a powder metallurgy method: a preliminary report.

PubMed

Eriksson, Mikael; Andersson, Matts; Carlström, Elis

2004-01-01

The purpose of this study was to determine if the Procera pressed-powder method can be used to fabricate titanium copings. Commercially pure titanium powder was used to prepare the copings. The powder was pressed onto an enlarged tooth preparation die of aluminum using cold isostatic pressing. The outer shape of the coping was formed using a Procera milling machine, and the copings were vacuum sintered. Titanium copings could be prepared using this method. The density of the sintered copings reached 97% to 99%+ of theoretic density, and the copings showed ductile behavior after sintering. Enlarging the tooth preparation die to compensate for the sintering shrinkage could optimize the final size of the copings. Ductile and dense titanium dental copings can be produced with powder-metal processing using cold isostatic pressing, followed by milling and sintering to final shape. The forming technique has, if properly optimized, a potential of becoming a more cost-efficient production method than spark erosion.

Effect of Sintering Atmosphere and Solution Treatment on Density, Microstructure and Tensile Properties of Duplex Stainless Steels Developed from Pre-alloyed Powders

NASA Astrophysics Data System (ADS)

Murali, Arun Prasad; Mahendran, Sudhahar; Ramajayam, Mariappan; Ganesan, Dharmalingam; Chinnaraj, Raj Kumar

2017-10-01

In this research, Powder Metallurgy (P/M) of Duplex Stainless Steels (DSS) of different compositions were prepared through pre-alloyed powders and elemental powders with and without addition of copper. The powder mix was developed by pot mill for 12 h to obtain the homogeneous mixture of pre-alloyed powder with elemental compositions. Cylindrical green compacts with the dimensions of 30 mm diameter and 12 mm height were compacted through universal testing machine at a pressure level of 560 ± 10 MPa. These green compacts were sintered at 1350 °C for 2 h in hydrogen and argon atmospheres. Some of the sintered stainless steel preforms were solution treated at 1050 °C followed by water quenching. The sintered as well as solution treated samples were analysed by metallography examination, Scanning Electron Microscopy and evaluation of mechanical properties. Ferrite content of sintered and solution treated DSS were measured by Fischer Ferritoscope. It is inferred that the hydrogen sintered DSS depicted better density (94% theoretical density) and tensile strength (695 MPa) than the argon sintered steels. Similarly the microstructure of solution treated DSS revealed existence of more volume of ferrite grains than its sintered condition. Solution treated hydrogen sintered DSS A (50 wt% 316L + 50 wt% 430L) exhibited higher tensile strength of 716 MPa and elongation of 17%, which are 10-13% increment than the sintered stainless steels.

THE NATURE OF ENERGY TRANSFER TO ELECTRODES IN A PULSE DISCHARGE WITH SMALL GAPS,

DTIC Science & Technology

SPARK MACHINING, ELECTRIC DISCHARGES), (*ELECTROMAGNETIC PULSES, SPARK MACHINING), ELECTROEROSIVE MACHINING, ENERGY, ELECTRON IRRADIATION, ION BOMBARDMENT, THERMAL CONDUCTIVITY, FILMS, KINETIC ENERGY, ZONE MELTING, USSR

Desktop Manufacturing Technologies.

ERIC Educational Resources Information Center

Snyder, Mark

1991-01-01

Desktop manufacturing is the use of data from a computer-assisted design system to construct actual models of an object. Emerging processes are stereolithography, laser sintering, ballistic particle manufacturing, laminated object manufacturing, and photochemical machining. (SK)

Wire electric-discharge machining and other fabrication techniques

NASA Technical Reports Server (NTRS)

Morgan, W. H.

1983-01-01

Wire electric discharge machining and extrude honing were used to fabricate a two dimensional wing for cryogenic wind tunnel testing. Electric-discharge cutting is done with a moving wire electrode. The cut track is controlled by means of a punched-tape program and the cutting feed is regulated according to the progress of the work. Electric-discharge machining involves no contact with the work piece, and no mechanical force is exerted. Extrude hone is a process for honing finish-machined surfaces by the extrusion of an abrasive material (silly putty), which is forced through a restrictive fixture. The fabrication steps are described and production times are given.

Experimental Investigation – Magnetic Assisted Electro Discharge Machining

NASA Astrophysics Data System (ADS)

Kesava Reddy, Chirra; Manzoor Hussain, M.; Satyanarayana, S.; Krishna, M. V. S. Murali

2018-04-01

Emerging technology needs advanced machined parts with high strength and temperature resistance, high fatigue life at low production cost with good surface quality to fit into various industrial applications. Electro discharge machine is one of the extensively used machines to manufacture advanced machined parts which cannot be machined by other traditional machine with high precision and accuracy. Machining of DIN 17350-1.2080 (High Carbon High Chromium steel), using electro discharge machining has been discussed in this paper. In the present investigation an effort is made to use permanent magnet at various positions near the spark zone to improve surface quality of the machined surface. Taguchi methodology is used to obtain optimal choice for each machining parameter such as peak current, pulse duration, gap voltage and Servo reference voltage etc. Process parameters have significant influence on machining characteristics and surface finish. Improvement in surface finish is observed when process parameters are set at optimum condition under the influence of magnetic field at various positions.

Fully-Enclosed Ceramic Micro-burners Using Fugitive Phase and Powder-based Processing

NASA Astrophysics Data System (ADS)

Do, Truong; Shin, Changseop; Kwon, Patrick; Yeom, Junghoon

2016-08-01

Ceramic-based microchemical systems (μCSs) are more suitable for operation under harsh environments such as high temperature and corrosive reactants compared to the more conventional μCS materials such as silicon and polymers. With the recent renewed interests in chemical manufacturing and process intensification, simple, inexpensive, and reliable ceramic manufacturing technologies are needed. The main objective of this paper is to introduce a new powder-based fabrication framework, which is a one-pot, cost-effective, and versatile process for ceramic μCS components. The proposed approach employs the compaction of metal-oxide sub-micron powders with a graphite fugitive phase that is burned out to create internal cavities and microchannels before full sintering. Pure alumina powder has been used without any binder phase, enabling more precise dimensional control and less structure shrinkage upon sintering. The key process steps such as powder compaction, graphite burnout during partial sintering, machining in a conventional machine tool, and final densification have been studied to characterize the process. This near-full density ceramic structure with the combustion chamber and various internal channels was fabricated to be used as a micro-burner for gas sensing applications.

Fully-Enclosed Ceramic Micro-burners Using Fugitive Phase and Powder-based Processing

PubMed Central

Do, Truong; Shin, Changseop; Kwon, Patrick; Yeom, Junghoon

2016-01-01

Ceramic-based microchemical systems (μCSs) are more suitable for operation under harsh environments such as high temperature and corrosive reactants compared to the more conventional μCS materials such as silicon and polymers. With the recent renewed interests in chemical manufacturing and process intensification, simple, inexpensive, and reliable ceramic manufacturing technologies are needed. The main objective of this paper is to introduce a new powder-based fabrication framework, which is a one-pot, cost-effective, and versatile process for ceramic μCS components. The proposed approach employs the compaction of metal-oxide sub-micron powders with a graphite fugitive phase that is burned out to create internal cavities and microchannels before full sintering. Pure alumina powder has been used without any binder phase, enabling more precise dimensional control and less structure shrinkage upon sintering. The key process steps such as powder compaction, graphite burnout during partial sintering, machining in a conventional machine tool, and final densification have been studied to characterize the process. This near-full density ceramic structure with the combustion chamber and various internal channels was fabricated to be used as a micro-burner for gas sensing applications. PMID:27546059

Comparing Sliding-Wear Characteristics of the Electro-Pressure Sintered and Wrought Cobalt

NASA Astrophysics Data System (ADS)

Lee, J. E.; Kim, Y. S.; Kim, T. W.

Dry sliding wear tests of hot-pressure sintered and wrought cobalt were carried out to compare their wear characteristics. Cobalt powders with average size of 1.5µm were electro-pressure sintered to make sintered-cobalt disk wear specimens. A vacuum-induction melted cobalt ingot was hot-rolled at 800°C to a plate, from which wrought-cobalt disk specimens were machined. The specimens were heat treated at various temperatures to vary grain size and phase fraction. Wear tests of the cobalt specimens were carried out using a pin-on-disk wear tester against a glass (83% SiO2) bead at 100N with the constant sliding speed and distance of 0.36m/s and 600m, respectively. Worn surfaces, their cross sections, and wear debris were examined by an SEM. The wear of the cobalt was found to be strongly influenced by the strain-induced phase transformation of ɛ-Co (hcp) to α-Co (fcc). The sintered cobalt had smaller uniform grain size and showed higher wear rate than the wrought cobalt. The higher wear rate of the sintered cobalt was explained by the more active deformation-induced phase transformation than in the wrought cobalt with larger irregular grains.

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.

[The study on fabrication of dental restoration using PMMA-ZrO2 composites via CAD/CAM].

PubMed

Li, Shi-bao; Wang, Zhong-yi; Chen, Zhao-hui; Hu, Hai-feng; Tang, Li-hui; Ma, Chu-fan

2005-01-01

To obtain dental restorations by machining PMMA-ZrO2 organic-inorganic composites with the dental CAD/CAM system. Partially sintered Zirconia compacts (PSZC) were prepared via isostatic pressing and partially sintering, with Zirconia nanopowder as raw materials. PMMA-Zirconia organic-inorganic composites were prepared by vacuum infiltrating the prepolymerized MMA into the PSZC, followed by in-situ polymerization. The mechanical properties and machinability of composites were studied. The composites were machined on the dental CAD/CAM system to obtain dental restoration. At 71.44% TD of PSZC, the composite had a 3-point bending strength of (202.56 +/- 3.09) MPa, fracture toughness of (4.30 +/- 0.16) MPa.m(1/2), elasticity modulus of (58.71 +/- 1.98) GPa, and Vickers hardness of (3.82 +/- 0.34) GPa, respectively. A premolar crown was fabricated by CAD/CAM system in 16 mins, and was verisimilitude, without any cracks. The composite at 71.44% TD of PSZC has good mechanical properties and dental restorations can be manufactured by PMMA-Zirconia composites via dental CAD/CAM system.

Processing of surrogate nuclear fuel pellets for better dimensional control with dry bag isostatic pressing

DOE PAGES

Hoggan, Rita E.; Zuck, Larry D.; Cannon, W. Roger; ...

2016-05-26

A study of improved methods of processing fuel pellets was undertaken using ceria and zirconia/yttria/alumina as surrogates. Through proper granulation and vertical vibration (tapping) of the parts bag prior to dry bag isostatic pressing (DBIP), reproducibility of diameter profiles among multiple pellets of ceria was improved by almost an order of magnitude. Reproducibility of sintered pellets was sufficiently good to possibly avoid grinding. Deviation from the mean diameter along the length of multiple pellets, as well as, deviation from roundness, decreased after sintering. This is not generally observed with dry pressed pellets. Thus it is possible to machine to tolerancemore » before sintering if grinding is necessary.« less

40 CFR 63.11167 - What definitions apply to this subpart?

Code of Federal Regulations, 2013 CFR

2013-07-01

...) of the sulfur contained in the charge. Sintering machine means any furnace in which calcines are... standard, or combination thereof. Zinc cathode melting furnace means any furnace used to melt the pure zinc...

40 CFR 63.11167 - What definitions apply to this subpart?

Code of Federal Regulations, 2014 CFR

2014-07-01

...) of the sulfur contained in the charge. Sintering machine means any furnace in which calcines are... standard, or combination thereof. Zinc cathode melting furnace means any furnace used to melt the pure zinc...

40 CFR 63.11167 - What definitions apply to this subpart?

Code of Federal Regulations, 2012 CFR

2012-07-01

...) of the sulfur contained in the charge. Sintering machine means any furnace in which calcines are... standard, or combination thereof. Zinc cathode melting furnace means any furnace used to melt the pure zinc...

Synthesis of lithium nickel cobalt manganese oxide cathode materials by infrared induction heating

NASA Astrophysics Data System (ADS)

Hsieh, Chien-Te; Chen, Yu-Fu; Pai, Chun-Ting; Mo, Chung-Yu

2014-12-01

This study adopts an in-situ infrared (IR) sintering incorporated with carbonization technique to synthesize carbon-coated LiNi1/3Co1/3Mn1/3O2 (LNCM) cathode materials for Li-ion batteries. Compared with electric resistance heating, the in-situ IR sintering is capable of rapidly producing highly-crystalline LNCM powders at 900 °C within a short period, i.e., 3 h in this case. Glucose additive is employed to serve a carbon precursor, which is carbonized and coated over the surface of LNCM crystals during the IR sintering process. The electrochemical performance of LNCM cathodes is well examined by charge-discharge cycling at 0.1-5C. An appropriate carbon coating is capable of raising discharge capacity (i.e., 181.5 mAh g-1 at 0.1C), rate capability (i.e., 75.0 mAh g-1 at 5C), and cycling stability (i.e., capacity retention: 94.2% at 1C after 50 cycles) of LNCM cathodes. This enhanced performance can be ascribed to the carbon coating onto the external surface of LNCM powders, creating an outer circuit of charge-transfer pathway and preventing cathode corrosion from direct contact to the electrolyte. Accordingly, the in-situ IR sintering technique offers a potential feasibility for synthesizing cathode materials commercially in large scale.

Significant improvements of electrical discharge machining performance by step-by-step updated adaptive control laws

NASA Astrophysics Data System (ADS)

Zhou, Ming; Wu, Jianyang; Xu, Xiaoyi; Mu, Xin; Dou, Yunping

2018-02-01

In order to obtain improved electrical discharge machining (EDM) performance, we have dedicated more than a decade to correcting one essential EDM defect, the weak stability of the machining, by developing adaptive control systems. The instabilities of machining are mainly caused by complicated disturbances in discharging. To counteract the effects from the disturbances on machining, we theoretically developed three control laws from minimum variance (MV) control law to minimum variance and pole placements coupled (MVPPC) control law and then to a two-step-ahead prediction (TP) control law. Based on real-time estimation of EDM process model parameters and measured ratio of arcing pulses which is also called gap state, electrode discharging cycle was directly and adaptively tuned so that a stable machining could be achieved. To this end, we not only theoretically provide three proved control laws for a developed EDM adaptive control system, but also practically proved the TP control law to be the best in dealing with machining instability and machining efficiency though the MVPPC control law provided much better EDM performance than the MV control law. It was also shown that the TP control law also provided a burn free machining.

Development of 2024 AA-Yttrium composites by Spark Plasma Sintering

NASA Astrophysics Data System (ADS)

Vidyasagar, CH S.; Karunakar, D. B.

2018-04-01

The method of fabrication of MMNCs is quite a challenge, which includes advanced processing techniques like Spark Plasma Sintering (SPS), etc. The objective of the present work is to fabricate aluminium based MMNCs with the addition of small amounts of yttrium using Spark Plasma Sintering and to evaluate their mechanical and microstructure properties. Samples of 2024 AA with yttrium ranging from 0.1% to 0.5 wt% are fabricated by Spark Plasma Sintering (SPS). Hardness of the samples is determined using Vickers hardness testing machine. The metallurgical characterization of the samples is evaluated by Optical Microscopy (OM), Field Emission Scanning Electron Microscopy (FE-SEM). Unreinforced 2024 AA sample is also fabricated as a benchmark to compare its properties with those of the composite developed. It is found that the yttrium addition increases the above mentioned properties by altering the precipitation kinetics and intermetallic formation to some extent and then decreases gradually when yttrium wt% increases beyond 0.3 wt%. High density (˂ 99.75) is achieved in the samples and highest hardness achieved is 114 Hv, fabricated by spark plasma sintering and uniform distribution of yttrium is observed.

Toughened and machinable glass matrix composites reinforced with graphene and graphene-oxide nano platelets

NASA Astrophysics Data System (ADS)

Porwal, Harshit; Tatarko, Peter; Grasso, Salvatore; Hu, Chunfeng; Boccaccini, Aldo R.; Dlouhý, Ivo; Reece, Mike J.

2013-10-01

The processing conditions for preparing well dispersed silica-graphene nanoplatelets and silica-graphene oxide nanoplatelets (GONP) composites were optimized using powder and colloidal processing routes. Fully dense silica-GONP composites with up to 2.5 vol% loading were consolidated using spark plasma sintering. The GONP aligned perpendicularly to the applied pressure during sintering. The fracture toughness of the composites increased linearly with increasing concentration of GONP and reached a value of ˜0.9 MPa m1/2 for 2.5 vol% loading. Various toughening mechanisms including GONP necking, GONP pull-out, crack bridging, crack deflection and crack branching were observed. GONP decreased the hardness and brittleness index (BI) of the composites by ˜30 and ˜50% respectively. The decrease in BI makes silica-GONP composites machinable compared to pure silica. When compared to silica-Carbon nanotube composites, silica-GONP composites show better process-ability and enhanced mechanical properties.

Toughened and machinable glass matrix composites reinforced with graphene and graphene-oxide nano platelets

PubMed Central

Porwal, Harshit; Tatarko, Peter; Grasso, Salvatore; Hu, Chunfeng; Boccaccini, Aldo R; Dlouhý, Ivo; Reece, Mike J

2013-01-01

The processing conditions for preparing well dispersed silica–graphene nanoplatelets and silica–graphene oxide nanoplatelets (GONP) composites were optimized using powder and colloidal processing routes. Fully dense silica–GONP composites with up to 2.5 vol% loading were consolidated using spark plasma sintering. The GONP aligned perpendicularly to the applied pressure during sintering. The fracture toughness of the composites increased linearly with increasing concentration of GONP and reached a value of ∼0.9 MPa m1/2 for 2.5 vol% loading. Various toughening mechanisms including GONP necking, GONP pull-out, crack bridging, crack deflection and crack branching were observed. GONP decreased the hardness and brittleness index (BI) of the composites by ∼30 and ∼50% respectively. The decrease in BI makes silica–GONP composites machinable compared to pure silica. When compared to silica–Carbon nanotube composites, silica–GONP composites show better process-ability and enhanced mechanical properties. PMID:27877614

Investigations of Effect of Rotary EDM Electrode on Machining Performance of Al6061 Alloy

NASA Astrophysics Data System (ADS)

Robinson Smart, D. S.; Jenish Smart, Joses; Periasamy, C.; Ratna Kumar, P. S. Samuel

2018-04-01

Electric Discharge Machining is an essential process which is being used for machining desired shape using electrical discharges which creates sparks. There will be electrodes subjected to electric voltage and which are separated by a dielectric liquid. Removing of material will be due to the continuous and rapid current discharges between two electrodes.. The spark is very carefully controlled and localized so that it only affects the surface of the material. Usually in order to prevent the defects which are arising due to the conventional machining, the Electric Discharge Machining (EDM) machining is preferred. Also intricate and complicated shapes can be machined effectively by use of Electric Discharge Machining (EDM). The EDM process usually does not affect the heat treat below the surface. This research work focus on the design and fabrication of rotary EDM tool for machining Al6061alloy and investigation of effect of rotary tool on surface finish, material removal rate and tool wear rate. Also the effect of machining parameters of EDM such as pulse on & off time, current on material Removal Rate (MRR), Surface Roughness (SR) and Electrode wear rate (EWR) have studied. Al6061 alloy can be used for marine and offshore applications by reinforcing some other elements. The investigations have revealed that MRR (material removal rate), surface roughness (Ra) have been improved with the reduction in the tool wear rate (TWR) when the tool is rotating instead of stationary. It was clear that as rotary speed of the tool is increasing the material removal rate is increasing with the reduction of surface finish and tool wear rate.

Synthesis of dense yttrium-stabilised hafnia pellets for nuclear applications by spark plasma sintering

NASA Astrophysics Data System (ADS)

Tyrpekl, Vaclav; Holzhäuser, Michael; Hein, Herwin; Vigier, Jean-Francois; Somers, Joseph; Svora, Petr

2014-11-01

Dense yttrium-stabilised hafnia pellets (91.35 wt.% HfO2 and 8.65 wt.% Y2O3) were prepared by spark plasma sintering consolidation of micro-beads synthesised by the "external gelation" sol-gel technique. This technique allows a preparation of HfO2-Y2O3 beads with homogenous yttria-hafnia solid solution. A sintering time of 5 min at 1600 °C was sufficient to produce high density pellets (over 90% of the theoretical density) with significant reproducibility. The pellets have been machined in a lathe to the correct dimensions for use as neutron absorbers in an experimental test irradiation in the High Flux Reactor (HFR) in Petten, Holland, in order to investigate the safety of americium based nuclear fuels.

Effect of sintering conditions on the microstructural and mechanical characteristics of porous magnesium materials prepared by powder metallurgy.

PubMed

Čapek, Jaroslav; Vojtěch, Dalibor

2014-02-01

There has recently been an increased demand for porous magnesium materials in many applications, especially in the medical field. Powder metallurgy appears to be a promising approach for the preparation of such materials. Many works have dealt with the preparation of porous magnesium; however, the effect of sintering conditions on material properties has rarely been investigated. In this work, we investigated porous magnesium samples that were prepared by powder metallurgy using ammonium bicarbonate spacer particles. The effects of the purity of the argon atmosphere and sintering time on the microstructure (SEM, EDX and XRD) and mechanical behaviour (universal loading machine and Vickers hardness tester) of porous magnesium were studied. The porosities of the prepared samples ranged from 24 to 29 vol.% depending on the sintering conditions. The purity of atmosphere played a significant role when the sintering time exceeded 6h. Under a gettered argon atmosphere, a prolonged sintering time enhanced diffusion connections between magnesium particles and improved the mechanical properties of the samples, whereas under a technical argon atmosphere, oxidation at the particle surfaces caused deterioration in the mechanical properties of the samples. These results suggest that a refined atmosphere is required to improve the mechanical properties of porous magnesium. © 2013.

Processing of sintered alpha SiC

NASA Technical Reports Server (NTRS)

Storm, R. S.

1984-01-01

Processing methods of sintered alpha SiC for engine applications are developed in a cost effective manner, using a submicron sized powder blended with sintering aids (boron and carbon). The processes for forming a green powder compact, such as dry pressing, cold isostatic pressing and green machining, slip casting, aqueous extrusion, plastic extrusion, and injection molding, are described. Dry pressing is the simplest route to component fabrication, and is carried out at approximately 10,000 psi pressure, while in the cold isostatic method the pressure could go as high as 20,000 psi. Surfactants are added to control settling rates and casting characteristics in the slip casting. The aqueous extrusion process is accomplished by a hydraulic ram forcing the aqueous mixture through a die. The plastic forming processes of extrusion and injection molding offer the potential of greater diversity in shape capacity. The physical properties of sintered alpha SiC (hardness, Young's modulus, shear modulus, and thermal diffusivity) are extensively tested. Corrosion resistance test results of silicon carbide are included.

Liquid Phase Sintering

NASA Technical Reports Server (NTRS)

2004-01-01

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Optical alignment of electrodes on electrical discharge machines

NASA Technical Reports Server (NTRS)

Boissevain, A. G.; Nelson, B. W.

1972-01-01

Shadowgraph system projects magnified image on screen so that alignment of small electrodes mounted on electrical discharge machines can be corrected and verified. Technique may be adapted to other machine tool equipment where physical contact cannot be made during inspection and access to tool limits conventional runout checking procedures.

Influence of metallic additives on manganese ferrites sintering

NASA Astrophysics Data System (ADS)

Shevelev, S. A.; Luchnikov, P. A.; Yarullina, A. R.

2018-01-01

Influence of cuprum nanopowder additive received by electric explosion on the process of manganese ferrites MgFe2O4 consolidating at thermal sintering was researched by dilatometry method. Cuprum nanopowder at a rate of 5 mass % was added into the original commercial-grade powder of manganese ferrite MgFe2O4. Powder mixture was numerously blended with screening for better blending before pressing. Powder compacts were formed by cold one-axle static pressing. It was proved that introduction of cuprum additive caused shrinkage increase at final heating stage. There was abnormal compact enlarging at sintering in the air at isothermal stage; the specified process was not observed in vacuum. This difference can be explained by changes in conditions of gaseous discharge from volume of pores.

Marginal Accuracy and Internal Fit of Dental Copings Fabricated by Modern Additive and Subtractive Digital Technologies.

PubMed

Nelson, Neha; K S, Jyothi; Sunny, Kiran

2017-03-01

The margins of copings for crowns and retainers of fixed partial dentures affect the progress of microleakage and dental caries. Failures occur due to altered fit which is also influenced by the method of fabrication. An in-vitro study was conducted to determine among the cast base metal, copy milled zirconia, computer aided designing computer aided machining/manufacturing zirconia and direct metal laser sintered copings which showed best marginal accuracy and internal fit. Forty extracted maxillary premolars were mounted on an acrylic model and reduced occlusally using a milling machine up to a final tooth height of 4 mm from the cementoenamel junction. Axial reduction was accomplished on a surveyor and a chamfer finish line was given. The impressions and dies were made for fabrication of copings which were luted on the prepared teeth under standardized loading, embedded in self-cure acrylic resin, sectioned and observed using scanning electron microscope for internal gap and marginal accuracy. The copings fabricated using direct metal laser sintering technique exhibited best marginal accuracy and internal fit. Comparison of mean between the four groups by ANOVA and post-hoc Tukey HSD tests showed a statistically significant difference between all the groups (p⟨0.05). It was concluded that the copings fabricated using direct metal laser sintering technique exhibited best marginal accuracy and internal fit. Additive digital technologies such as direct metal laser sintering could be cost-effective for the clinician, minimize failures related to fit and increase longevity of teeth and prostheses. Copyright© 2017 Dennis Barber Ltd.

Scale effects and a method for similarity evaluation in micro electrical discharge machining

NASA Astrophysics Data System (ADS)

Liu, Qingyu; Zhang, Qinhe; Wang, Kan; Zhu, Guang; Fu, Xiuzhuo; Zhang, Jianhua

2016-08-01

Electrical discharge machining(EDM) is a promising non-traditional micro machining technology that offers a vast array of applications in the manufacturing industry. However, scale effects occur when machining at the micro-scale, which can make it difficult to predict and optimize the machining performances of micro EDM. A new concept of "scale effects" in micro EDM is proposed, the scale effects can reveal the difference in machining performances between micro EDM and conventional macro EDM. Similarity theory is presented to evaluate the scale effects in micro EDM. Single factor experiments are conducted and the experimental results are analyzed by discussing the similarity difference and similarity precision. The results show that the output results of scale effects in micro EDM do not change linearly with discharge parameters. The values of similarity precision of machining time significantly increase when scaling-down the capacitance or open-circuit voltage. It is indicated that the lower the scale of the discharge parameter, the greater the deviation of non-geometrical similarity degree over geometrical similarity degree, which means that the micro EDM system with lower discharge energy experiences more scale effects. The largest similarity difference is 5.34 while the largest similarity precision can be as high as 114.03. It is suggested that the similarity precision is more effective in reflecting the scale effects and their fluctuation than similarity difference. Consequently, similarity theory is suitable for evaluating the scale effects in micro EDM. This proposed research offers engineering values for optimizing the machining parameters and improving the machining performances of micro EDM.

Effect of TiN Addition on 3Y-TZP Ceramics with Emphasis on Making EDM-Able Bodies

NASA Astrophysics Data System (ADS)

Khosravifar, Mahnoosh; Mirkazemi, Seyyed Mohammad; Taheri, Mahdiar; Golestanifard, Farhad

2018-05-01

In this study, to produce electrically conductive ceramics, rapid hot press (RHP) sintering of 3 mol.% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP) and 3Y-TZP/TiN composites with TiN amounts of 25, 35, and 45 vol.% was performed at 1300, 1350, and 1400 °C. Interestingly, the toughness and hardness were improved in the presence of TiN up to 35 vol.% and maximum fracture toughness and hardness of 5.40 ± 0.05 MPa m1/2 and 14.50 ± 0.06 GPa, respectively, were obtained. However, the bending strength was decreased which could be attributed to the rather weak interfaces of nitride and oxide phases. Regarding the zirconia matrix, the effect of grain size on fracture toughness of the samples has been studied using x-ray diffraction and field emission scanning electron microscope (FESEM) analysis. It was also found that electrical resistivity decreased to the value of 6.88 × 10-6 Ω m at 45 vol.% of TiN. It seems the TiN grains form a network to impose conductivity on the ZrO2 body; however, below 35 vol.% TiN, due to lack of percolation effect, this conductivity could not be maintained according to FESEM studies. Finally, electrically conductive samples were successfully machined by electrical discharge machining (EDM).

Microporous Ti implant compact coated with hydroxyapatite produced by electro-discharge-sintering and electrostatic-spray-deposition.

PubMed

Jo, Y J; Kim, Y H; Jo, Y H; Seong, J G; Chang, S Y; Van Tyne, C J; Lee, W H

2014-11-01

A single pulse of 1.5 kJ/0.7 g of atomized spherical Ti powder from 300 μF capacitor was applied to produce the porous-surfaced Ti implant compact by electro-discharge-sintering (EDS). A solid core surrounded by porous layer was self-consolidated by a discharge in the middle of the compact in 122 μsec. Average pore size, porosity, and compressive yield strength of EDS Ti compact were estimated to be about 68.2 μm, 25.5%, and 266.4 MPa, respectively. Coatings with hydroxyapatite (HAp) on the Ti compact were conducted by electrostatic-spray-deposition (ESD) method. As-deposited HAp coating was in the form of porous structure and consisted of HAp particles which were uniformly distributed on the Ti porous structure. By heat-treatment at 700 degrees C, HAp particles were agglomerated each other and melted to form a highly smooth and homogeneous HAp thin film consisted of equiaxed nano-scaled grains. Porous-surfaced Ti implant compacts coated with highly crystalline apatite phase were successfully obtained by using the EDS and ESD techniques.

Improvement of mechanical strength of sintered Mo alloyed steel by optimization of sintering and cold-forging processes with densification

NASA Astrophysics Data System (ADS)

Kamakoshi, Y.; Shohji, I.; Inoue, Y.; Fukuda, S.

2017-10-01

Powder metallurgy (P/M) materials have been expected to be spread in automotive industry. Generally, since sintered materials using P/M ones contain many pores and voids, mechanical properties of them are inferior to those of conventional wrought materials. To improve mechanical properties of the sintered materials, densification is effective. The aim of this study is to improve mechanical strength of sintered Mo-alloyed steel by optimizing conditions in sintering and cold-forging processes. Mo-alloyed steel powder was compacted. Then, pre-sintering (PS) using a vacuum sintering furnace was conducted. Subsequently, coldforging (CF) by a backward extrusion method was conducted to the pre-sintered specimen. Moreover, the cold-forged specimen was heat treated by carburizing, tempering and quenching (CQT). Afterwards, mechanical properties were investigated. As a result, it was found that the density of the PS specimen is required to be more than 7.4 Mg/m3 to strengthen the specimen by heat treatment after CF. Furthermore, density and the microstructure of the PS specimen are most important factors to make the high density and strength material by CF. At the CF load of 1200 kN, the maximum density ratio reached approximately 99% by the use of the PS specimen with proper density and microstructure. At the CF load of 900 kN, although density ratio was high like more than 97.8%, transverse rupture strength decreased sharply. Since densification caused high shear stress and stress concentration in the surface layer, microcracks occurred by the damages of inter-particle sintered connection of the surface layer. On the contrary, in case of the CF load of 1200 kN, ultra-densification of the surface layer occurred by a sufficient plastic flow. Such sufficient compressed specimens regenerated the sintered connections by high temperature heat treatment and thus the high strength densified material was obtained. These processes can be applicable to near net shape manufacturing without surface machining.

Analysis of 3D printing parameters of gears for hybrid manufacturing

NASA Astrophysics Data System (ADS)

Budzik, Grzegorz; Przeszlowski, Łukasz; Wieczorowski, Michal; Rzucidlo, Arkadiusz; Gapinski, Bartosz; Krolczyk, Grzegorz

2018-05-01

The paper deals with analysis and selection of parameters of rapid prototyping of gears by selective sintering of metal powders. Presented results show wide spectrum of application of RP systems in manufacturing processes of machine elements, basing on analysis of market in term of application of additive manufacturing technology in different sectors of industry. Considerable growth of these methods over the past years can be observed. The characteristic errors of printed model with respect to ideal one for each technique were pointed out. Special attention was paid to the method of preparation of numerical data CAD/STL/RP. Moreover the analysis of manufacturing processes of gear type elements was presented. The tested gears were modeled with different allowances for final machining and made by DMLS. Metallographic analysis and strength tests on prepared specimens were performed. The above mentioned analysis and tests were used to compare the real properties of material with the nominal ones. To improve the quality of surface after sintering the gears were subjected to final machining. The analysis of geometry of gears after hybrid manufacturing method was performed (fig.1). The manufacturing process was defined in a traditional way as well as with the aid of modern manufacturing techniques. Methodology and obtained results can be used for other machine elements than gears and constitutes the general theory of production processes in rapid prototyping methods as well as in designing and implementation of production.

Efficient production by laser materials processing integrated into metal cutting machines

NASA Astrophysics Data System (ADS)

Wiedmaier, M.; Meiners, E.; Dausinger, Friedrich; Huegel, Helmut

1994-09-01

Beam guidance of high power YAG-laser (cw, pulsed, Q-switched) with average powers up to 2000 W by flexible glass fibers facilitates the integration of the laser beam as an additional tool into metal cutting machines. Hence, technologies like laser cutting, joining, hardening, caving, structuring of surfaces and laser-marking can be applied directly inside machining centers in one setting, thereby reducing the flow of workpieces resulting in a lowering of costs and production time. Furthermore, materials with restricted machinability--especially hard materials like ceramics, hard metals or sintered alloys--can be shaped by laser-caving or laser assisted machining. Altogether, the flexibility of laser integrated machining centers is substantially increased or the efficiency of a production line is raised by time-savings or extended feasibilities with techniques like hardening, welding or caving.

Nondestructive Evaluation of the J-2X Direct Metal Laser Sintered Gas Generator Discharge Duct

NASA Technical Reports Server (NTRS)

Esther, Elizabeth A.; Beshears, Ronald D.; Lash, Rhonda K.

2012-01-01

The J-2X program at NASA's Marshall Space Flight Center (MSFC) procured a direct metal laser sintered (DMLS) gas generator discharge duct from Pratt & Whitney Rocketdyne and Morris Technologies for a test program that would evaluate the material properties and durability of the duct in an engine-like environment. DMLS technology was pursued as a manufacturing alternative to traditional techniques, which used off nominal practices to manufacture the gas generator duct's 180 degree turn geometry. MSFC's Nondestructive Evaluation (NDE) Team performed radiographic, ultrasonic, computed tomographic, and fluorescent penetrant examinations of the duct. Results from the NDE examinations reveal some shallow porosity but no major defects in the as-manufactured material. NDE examinations were also performed after hot-fire testing the gas generator duct and yielded similar results pre and post-test and showed no flaw growth or development.

40 CFR 63.1541 - Applicability.

Code of Federal Regulations, 2010 CFR

2010-07-01

... Hazardous Air Pollutants for Primary Lead Smelting § 63.1541 Applicability. (a) The provisions of this subpart apply to the following affected sources at primary lead smelters: sinter machine, blast furnace... not apply to secondary lead smelters, lead refiners, or lead remelters. (b) Table 1 of this subpart...

EQUIPMENT FOR SPARK-ASSISTED MACHINING (OBORUDOVANIE DLYA ELEKTROISKROVOI OBRABOTKI),

DTIC Science & Technology

MACHINE TOOLS, * ELECTROEROSIVE MACHINING), MACHINE TOOL INDUSTRY, ELECTROFORMING, ELECTRODES, ELECTROLYTIC CAPACITORS, ELECTRIC DISCHARGES, TOLERANCES(MECHANICS), SURFACE ROUGHNESS, DIES, MOLDINGS, SYNTHETIC FIBERS, USSR

Geometry and surface damage in micro electrical discharge machining of micro-holes

NASA Astrophysics Data System (ADS)

Ekmekci, Bülent; Sayar, Atakan; Tecelli Öpöz, Tahsin; Erden, Abdulkadir

2009-10-01

Geometry and subsurface damage of blind micro-holes produced by micro electrical discharge machining (micro-EDM) is investigated experimentally to explore the relational dependence with respect to pulse energy. For this purpose, micro-holes are machined with various pulse energies on plastic mold steel samples using a tungsten carbide tool electrode and a hydrocarbon-based dielectric liquid. Variations in the micro-hole geometry, micro-hole depth and over-cut in micro-hole diameter are measured. Then, unconventional etching agents are applied on the cross sections to examine micro structural alterations within the substrate. It is observed that the heat-damaged segment is composed of three distinctive layers, which have relatively high thicknesses and vary noticeably with respect to the drilling depth. Crack formation is identified on some sections of the micro-holes even by utilizing low pulse energies during machining. It is concluded that the cracking mechanism is different from cracks encountered on the surfaces when machining is performed by using the conventional EDM process. Moreover, an electrically conductive bridge between work material and debris particles is possible at the end tip during machining which leads to electric discharges between the piled segments of debris particles and the tool electrode during discharging.

Development of dense glass-ceramic from recycled soda-lime-silicate glass and fly ash for tiling

NASA Astrophysics Data System (ADS)

Mustaffar, Mohd Idham; Mahmud, Mohamad Haniza; Hassan, Mahadi Abu

2017-12-01

Dense glass-ceramics were prepared by sinter-crystallization process from a combination of soda-lime-silicate glass waste and fly ash. Bentonite clay that acted as a binder was also added in a prepared formulation. The powder mixture of soda-lime glass, fly ash and bentonite clay were compacted by using uniaxial hydraulic press machine and sintered at six (6) various temperatures namely 750, 800, 850, 900, 950 and 1000 °C. The heating rate and sintering time were set at 5 °C/min and 30 minutes respectively. The results revealed that modulus of rupture (MOR), density and linear shrinkage increase first from 750 to 800 °C but decrease later after 800 to 1000 °C. In the meantime, water absorption was showing completely an opposite trend. The glass-ceramic sintered at 800 °C was found to have the best combination of physical-mechanical properties and has the potential to be applied in the construction industry particularly as floor and wall tiles because of the simple manufacturing process at low temperature.

Advances in Ultra High Temperature Ceramics for Hot Structures

NASA Astrophysics Data System (ADS)

Scatteia, Luigi; Monteverde, Federico; Alfano, Davide; Cantoni, Stefania

The objective of this paper is to describe the current state of the art of the research on Ultra High Temperature Ceramic materials with particular reference to their space applications, and also to report on the activities performed on UHTC in the past decade by the Italian Aerospace Research Centre in the specific technological field of structural thermal protection systems. Within several internal research project, various UHTC composition, mainly based upon Zirconium Diboride and Hafnium Diboride with added secondary phases and sintering aid were examined characterized in their mechanical properties and oxidation resistance. Two main composition were selected as the most promising for hot structure manufacturing: these materials were extensively characterized in order to obtain a comprehensive database of properties to feed the thermomechanical design of prototype hot structures. Technological demonstrators were manufactured by hot pressing followed by further fine machining with Electrical Discharge methods, and then tested at high temperature for long times in a plasma torch facility. The main outstanding results obtained are discussed in this paper. Future outlooks related to the UHTC technology and its further development are also provided.

40 CFR 60.170 - Applicability and designation of affected facility.

Code of Federal Regulations, 2011 CFR

2011-07-01

... (CONTINUED) AIR PROGRAMS (CONTINUED) STANDARDS OF PERFORMANCE FOR NEW STATIONARY SOURCES Standards of Performance for Primary Zinc Smelters § 60.170 Applicability and designation of affected facility. (a) The...: roaster and sintering machine. (b) Any facility under paragraph (a) of this section that commences...

Producing Zirconium Diboride Components with Complex, Near-Net Shape Geometries by Aqueous Room-Temperature Injection Molding

NASA Technical Reports Server (NTRS)

Wiesner, Valerie L.; Youngblood, Jeffrey; Trice, Rodney

2014-01-01

Room-temperature injection molding is proposed as a novel, low-cost and more energy efficient manufacturing process capable of forming complex-shaped zirconium diboride (ZrB2) parts. This innovative processing method utilized aqueous suspensions with high powder loading and a minimal amount (5 vol.) of water-soluble polyvinylpyrrolidone (PVP), which was used as a viscosity modifier. Rheological characterization was performed to evaluate the room-temperature flow properties of ZrB2-PVP suspensions. ZrB2 specimens were fabricated with high green body strength and were machinable prior to binder removal despite their low polymer content. After binder burnout and pressureless sintering, the bulk density and microstructure of specimens were characterized using Archimedes technique and scanning electron microscopy. X-Ray Diffraction was used to determine the phase compositions present in sintered specimens. Ultimate strength of sintered specimens will be determined using ASTM C1323-10 compressive C-ring test.

Fracture behavior of metal-ceramic fixed dental prostheses with frameworks from cast or a newly developed sintered cobalt-chromium alloy.

PubMed

Krug, Klaus-Peter; Knauber, Andreas W; Nothdurft, Frank P

2015-03-01

The aim of this study was to investigate the fracture behavior of metal-ceramic bridges with frameworks from cobalt-chromium-molybdenum (CoCrMo), which are manufactured using conventional casting or a new computer-aided design/computer-aided manufacturing (CAD/CAM) milling and sintering technique. A total of 32 metal-ceramic fixed dental prostheses (FDPs), which are based on a nonprecious metal framework, was produced using a conventional casting process (n = 16) or a new CAD/CAM milling and sintering process (n = 16). Eight unveneered frameworks were manufactured using each of the techniques. After thermal and mechanical aging of half of the restorations, all samples were subjected to a static loading test in a universal testing machine, in which acoustic emission monitoring was performed. Three different critical forces were revealed: the fracture force (F max), the force at the first reduction in force (F decr1), and the force at the critical acoustic event (F acoust1). With the exception of the veneered restorations with cast or sintered metal frameworks without artificial aging, which presented a statistically significant but slightly different F max, no statistically significant differences between cast and CAD/CAM sintered and milled FDPs were detected. Thermal and mechanical loading did not significantly affect the resulting forces. Cast and CAD/CAM milled and sintered metal-ceramic bridges were determined to be comparable with respect to the fracture behavior. FDPs based on CAD/CAM milled and sintered frameworks may be an applicable and less technique-sensitive alternative to frameworks that are based on conventionally cast frameworks.

Method for forming precision clockplate with pivot pins

DOEpatents

Wild, Ronald L [Albuquerque, NM

2010-06-01

Methods are disclosed for producing a precision clockplate with rotational bearing surfaces (e.g. pivot pins). The methods comprise providing an electrically conductive blank, conventionally machining oversize features comprising bearing surfaces into the blank, optionally machining of a relief on non-bearing surfaces, providing wire accesses adjacent to bearing surfaces, threading the wire of an electrical discharge machine through the accesses and finishing the bearing surfaces by wire electrical discharge machining. The methods have been shown to produce bearing surfaces of comparable dimension and tolerances as those produced by micro-machining methods such as LIGA, at reduced cost and complexity.

Morphology and phase identification of micron to nanosized manganese oxide (MnO) with variations in sintering time

NASA Astrophysics Data System (ADS)

Sasongko, Muhammad Ilman Nur; Puspitasari, Poppy; Yazirin, Cepi; Tsamroh, Dewi Izzatus; Risdanareni, Puput

2017-09-01

Manganese oxide (MnO) occurs in many rock types and may take the form of minerals. MnO has its drawbacks, namely highly reactive oxidizing species classified as dangerous and explosive at temperatures above 55 °C. Despite this,MnO has excellent magnetic, electrochemical, and conductivity properties, which should be reduced to nano-size to maximize their use and improve the properties of MnO. Phase and morphology characterization of powder this research aims to reduce the grain size of the MnO from micro to nano using the sol-gel method with various sintering times. Sol-gel is a simple synthesis method that has been proven capable of synthesizing a wide variety of micro-sized oxide materials into nano. Sintering time is a technique performed in the synthesis process to dry the material to a temperature above the normal temperature. The temperature used for sintering starting from 600 °C to 1000 °C. Characterizations were done using XRD, SEM, EDX, and FTIR machines. The sintering processes in this study used a temperature of 600 °C with different sintering periods of 30, 60 and 90 minutes. The XRD characterization with a 30-minute sintering time resulted in the smallest MnO in the form crystalline powder of 47.3 nm. The highest intensity (degree of crystallinity) found in MnO sintered for 90 minutes. The results of the morphological characterization of SEM showed a morphological change in MnO from micro-sized triangular to nano-sized spherical shape. The EDX characterization results indicated that the 30-minute sintering caused the lowest change in Mn and the highest change in O. The results of FTIR characterization showed a shift in C-H and Mn-O followed by an increase in the group of N-H, C=O and Mn-O.

AFM surface imaging of AISI D2 tool steel machined by the EDM process

NASA Astrophysics Data System (ADS)

Guu, Y. H.

2005-04-01

The surface morphology, surface roughness and micro-crack of AISI D2 tool steel machined by the electrical discharge machining (EDM) process were analyzed by means of the atomic force microscopy (AFM) technique. Experimental results indicate that the surface texture after EDM is determined by the discharge energy during processing. An excellent machined finish can be obtained by setting the machine parameters at a low pulse energy. The surface roughness and the depth of the micro-cracks were proportional to the power input. Furthermore, the AFM application yielded information about the depth of the micro-cracks is particularly important in the post treatment of AISI D2 tool steel machined by EDM.

Surface structuring of boron doped CVD diamond by micro electrical discharge machining

NASA Astrophysics Data System (ADS)

Schubert, A.; Berger, T.; Martin, A.; Hackert-Oschätzchen, M.; Treffkorn, N.; Kühn, R.

2018-05-01

Boron doped diamond materials, which are generated by Chemical Vapor Deposition (CVD), offer a great potential for the application on highly stressed tools, e. g. in cutting or forming processes. As a result of the CVD process rough surfaces arise, which require a finishing treatment in particular for the application in forming tools. Cutting techniques such as milling and grinding are hardly applicable for the finish machining because of the high strength of diamond. Due to its process principle of ablating material by melting and evaporating, Electrical Discharge Machining (EDM) is independent of hardness, brittleness or toughness of the workpiece material. EDM is a suitable technology for machining and structuring CVD diamond, since boron doped CVD diamond is electrically conductive. In this study the ablation characteristics of boron doped CVD diamond by micro electrical discharge machining are investigated. Experiments were carried out to investigate the influence of different process parameters on the machining result. The impact of tool-polarity, voltage and discharge energy on the resulting erosion geometry and the tool wear was analyzed. A variation in path overlapping during the erosion of planar areas leads to different microstructures. The results show that micro EDM is a suitable technology for finishing of boron doped CVD diamond.

Machinability of nickel based alloys using electrical discharge machining process

NASA Astrophysics Data System (ADS)

Khan, M. Adam; Gokul, A. K.; Bharani Dharan, M. P.; Jeevakarthikeyan, R. V. S.; Uthayakumar, M.; Thirumalai Kumaran, S.; Duraiselvam, M.

2018-04-01

The high temperature materials such as nickel based alloys and austenitic steel are frequently used for manufacturing critical aero engine turbine components. Literature on conventional and unconventional machining of steel materials is abundant over the past three decades. However the machining studies on superalloy is still a challenging task due to its inherent property and quality. Thus this material is difficult to be cut in conventional processes. Study on unconventional machining process for nickel alloys is focused in this proposed research. Inconel718 and Monel 400 are the two different candidate materials used for electrical discharge machining (EDM) process. Investigation is to prepare a blind hole using copper electrode of 6mm diameter. Electrical parameters are varied to produce plasma spark for diffusion process and machining time is made constant to calculate the experimental results of both the material. Influence of process parameters on tool wear mechanism and material removal are considered from the proposed experimental design. While machining the tool has prone to discharge more materials due to production of high energy plasma spark and eddy current effect. The surface morphology of the machined surface were observed with high resolution FE SEM. Fused electrode found to be a spherical structure over the machined surface as clumps. Surface roughness were also measured with surface profile using profilometer. It is confirmed that there is no deviation and precise roundness of drilling is maintained.

Filter for on-line air monitor unaffected by radon progeny and method of using same

DOEpatents

Phillips, Terrance D.; Edwards, Howard D.

1999-01-01

An apparatus for testing air having contaminants and radon progeny therein. The apparatus includes a sampling box having an inlet for receiving the air and an outlet for discharging the air. The sampling box includes a filter made of a plate of sintered stainless steel. The filter traps the contaminants, yet allows at least a portion of the radon progeny to pass therethrough. A method of testing air having contaminants and radon progeny therein. The method includes providing a testing apparatus that has a sampling box with an inlet for receiving the air and an outlet for discharging the air, and has a sintered stainless steel filter disposed within said sampling box; drawing air from a source into the sampling box using a vacuum pump; passing the air through the filter; monitoring the contaminants trapped by the filter; and providing an alarm when a selected level of contaminants is reached. The filter traps the contaminants, yet allows at least a portion of the radon progeny to pass therethrough.

Mechanical properties of ZrB2- and HfB2-based ultra-high temperature ceramics fabricated by spark plasma sintering

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

Zapata-Solvas, E.; Jayaseelan, D.; Lin, Hua-Tay

2013-01-01

Flexural strengths at room temperature, at 1400 C in air and at room temperature after 1 h oxidation at 1400 C were determined for ZrB2- and HfB2-based ultra-high temperature ceramics (UHTCs). Defects caused by electrical discharge machining (EDM) lowered measured strengths significantly and were used to calculate fracture toughness via a fracture mechanics approach. ZrB2 with 20 vol.% SiC had room temperature strength of 700 90 MPa, fracture toughness of 6.4 0.6 MPa, Vickers hardness at 9.8 N load of 21.1 0.6 GPa, 1400 C strength of 400 30 MPa and room temperature strength after 1 h oxidation at 1400more » C of 678 15 MPa with an oxide layer thickness of 45 5 m. HfB2 with 20 vol.% SiC showed room temperature strength of 620 50 MPa, fracture toughness of 5.0 0.4 MPa, Vickers hardness at 9.8 N load of 27.0 0.6 GPa, 1400 C strength of 590 150 MPa and room temperature strength after 1 h oxidation at 1400 C of 660 25 MPa with an oxide layer thickness of 12 1 m. 2 wt.% La2O3 addition to UHTCs slightly reduced mechanical performance while increasing tolerance to property degradation after oxidation and effectively aided internal stress relaxation during spark plasma sintering (SPS) cooling, as quantified by X-ray diffraction (XRD). Slow crack growth was suggested as the failure mechanism at high temperatures as a consequence of sharp cracks formation during oxidation.« less

Geometric improvement of electrochemical discharge micro-drilling using an ultrasonic-vibrated electrolyte

NASA Astrophysics Data System (ADS)

Han, Min-Seop; Min, Byung-Kwon; Lee, Sang Jo

2009-06-01

Electrochemical discharge machining (ECDM) is a spark-based micromachining method especially suitable for the fabrication of various microstructures on nonconductive materials, such as glass and some engineering ceramics. However, since the spark discharge frequency is drastically reduced as the machining depth increases ECDM microhole drilling has confronted difficulty in achieving uniform geometry for machined holes. One of the primary reasons for this is the difficulty of sustaining an adequate electrolyte flow in the narrow gap between the tool and the workpiece, which results in a widened taper at the hole entrance, as well as a significant reduction of the machining depth. In this paper, ultrasonic electrolyte vibration was used to enhance the machining depth of the ECDM drilling process by assuring an adequate electrolyte flow, thus helping to maintain consistent spark generation. Moreover, the stability of the gas film formation, as well as the surface quality of the hole entrance, was improved with the aid of a side-insulated electrode and a pulse-power generator. The side-insulated electrode prevented stray electrolysis and concentrated the spark discharge at the tool tip, while the pulse voltage reduced thermal damage to the workpiece surface by introducing a periodic pulse-off time. Microholes were fabricated in order to investigate the effects of ultrasonic assistance on the overcut and machining depth of the holes. The experimental results demonstrated that the possibility of consistent spark generation and the machinability of microholes were simultaneously enhanced.

Effect of magnetic polarity on surface roughness during magnetic field assisted EDM of tool steel

NASA Astrophysics Data System (ADS)

Efendee, A. M.; Saifuldin, M.; Gebremariam, MA; Azhari, A.

2018-04-01

Electrical discharge machining (EDM) is one of the non-traditional machining techniques where the process offers wide range of parameters manipulation and machining applications. However, surface roughness, material removal rate, electrode wear and operation costs were among the topmost issue within this technique. Alteration of magnetic device around machining area offers exciting output to be investigated and the effects of magnetic polarity on EDM remain unacquainted. The aim of this research is to investigate the effect of magnetic polarity on surface roughness during magnetic field assisted electrical discharge machining (MFAEDM) on tool steel material (AISI 420 mod.) using graphite electrode. A Magnet with a force of 18 Tesla was applied to the EDM process at selected parameters. The sparks under magnetic field assisted EDM produced better surface finish than the normal conventional EDM process. At the presence of high magnetic field, the spark produced was squeezed and discharge craters generated on the machined surface was tiny and shallow. Correct magnetic polarity combination of MFAEDM process is highly useful to attain a high efficiency machining and improved quality of surface finish to meet the demand of modern industrial applications.

40 CFR 63.11161 - What are my compliance dates?

Code of Federal Regulations, 2014 CFR

2014-07-01

... subpart by January 23, 2007. If you startup a new sintering machine at an existing affected source after... than 180 days after startup. (b) If you have a new affected source, you must achieve compliance with...) If you startup a new affected source on or before January 23, 2007, you must achieve compliance with...

40 CFR 63.11161 - What are my compliance dates?

Code of Federal Regulations, 2010 CFR

2010-07-01

... subpart by January 23, 2007. If you startup a new sintering machine at an existing affected source after... than 180 days after startup. (b) If you have a new affected source, you must achieve compliance with...) If you startup a new affected source on or before January 23, 2007, you must achieve compliance with...

40 CFR 63.11161 - What are my compliance dates?

Code of Federal Regulations, 2012 CFR

2012-07-01

... subpart by January 23, 2007. If you startup a new sintering machine at an existing affected source after... than 180 days after startup. (b) If you have a new affected source, you must achieve compliance with...) If you startup a new affected source on or before January 23, 2007, you must achieve compliance with...

40 CFR 63.11161 - What are my compliance dates?

Code of Federal Regulations, 2011 CFR

2011-07-01

... subpart by January 23, 2007. If you startup a new sintering machine at an existing affected source after... than 180 days after startup. (b) If you have a new affected source, you must achieve compliance with...) If you startup a new affected source on or before January 23, 2007, you must achieve compliance with...

40 CFR 63.11161 - What are my compliance dates?

Code of Federal Regulations, 2013 CFR

2013-07-01

... subpart by January 23, 2007. If you startup a new sintering machine at an existing affected source after... than 180 days after startup. (b) If you have a new affected source, you must achieve compliance with...) If you startup a new affected source on or before January 23, 2007, you must achieve compliance with...

Weldability Characteristics of Sintered Hot-Forged AISI 4135 Steel Produced through P/M Route by Using Pulsed Current Gas Tungsten Arc Welding

NASA Astrophysics Data System (ADS)

Joseph, Joby; Muthukumaran, S.; Pandey, K. S.

2016-01-01

Present investigation is an attempt to study the weldability characteristics of sintered hot-forged plates of AISI 4135 steel produced through powder metallurgy (P/M) route using matching filler materials of ER80S B2. Compacts of homogeneously blended elemental powders corresponding to the above steel were prepared on a universal testing machine (UTM) by taking pre-weighed powder blend with a suitable die, punch and bottom insert assembly. Indigenously developed ceramic coating was applied on the entire surface of the compacts in order to protect them from oxidation during sintering. Sintered preforms were hot forged to flat, approximately rectangular plates, welded by pulsed current gas tungsten arc welding (PCGTAW) processes with aforementioned filler materials. Microstructural, tensile and hardness evaluations revealed that PCGTAW process with low heat input could produce weldments of good quality with almost nil defects. It was established that PCGTAW joints possess improved tensile properties compared to the base metal and it was mainly attributed to lower heat input, resulting in finer fusion zone grains and higher fusion zone hardness. Thus, the present investigation opens a new and demanding field in research.

Influence of Pre-Sintered Zirconia Surface Conditioning on Shear Bond Strength to Resin Cement

PubMed Central

Sawada, Tomofumi; Spintzyk, Sebastian; Schille, Christine; Zöldföldi, Judit; Paterakis, Angelos; Schweizer, Ernst; Stephan, Ingrid; Rupp, Frank; Geis-Gerstorfer, Jürgen

2016-01-01

This study analyzed the shear bond strength (SBS) of resin composite on zirconia surface to which a specific conditioner was applied before sintering. After sintering of either conditioner-coated or uncoated specimens, both groups were divided into three subgroups by their respective surface modifications (n = 10 per group): no further treatment; etched with hydrofluoric acid; and sandblasted with 50 µm Al2O3 particles. Surfaces were characterized by measuring different surface roughness parameters (e.g., Ra and Rmax) and water contact angles. Half of the specimens underwent thermocycling (10,000 cycles, 5–55 °C) after self-adhesive resin cement build-up. The SBSs were measured using a universal testing machine, and the failure modes were analyzed by microscopy. Data were analyzed by nonparametric and parametric tests followed by post-hoc comparisons (α = 0.05). Conditioner-coated specimens increased both surface roughness and hydrophilicity (p < 0.01). In the non-thermocycled condition, sandblasted surfaces showed higher SBSs than other modifications, irrespective of conditioner application (p < 0.05). Adhesive fractures were commonly observed in the specimens. Thermocycling favored debonding and decreased SBSs. However, conditioner-coated specimens upon sandblasting showed the highest SBS (p < 0.05) and mixed fractures were partially observed. The combination of conditioner application before sintering and sandblasting after sintering showed the highest shear bond strength and indicated improvements concerning the failure mode. PMID:28773641

Effect of electric discharge machining on the fatigue life of Inconel 718

NASA Technical Reports Server (NTRS)

Jeelani, S.; Collins, M. R.

1988-01-01

The effect of electric discharge machining on the fatigue life of Inconel 718 alloy at room temperature was investigated. Data were generated in the uniaxial tension fatigue mode at ambient temperature using flat 3.175 mm thick specimens. The specimens were machined on a wire-cut electric discharge machine at cutting speeds ranging from 0.5 to 2 mm per minute. The specimens were fatigued at a selected stress, and the resulting fatigue lives compared with that of the virgin material. The surfaces of the fatigued specimens were examined under optical and scanning electron microscopes, and the roughness of the surfaces was measured using a standard profilometer. From the results of the investigation, it was concluded that the fatigue life of the specimens machined using EDM decreased slightly as compared with that of the virgin material, but remained unchanged as the cutting speed was changed. The results are explained using data produced employing microhardness measurements, profilometry, and optical and scanning microscopy.

Effect of Width of Kerf on Machining Accuracy and Subsurface Layer After WEDM

NASA Astrophysics Data System (ADS)

Mouralova, K.; Kovar, J.; Klakurkova, L.; Prokes, T.

2018-02-01

Wire electrical discharge machining is an unconventional machining technology that applies physical principles to material removal. The material is removed by a series of recurring current discharges between the workpiece and the tool electrode, and a `kerf' is created between the wire and the material being machined. The width of the kerf is directly dependent not only on the diameter of the wire used, but also on the machine parameter settings and, in particular, on the set of mechanical and physical properties of the material being machined. To ensure precise machining, it is important to have the width of the kerf as small as possible. The present study deals with the evaluation of the width of the kerf for four different metallic materials (some of which were subsequently heat treated using several methods) with different machine parameter settings. The kerf is investigated on metallographic cross sections using light and electron microscopy.

Microstructure and mechanical properties of nickel coated multi walled carbon nanotube reinforced stainless steel 316L matrix composites by laser sintering process

NASA Astrophysics Data System (ADS)

Mahanthesha, P.; Mohankumar, G. C.

2018-04-01

Electroless Ni coated Multi-walled Carbon nanotubes reinforced with Stainless Steel 316L matrix composite was developed by Direct Metal Laser Sintering process (DMLS). Homogeneous mixture of Stainless Steel 316L powder and carbon nanotubes in different vol. % was obtained by using double cone blender machine. Characterization of electroless Ni coated carbon nanotubes was done by using X-ray diffraction, FESEM and EDS. Test samples were fabricated at different laser scan speeds. Effect of process parameters and CNT vol. % content on solidification microstructure and mechanical properties of test samples was investigated by using Optical microscopy, FESEM, and Hounsfield tensometer. Experimental results reveal DMLS process parameters affect the density and microstructure of sintered parts. Dense parts with minimum porosity when processed at low laser scan speeds and low CNT vol. %. Tensile fractured surface of test specimens evidences the survival of carbon nanotubes under high temperature processing condition.

Microgravity

NASA Image and Video Library

2004-04-15

Industry spends billions of dollars each year on machine tools to manufacture products out of metal. This includes tools for cutting every kind of metal part from engine blocks to Shuttle main engine components. Cutting tool tips often break because of weak spots or defects in their composition. Based on a new concept called defect trapping, space offers a novel environment to study defect formation in molten metal materials as they solidify. After the return of these materials from space, researchers can evaluate the source of the defect and seek ways to eliminate them in products prepared on Earth. A widely used process for cutting tip manufacturing is liquid phase sintering. Compared to Earth-sintered samples which slump due to buoyancy induced by gravity, space samples are uniformly shaped and defects remain where they are formed. By studying metals sintered in space the US tool industry can potentially enhance its worldwide competitiveness. The Consortium for Materials Development in Space along with Wyle Labs, Teledyne Advanced Materials, and McDornell Douglas have conducted experiments in space.

Vacuum-sintered body of a novel apatite for artificial bone

NASA Astrophysics Data System (ADS)

Tamura, Kenichi; Fujita, Tatsushi; Morisaki, Yuriko

2013-12-01

We produced regenerative artificial bone material and bone parts using vacuum-sintered bodies of a novel apatite called "Titanium medical apatite (TMA®)" for biomedical applications. TMA was formed by chemically connecting a Ti oxide molecule with the reactive [Ca10(PO4)6] group of Hydroxyapatite (HAp). The TMA powders were kneaded with distilled water, and solid cylinders of compacted TMA were made by compression molding at 10 MPa using a stainless-steel vessel. The TMA compacts were dried and then sintered in vacuum (about 10-3 Pa) or in air using a resistance heating furnace in the temperature range 1073-1773 K. TMA compacts were sintered at temperatures greater than 1073 K, thus resulting in recrystallization. The TMA compact bodies sintered in the range 1273-1773 K were converted into mixtures composed of three crystalline materials: α-TCP (tricalcium phosphate), β-TCP, and Perovskite-CaTiO3. The Perovskite crystals were stable and hard. In vacuum-sintering, the Perovskite crystals were transformed into fibers (approximately 1 µm in diameter × 8 µm in length), and the fiber distribution was uniform in various directions. We refer to the TMA vacuum-sintered bodies as a "reinforced composite material with Perovskite crystal fibers." However, in atmospheric sintering, the Perovskite crystals were of various sizes and were irregularly distributed as a result of the effect of oxygen. After sintering temperature at 1573 K, the following results were obtained: the obtained TMA vacuum-sintered bodies (1) were white, (2) had a density of approximately 2300 kg/m3 (corresponding to that of a compact bone or a tooth), and had a thermal conductivity of approximately 31.3 W/(m·K) (corresponding to those of metal or ceramic implants). Further, it was possible to cut the TMA bodies into various forms with a cutting machine. An implant made of TMA and inserted into a rabbit jaw bone was covered by new bone tissues after just one month because of the high biocompatibility of the TMA implant. TMA vacuum-sintered bodies are promising biomaterials for use as artificial bone materials to regenerate bone parts and produce bone reinforcement structures that are used for bone junctions in dental and orthopedic surgery.

Traveling wire electrode increases productivity of Electrical Discharge Machining /EDM/ equipment

NASA Technical Reports Server (NTRS)

Kotora, J., Jr.; Smith, S. V.

1967-01-01

Traveling wire electrode on electrical discharge machining /EDM/ equipment reduces the time requirements for precision cutting. This device enables cutting with a minimum of lost material and without inducing stress beyond that inherent in the material. The use of wire increases accuracy and enables tighter tolerances to be maintained.

An experimental study of factors affecting the selective inhibition of sintering process

NASA Astrophysics Data System (ADS)

Asiabanpour, Bahram

Selective Inhibition of Sintering (SIS) is a new rapid prototyping method that builds parts in a layer-by-layer fabrication basis. SIS works by joining powder particles through sintering in the part's body, and by sintering inhibition of some selected powder areas. The objective of this research has been to improve the new SIS process, which has been invented at USC. The process improvement is based on statistical design of experiments. To conduct the needed experiments a working machine and related path generator software were needed. The machine and its control software were made available prior to this research. The path generator algorithms and software had to be created. This program should obtain model geometry data from a CAD file and generate an appropriate path file for the printer nozzle. Also, the program should generate a simulation file for path file inspection using virtual prototyping. The activities related to path generator constitute the first part of this research, which has resulted in an efficient path generator. In addition, to reach an acceptable level of accuracy, strength, and surface quality in the fabricated parts, all effective factors in the SIS process should be identified and controlled. Simultaneous analytical and experimental studies were conducted to recognize effective factors and to control the SIS process. Also, it was known that polystyrene was the most appropriate polymer powder and saturated potassium iodide was the most effective inhibitor among the available candidate materials. In addition, statistical tools were applied to improve the desirable properties of the parts fabricated by the SIS process. An investigation of part strength was conducted using the Response Surface Methodology (RSM) and a region of acceptable operating conditions for the part strength was found. Then, through analysis of the experimental results, the impact of the factors on the final part surface quality and dimensional accuracy was modeled. After developing a desirability function model, process operating conditions for maximum desirability were identified. Finally, the desirability model was validated.

A Review on High-Speed Machining of Titanium Alloys

NASA Astrophysics Data System (ADS)

Rahman, Mustafizur; Wang, Zhi-Gang; Wong, Yoke-San

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.

Effects of Process Parameters and Cryotreated Electrode on the Radial Overcut of Aisi 304 IN SiC Powder Mixed Edm

NASA Astrophysics Data System (ADS)

Bhaumik, Munmun; Maity, Kalipada

Powder mixed electro discharge machining (PMEDM) is further advancement of conventional electro discharge machining (EDM) where the powder particles are suspended in the dielectric medium to enhance the machining rate as well as surface finish. Cryogenic treatment is introduced in this process for improving the tool life and cutting tool properties. In the present investigation, the characterization of the cryotreated tempered electrode was performed. An attempt has been made to study the effect of cryotreated double tempered electrode on the radial overcut (ROC) when SiC powder is mixed in the kerosene dielectric during electro discharge machining of AISI 304. The process performance has been evaluated by means of ROC when peak current, pulse on time, gap voltage, duty cycle and powder concentration are considered as process parameters and machining is performed by using tungsten carbide electrodes (untreated and double tempered electrodes). A regression analysis was performed to correlate the data between the response and the process parameters. Microstructural analysis was carried out on the machined surfaces. Least radial overcut was observed for conventional EDM as compared to powder mixed EDM. Cryotreated double tempered electrode significantly reduced the radial overcut than untreated electrode.

2. DETAIL OF DISCHARGE CHUTES FROM VOGT AUTOMATIC TUBE ICE ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

2. DETAIL OF DISCHARGE CHUTES FROM VOGT AUTOMATIC TUBE ICE MACHINE IN SOUTHWEST CORNER OF LEVEL 5; ICE DROPPED INTO HOLDING BIN BEFORE BEING TRANSFERRED TO RAIL CARS OUTSIDE BUILDING (HENRY VOGT MACHINE COMPANY, LOUISVILLE, USA, PATENT NO. 2,200,424 - Rath Packing Company, Cooler Building, Sycamore Street between Elm & Eighteenth Streets, Waterloo, Black Hawk County, IA

Investigation on Surface Insulation Strength of Machinable Ceramic Material under Pulsed Voltage in Vacuum

NASA Astrophysics Data System (ADS)

Zhang, Guan-Jun; Zhao, Wen-Bin; Ma, Xin-Pei; Li, Guang-Xin; Ma, Kui; Zheng, Nan; Yan, Zhang

Ceramic material has been widely used as insulator in vacuum. Their high hardness and brittle property brings some difficulty in the application. A new kind of machinable ceramic was invented recently. The ceramic can be machined easily and accurately after being sintered, which provides the possibility of making the insulator with fine and complicated configuration. The paper studies its surface insulation performance and flashover phenomena under pulsed excitation in vacuum. The ceramic samples with different crystallization parameters are tested under the vacuum level of 10-4 Pa. The machinable ceramic behaves better surface insulation performance than comparative the Al2O3 and glass sample. The effect of crystallization level on the trap density and flashover current is also presented. After flashover shots many times, the surface microscopic patterns of different samples are observed to investigate the damage status, which can be explained by the thermal damage mechanism.

Development of an Eco-Friendly Electrical Discharge Machine (E-EDM) Using TRIZ Approach

NASA Astrophysics Data System (ADS)

Sreebalaji, V. S.; Saravanan, R.

Electrical Discharge Machine (EDM) is one of the non-traditional machining processes. EDM process is based on thermoelectric energy between the work and an electrode. A pulse discharge occurs in a small gap between the work piece and the electrode and removes the unwanted material from the parent metal through melting and vaporization. The electrode and the work piece must have an electrical conductivity in order to generate the spark. Dielectric fluid acts as a spark conductor, concentrating the energy to a very narrow region. There are various types of products can be produced and finished using EDM such as Moulds, Dies, Parts of Aerodynamics, Automotives and Surgical components. This research work reveals how an Eco friendly EDM (E-EDM) can be modeled to replace die electric fluid and introducing ozonised oxygen in to EDM to eliminate harmful effects generated while machining by using dielectric, to make pollution free machining environment through a new design of EEDM using TRIZ (a Russian acronym for Theory of Inventive Problem Solving) approach, since Eco friendly design is the need of the hour.

Influence of the direction of selective laser sintering on machinability of parts from 316L steel

NASA Astrophysics Data System (ADS)

Alexeev, V. P.; Balyakin, A. V.; Khaimovich, A. I.

2017-02-01

This work presents the results of research of the impact of layer-by-layer growing of workpieces made of 316L steel on their machinability. The results of determination of residual stresses and measurement of hardness of the workpieces grown have been demonstrated. A series of experimental studies has been performed in order to determine the cutting force which occurs in the process of machining. The microstructure of the workpieces grown has been examined. It has been shown that the workpieces machined using Selective Laser Melting technology have the microstructure which is a totality of ‘microwelded seams’, which have a significant influence on the behavior of deformation processes in case of machining. The studies have shown that in case of lateral milling of the horizontally grown workpiece, the codirectional microwelded borders prevent any significant deformation of the misalignment which increases the cutting force by up to 10% as compared with milling of the vertically grown workpiece.

Combined Inkjet Printing and Infrared Sintering of Silver Nanoparticles using a Swathe-by-Swathe and Layer-by-Layer Approach for 3-Dimensional Structures.

PubMed

Vaithilingam, Jayasheelan; Simonelli, Marco; Saleh, Ehab; Senin, Nicola; Wildman, Ricky D; Hague, Richard J M; Leach, Richard K; Tuck, Christopher J

2017-02-22

Despite the advancement of additive manufacturing (AM)/3-dimensional (3D) printing, single-step fabrication of multifunctional parts using AM is limited. With the view of enabling multifunctional AM (MFAM), in this study, sintering of metal nanoparticles was performed to obtain conductivity for continuous line inkjet printing of electronics. This was achieved using a bespoke three-dimensional (3D) inkjet-printing machine, JETx, capable of printing a range of materials and utilizing different post processing procedures to print multilayered 3D structures in a single manufacturing step. Multiple layers of silver were printed from an ink containing silver nanoparticles (AgNPs) and infrared sintered using a swathe-by-swathe (SS) and layer-by-layer sintering (LS) regime. The differences in the heat profile for the SS and LS was observed to influence the coalescence of the AgNPs. Void percentage of both SS and LS samples was higher toward the top layer than the bottom layer due to relatively less IR exposure in the top than the bottom. The results depicted a homogeneous microstructure for LS of AgNPs and showed less deformation compared to the SS. Electrical resistivity of the LS tracks (13.6 ± 1 μΩ cm) was lower than the SS tracks (22.5 ± 1 μΩ cm). This study recommends the use of LS method to sinter the AgNPs to obtain a conductive track in 25% less time than SS method for MFAM.

Investigation of Boron addition and compaction pressure on the compactibility, densification and microhardness of 316L Stainless Steel

NASA Astrophysics Data System (ADS)

Ali, S.; Rani, A. M. A.; Altaf, K.; Baig, Z.

2018-04-01

Powder Metallurgy (P/M) is one of the continually evolving technologies used for producing metal materials of various sizes and shapes. However, some P/M materials have limited use in engineering for their performance deficiency including fully dense components. AISI 316L Stainless Steel (SS) is one of the promising materials used in P/M that combines outstanding corrosion resistance, strength and ductility for numerous applications. It is important to analyze the material composition along with the processing conditions that lead to a superior behaviour of the parts manufactured with P/M technique. This research investigates the effect of Boron addition on the compactibility, densification, sintering characteristics and microhardness of 316L SS parts produced with P/M. In this study, 0.25% Boron was added to the 316L Stainless Steel matrix to study the increase in densification of the 316L SS samples. The samples were made at different compaction pressures ranging from 100 MPa to 600 MPa and sintered in Nitrogen atmosphere at a temperature of 1200°C. The effect of compaction pressure and sintering temperature and atmosphere on the density and microhardness was evaluated. The microstructure of the samples was examined by optical microscope and microhardness was found using Vickers hardness machine. Results of the study showed that sintered samples with Boron addition exhibited high densification with increase in microhardness as compared to pure 316L SS sintered samples.

Method and apparatus for making articles from particle based materials

DOEpatents

Moorhead, Arthur J.; Menchhofer, Paul A.

1995-01-01

A method and apparatus for the production of articles made of a particle-based material; e.g., ceramics and sintered metals. In accordance with the invention, a thermally settable slurry containing a relatively high concentration of the particles is conveyed through an elongate flow area having a desired cross-sectional configuration. The slurry is heated as it is advanced through the flow area causing the slurry to set or harden in a shape which conforms to the cross-sectional configuration of the flow area. The material discharges from the flow area as a self-supporting solid of near net final dimensions. The article may then be sintered to consolidate the particles and provide a high density product.

Standard surface grinder for precision machining of thin-wall tubing

NASA Technical Reports Server (NTRS)

Jones, A.; Kotora, J., Jr.; Rein, J.; Smith, S. V.; Strack, D.; Stuckey, D.

1967-01-01

Standard surface grinder performs precision machining of thin-wall stainless steel tubing by electrical discharge grinding. A related adaptation, a traveling wire electrode fixture, is used for machining slots in thin-walled tubing.

Porous calcium polyphosphate bone substitutes: additive manufacturing versus conventional gravity sinter processing-effect on structure and mechanical properties.

PubMed

Hu, Youxin; Shanjani, Yaser; Toyserkani, Ehsan; Grynpas, Marc; Wang, Rizhi; Pilliar, Robert

2014-02-01

Porous calcium polyphosphate (CPP) structures proposed as bone-substitute implants and made by sintering CPP powders to form bending test samples of approximately 35 vol % porosity were machined from preformed blocks made either by additive manufacturing (AM) or conventional gravity sintering (CS) methods and the structure and mechanical characteristics of samples so made were compared. AM-made samples displayed higher bending strengths (≈1.2-1.4 times greater than CS-made samples), whereas elastic constant (i.e., effective elastic modulus of the porous structures) that is determined by material elastic modulus and structural geometry of the samples was ≈1.9-2.3 times greater for AM-made samples. X-ray diffraction analysis showed that samples made by either method displayed the same crystal structure forming β-CPP after sinter annealing. The material elastic modulus, E, determined using nanoindentation tests also showed the same value for both sample types (i.e., E ≈ 64 GPa). Examination of the porous structures indicated that significantly larger sinter necks resulted in the AM-made samples which presumably resulted in the higher mechanical properties. The development of mechanical properties was attributed to the different sinter anneal procedures required to make 35 vol % porous samples by the two methods. A primary objective of the present study, in addition to reporting on bending strength and sample stiffness (elastic constant) characteristics, was to determine why the two processes resulted in the observed mechanical property differences for samples of equivalent volume percentage of porosity. An understanding of the fundamental reason(s) for the observed effect is considered important for developing improved processes for preparation of porous CPP implants as bone substitutes for use in high load-bearing skeletal sites. Copyright © 2013 Wiley Periodicals, Inc.

Making Positive Electrodes For Sodium/Metal Chloride Cells

NASA Technical Reports Server (NTRS)

Bugga, Ratnakumar V.; Distefano, Salvador; Bankston, C. Perry

1992-01-01

High coulombic yields provided by sodium/metal chloride battery in which cathode formed by impregnating sintered nickel plaque with saturated solution of nickel chloride. Charge/discharge cycling of nickel chloride electrode results in very little loss of capacity. Used in spacecraft, electric land vehicles, and other applications in which high-energy-density power systems required.

Effects of CaO on the compaction and sintering by plasma of Powder-metallurgical iron

NASA Astrophysics Data System (ADS)

Ariza Suarez, H. G.; Sarmiento Santos, A.; Ortiz Otálora, C. A.

2017-12-01

This work the effect of the addition of Calcium Oxide (CaO) in the compaction and sintering of powder metallurgical iron Ancoor Steel 1000® is studied. Iron samples were made with proportions of: 0.5%, 1%, 1.5% and 2% by weight of CaO. The samples were sintered in a luminescent discharge furnace, in an atmosphere of H2+Ar at a temperature of 1150°C. XRD analysis was used to determine the formation of compounds, this analysis evidenced the formation of: hematite and magnetite, which were found both on the surface and in the volume. A characterization of the ability to protect against corrosive effects was carried out using the EIS electrochemical impedance spectroscopy method on the samples, in a solution of 1000ppm of chloride, with this procedure it was found that at a concentration of 0.5% and 1% CaO, the electrochemical impedance value is increased with values of 11.7MΩ, 2.2MΩ respectively.

A comparative study on NbOx films reactively sputtered from sintered and cold gas sprayed targets

NASA Astrophysics Data System (ADS)

Lorenz, Roland; O'Sullivan, Michael; Fian, Alexander; Sprenger, Dietmar; Lang, Bernhard; Mitterer, Christian

2018-04-01

The aim of this work is to evaluate novel cold gas sprayed Nb targets in a reactive sputter deposition process of thin films with respect to the widely used sintered Nb targets. With the exception of a higher target discharge voltage of ∼100 V for the cold gas sprayed targets and the thus higher film growth rate compared to sintered targets, NbOx films with comparable microstructure and properties were obtained for both target variants. The amorphous films with thicknesses between 2.9 and 4.9 μm present an optical shift from dark and non-transparent towards transparent properties, as the oxygen partial pressure increases. X-ray photoelectron spectroscopy confirms the occurrence of the Nb5+ oxidation state for the highest oxygen partial pressure, while Nb4+ is additionally present at lower oxygen partial pressure settings. With a maximal transparency of ∼80% and a refractive index of ∼2.5, the transparent films show characteristics similar to Nb2O5.

Estimation of tool wear compensation during micro-electro-discharge machining of silicon using process simulation

NASA Astrophysics Data System (ADS)

Muralidhara, .; Vasa, Nilesh J.; Singaperumal, M.

2010-02-01

A micro-electro-discharge machine (Micro EDM) was developed incorporating a piezoactuated direct drive tool feed mechanism for micromachining of Silicon using a copper tool. Tool and workpiece materials are removed during Micro EDM process which demand for a tool wear compensation technique to reach the specified depth of machining on the workpiece. An in-situ axial tool wear and machining depth measurement system is developed to investigate axial wear ratio variations with machining depth. Stepwise micromachining experiments on silicon wafer were performed to investigate the variations in the silicon removal and tool wear depths with increase in tool feed. Based on these experimental data, a tool wear compensation method is proposed to reach the desired depth of micromachining on silicon using copper tool. Micromachining experiments are performed with the proposed tool wear compensation method and a maximum workpiece machining depth variation of 6% was observed.

Catalytic aided electrical discharge machining of polycrystalline diamond - parameter analysis of finishing condition

NASA Astrophysics Data System (ADS)

Haikal Ahmad, M. A.; Zulafif Rahim, M.; Fauzi, M. F. Mohd; Abdullah, Aslam; Omar, Z.; Ding, Songlin; Ismail, A. E.; Rasidi Ibrahim, M.

2018-01-01

Polycrystalline diamond (PCD) is regarded as among the hardest material in the world. Electrical Discharge Machining (EDM) typically used to machine this material because of its non-contact process nature. This investigation was purposely done to compare the EDM performances of PCD when using normal electrode of copper (Cu) and newly proposed graphitization catalyst electrode of copper nickel (CuNi). Two level full factorial design of experiment with 4 center points technique was used to study the influence of main and interaction effects of the machining parameter namely; pulse-on, pulse-off, sparking current, and electrode materials (categorical factor). The paper shows interesting discovery in which the newly proposed electrode presented positive impact to the machining performance. With the same machining parameters of finishing, CuNi delivered more than 100% better in Ra and MRR than ordinary Cu electrode.

A study on the effect of tool electrode thickness on MRR, and TWR in electrical discharge turning process

NASA Astrophysics Data System (ADS)

Gohil, Vikas; Puri, YM

2018-04-01

Turning by electrical discharge machining (EDM) is an emerging area of research. Generally, wire-EDM is used in EDM turning because it is not concerned with electrode tooling cost. In EDM turning wire electrode leaves cusps on the machined surface because of its small diameters and wire breakage which greatly affect the surface finish of the machined part. Moreover, one of the limitations of the process is low machining speed as compared to constituent processes. In this study, conventional EDM was employed for turning purpose in order to generate free-form cylindrical geometries on difficult-to-cut materials. Therefore, a specially designed turning spindle was mounted on a conventional die-sinking EDM machine to rotate the work piece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating work piece; thus, a mirror image of the tool is formed on the circumference of the work piece. In this way, an axisymmetric work piece can be made with small tools. The developed process is termed as the electrical discharge turning (EDT). In the experiments, the effect of machining parameters, such as pulse-on time, peak current, gap voltage and tool thickness on the MRR, and TWR were investigated and practical machining was carried out by turning of SS-304 stainless steel work piece.

Effect of Cu Doping on the Structural and Electrochemical Performance of LiNi1/3Co1/3Mn1/3O2 Cathode Materials

NASA Astrophysics Data System (ADS)

Yang, Li; Ren, Fengzhagn; Feng, Qigao; Xu, Guangri; Li, Xiaobo; Li, Yuanchao; Zhao, Erqing; Ma, Jignjign; Fan, Shumin

2018-04-01

The structural and electrochemical performance of Cu-doped, Li[Ni1/3-xCo1/3 Mn1/3Cux]O2 (x = 0-0.1) cathode materials obtained by means of the sol-gel method are discussed; we used critic acid as gels and spent mixed batteries as the raw materials. The effects of the sintering time, sintering temperature, and Cu doping ratio on the phase structure, morphology, and element composition and the behavior in a galvanostatical charge/discharge test have been systemically studied. The results show that the Cu-doped material exhibits better galvanostatic charge/discharge cycling performance. At 0.2 C, its original discharge specific capacity is 180.4 mAh g-1 and its Coulomb efficiency is 90.3%. The Cu-doped material demonstrate an outstanding specific capacity at 0.2 C, 0.5 C, and 2.0 C. In comparison with the original capacities of 178 mAh g-1, 159.5 mAh g-1, and 119.4 mAh g-1, the discharge capacity after 50 cycles is 160.8 mAh g-1, 143.4 mAh g-1, and 90.1 mAh g-1, respectively. This obvious improvement relative to bare Li[Ni1/3Co1/3Mn1/3]O2 cathode materials arises from an enlarged Li layer spacing and a reduced degree of cation mixing. Therefore, Cu-doped cathode materials have obvious advantages in the field of lithium-ion batteries and their applications.

Effect of Cu Doping on the Structural and Electrochemical Performance of LiNi1/3Co1/3Mn1/3O2 Cathode Materials

NASA Astrophysics Data System (ADS)

Yang, Li; Ren, Fengzhagn; Feng, Qigao; Xu, Guangri; Li, Xiaobo; Li, Yuanchao; Zhao, Erqing; Ma, Jignjign; Fan, Shumin

2018-07-01

The structural and electrochemical performance of Cu-doped, Li[Ni1/3-xCo1/3 Mn1/3Cux]O2 ( x = 0-0.1) cathode materials obtained by means of the sol-gel method are discussed; we used critic acid as gels and spent mixed batteries as the raw materials. The effects of the sintering time, sintering temperature, and Cu doping ratio on the phase structure, morphology, and element composition and the behavior in a galvanostatical charge/discharge test have been systemically studied. The results show that the Cu-doped material exhibits better galvanostatic charge/discharge cycling performance. At 0.2 C, its original discharge specific capacity is 180.4 mAh g-1 and its Coulomb efficiency is 90.3%. The Cu-doped material demonstrate an outstanding specific capacity at 0.2 C, 0.5 C, and 2.0 C. In comparison with the original capacities of 178 mAh g-1, 159.5 mAh g-1, and 119.4 mAh g-1, the discharge capacity after 50 cycles is 160.8 mAh g-1, 143.4 mAh g-1, and 90.1 mAh g-1, respectively. This obvious improvement relative to bare Li[Ni1/3Co1/3Mn1/3]O2 cathode materials arises from an enlarged Li layer spacing and a reduced degree of cation mixing. Therefore, Cu-doped cathode materials have obvious advantages in the field of lithium-ion batteries and their applications.

Research on the EDM Technology for Micro-holes at Complex Spatial Locations

NASA Astrophysics Data System (ADS)

Y Liu, J.; Guo, J. M.; Sun, D. J.; Cai, Y. H.; Ding, L. T.; Jiang, H.

2017-12-01

For the demands on machining micro-holes at complex spatial location, several key technical problems are conquered such as micro-Electron Discharge Machining (micro-EDM) power supply system’s development, the host structure’s design and machining process technical. Through developing low-voltage power supply circuit, high-voltage circuit, micro and precision machining circuit and clearance detection system, the narrow pulse and high frequency six-axis EDM machining power supply system is developed to meet the demands on micro-hole discharging machining. With the method of combining the CAD structure design, CAE simulation analysis, modal test, ODS (Operational Deflection Shapes) test and theoretical analysis, the host construction and key axes of the machine tool are optimized to meet the position demands of the micro-holes. Through developing the special deionized water filtration system to make sure that the machining process is stable enough. To verify the machining equipment and processing technical developed in this paper through developing the micro-hole’s processing flow and test on the real machine tool. As shown in the final test results: the efficient micro-EDM machining pulse power supply system, machine tool host system, deionized filtration system and processing method developed in this paper meet the demands on machining micro-holes at complex spatial locations.

Selection of Wire Electrical Discharge Machining Process Parameters on Stainless Steel AISI Grade-304 using Design of Experiments Approach

NASA Astrophysics Data System (ADS)

Lingadurai, K.; Nagasivamuni, B.; Muthu Kamatchi, M.; Palavesam, J.

2012-06-01

Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. Parts having sharp edges that pose difficulties to be machined by the main stream machining processes can be easily machined by WEDM process. Design of Experiments approach (DOE) has been reported in this work for stainless steel AISI grade-304 which is used in cryogenic vessels, evaporators, hospital surgical equipment, marine equipment, fasteners, nuclear vessels, feed water tubing, valves, refrigeration equipment, etc., is machined by WEDM with brass wire electrode. The DOE method is used to formulate the experimental layout, to analyze the effect of each parameter on the machining characteristics, and to predict the optimal choice for each WEDM parameter such as voltage, pulse ON, pulse OFF and wire feed. It is found that these parameters have a significant influence on machining characteristic such as metal removal rate (MRR), kerf width and surface roughness (SR). The analysis of the DOE reveals that, in general the pulse ON time significantly affects the kerf width and the wire feed rate affects SR, while, the input voltage mainly affects the MRR.

Nondestructive evaluation of structural ceramics by photoacoustic microscopy

NASA Technical Reports Server (NTRS)

Khandelwal, Pramod K.

1987-01-01

A photoacoustic microscopy (PAM) digital imaging system was developed and utilized to characterize silicon nitride material at the various stages of the ceramic fabrication process. Correlation studies revealed that photoacoustic microscopy detected failure initiating defects in substantially more specimens than microradiography and ultrasonic techniques. Photoacoustic microscopy detected 10 to 100 micron size surface and subsurface pores and inclusions, respectively, up to 80 microns below the interrogating surface in machined sintered silicon nitride. Microradiography detected 50 micron diameter fracture controlling pores and inclusions. Subsurface holes were detected up to a depth of 570 microns and 1.00 mm in sintered silicon nitride and silicon carbide, respectively. Seeded voids of 20 to 30 micron diameters at the surface and 50 microns below the interrogating surface were detected by photoacoustic microscopy and microradiography with 1 percent X-ray thickness sensitivity. Tight surface cracks of 96 micron length x 48 micron depth were detected by photoacoustic microscopy. PAM volatilized and removed material in the green state which resulted in linear shallow microcracks after sintering. This significantly limits the use of PAM as an in-process NDE technique.

2007 SB14 Source Reduction Plan/Report

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

Chang, L

2007-07-24

Aqueous solutions (mixed waste) generated from various LLNL operations, such as debris washing, sample preparation and analysis, and equipment maintenance and cleanout, were combined for storage in the B695 tank farm. Prior to combination the individual waste streams had different codes depending on the particular generating process and waste characteristics. The largest streams were CWC 132, 791, 134, 792. Several smaller waste streams were also included. This combined waste stream was treated at LLNL's waste treatment facility using a vacuum filtration and cool vapor evaporation process in preparation for discharge to sanitary sewer. Prior to discharge, the treated waste streammore » was sampled and the results were reviewed by LLNL's water monitoring specialists. The treated solution was discharged following confirmation that it met the discharge criteria. A major source, accounting for 50% for this waste stream, is metal machining, cutting and grinding operations in the engineering machine shops in B321/B131. An additional 7% was from similar operations in B131 and B132S. This waste stream primarily contains metal cuttings from machined parts, machining coolant and water, with small amounts of tramp oil from the machining and grinding equipment. Several waste reduction measures for the B321 machine shop have been taken, including the use of a small point-of-use filtering/tramp-oil coalescing/UV-sterilization coolant recycling unit, and improved management techniques (testing and replenishing) for coolants. The recycling unit had some operational problems during 2006. The machine shop is planning to have it repaired in the near future. A major source, accounting for 50% for this waste stream, is metal machining, cutting and grinding operations in the engineering machine shops in B321/B131. An additional 7% was from similar operations in B131 and B132S. This waste stream primarily contains metal cuttings from machined parts, machining coolant and water, with small amounts of tramp oil from the machining and grinding equipment. Several waste reduction measures for the B321 machine shop have been taken, including the use of a small point-of-use filtering/tramp-oil coalescing/UV-sterilization coolant recycling unit, and improved management techniques (testing and replenishing) for coolants. The recycling unit had some operational problems during 2006. The machine shop is planning to have it repaired in the near future. Quarterly waste generation data prepared by the Environmental Protection Department's P2 Team are regularly provided to engineering shops as well as other facilities so that generators can track the effectiveness of their waste minimization efforts.« less

Multiple performance characteristics optimization for Al 7075 on electric discharge drilling by Taguchi grey relational theory

NASA Astrophysics Data System (ADS)

Khanna, Rajesh; Kumar, Anish; Garg, Mohinder Pal; Singh, Ajit; Sharma, Neeraj

2015-12-01

Electric discharge drill machine (EDDM) is a spark erosion process to produce micro-holes in conductive materials. This process is widely used in aerospace, medical, dental and automobile industries. As for the performance evaluation of the electric discharge drilling machine, it is very necessary to study the process parameters of machine tool. In this research paper, a brass rod 2 mm diameter was selected as a tool electrode. The experiments generate output responses such as tool wear rate (TWR). The best parameters such as pulse on-time, pulse off-time and water pressure were studied for best machining characteristics. This investigation presents the use of Taguchi approach for better TWR in drilling of Al-7075. A plan of experiments, based on L27 Taguchi design method, was selected for drilling of material. Analysis of variance (ANOVA) shows the percentage contribution of the control factor in the machining of Al-7075 in EDDM. The optimal combination levels and the significant drilling parameters on TWR were obtained. The optimization results showed that the combination of maximum pulse on-time and minimum pulse off-time gives maximum MRR.

Evaluating the electrical discharge machining (EDM) parameters with using carbon nanotubes

NASA Astrophysics Data System (ADS)

Sari, M. M.; Noordin, M. Y.; Brusa, E.

2012-09-01

Electrical discharge machining (EDM) is one of the most accurate non traditional manufacturing processes available for creating tiny apertures, complex or simple shapes and geometries within parts and assemblies. Performance of the EDM process is usually evaluated in terms of surface roughness, existence of cracks, voids and recast layer on the surface of product, after machining. Unfortunately, the high heat generated on the electrically discharged material during the EDM process decreases the quality of products. Carbon nanotubes display unexpected strength and unique electrical and thermal properties. Multi-wall carbon nanotubes are therefore on purpose added to the dielectric used in the EDM process to improve its performance when machining the AISI H13 tool steel, by means of copper electrodes. Some EDM parameters such as material removal rate, electrode wear rate, surface roughness and recast layer are here first evaluated, then compared to the outcome of EDM performed without using nanotubes mixed to the dielectric. Independent variables investigated are pulse on time, peak current and interval time. Experimental evidences show that EDM process operated by mixing multi-wall carbon nanotubes within the dielectric looks more efficient, particularly if machining parameters are set at low pulse of energy.

Low density microcellular carbon or catalytically impregnated carbon forms and process for their preparation

DOEpatents

Hopper, Robert W.; Pekala, Richard W.

1989-01-01

Machinable and structurally stable, low density microcellular carbon, and catalytically impregnated carbon, foams, and process for their preparation, are provided. Pulverized sodium chloride is classified to improve particle size uniformity, and the classified particles may be further mixed with a catalyst material. The particles are cold pressed into a compact having internal pores, and then sintered. The sintered compact is immersed and then submerged in a phenolic polymer solution to uniformly fill the pores of the compact with phenolic polymer. The compact is then heated to pyrolyze the phenolic polymer into carbon in the form of a foam. Then the sodium chloride of the compact is leached away with water, and the remaining product is freeze dried to provide the carbon, or catalytically impregnated carbon, foam.

Low density microcellular carbon or catalytically impregnated carbon foams and process for their prepartion

DOEpatents

Hopper, Robert W.; Pekala, Richard W.

1988-01-01

Machinable and structurally stable, low density microcellular carbon, and catalytically impregnated carbon, foams, and process for their preparation, are provided. Pulverized sodium chloride is classified to improve particle size uniformity, and the classified particles may be further mixed with a catalyst material. The particles are cold pressed into a compact having internal pores, and then sintered. The sintered compact is immersed and then submerged in a phenolic polymer solution to uniformly fill the pores of the compact with phenolic polymer. The compact is then heated to pyrolyze the phenolic polymer into carbon in the form of a foam. Then the sodium chloride of the compact is leached away with water, and the remaining product is freeze dried to provide the carbon, or catalytically impregnated carbon, foam.

Low density microcellular carbon or catalytically impregnated carbon foams and process for their preparation

DOEpatents

Hooper, R.W.; Pekala, R.W.

1987-04-30

Machinable and structurally stable, low density microcellular carbon, and catalytically impregnated carbon, foams, and process for their preparation, are provided. Pulverized sodium chloride is classified to improve particle size uniformity, and the classified particles may be further mixed with a catalyst material. The particles are cold pressed into a compact having internal pores, and then sintered. The sintered compact is immersed and then submerged in a phenolic polymer solution to uniformly fill the pores of the compact with phenolic polymer. The compact is then heated to pyrolyze the phenolic polymer into carbon in the form of a foam. Then the sodium chloride of the compact is leached away with water, and the remaining product is freeze dried to provide the carbon, or catalytically impregnated carbon, foam.

Compositions Comprising Nickel-Titanium, Methods Manufacture Thereof and Articles Comprising the Same

NASA Technical Reports Server (NTRS)

DellaCorte, Christopher (Inventor); Glennon, Glenn N. (Inventor)

2016-01-01

Disclosing herein is a method for manufacturing nickel-titanium compositions. The method includes disposing a powdered composition in a mold; the powdered composition comprising nickel and titanium; the titanium being present in an amount of about 38 to about 42 wt % and the nickel being present in an amount of about 58 to about 62 wt %; sintering the powdered composition to produce a sintered preform; compacting the preform; machining the preform to form an article; heat treating the article; the annealing being conducted at a temperature of about 1650.degree. F. to about 1900.degree. F. at a pressure of about 3 Torr to about 5 Kg-f/cm.sup.2 for a time period of about 10 minutes to about 5 hours; and quenching the article.

Research Progresses and Suggestions of Manufacturing Technologies of Engine Bearing Bushes

NASA Astrophysics Data System (ADS)

Cao, J.; Yin, Z. W.; Li, H. L.; Y Gao, G.

2017-12-01

Bearing bush is a key part of diesel engine, and its performance directly influences the life of whole machine. Several manufacturing technologies of bearing bush such as centrifugal casting, sintering, electroplating and magnetron sputtering have been overviewed. Their bond strength, porosity, production efficient, layer thickness, frictional coefficient and corresponding materials analyzed and compared. Results show that the porosity and oxidation of sintering and centrifugal casting are higher than that of other two methods. However, the production efficiency and coating thickness are better than that of electroplating and magnetron sputtering. Based on above comparisons and discussions, the improvements of all manufacturing technologies are suggested and supersonic cold spraying is suggested. It is proved that cold spraying technology is the best choice in the future with the developing of low frictional materials.

40 CFR Table 2 to Subpart Fffff of... - Initial Compliance With Emission and Opacity Limits

Code of Federal Regulations, 2013 CFR

2013-07-01

... flow-weighted average concentration of particulate matter from one or more control devices applied to...). 4. Each discharge end at a new sinter plant a. The flow-weighted average concentration of... BOPF at a new or existing BOPF shop a. The average concentration of particulate matter from a primary...

40 CFR Table 2 to Subpart Fffff of... - Initial Compliance With Emission and Opacity Limits

Code of Federal Regulations, 2012 CFR

2012-07-01

... flow-weighted average concentration of particulate matter from one or more control devices applied to...). 4. Each discharge end at a new sinter plant a. The flow-weighted average concentration of... BOPF at a new or existing BOPF shop a. The average concentration of particulate matter from a primary...

40 CFR Table 2 to Subpart Fffff of... - Initial Compliance With Emission and Opacity Limits

Code of Federal Regulations, 2011 CFR

2011-07-01

... flow-weighted average concentration of particulate matter from one or more control devices applied to...). 4. Each discharge end at a new sinter plant a. The flow-weighted average concentration of... BOPF at a new or existing BOPF shop a. The average concentration of particulate matter from a primary...

40 CFR Table 2 to Subpart Fffff of... - Initial Compliance With Emission and Opacity Limits

Code of Federal Regulations, 2014 CFR

2014-07-01

... flow-weighted average concentration of particulate matter from one or more control devices applied to...). 4. Each discharge end at a new sinter plant a. The flow-weighted average concentration of... BOPF at a new or existing BOPF shop a. The average concentration of particulate matter from a primary...

Sample preparation of metal alloys by electric discharge machining

NASA Technical Reports Server (NTRS)

Chapman, G. B., II; Gordon, W. A.

1976-01-01

Electric discharge machining was investigated as a noncontaminating method of comminuting alloys for subsequent chemical analysis. Particulate dispersions in water were produced from bulk alloys at a rate of about 5 mg/min by using a commercially available machining instrument. The utility of this approach was demonstrated by results obtained when acidified dispersions were substituted for true acid solutions in an established spectrochemical method. The analysis results were not significantly different for the two sample forms. Particle size measurements and preliminary results from other spectrochemical methods which require direct aspiration of liquid into flame or plasma sources are reported.

BLAISDELL SLOW SAND FILTER WASHING MACHINE. VIEW LOOKING SOUTH. THE ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

BLAISDELL SLOW SAND FILTER WASHING MACHINE. VIEW LOOKING SOUTH. THE SUCTION (INTAKE) HOSE IS SEEN AT THE LEFT RESTING ON THE FILTER BED SURFACE; THE DISCHARGE HOSE IS AT THE RIGHT, RUNNING FROM THE BOTTOM OF THE CENTRAL VERTICAL AXLE TO THE CENTRIFUGAL PUMP. FROM THE PUMP WATER IS DISCHARGED THROUGH THE HORIZONTAL PIPE LOCATED UNDER THE EDGE OF PLATFORM DECK INTO THE WASTE-WATER TROUGH (NOT SEEN IN THIS VIEW). - Yuma Main Street Water Treatment Plant, Blaisdell Slow Sand Filter Washing Machine, Jones Street at foot of Main Street, Yuma, Yuma County, AZ

Method and apparatus for making articles from particle based materials

DOEpatents

Moorhead, A.J.; Menchhofer, P.A.

1995-12-19

A method and apparatus are disclosed for the production of articles made of a particle-based material; e.g., ceramics and sintered metals. In accordance with the invention, a thermally settable slurry containing a relatively high concentration of the particles is conveyed through an elongate flow area having a desired cross-sectional configuration. The slurry is heated as it is advanced through the flow area causing the slurry to set or harden in a shape which conforms to the cross-sectional configuration of the flow area. The material discharges from the flow area as a self-supporting solid of near net final dimensions. The article may then be sintered to consolidate the particles and provide a high density product. 10 figs.

Is laser conditioning a valid alternative to conventional etching for aesthetic brackets?

PubMed

Sfondrini, M F; Calderoni, G; Vitale, M C; Gandini, P; Scribante, A

2018-03-01

ER:Yag lasers have been described as a more conservative alternative to conventional acid-etching enamel conditioning technique, when bonding conventional metallic orthodontic brackets. Since the use of aesthetic orthodontic brackets is constantly increasing, the purpose of the present report has been to test laser conditioning with different aesthetic brackets. Study Design: Five different aesthetic brackets (microfilled copolymer, glass fiber, sapphire, polyoxymethylene and sintered ceramic) were tested for shear bond strength and Adhesive Remnant Index scores using two different enamel conditioning techniques (acid etching and ER:Yag laser application). Two hundred bovine incisors were extracted, cleaned and embedded in resin. Specimens were then divided into 10 groups with random tables. Half of the specimens were conditioned with conventional orthophosphoric acid gel, the other half with ER:Yag laser. Different aesthetic brackets (microfilled copolymer, glass fiber, sapphire, polyoxymethylene and sintered ceramic) were then bonded to the teeth. Subsequently all groups were tested in shear mode with a Universal Testing Machine. Shear bond strength values and adhesive remnant index scores were recorded. Statistical analysis was performed. When considering conventional acid etching technique, sapphire, polyoxymethylene and sintered ceramic brackets exhibited the highest SBS values. Lowest values were reported for microfilled copolymer and glass fiber appliances. A significant decrease in SBS values after laser conditioning was reported for sapphire, polyoxymethylene and sintered ceramic brackets, whereas no significant difference was reported for microfilled copolymer and glass fiber brackets. Significant differences in ARI scores were also reported. Laser etching can significantly reduce bonding efficacy of sapphire, polyoxymethylene and sintered ceramic brackets.

Tribological properties of self-lubricating fluoride-metal composites to 900 C (1650 F): A review and some new developments

NASA Technical Reports Server (NTRS)

Sliney, H. E.; Graham, J. W.

1974-01-01

The friction and wear behavior of some fluoride-metal, self-lubricating composites are summarized. Fluoride-infiltrated sintered nickel alloy composites and plasma-sprayed, co-deposited fluoride-nickel alloy composites are described. The importance of proper surface-conditioning of the composites is stressed. Performance of fluoride-metal composites in some machine application evaluation is discussed.

Forming a single layer of a composite powder based on the Ti-Nb system via selective laser melting (SLM)

NASA Astrophysics Data System (ADS)

Saprykin, A. A.; Sharkeev, Yu P.; Ibragimov, E. A.; Babakova, E. V.; Dudikhin, D. V.

2016-07-01

Alloys based on the titanium-niobium system are widely used in implant production. It is conditional, first of all, on the low modulus of elasticity and bio-inert properties of an alloy. These alloys are especially important for tooth replacement and orthopedic surgery. At present alloys based on the titanium-niobium system are produced mainly using conventional metallurgical methods. The further subtractive manufacturing an end product results in a lot of wastes, increasing, therefore, its cost. The alternative of these processes is additive manufacturing. Selective laser melting is a technology, which makes it possible to synthesize products of metal powders and their blends. The point of this technology is laser melting a layer of a powdered material; then a sintered layer is coated with the next layer of powder etc. Complex products and working prototypes are made on the base of this technology. The authors of this paper address to the issue of applying selective laser melting in order to synthesize a binary alloy of a composite powder based on the titanium-niobium system. A set of 10x10 mm samples is made in various process conditions. The samples are made by an experimental selective laser synthesis machine «VARISKAF-100MB». The machine provides adjustment of the following process variables: laser emission power, scanning rate and pitch, temperature of powder pre-heating, thickness of the layer to be sprinkled, and diameter of laser spot focusing. All samples are made in the preliminary vacuumized shielding atmosphere of argon. The porosity and thickness of the sintered layer related to the laser emission power are shown at various scanning rates. It is revealed that scanning rate and laser emission power are adjustable process variables, having the greatest effect on forming the sintered layer.

Identification and Characterization of New Materials for Construction of Heating Plates for High-Temperature Guarded Hot Plates

NASA Astrophysics Data System (ADS)

Hameury, J.; Koenen, A.; Hay, B.; Wu, J.; Hammerschmidt, U.; Rafeld, E. K.; Pennewitz, E.; Turzó-András, E.; Strnad, R.; Blahut, A.

2018-01-01

The selection of a material for making the hot and cold plates of high-temperature guarded hot plates (HTGHPs) working up to 800°C is still an issue. The material must be machinable, have a high mechanical stability to keep the high level of flatness of the plates and have a high thermal conductivity and a high resistance to oxidation when used in air. Nickel 201 alloy has been used in several instruments, but has shown, sometimes, problems of mechanical stability. The total hemispherical emissivity of the plates must be higher than 0.8 as recommended by the standards. Three ceramic materials, a silicon infiltrated silicon carbide (SiSiC), a machinable aluminum nitride and a sintered aluminum nitride (AlN) with high thermal conductivity claimed at ambient temperature, were selected for tests in thermal conductivity and opacity to thermal radiation. Three paints withstanding high temperatures were tested in total hemispherical emissivity and durability at high temperature. Above 600°C, Nickel 201 alloy has a higher thermal conductivity than the three ceramics. Below 600°C, the SiSiC and the sintered AlN have a thermal conductivity significantly higher than Nickel 201, but the sintered AlN shows a wide transparency spectral band at short wavelengths (below 6.5 μ m). Above 300°C, the three paints have a total hemispherical emissivity above 0.8. One of the paints has polluted the specimens of an insulation material tested in thermal conductivity up to 650°C. The other two can be recommended to coat the hot and cold plates of HTGHPs used up to 800°C.

Bioactive calcium pyrophosphate glasses and glass-ceramics.

PubMed

Kasuga, Toshihiro

2005-01-01

Calcium phosphate glass-based materials in the pyrophosphate region are briefly reviewed. Calcium pyrophosphate glasses can be prepared by including a small amount of TiO(2) (

Correlation of gold in siliceous sinters with 3He 4He in hot spring waters of Yellowstone National Park

USGS Publications Warehouse

Fournier, R.O.; Kennedy, B.M.; Aoki, M.; Thompson, J.M.

1994-01-01

Opaline sinter samples collected at Yellowstone National Park (YNP) were analyzed for gold by neutron activation and for other trace elements by the inductively coupled plasma optical emission spectroscopy (ICP-OES) method. No correlation was found between Au and As, Sb, or total Fe in the sinters, although the sample containing the highest Au also contains the highest Sb. There also was no correlation of Au in the sinter with the H2S concentration in the discharged hot spring water or with the estimated temperature of last equilibration of the water with the surrounding rock. The Au in rhyolitic tuffs and lavas at YNP found within the Yellowstone caldera show the same range in Au as do those outside the caldera, while thermal waters from within this caldera all have been found to contain relatively low dissolved Au and to deposit sinters that contain relatively little Au. Therefore, it is not likely that variations in Au concentrations among these sinters simply reflect differences in leachable Au in the rocks through which the hydrothermal fluids have passed. Rather, variations in [H2S], the concentration of total dissolved sulfide, that result from different physical and chemical processes that occur in different parts of the hydrothermal system appear to exert the main control on the abundance of Au in these sinters. Hydrothermal fluids at YNP convect upward through a series of successively shallower and cooler reservoirs where water-rock chemical and isotopic reactions occur in response to changing temperature and pressure. In some parts of the system the fluids undergo decompressional boiling, and in other parts they cool conductively without boiling. Mixing of ascending water from deep in the system with shallow groundwaters is common. All three processes generally result in a decrease in [H2S] and destabilize dissolved gold bisulfide complexes in reservoir waters in the YNP system. Thus, different reservoirs in rocks of similar composition and at similar temperatures may contain waters with different [H2S] and [Au]. The [H2S] in a subsurface reservoir water is difficult to assess on the basis of analyses of hot spring waters because of uncertainties about steam loss during fluid ascent. However, the same processes that result in low [H2S] in reservoir waters also tend to result in decreases in the ratio of 3He 4He(R) dissolved in that water. Values of R relative to this ratio in air (Ra) attain values > 15 in YNP thermal waters. To date, all of the thermal waters at YNP that have R Ra values <9 have been found to deposit sinters with relatively low gold concentrations. These include all of the thermal waters that discharge from 180-215??C reservoirs at Upper, Midway, and Lower Geyser Basins within the western part of the Yellowstone caldera, and thermal waters at Norris Geyser Basin, outside the Yellowstone caldera, where some of the waters flow directly to the surface from a reservoir where the temperature is about 300??C. A high 3He 4He ratio in thermal water discharged at the surface does not guarantee high gold concentrations in the sinter deposited by this water. Boiling with loss of steam (the gas phase takes a separate route to the surface) during rapid upflow from the shallowest reservoir to the surface decreases the [H2S] and total He dissolved in the residual liquid without appreciably changing the 3He 4He ratio. This is because the isotopic composition of the He of the initial bulk fluid is unchanged and there is too little time for much radiogenic 4He to build back into the liquid during this rapid ascent from the near-surface reservoir. However, if boiling with phase separation and loss of steam occurs deep in the system, the 3He 4He ratio in the residual liquid, now depleted in H2S and total He, will be susceptible to dilution with radiogenic 4He that is acquired during the longer residence time underground. Some or all of the Au that comes out of solution when an initial gold bisulfide complex breaks

Ceramic components manufacturing by selective laser sintering

NASA Astrophysics Data System (ADS)

Bertrand, Ph.; Bayle, F.; Combe, C.; Goeuriot, P.; Smurov, I.

2007-12-01

In the present paper, technology of selective laser sintering/melting is applied to manufacture net shaped objects from pure yttria-zirconia powders. Experiments are carried out on Phenix Systems PM100 machine with 50 W fibre laser. Powder is spread by a roller over the surface of 100 mm diameter alumina cylinder. Design of experiments is applied to identify influent process parameters (powder characteristics, powder layering and laser manufacturing strategy) to obtain high-quality ceramic components (density and micro-structure). The influence of the yttria-zirconia particle size and morphology onto powder layering process is analysed. The influence of the powder layer thickness on laser sintering/melting is studied for different laser beam velocity V ( V = 1250-2000 mm/s), defocalisation (-6 to 12 mm), distance between two neighbour melted lines (so-called "vectors") (20-40 μm), vector length and temperature in the furnace. The powder bed density before laser sintering/melting also has significant influence on the manufactured samples density. Different manufacturing strategies are applied and compared: (a) different laser beam scanning paths to fill the sliced surfaces of the manufactured object, (b) variation of vector length (c) different strategies of powder layering, (d) temperature in the furnace and (e) post heat treatment in conventional furnace. Performance and limitations of different strategies are analysed applying the following criteria: geometrical accuracy of the manufactured samples, porosity. The process stability is proved by fabrication of 1 cm 3 volume cube.

Concerns of Hydrothermal Degradation in CAD/CAM Zirconia

PubMed Central

Kim, J.-W.; Covel, N.S.; Guess, P.C.; Rekow, E.D.; Zhang, Y.

2010-01-01

Zirconia-based restorations are widely used in prosthetic dentistry; however, their susceptibility to hydrothermal degradation remains elusive. We hypothesized that CAD/CAM machining and subsequent surface treatments, i.e., grinding and/or grit-blasting, have marked effects on the hydrothermal degradation behavior of Y-TZP. CAD/CAM-machined Y-TZP plates (0.5 mm thick), both with and without subsequent grinding with various grit sizes or grit-blasting with airborne alumina particles, were subjected to accelerated aging tests in a steam autoclave. Results showed that the CAD/CAM-machined surfaces initially exhibited superior hydrothermal degradation resistance, but deteriorated at a faster rate upon prolonged autoclave treatment compared with ground and grit-blasted surfaces. The accelerated hydrothermal degradation of CAD/CAM surfaces is attributed to the CAD/CAM machining damage and the absence of surface compressive stresses in the fully sintered material. Clinical relevance for surface treatments of zirconia frameworks in terms of hydrothermal and structural stabilities is addressed. PMID:19966039

Importance of polarity change in the electrical discharge machining

NASA Astrophysics Data System (ADS)

Schulze, H.-P.

2017-10-01

The polarity change in the electrical discharge machining is still a problem and is often performed completely unmotivated or randomly. The polarity must be designated primarily, i.e. the anodic part must be clearly assigned to the tool or the workpiece. Normally, the polarity of the workpiece electrode is named. In paper, will be shown which determine fundamental causes the structural behavior of the cathode and anode, and when it makes sense to change the polarity. The polarity change is primarily dependent on the materials that are used as cathode and anode. This distinction must be made if there are pure metals or complex materials. Secondary of the polarity change is also affected by the process energy source (PES) and the supply line. The polarity change is mostly influenced by the fact that the removal is to be maximized on the workpiece while the tool is minimal removal (wear) occur. A second factor that makes a polarity change needed is the use of electrical discharge in combination with other machining methods, such as electrochemical machining (ECM).

Energy landscapes for a machine-learning prediction of patient discharge

NASA Astrophysics Data System (ADS)

Das, Ritankar; Wales, David J.

2016-06-01

The energy landscapes framework is applied to a configuration space generated by training the parameters of a neural network. In this study the input data consists of time series for a collection of vital signs monitored for hospital patients, and the outcomes are patient discharge or continued hospitalisation. Using machine learning as a predictive diagnostic tool to identify patterns in large quantities of electronic health record data in real time is a very attractive approach for supporting clinical decisions, which have the potential to improve patient outcomes and reduce waiting times for discharge. Here we report some preliminary analysis to show how machine learning might be applied. In particular, we visualize the fitting landscape in terms of locally optimal neural networks and the connections between them in parameter space. We anticipate that these results, and analogues of thermodynamic properties for molecular systems, may help in the future design of improved predictive tools.

Effect of hole geometry and Electric-Discharge Machining (EDM) on airflow rates through small diameter holes in turbine blade material

NASA Technical Reports Server (NTRS)

Hippensteele, S. A.; Cochran, R. P.

1980-01-01

The effects of two design parameters, electrode diameter and hole angle, and two machine parameters, electrode current and current-on time, on air flow rates through small-diameter (0.257 to 0.462 mm) electric-discharge-machined holes were measured. The holes were machined individually in rows of 14 each through 1.6 mm thick IN-100 strips. The data showed linear increase in air flow rate with increases in electrode cross sectional area and current-on time and little change with changes in hole angle and electrode current. The average flow-rate deviation (from the mean flow rate for a given row) decreased linearly with electrode diameter and increased with hole angle. Burn time and finished hole diameter were also measured.

Optimization of machining parameters in dry EDM of EN31 steel

NASA Astrophysics Data System (ADS)

Brar, G. S.

2018-03-01

Dry electric discharge machining (Dry EDM) is one of the novel EDM technology in which gases namely helium, argon, oxygen, nitrogen etc. are used as a dielectric medium at high pressure instead of oil based liquid dielectric. The present study investigates dry electric discharge machining (with rotary tool) of EN-31 steel to achieve lower tool wear rate (TWR) and better surface roughness (Ra) by performing a set of exploratory experiments with oxygen gas as dielectric. The effect of polarity, discharge current, gas flow pressure, pulse-on time, R.P.M. and gap voltage on the MRR, TWR and surface roughness (Ra) in dry EDM was studied with copper as rotary tool. The significant factors affecting MRR are discharge current and pulse on time. The significant factors affecting TWR are gas flow pressure, pulse on time and R.P.M. TWR was found close to zero in most of the experiments. The significant factors affecting Ra are pulse on time, gas flow pressure and R.P.M. It was found that polarity has nearly zero effect on all the three output variables.

Factors that affect micro-tooling features created by direct printing approach

NASA Astrophysics Data System (ADS)

Kumbhani, Mayur N.

Current market required faster pace production of smaller, better, and improved products in shorter amount of time. Traditional high-rate manufacturing process such as hot embossing, injection molding, compression molding, etc. use tooling to replicate feature on a products. Miniaturization of many product in the field of biomedical, electronics, optical, and microfluidic is occurring on a daily bases. There is a constant need to produce cheaper, and faster tooling, which can be utilize by existing manufacturing processes. Traditionally, in order to manufacture micron size tooling features processes such as micro-machining, Electrical Discharge Machining (EDM), etc. are utilized. Due to a higher difficulty to produce smaller size features, and longer production cycle time, various additive manufacturing approaches are proposed, e.g. selective laser sintering (SLS), inkjet printing (3DP), fused deposition modeling (FDM), etc. were proposed. Most of these approaches can produce net shaped products from different materials such as metal, ceramic, or polymers. Several attempts were made to produce tooling features using additive manufacturing approaches. Most of these produced tooling were not cost effective, and the life cycle of these tooling was reported short. In this research, a method to produce tooling features using direct printing approach, where highly filled feedstock was dispensed on a substrate. This research evaluated different natural binders, such as guar gum, xanthan gum, and sodium carboxymethyl cellulose (NaCMC) and their combinations were evaluated. The best binder combination was then use to evaluate effect of different metal (316L stainless steel (3 mum), 316 stainless steel (45 mum), and 304 stainless steel (45 mum)) particle size on feature quality. Finally, the effect of direct printing process variables such as dispensing tip internal diameter (500 mum, and 333 mum) at different printing speeds were evaluated.

Durability characterization of ceramic materials for gas turbines

NASA Technical Reports Server (NTRS)

Carruthers, W. D.; Lindberg, L. J.

1987-01-01

The strength retention of ceramic materials during extended high-temperature cyclic exposure is critical to their widespread application in gas turbine engines. During a continuing NASA funded program initated in 1979, reaction bonded silicon nitride (RBSN), sintered silicon carbide (SSC), reaction sintered silicon carbide (RSSC), and sintered silicon nitride (SSN) materials were evaluated following simulated gas turbine engine exposures. Exposures were performed by cycling specimens five times per hour between a high velocity burner discharge and a rapid air quench. The retained flexural strengths were determined following up to 3500 hours of exposure at temperatures up to 1370 C. Post-exposure strengths have been correlated with fractography and surface examination using SEM. Results illustrate excellent strength retention of SSC materials after 3500 hours of exposure to 1370 C. At 1200 C, RBSN and RSSC also demonstrate significant strength retention. Although SSN materials typically suffer significant strength losses during exposures at 1200 C, a new composition, which has improved high-temperature strength, also shows improved durability. In the majority of the materials, strength loss is typically associated with flaw formation in the protective SiO2 layer.

Rapid Prototyping: State of the Art

DTIC Science & Technology

2003-10-23

Rapid Prototyping SCS Solid Creation System SLM Selective Laser Melting SLP Solid Laser diode Plotter SLS Selective Laser Sintering SOAR State of the...121,000, respectively. SLP stands for Sold Laser Diode Plotter. The machines are relatively slow and parts are small, so, to date, the products have been...Gigerenzer, H., “Directed Laser Welding of Metal Matrix Composite Structures for Space Based Applications,“ Triton Systems Inc., Chelmsford, MA., 1

Investigation of Anisotropic Bonded Magnets in Permanent Magnet Machine Applications

NASA Astrophysics Data System (ADS)

Khazdozian, H. A.; McCall, S. K.; Kramer, M. J.; Paranthaman, M. P.; Nlebedim, I. C.

Rare earth elements (REE) provide the high energy product necessary for permanent magnets, such as sintered Nd2Fe14B, in many applications like wind energy generators. However, REEs are considered critical materials due to risk in their supply. To reduce the use of critical materials in permanent magnet machines, the performance of anisotropic bonded NdFeB magnets, aligned under varying magnetic field strength, was simulated using 3D finite element analysis in a 3MW direct-drive permanent magnet generator (DDPMG), with sintered N42 magnets used as a baseline for comparison. For direct substitution of the anisotropic bonded magnets, approximately 85% of the efficiency of the baseline model was achieved, irrespective of the alignment field. The torque and power generation of the DDPMG was not found to vary significantly with increase in the alignment field. Finally, design changes were studied to allow for the achievement of rated torque and power with the use of anisotropic bonded magnets, demonstrating the potential for reduction of critical materials in permanent magnets for renewable energy applications. This work was supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office.

A study on the development of engineering plastic piston used in the shock absorber

NASA Astrophysics Data System (ADS)

Kim, Young-Ho; Bae, Won-Byong; Lim, Dong-Ju; Suh, Yun-Soo

1998-08-01

A piston is an important component of the shock absorber which determines comfortable riding and handling. Conventional piston is made of metal powder that is pressed in a mold, and then sintered at high temperatures below the melting point before machining processes such as drilling, sizing and teflon banding. This study aims at cutting down cost and weight, and improving the process by replacing the traditional sintering process used for manufacturing the shock absorber with the injection molding process adopting engineering plastics as raw material. To analyze the injection molding process, we used the commercial program, MOLDFLOW, and obtained an optimal combination of the process parameters. In addition, by comparing the engineering plastic piston with the metal powder piston through the formability and the performance experiments, we confirmed the availability of this alternative process suggested.

Machining of Molybdenum by EDM-EP and EDC Processes

NASA Astrophysics Data System (ADS)

Wu, K. L.; Chen, H. J.; Lee, H. M.; Lo, J. S.

2017-12-01

Molybdenum metal (Mo) can be machined with conventional tools and equipment, however, its refractory propertytends to chip when being machined. In this study, the nonconventional processes of electrical discharge machining (EDM) and electro-polishing (EP) have been conducted to investigate the machining of Mo metal and fabrication of Mo grid. Satisfactory surface quality was obtained using appropriate EDM parameters of Ip ≦ 3A and Ton < 80μs at a constant pulse interval of 100μs. The finished Mometal has accomplished by selecting appropriate EP parameters such as electrolyte flow rate of 0.42m/s under EP voltage of 50V and flush time of 20 sec to remove the recast layer and craters on the surface of Mo metal. The surface roughness of machined Mo metal can be improved from Ra of 0.93μm (Rmax = 8.51μm) to 0.23μm (Rmax = 1.48μm). Machined Mo metal surface, when used as grid component in electron gun, needs to be modified by coating materials with high work function, such as silicon carbide (SiC). The main purpose of this study is to explore the electrical discharge coating (EDC) process for coating the SiC layer on EDMed Mo metal. Experimental results proved that the appropriate parameters of Ip = 5A and Ton = 50μs at Toff = 10μs can obtain the deposit with about 60μm thickness. The major phase of deposit on machined Mo surface was SiC ceramic, while the minor phases included MoSi2 and/or SiO2 with the presence of free Si due to improper discharging parameters and the use of silicone oil as the dielectric fluid.

Tribological behaviour and statistical experimental design of sintered iron-copper based composites

NASA Astrophysics Data System (ADS)

Popescu, Ileana Nicoleta; Ghiţă, Constantin; Bratu, Vasile; Palacios Navarro, Guillermo

2013-11-01

The sintered iron-copper based composites for automotive brake pads have a complex composite composition and should have good physical, mechanical and tribological characteristics. In this paper, we obtained frictional composites by Powder Metallurgy (P/M) technique and we have characterized them by microstructural and tribological point of view. The morphology of raw powders was determined by SEM and the surfaces of obtained sintered friction materials were analyzed by ESEM, EDS elemental and compo-images analyses. One lot of samples were tested on a "pin-on-disc" type wear machine under dry sliding conditions, at applied load between 3.5 and 11.5 × 10-1 MPa and 12.5 and 16.9 m/s relative speed in braking point at constant temperature. The other lot of samples were tested on an inertial test stand according to a methodology simulating the real conditions of dry friction, at a contact pressure of 2.5-3 MPa, at 300-1200 rpm. The most important characteristics required for sintered friction materials are high and stable friction coefficient during breaking and also, for high durability in service, must have: low wear, high corrosion resistance, high thermal conductivity, mechanical resistance and thermal stability at elevated temperature. Because of the tribological characteristics importance (wear rate and friction coefficient) of sintered iron-copper based composites, we predicted the tribological behaviour through statistical analysis. For the first lot of samples, the response variables Yi (represented by the wear rate and friction coefficient) have been correlated with x1 and x2 (the code value of applied load and relative speed in braking points, respectively) using a linear factorial design approach. We obtained brake friction materials with improved wear resistance characteristics and high and stable friction coefficients. It has been shown, through experimental data and obtained linear regression equations, that the sintered composites wear rate increases with increasing applied load and relative speed, but in the same conditions, the frictional coefficients slowly decrease.

The Fabrication of All-Solid-State Lithium-Ion Batteries via Spark Plasma Sintering

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

Wei, Xialu; Rechtin, Jack; Olevsky, Eugene

Spark plasma sintering (SPS) has been successfully used to produce all-solid-state lithium-ion batteries (ASSLibs). Both regular and functionally graded electrodes are implemented into novel three-layer and five-layer battery designs together with solid-state composite electrolyte. The electrical capacities and the conductivities of the SPS-processed ASSLibs are evaluated using the galvanostatic charge-discharge test. Experimental results have shown that, compared to the three-layer battery, the five-layer battery is able to improve energy and power densities. Scanning electron microscopy (SEM) is employed to examine the microstructures of the batteries especially at the electrode–electrolyte interfaces. It reveals that the functionally graded structure can eliminate themore » delamination effect at the electrode–electrolyte interface and, therefore, retains better performance.« less

The Fabrication of All-Solid-State Lithium-Ion Batteries via Spark Plasma Sintering

DOE PAGES

Wei, Xialu; Rechtin, Jack; Olevsky, Eugene

2017-09-14

Spark plasma sintering (SPS) has been successfully used to produce all-solid-state lithium-ion batteries (ASSLibs). Both regular and functionally graded electrodes are implemented into novel three-layer and five-layer battery designs together with solid-state composite electrolyte. The electrical capacities and the conductivities of the SPS-processed ASSLibs are evaluated using the galvanostatic charge-discharge test. Experimental results have shown that, compared to the three-layer battery, the five-layer battery is able to improve energy and power densities. Scanning electron microscopy (SEM) is employed to examine the microstructures of the batteries especially at the electrode–electrolyte interfaces. It reveals that the functionally graded structure can eliminate themore » delamination effect at the electrode–electrolyte interface and, therefore, retains better performance.« less

Examination of redirected continuous miner scrubber discharge configurations for exhaust face ventilation systems

PubMed Central

Organiscak, J.A.; Beck, T.W.

2015-01-01

The U.S. National Institute for Occupational Safety and Health (NIOSH) Office of Mine Safety and Health Research (OMSHR) has recently studied several redirected scrubber discharge configurations in its full-scale continuous miner gallery for both dust and gas control when using an exhaust face ventilation system. Dust and gas measurements around the continuous mining machine in the laboratory showed that the conventional scrubber discharge directed outby the face with a 12.2-m (40-ft) exhaust curtain setback appeared to be one of the better configurations for controlling dust and gas. Redirecting all the air toward the face equally up both sides of the machine increased the dust and gas concentrations around the machine. When all of the air was redirected toward the face on the off-curtain side of the machine, gas accumulations tended to be reduced at the face, at the expense of increased dust levels in the return and on the curtain side of the mining machine. A 6.1-m (20-ft) exhaust curtain setback without the scrubber operating resulted in the lowest dust levels around the continuous mining machine, but this configuration resulted in some of the highest levels of dust in the return and gas on the off-curtain side of the mining face. Two field studies showed some similarities to the laboratory findings, with elevated dust levels at the rear corners of the continuous miner when all of the scrubber exhaust was redirected toward the face either up the off-tubing side or equally up both sides of the mining machine. PMID:26251566

SpikeGUI: software for rapid interictal discharge annotation via template matching and online machine learning.

PubMed

Jing Jin; Dauwels, Justin; Cash, Sydney; Westover, M Brandon

2014-01-01

Detection of interictal discharges is a key element of interpreting EEGs during the diagnosis and management of epilepsy. Because interpretation of clinical EEG data is time-intensive and reliant on experts who are in short supply, there is a great need for automated spike detectors. However, attempts to develop general-purpose spike detectors have so far been severely limited by a lack of expert-annotated data. Huge databases of interictal discharges are therefore in great demand for the development of general-purpose detectors. Detailed manual annotation of interictal discharges is time consuming, which severely limits the willingness of experts to participate. To address such problems, a graphical user interface "SpikeGUI" was developed in our work for the purposes of EEG viewing and rapid interictal discharge annotation. "SpikeGUI" substantially speeds up the task of annotating interictal discharges using a custom-built algorithm based on a combination of template matching and online machine learning techniques. While the algorithm is currently tailored to annotation of interictal epileptiform discharges, it can easily be generalized to other waveforms and signal types.

SpikeGUI: Software for Rapid Interictal Discharge Annotation via Template Matching and Online Machine Learning

PubMed Central

Jin, Jing; Dauwels, Justin; Cash, Sydney; Westover, M. Brandon

2015-01-01

Detection of interictal discharges is a key element of interpreting EEGs during the diagnosis and management of epilepsy. Because interpretation of clinical EEG data is time-intensive and reliant on experts who are in short supply, there is a great need for automated spike detectors. However, attempts to develop general-purpose spike detectors have so far been severely limited by a lack of expert-annotated data. Huge databases of interictal discharges are therefore in great demand for the development of general-purpose detectors. Detailed manual annotation of interictal discharges is time consuming, which severely limits the willingness of experts to participate. To address such problems, a graphical user interface “SpikeGUI” was developed in our work for the purposes of EEG viewing and rapid interictal discharge annotation. “SpikeGUI” substantially speeds up the task of annotating interictal discharges using a custom-built algorithm based on a combination of template matching and online machine learning techniques. While the algorithm is currently tailored to annotation of interictal epileptiform discharges, it can easily be generalized to other waveforms and signal types. PMID:25570976

Performance of laser sintered Ti-6Al-4V implants with bone-inspired porosity and micro/nanoscale surface roughness in the rabbit femur

PubMed Central

Cohen, David J.; Cheng, Alice; Sahingur, Kaan; Clohessy, Ryan M.; Hopkins, Louis B.; Boyan, Barbara D.; Schwartz, Zvi

2018-01-01

Long term success of bone-interfacing implants remains a challenge in compromised patients and in areas of low bone quality. While surface roughness at the micro/nanoscale can promote osteogenesis, macro-scale porosity is important for promoting mechanical stability of the implant over time. Currently, machining techniques permit pores to be placed throughout the implant, but the pores are generally uniform in dimension. The advent of laser sintering provides a way to design and manufacture implants with specific porosity and variable dimensions at high resolution. This approach enables production of metal implants that mimic complex geometries found in biology. In this study, we used a rabbit femur model to compare osseointegration of laser sintered solid and porous implants. Ti-6Al-4V implants were laser sintered in a clinically relevant size and shape. One set of implants had a novel porosity based on human trabecular bone; both sets had grit-blasted/acid-etched surfaces. After characterization, implants were inserted transaxially into rabbit femora; mechanical testing, microCT and histomorphometry were conducted 10 weeks postoperatively. There were no differences in pull-out strength or bone-to-implant contact. However, both microCT and histomorphometry showed significantly higher new bone volume for porous compared to solid implants. Bone growth was observed into porous implant pores, especially near apical portions of the implant interfacing with cortical bone. These results show that laser sintered Ti-6Al-4V implants with micro/nanoscale surface roughness and trabecular bone-inspired porosity promote bone growth and may be used as a superior alternative to solid implants for bone-interfacing implants. PMID:28452335

Performance of laser sintered Ti-6Al-4V implants with bone-inspired porosity and micro/nanoscale surface roughness in the rabbit femur.

PubMed

Cohen, David J; Cheng, Alice; Sahingur, Kaan; Clohessy, Ryan M; Hopkins, Louis B; Boyan, Barbara D; Schwartz, Zvi

2017-04-28

Long term success of bone-interfacing implants remains a challenge in compromised patients and in areas of low bone quality. While surface roughness at the micro/nanoscale can promote osteogenesis, macro-scale porosity is important for promoting mechanical stability of the implant over time. Currently, machining techniques permit pores to be placed throughout the implant, but the pores are generally uniform in dimension. The advent of laser sintering provides a way to design and manufacture implants with specific porosity and variable dimensions at high resolution. This approach enables production of metal implants that mimic complex geometries found in biology. In this study, we used a rabbit femur model to compare osseointegration of laser sintered solid and porous implants. Ti-6Al-4V implants were laser sintered in a clinically relevant size and shape. One set of implants had a novel porosity based on human trabecular bone; both sets had grit-blasted/acid-etched surfaces. After characterization, implants were inserted transaxially into rabbit femora; mechanical testing, micro-computed tomography (microCT) and histomorphometry were conducted 10 weeks post-operatively. There were no differences in pull-out strength or bone-to-implant contact. However, both microCT and histomorphometry showed significantly higher new bone volume for porous compared to solid implants. Bone growth was observed into porous implant pores, especially near apical portions of the implant interfacing with cortical bone. These results show that laser sintered Ti-6Al-4V implants with micro/nanoscale surface roughness and trabecular bone-inspired porosity promote bone growth and may be used as a superior alternative to solid implants for bone-interfacing implants.

Servo scanning 3D micro EDM for array micro cavities using on-machine fabricated tool electrodes

NASA Astrophysics Data System (ADS)

Tong, Hao; Li, Yong; Zhang, Long

2018-02-01

Array micro cavities are useful in many fields including in micro molds, optical devices, biochips and so on. Array servo scanning micro electro discharge machining (EDM), using array micro electrodes with simple cross-sectional shape, has the advantage of machining complex 3D micro cavities in batches. In this paper, the machining errors caused by offline-fabricated array micro electrodes are analyzed in particular, and then a machining process of array servo scanning micro EDM is proposed by using on-machine fabricated array micro electrodes. The array micro electrodes are fabricated on-machine by combined procedures including wire electro discharge grinding, array reverse copying and electrode end trimming. Nine-array tool electrodes with Φ80 µm diameter and 600 µm length are obtained. Furthermore, the proposed process is verified by several machining experiments for achieving nine-array hexagonal micro cavities with top side length of 300 µm, bottom side length of 150 µm, and depth of 112 µm or 120 µm. In the experiments, a chip hump accumulates on the electrode tips like the built-up edge in mechanical machining under the conditions of brass workpieces, copper electrodes and the dielectric of deionized water. The accumulated hump can be avoided by replacing the water dielectric by an oil dielectric.

High magnetic-refrigeration performance of plate-shaped La{sub 0.5}Pr{sub 0.5}Fe{sub 11.4}Si{sub 1.6} hydrides sintered in high-pressure H{sub 2} atmosphere

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

Sun, N. K., E-mail: naikunsun@163.com; Guo, J.; Zhao, X. G., E-mail: xgzhao@imr.ac.cn

2015-03-02

La(Fe, Si){sub 13} hydride is regarded as one of the most promising room-temperature refrigerants. However, to use the alloys in an active magnetic regenerator machine, it is vital to prepare thin refrigerants. In this work, a high H{sub 2} gas pressure of 50 MPa was employed to suppress the desorption of hydrogen atoms during the sintering process of plate-shaped La{sub 0.5}Pr{sub 0.5}Fe{sub 11.4}Si{sub 1.6} hydrides. At 330 K, a high-density sintered thin plate shows a large magnetic-entropy change ΔS{sub m} of 15.5 J/kg K (106 mJ/cm{sup 3 }K) for a field change of 2 T. The volumetric ΔS{sub m} is almost twice as large as that ofmore » bonded La(Fe,Si){sub 13} hydrides. Favorably, hysteresis is almost absent due to the existence of micropores with a porosity of 0.69% which has been analyzed with high-resolution X-ray microtomography.« less

Influence of Wire Electrical Discharge Machining (WEDM) process parameters on surface roughness

NASA Astrophysics Data System (ADS)

Yeakub Ali, Mohammad; Banu, Asfana; Abu Bakar, Mazilah

2018-01-01

In obtaining the best quality of engineering components, the quality of machined parts surface plays an important role. It improves the fatigue strength, wear resistance, and corrosion of workpiece. This paper investigates the effects of wire electrical discharge machining (WEDM) process parameters on surface roughness of stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The parameters selected are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical model was developed for the estimation of surface roughness. The analysis revealed that off time has a major influence on surface roughness. The optimum machining parameters for minimum surface roughness were found to be at a 10 V open voltage, 2.84 μs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap.

CFD analysis on gas distribution for different scrubber redirection configurations in sump cut.

PubMed

Zheng, Y; Organiscak, J A; Zhou, L; Beck, T W; Rider, J P

2015-01-01

The National Institute for Occupational Safety and Health's Office of Mine Safety and Health Research recently developed a series of models using computational fluid dynamics (CFD) to study the gas distribution around a continuous mining machine with various fan-powered flooded bed scrubber discharge configurations. CFD models using Species Transport Model without reactions in FLUENT were constructed to evaluate the redirection of scrubber discharge toward the mining face rather than behind the return curtain. The following scenarios are considered in this study: 100 percent of the discharge redirected back toward the face on the off-curtain side of the continuous miner; 100 percent of the discharge redirected back toward the face, but divided equally to both sides of the machine; and 15 percent of the discharge redirected toward the face on the off-curtain side of the machine, with 85 percent directed into the return. These models were compared against a model with a conventional scrubber discharge, where air is directed away from the face into the return. The CFD models were calibrated and validated based on experimental data and accurately predicted sulfur hexafluoride (SF 6 ) gas levels at four gas monitoring locations. One additional prediction model was simulated to consider a different scrubber discharge angle for the 100 percent redirected, equally divided case. These models identified relatively high gassy areas around the continuous miner, which may not warrant their use in coal mines with medium to high methane liberation rates. This paper describes the methodology used to develop the CFD models, and the validation of the models based on experimental data.

MRR and TWR evaluation on electrical discharge machining of Ti-6Al-4V using tungsten : copper composite electrode

NASA Astrophysics Data System (ADS)

Prasanna, J.; Rajamanickam, S.; Amith Kumar, O.; Karthick Raj, G.; Sathya Narayanan, P. V. V.

2017-05-01

In this paper Ti-6Al-4V used as workpiece material and it is keenly seen in variety of field including medical, chemical, marine, automotive, aerospace, aviation, electronic industries, nuclear reactor, consumer products etc., The conventional machining of Ti-6Al-4V is very difficult due to its distinctive properties. The Electrical Discharge Machining (EDM) is right choice of machining this material. The tungsten copper composite material is employed as tool material. The gap voltage, peak current, pulse on time and duty factor is considered as the machining parameter to analyze the machining characteristics Material Removal Rate (MRR) and Tool Wear Rate (TWR). The Taguchi method is provided to work for finding the significant parameter of EDM. It is found that for MRR significant parameters rated in the following order Gap Voltage, Pulse On-Time, Peak Current and Duty Factor. On the other hand for TWR significant parameters are listed in line of Gap Voltage, Duty Factor, Peak Current and Pulse On-Time.

Laser-Sintered Constructs with Bio-inspired Porosity and Surface Micro/Nano-Roughness Enhance Mesenchymal Stem Cell Differentiation and Matrix Mineralization In Vitro.

PubMed

Cheng, Alice; Cohen, David J; Boyan, Barbara D; Schwartz, Zvi

2016-12-01

Direct metal laser sintering can produce porous Ti-6Al-4V orthopedic and dental implants. The process requires reduced resources and time and can provide greater structural control than machine manufacturing. Implants in bone are colonized by mesenchymal stem cells (MSCs), which can differentiate into osteoblasts and contribute to osseointegration. This study examined osteoblast differentiation and matrix mineralization of human MSCs cultured on laser-sintered Ti-6Al-4V constructs with varying porosity and at different time scales. 2D solid disks and low, medium and high porosity (LP, MP, and HP) 3D constructs based on a human trabecular bone template were laser sintered from Ti-6Al-4V powder and further processed to have micro- and nanoscale roughness. hMSCs exhibited greater osteoblastic differentiation and local factor production on all 3D porous constructs compared to 2D surfaces, which was sustained for 9 days without use of exogenous factors. hMSCs cultured for 8 weeks on MP constructs in osteogenic medium (OM), OM supplemented with BMP2 or collagen-coated MP constructs in OM exhibited bone-like extracellular matrix mineralization. Use of bio-inspired porosity for the 3D architecture of additively manufactured Ti-6Al-4V enhanced osteogenic differentiation of hMSCs beyond surface roughness alone. This study suggests that a 3D architecture may enhance the osseointegration of orthopedic and dental implants in vivo.

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.

Fabrication of 13-93 bioactive glass scaffolds for bone tissue engineering using indirect selective laser sintering.

PubMed

Kolan, Krishna C R; Leu, Ming C; Hilmas, Gregory E; Brown, Roger F; Velez, Mariano

2011-06-01

Bioactive glasses are promising materials for bone scaffolds due to their ability to assist in tissue regeneration. When implanted in vivo, bioactive glasses can convert into hydroxyapatite, the main mineral constituent of human bone, and form a strong bond with the surrounding tissues, thus providing an advantage over polymer scaffold materials. Bone scaffold fabrication using additive manufacturing techniques can provide control over pore interconnectivity during fabrication of the scaffold, which helps in mimicking human trabecular bone. 13-93 glass, a third-generation bioactive material designed to accelerate the body's natural ability to heal itself, was used in the research described herein to fabricate bone scaffolds using the selective laser sintering (SLS) process. 13-93 glass mixed with stearic acid (as the polymer binder) by ball milling was used as the powder feedstock for the SLS machine. The fabricated green scaffolds underwent binder burnout to remove the stearic acid binder and were then sintered at temperatures between 675 °C and 695 °C. The sintered scaffolds had pore sizes ranging from 300 to 800 µm with 50% apparent porosity and an average compressive strength of 20.4 MPa, which is excellent for non-load bearing applications and among the highest reported for an interconnected porous scaffold fabricated with bioactive glasses using the SLS process. The MTT labeling experiment and measurements of MTT formazan formation are evidence that the rough surface of SLS scaffolds provides a cell-friendly surface capable of supporting robust cell growth.

Influence of electrical resistivity and machining parameters on electrical discharge machining performance of engineering ceramics.

PubMed

Ji, Renjie; Liu, Yonghong; Diao, Ruiqiang; Xu, Chenchen; Li, Xiaopeng; Cai, Baoping; Zhang, Yanzhen

2014-01-01

Engineering ceramics have been widely used in modern industry for their excellent physical and mechanical properties, and they are difficult to machine owing to their high hardness and brittleness. Electrical discharge machining (EDM) is the appropriate process for machining engineering ceramics provided they are electrically conducting. However, the electrical resistivity of the popular engineering ceramics is higher, and there has been no research on the relationship between the EDM parameters and the electrical resistivity of the engineering ceramics. This paper investigates the effects of the electrical resistivity and EDM parameters such as tool polarity, pulse interval, and electrode material, on the ZnO/Al2O3 ceramic's EDM performance, in terms of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The results show that the electrical resistivity and the EDM parameters have the great influence on the EDM performance. The ZnO/Al2O3 ceramic with the electrical resistivity up to 3410 Ω·cm can be effectively machined by EDM with the copper electrode, the negative tool polarity, and the shorter pulse interval. Under most machining conditions, the MRR increases, and the SR decreases with the decrease of electrical resistivity. Moreover, the tool polarity, and pulse interval affect the EWR, respectively, and the electrical resistivity and electrode material have a combined effect on the EWR. Furthermore, the EDM performance of ZnO/Al2O3 ceramic with the electrical resistivity higher than 687 Ω·cm is obviously different from that with the electrical resistivity lower than 687 Ω·cm, when the electrode material changes. The microstructure character analysis of the machined ZnO/Al2O3 ceramic surface shows that the ZnO/Al2O3 ceramic is removed by melting, evaporation and thermal spalling, and the material from the working fluid and the graphite electrode can transfer to the workpiece surface during electrical discharge machining ZnO/Al2O3 ceramic.

Powder Metallurgy Fabrication of Molybdenum Accelerator Target Disks

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

Lowden, Richard Andrew; Kiggans Jr., James O.; Nunn, Stephen D.

2015-07-01

Powder metallurgy approaches for the fabrication of accelerator target disks are being examined to support the development of Mo-99 production by NorthStar Medical Technologies, LLC. An advantage of powder metallurgy is that very little material is wasted and, at present, dense, quality parts are routinely produced from molybdenum powder. The proposed targets, however, are thin wafers, 29 mm in diameter with a thickness of 0.5 mm, with very stringent dimensional tolerances. Although tooling can be machined to very high tolerance levels, the operations of powder feed, pressing and sintering involve complicated mechanisms, each of which affects green density and shrinkage,more » and therefore the dimensions and shape of the final product. Combinations of powder morphology, lubricants and pressing technique have been explored to produce target disks with minimal variations in thickness and little or no distortion. In addition, sintering conditions that produce densities for optimum target dissolvability are being determined.« less

A microstructure-based model for shape distortion during liquid phase sintering

NASA Astrophysics Data System (ADS)

Upadhyaya, Anish

Tight dimensional control is a major concern in consolidation of alloys via liquid phase sintering. This research demonstrates the role of microstructure in controlling the bulk dimensional changes that occur during liquid phase sintering. The dimensional changes were measured using a coordinate measuring machine and also on a real-time basis using in situ video imaging. To quantify compact distortion, a distortion parameter is formulated which takes into consideration the compact distortion in radial as well as axial directions. The microstructural attributes considered in this study are as follows: solid content, dihedral angle, grain size, grain contiguity and connectivity, and solid-solubility. Sintering experiments were conducted with the W-Ni-Cu, W-Ni-Fe, Mo-Ni-Cu, and Fe-Cu systems. The alloy systems and the compositions were selected to give a range of microstructures during liquid phase sintering. The results show that distortion correlates with the measured microstructural attributes. Systems containing a high solid content, high grain coordination number and contiguity, and large dihedral angle have more structural rigidity. The results show that a minimum two-dimensional grain coordination number of 3.0 is necessary for shape preservation. Based on the experimental observations, a model is derived that relates the critical solid content required for maintaining structural rigidity to the dihedral angle. The critical solid content decreases with an increasing dihedral angle. Consequently, W-Cu alloys, which have a dihedral angle of about 95sp°, can be consolidated without gross distortion with as little as 20 vol.% solid. To comprehensively understand the gravitational effects in the evolution of both the microstructure and the macrostructure during liquid phase sintering, W-Ni-Fe alloys with W content varying from 78 to 93 wt.% were sintered in microgravity. Compositions that slump during ground-based sintering also distort when sintered under microgravity. In ground-based sintering, low solid content alloys distort with a typical elephant-foot profile, while in microgravity, the compacts tend to spheroidize. This study shows that microstructural segregation occurs in both ground-based as well as microgravity sintering. In ground-based experiments, because of the density difference between the solid and the liquid phase, the solid content increases from top to the bottom of the sample. In microgravity, the solid content increases from periphery to the center of the samples. A model is derived to show that grain agglomeration and segregation are energetically favored events and will therefore be inherent to the system, even in the absence of gravity. Real time distortion measurement in alloys having appreciable solid-solubility in the liquid phase, such as W-Ni-Fe and Fe-Cu, show that the bulk of distortion occur within the first 5 min of melt formation. Distortion in such systems can be minimized by presaturating the matrix with the solid phase.

Design and Development of an Engineering Prototype Compact X-Ray Scanner (FMS 5000)

DTIC Science & Technology

1989-03-31

machined by "wire-EDM" (electro discharge machining ). Three different slice thicknesses can be selected from the scan menu. The set of slice thicknesses...circuit. This type of circuit is used whenever more than ten kilowatts of power are needed by a machine . For example, lathes and milling machines in a... machine shop usually use this type of input power. A three- phase circuit delivers power more efficiently than a single-phase circuit because three

High-intensity fibre laser design for micro-machining applications

NASA Astrophysics Data System (ADS)

Ortiz-Neria, D. I.; Martinez-Piñón, F.; Hernandez-Escamilla, H.; Alvarez-Chavez, J. A.

2010-11-01

This work is focused on the design of a 250W high-intensity continuous-wave fibre optic laser with a 15μm spot size beam and a beam parameter product (BPP) of 1.8 for its use on Laser-assisted Cold Spray process (LCS) in the micro-machining areas. The metal-powder deposition process LCS, is a novel method based on Cold Spray technique (CS) assisted by laser technology. The LCS accelerates metal powders by the use of a high-pressure gas in order to achieve flash welding of particles over substrate. In LCS, the critical velocity of impact is lower with respect with CS while the powder particle is heated before the deposition by a laser beam. Furthermore, LCS does not heat the powder to achieve high temperatures as it happens in plasma processes. This property puts aside cooling problems which normally happen in sintered processes with high oxygen/nitrogen concentration levels. LCS will be used not only in deposition of thin layers. After careful design, proof of concept, experimental data, and prototype development, it should be feasible to perform micro-machining precise work with the use of the highintensity fibre laser presented in this work, and selective deposition of particles, in a similar way to the well-known Direct Metal Laser Sintering process (DMLS). The fibre laser consists on a large-mode area, Yb3+-doped, semi-diffraction limited, 25-m fibre laser cavity, operating in continuous wave regime. The fibre shows an arguably high slope-efficiency with no signs of roll-over. The measured M2 value is 1.8 and doping concentration of 15000ppm. It was made with a slight modification of the traditional MCVD technique. A full optical characterization will be presented.

Characteristics of Partial Discharge and Ozone Generation for Twisted-pair of Enameled Wires under High-repetitive Impulse Voltage Application

NASA Astrophysics Data System (ADS)

Kanazawa, Seiji; Enokizono, Masato; Shibakita, Toshihide; Umehara, Eiji; Toshimitsu, Jun; Ninomiya, Shinji; Taniguchi, Hideki; Abe, Yukari

In recent years, inverter drive machines such as a hybrid vehicle and an electric vehicle are operated under high voltage pulse with high repetition rate. In this case, inverter surge is generated and affected the machine operation. Especially, the enameled wire of a motor is deteriorated due to the partial discharge (PD) and finally breakdown of the wire will occur. In order to investigate a PD on a resistant enameled wire, characteristics of PD in the twisted pair sample under bipolar repetitive impulse voltages are investigated experimentally. The relationship between the applied voltage and discharge current was measured at PD inception and extinction, and we estimated the repetitive PD inception and extinction voltages experimentally. The corresponding optical emission of the discharge was also observed by using an ICCD camera. Furthermore, ozone concentration due to the discharge was measured during the life-time test of the resistant enameled wires from a working environmental point of view.

Long Life Nickel Electrodes for Nickel-Hydrogen Cells: Fiber Substrates Nickel Electrodes

NASA Technical Reports Server (NTRS)

Rogers, Howard H.

2000-01-01

Samples of nickel fiber mat electrodes were investigated over a wide range of fiber diameters, electrode thickness, porosity and active material loading levels. Thickness' were 0.040, 0.060 and 0.080 inches for the plaque: fiber diameters were primarily 2, 4, and 8 micron and porosity was 85, 90, and 95%. Capacities of 3.5 in. diameter electrodes were determined in the flooded condition with both 26 and 31% potassium hydroxide solution. These capacity tests indicated that the highest capacities per unit weight were obtained at the 90% porosity level with a 4 micron diameter fiber plaque. It appeared that the thinner electrodes had somewhat better performance, consistent with sintered electrode history. Limited testing with two-positive-electrode boiler plate cells was also carried out. Considerable difficulty with constructing the cells was encountered with short circuits the major problem. Nevertheless, four cells were tested. The cell with 95% porosity electrodes failed during conditioning cycling due to high voltage during charge. Discharge showed that this cell had lost nearly all of its capacity. The other three cells after 20 conditioning cycles showed capacities consistent with the flooded capacities of the electrodes. Positive electrodes made from fiber substrates may well show a weight advantage of standard sintered electrodes, but need considerably more work to prove this statement. A major problem to be investigated is the lower strength of the substrate compared to standard sintered electrodes. Problems with welding of leads were significant and implications that the electrodes would expand more than sintered electrodes need to be investigated. Loading levels were lower than had been expected based on sintered electrode experiences and the lower loading led to lower capacity values. However, lower loading causes less expansion and contraction during cycling so that stress on the substrate is reduced.

Fundamental studies on initiation and evolution of multi-channel discharges and their application to next generation pulsed power machines.

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

Schwarz, Jens; Savage, Mark E.; Lucero, Diego Jose

Future pulsed power systems may rely on linear transformer driver (LTD) technology. The LTD's will be the building blocks for a driver that can deliver higher current than the Z-Machine. The LTD's would require tens of thousands of low inductance ( %3C 85nH), high voltage (200 kV DC) switches with high reliability and long lifetime ( 10 4 shots). Sandia's Z-Machine employs 36 megavolt class switches that are laser triggered by a single channel discharge. This is feasible for tens of switches but the high inductance and short switch life- time associated with the single channel discharge are undesirable formore » future machines. Thus the fundamental problem is how to lower inductance and losses while increasing switch life- time and reliability. These goals can be achieved by increasing the number of current-carrying channels. The rail gap switch is ideal for this purpose. Although those switches have been extensively studied during the past decades, each effort has only characterized a particular switch. There is no comprehensive understanding of the underlying physics that would allow predictive capability for arbitrary switch geometry. We have studied rail gap switches via an extensive suite of advanced diagnostics in synergy with theoretical physics and advanced modeling capability. Design and topology of multichannel switches as they relate to discharge dynamics are investigated. This involves electrically and optically triggered rail gaps, as well as discrete multi-site switch concepts.« less

INTERIOR VIEW OF FILTER WHEEL MACHINE USED TO FILTER OUT ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

INTERIOR VIEW OF FILTER WHEEL MACHINE USED TO FILTER OUT AND SEPARATE BICARBONATE FROM AMMONIONATED BRINE. DISCHARGE FROM STRIPPER COLUMNS (SOLVAY COLUMNS). - Solvay Process Company, SA Wetside Building, Between Willis & Milton Avenue, Solvay, Onondaga County, NY

Antimicrobial and osteogenic properties of a hydrophilic-modified nanoscale hydroxyapatite coating on titanium.

PubMed

Murakami, Asuka; Arimoto, Takafumi; Suzuki, Dai; Iwai-Yoshida, Misato; Otsuka, Fukunaga; Shibata, Yo; Igarashi, Takeshi; Kamijo, Ryutaro; Miyazaki, Takashi

2012-04-01

Hydroxyapatite (HA)-coated titanium (Ti) is commonly used for implantable medical devices. This study examined in vitro osteoblast gene expression and antimicrobial activity against early and late colonizers of supra-gingival plaque on nanoscale HA-coated Ti prepared by discharge in a physiological buffered solution. The HA-coated Ti surface showed super-hydrophilicity, whereas the densely sintered HA and Ti surfaces alone showed lower hydrophilicity. The sintered HA and HA-coated Ti surfaces enhanced osteoblast phenotypes in comparison with the bare Ti surface. The HA-coated Ti enabled antimicrobial activity against early colonizers of supra-gingival plaques, namely Streptococcus mitis and Streptococcus gordonii. Such antimicrobial activity may be caused by the surface hydrophilicity, thereby leading to a repulsion force between the HA-coated Ti surface and the bacterial cell membranes. On the contrary, the sintered HA sample was susceptible to infection of microorganisms. Thus, hydrophilic-modified HA-coated Ti may have potential for use in implantable medical devices. From the Clinical Editor: This study establishes that Hydroxyapatite (HA)-coated titanium (Ti) surface of implanted devices may result in an optimal microenvironment to control and prevent infections and may have potential future clinical applications. Copyright © 2012 Elsevier Inc. All rights reserved.

Fractal Loop Heat Pipe Performance Comparisons of a Soda Lime Glass and Compressed Carbon Foam Wick

NASA Technical Reports Server (NTRS)

Myre, David; Silk, Eric A.

2014-01-01

This study compares heat flux performance of a Loop Heat Pipe (LHP) wick structure fabricated from compressed carbon foam with that of a wick structure fabricated from sintered soda lime glass. Each wick was used in an LHP containing a fractal based evaporator. The Fractal Loop Heat Pipe (FLHP) was designed and manufactured by Mikros Manufacturing Inc. The compressed carbon foam wick structure was manufactured by ERG Aerospace Inc., and machined to specifications comparable to that of the initial soda lime glass wick structure. Machining of the compressed foam as well as performance testing was conducted at the United States Naval Academy. Performance testing with the sintered soda lime glass wick structures was conducted at NASA Goddard Space Flight Center. Heat input for both wick structures was supplied via cartridge heaters mounted in a copper block. The copper heater block was placed in contact with the FLHP evaporator which had a circular cross-sectional area of 0.88 cm(sup 2). Twice distilled, deionized water was used as the working fluid in both sets of experiments. Thermal performance data was obtained for three different Condenser/Subcooler temperatures under degassed conditions. Both wicks demonstrated comparable heat flux performance with a maximum of 75 W/cm observed for the soda lime glass wick and 70 W /cm(sup 2) for the compressed carbon foam wick.

Study of wire electrical discharge machined folded-up corner cube retroreflector with a tunable cantilever beam

NASA Astrophysics Data System (ADS)

Chen, Yu-Fan; Wang, Yen-Hung; Tsai, Jui-che

2018-03-01

This work has developed an approach to construct a corner cube retroreflector (CCR). A two-dimensional cutout pattern is first fabricated with wire electrical discharge machining process. It is then folded up into a three-dimensional CCR suspended on a cantilever beam. The folded-up CCR may be driven through external actuators for optical modulation; it can also mechanically respond to perturbation, acceleration, etc., to function as a sensor. Mechanical (static and dynamic modeling) and optical (ray tracing) analyses are also performed.

STABILIZED PINCH MACHINE

DOEpatents

Anderson, O.A.

1962-04-24

A device for heating and confining a high temperature gas or plasma utilizing the linear pinch effect is described. The pinch discharge produced is the form of an elongated cylinder. The electrical discharge current is returned in parallel along an axial and a concentric conductor whereby the magnetic field of the conductors compresses and stabilizes the pinch discharge against lateral instability. (AEC)

TOPICAL REVIEW: Electric current activated/assisted sintering (ECAS): a review of patents 1906-2008

NASA Astrophysics Data System (ADS)

Grasso, Salvatore; Sakka, Yoshio; Maizza, Giovanni

2009-10-01

The electric current activated/assisted sintering (ECAS) is an ever growing class of versatile techniques for sintering particulate materials. Despite the tremendous advances over the last two decades in ECASed materials and products there is a lack of comprehensive reviews on ECAS apparatuses and methods. This paper fills the gap by tracing the progress of ECAS technology from 1906 to 2008 and surveys 642 ECAS patents published over more than a century. It is found that the ECAS technology was pioneered by Bloxam (1906 GB Patent No. 9020) who developed the first resistive sintering apparatus. The patents were searched by keywords or by cross-links and were withdrawn from the Japanese Patent Office (342 patents), the United States Patent and Trademark Office (175 patents), the Chinese State Intellectual Property Office of P.R.C. (69 patents) and the World Intellectual Property Organization (12 patents). A subset of 119 (out of 642) ECAS patents on methods and apparatuses was selected and described in detail with respect to their fundamental concepts, physical principles and importance in either present ECAS apparatuses or future ECAS technologies for enhancing efficiency, reliability, repeatability, controllability and productivity. The paper is divided into two parts, the first deals with the basic concepts, features and definitions of basic ECAS and the second analyzes the auxiliary devices/peripherals. The basic ECAS is classified with reference to discharge time (fast and ultrafast ECAS). The fundamental principles and definitions of ECAS are outlined in accordance with the scientific and patent literature.

Method for fabricating ceramic filaments and high density tape casting method

NASA Technical Reports Server (NTRS)

Collins, Jr., Earl R. (Inventor)

1990-01-01

An apparatus and method is disclosed for fabricating mats of ceramic material comprising preparing a slurry of ceramic particles in a binder/solvent, charging the slurry into a vessel, forcing the slurry from the vessel into spinneret nozzles, discharging the slurry from the nozzles into the path of airjets to enhance the sinuous character of the slurry exudate and to dry it, collecting the filaments on a moving belt so that the filaments overlap each other thereby forming a mat, curing the binder therein, compressing and sintering the mat to form a sintered mat, and crushing the sintered mat to produce filament shaped fragments. A process is also disclosed for producing a tape of densely packed, bonded ceramic particles comprising forming a slurry of ceramic particles and a binder/solvent, applying the slurry to a rotating internal molding surface, applying a large centrifugal force to the slurry to compress it and force excess binder/solvent from the particles, evaporating solvent and curing the binder thereby forming layers of bonded ceramic particles and cured binder, and separating the binder layer from the layer of particles. Multilayers of ceramic particles are cast in an analogous manner on top of previously formed layers. When all of the desired layers have been cast the tape is fired to produce a sintered tape. For example, a three-layer tape is produced having outer layers of highly compressed filament shaped fragments of strontium doped lanthanum (LSM) particles and a center layer of yttria stabilized zicronia (YSZ) particles.

Application of grey-fuzzy approach in parametric optimization of EDM process in machining of MDN 300 steel

NASA Astrophysics Data System (ADS)

Protim Das, Partha; Gupta, P.; Das, S.; Pradhan, B. B.; Chakraborty, S.

2018-01-01

Maraging steel (MDN 300) find its application in many industries as it exhibits high hardness which are very difficult to machine material. Electro discharge machining (EDM) is an extensively popular machining process which can be used in machining of such materials. Optimization of response parameters are essential for effective machining of these materials. Past researchers have already used Taguchi for obtaining the optimal responses of EDM process for this material with responses such as material removal rate (MRR), tool wear rate (TWR), relative wear ratio (RWR), and surface roughness (SR) considering discharge current, pulse on time, pulse off time, arc gap, and duty cycle as process parameters. In this paper, grey relation analysis (GRA) with fuzzy logic is applied to this multi objective optimization problem to check the responses by an implementation of the derived parametric setting. It was found that the parametric setting derived by the proposed method results in better a response than those reported by the past researchers. Obtained results are also verified using the technique for order of preference by similarity to ideal solution (TOPSIS). The predicted result also shows that there is a significant improvement in comparison to the results of past researchers.

Prediction of antiepileptic drug treatment outcomes using machine learning.

PubMed

Colic, Sinisa; Wither, Robert G; Lang, Min; Zhang, Liang; Eubanks, James H; Bardakjian, Berj L

2017-02-01

Antiepileptic drug (AED) treatments produce inconsistent outcomes, often necessitating patients to go through several drug trials until a successful treatment can be found. This study proposes the use of machine learning techniques to predict epilepsy treatment outcomes of commonly used AEDs. Machine learning algorithms were trained and evaluated using features obtained from intracranial electroencephalogram (iEEG) recordings of the epileptiform discharges observed in Mecp2-deficient mouse model of the Rett Syndrome. Previous work have linked the presence of cross-frequency coupling (I CFC ) of the delta (2-5 Hz) rhythm with the fast ripple (400-600 Hz) rhythm in epileptiform discharges. Using the I CFC to label post-treatment outcomes we compared support vector machines (SVMs) and random forest (RF) machine learning classifiers for providing likelihood scores of successful treatment outcomes. (a) There was heterogeneity in AED treatment outcomes, (b) machine learning techniques could be used to rank the efficacy of AEDs by estimating likelihood scores for successful treatment outcome, (c) I CFC features yielded the most effective a priori identification of appropriate AED treatment, and (d) both classifiers performed comparably. Machine learning approaches yielded predictions of successful drug treatment outcomes which in turn could reduce the burdens of drug trials and lead to substantial improvements in patient quality of life.

Prediction of antiepileptic drug treatment outcomes using machine learning

NASA Astrophysics Data System (ADS)

Colic, Sinisa; Wither, Robert G.; Lang, Min; Zhang, Liang; Eubanks, James H.; Bardakjian, Berj L.

2017-02-01

Objective. Antiepileptic drug (AED) treatments produce inconsistent outcomes, often necessitating patients to go through several drug trials until a successful treatment can be found. This study proposes the use of machine learning techniques to predict epilepsy treatment outcomes of commonly used AEDs. Approach. Machine learning algorithms were trained and evaluated using features obtained from intracranial electroencephalogram (iEEG) recordings of the epileptiform discharges observed in Mecp2-deficient mouse model of the Rett Syndrome. Previous work have linked the presence of cross-frequency coupling (I CFC) of the delta (2-5 Hz) rhythm with the fast ripple (400-600 Hz) rhythm in epileptiform discharges. Using the I CFC to label post-treatment outcomes we compared support vector machines (SVMs) and random forest (RF) machine learning classifiers for providing likelihood scores of successful treatment outcomes. Main results. (a) There was heterogeneity in AED treatment outcomes, (b) machine learning techniques could be used to rank the efficacy of AEDs by estimating likelihood scores for successful treatment outcome, (c) I CFC features yielded the most effective a priori identification of appropriate AED treatment, and (d) both classifiers performed comparably. Significance. Machine learning approaches yielded predictions of successful drug treatment outcomes which in turn could reduce the burdens of drug trials and lead to substantial improvements in patient quality of life.

Melt-Pool Temperature and Size Measurement During Direct Laser Sintering

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

List, III, Frederick Alyious; Dinwiddie, Ralph Barton; Carver, Keith

2017-08-01

Additive manufacturing has demonstrated the ability to fabricate complex geometries and components not possible with conventional casting and machining. In many cases, industry has demonstrated the ability to fabricate complex geometries with improved efficiency and performance. However, qualification and certification of processes is challenging, leaving companies to focus on certification of material though design allowable based approaches. This significantly reduces the business case for additive manufacturing. Therefore, real time monitoring of the melt pool can be used to detect the development of flaws, such as porosity or un-sintered powder and aid in the certification process. Characteristics of the melt poolmore » in the Direct Laser Sintering (DLS) process is also of great interest to modelers who are developing simulation models needed to improve and perfect the DLS process. Such models could provide a means to rapidly develop the optimum processing parameters for new alloy powders and optimize processing parameters for specific part geometries. Stratonics’ ThermaViz system will be integrated with the Renishaw DLS system in order to demonstrate its ability to measure melt pool size, shape and temperature. These results will be compared with data from an existing IR camera to determine the best approach for the determination of these critical parameters.« less

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

Nandwana, Peeyush; Elliott, Amy M.; Siddel, Derek

Traditional manufacturing of Inconel 718 components from castings and thermomechanical processing routes involve extensive post processing and machining to attain the desired geometry. Additive manufacturing (AM) technologies including direct energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM) and binder jet 3D printing (BJ3DP) can minimize scrap generation and reduce lead times. While there is extensive literature on the use of melting and solidification based AM technologies, there has been limited research on the use of binder jet 3D printing. In this paper, a brief review on binder jet additive manufacturing of Inconel 718 is presented. In addition,more » existing knowledge on sintering of Inconel 718 has been extended to binder jet 3D printing. We found that supersolidus liquid phase sintering (SLPS) is necessary to achieve full densification of Inconel 718. SLPS is sensitive to the feedstock chemistry that has a strong influence on the liquid volume fraction at the processing temperature. Based on these results, we discuss an empirical framework to determine the role of powder particle size and liquid volume fraction on sintering kinetics. In conclusion, the role of powder packing factor and binder saturation on microstructural evolution is discussed. The current challenges in the use of BJ3DP for fabrication of Inconel 718, as well as, extension to other metal systems, are presented.« less

Vertical misfit of laser-sintered and vacuum-cast implant-supported crown copings luted with definitive and temporary luting agents

PubMed Central

Sánchez-Turrión, Andrés; López-Lozano, José F.; Albaladejo, Alberto; Torres-Lagares, Daniel; Montero, Javier; Suárez-García, Maria J.

2012-01-01

Objectives. This study aimed to evaluate the vertical discrepancy of implant-supported crown structures constructed with vacuum-casting and Direct Metal Laser Sintering (DMLS) technologies, and luted with different cement types. Study Design. Crown copings were fabricated using: (1) direct metal laser sintered Co-Cr (LS); (2) vacuum-cast Co-Cr (CC); and (3) vacuum-cast Ti (CT). Frameworks were luted onto machined implant abutments under constant seating pressure. Each alloy group was randomly divided into 5 subgroups (n = 10 each) according to the cement system utilized: Subgroup 1 (KC) used resin-modified glass-ionomer Ketac Cem Plus; Subgroup 2 (PF) used Panavia F 2.0 dual-cure resin cement; Subgroup 3 (RXU) used RelyX Unicem 2 Automix self-adhesive dual-cure resin cement; Subgroup 4 (PIC) used acrylic/urethane-based temporary Premier Implant Cement; and Subgroup 5 (DT) used acrylic/urethane-based temporary DentoTemp cement. Vertical misfit was measured by scanning electron microscopy (SEM). Two-way ANOVA and Student-Newman-Keuls tests were run to investigate the effect of alloy/fabrication technique, and cement type on vertical misfit. The statistical significance was set at α = 0.05. Results. The alloy/manufacturing technique and the luting cement affected the vertical discrepancy (p < 0.001). For each cement type, LS samples exhibited the best fit (p < 0.01) whereas CC and CT frames were statistically similar. Within each alloy group, PF and RXU provided comparably greater discrepancies than KC, PIC, and DT, which showed no differences. Conclusions. Laser sintering may be an alternative to vacuum-casting of base metals to obtain passive-fitting implant-supported crown copings. The best marginal adaptation corresponded to laser sintered structures luted with glass-ionomer KC, or temporary PIC or DT cements. The highest discrepancies were recorded for Co-Cr and Ti cast frameworks bonded with PF or RXU resinous agents. All groups were within the clinically acceptable misfit range. Key words:Dental alloy, laser sintering, implant-supported prostheses, vertical discrepancy, vertical misfit. PMID:22322524

Measurement of J-integral in CAD/CAM dental ceramics and composite resin by digital image correlation.

PubMed

Jiang, Yanxia; Akkus, Anna; Roperto, Renato; Akkus, Ozan; Li, Bo; Lang, Lisa; Teich, Sorin

2016-09-01

Ceramic and composite resin blocks for CAD/CAM machining of dental restorations are becoming more common. The sample sizes affordable by these blocks are smaller than ideal for stress intensity factor (SIF) based tests. The J-integral measurement calls for full field strain measurement, making it challenging to conduct. Accordingly, the J-integral values of dental restoration materials used in CAD/CAM restorations have not been reported to date. Digital image correlation (DIC) provides full field strain maps, making it possible to calculate the J-integral value. The aim of this study was to measure the J-integral value for CAD/CAM restorative materials. Four types of materials (sintered IPS E-MAX CAD, non-sintered IPS E-MAX CAD, Vita Mark II and Paradigm MZ100) were used to prepare beam samples for three-point bending tests. J-integrals were calculated for different integral path size and locations with respect to the crack tip. J-integral at path 1 for each material was 1.26±0.31×10(-4)MPam for MZ 100, 0.59±0.28×10(-4)MPam for sintered E-MAX, 0.19±0.07×10(-4)MPam for VM II, and 0.21±0.05×10(-4)MPam for non-sintered E-MAX. There were no significant differences between different integral path size, except for the non-sintered E-MAX group. J-integral paths of non-sintered E-MAX located within 42% of the height of the sample provided consistent values whereas outside this range resulted in lower J-integral values. Moreover, no significant difference was found among different integral path locations. The critical SIF was calculated from J-integral (KJ) along with geometry derived SIF values (KI). KI values were comparable with KJ and geometry based SIF values obtained from literature. Therefore, DIC derived J-integral is a reliable way to assess the fracture toughness of small sized specimens for dental CAD/CAM restorative materials; however, with caution applied to the selection of J-integral path. Copyright © 2016 Elsevier Ltd. All rights reserved.

Study of the Productivity and Surface Quality of Hybrid EDM

NASA Astrophysics Data System (ADS)

Wankhade, Sandeepkumar Haribhau; Sharma, Sunil Bansilal

2016-01-01

The development of new, advanced engineering materials and the need for precise prototypes and low-volume production have made the electric discharge machining (EDM), an important manufacturing process to meet such demands. It is capable of machining geometrically complex and hard material components, that are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides etc. Conversely the low MRR limits its productivity. Abrasive water jet machine (AJM) tools are quick to setup and offer quick turn-around on the machine and could make parts out of virtually any material. They do not heat the material hence no heat affected zone and can make any intricate shape easily. The main advantages are flexibility, low heat production and ability to machine hard and brittle materials. Main disadvantages comprise the process produces a tapered cut and health hazards due to dry abrasives. To overcome the limitations and exploit the best of each of above processes; an attempt has been made to hybridize the processes of AJM and EDM. The appropriate abrasives routed with compressed air through the hollow electrode to construct the hybrid process i.e., abrasive jet electric discharge machining (AJEDM), the high speed abrasives could impinge on the machined surface to remove the recast layer caused by EDM process. The main process parameters were varied to explore their effects and experimental results show that AJEDM enhances the machining efficiency with better surface finish hence can fit the requirements of modern manufacturing applications.

INTERIOR VIEW FROM CATWALKS LOOKING DOWN ON FILTER WHEEL MACHINES. ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

INTERIOR VIEW FROM CATWALKS LOOKING DOWN ON FILTER WHEEL MACHINES. USED TO FILTER OUT AND SEPARATE BICARBONATE FROM AMMONIONATED BRINE. DISCHARGE FROM STRIPPER COLUMNS (SOLVAY COLUMNS). - Solvay Process Company, SA Wetside Building, Between Willis & Milton Avenue, Solvay, Onondaga County, NY

3500-hour durability testing of ceramic materials for automotive gas turbine engines

NASA Technical Reports Server (NTRS)

Carruthers, W. D.; Richerson, D. W.; Benn, K. W.

1980-01-01

A two-year durability program was performed by AiResearch Phoenix to evaluate four commercially available ceramic materials under simulated automotive gas turbine combustor discharge conditions. These conditions included extended cyclic thermal exposures up to 2500 F and 3500 hr. The four materials selected for evaluation were Norton NCX-34 hot pressed silicon nitride, AiResearch RBN 101 reaction bonded silicon nitride, Carborundum pressureless sintered alpha-SiC and Pure Carbon Co. (British Nuclear Fuels, Ltd.) Refel reaction sintered silicon carbide. These materials were initially exposed to 350 hr/1750 cycles at 1200 and 1370 C. Subsequent exposures to 1050, 2100 and 3500 hr were performed on those materials maintaining 50% of baseline strength after the initial exposure. Additional evaluations of exposed bars included dimensional and weight changes, dye penetrant, specific damping capacity changes, SEM fractography, and X-ray diffraction.

Synergistic responses of superficial chemistry and micro topography of titanium created by wire-type electric discharge machining.

PubMed

Kataoka, Yu; Tamaki, Yukimichi; Miyazaki, Takashi

2011-01-01

Wire-type electric discharge machining has been applied to the manufacture of endosseous titanium implants as this computer associated technique allows extremely accurate complex sample shaping with an optimal micro textured surface during the processing. Since the titanium oxide layer is sensitively altered by each processing, the authors hypothesized that this technique also up-regulates biological responses through the synergistic effects of the superficial chemistry and micro topography. To evaluate the respective in vitro cellular responses on the superficial chemistry and micro topography of titanium surface processed by wire-type electric discharge, we used titanium-coated epoxy resin replica of the surface. An oxide layer on the titanium surface processed by wire-type electric discharge activated the initial responses of osteoblastic cells through an integrin-mediated mechanism. Since the mRNA expression of ALP on those replicas was up-regulated compared to smooth titanium samples, the micro topography of a titanium surface processed by wire-type electric discharge promotes the osteogenic potential of cells. The synergistic response of the superficial chemistry and micro topography of titanium processed by wire-type electric discharge was demonstrated in this study.

Influence of Electrical Resistivity and Machining Parameters on Electrical Discharge Machining Performance of Engineering Ceramics

PubMed Central

Ji, Renjie; Liu, Yonghong; Diao, Ruiqiang; Xu, Chenchen; Li, Xiaopeng; Cai, Baoping; Zhang, Yanzhen

2014-01-01

Engineering ceramics have been widely used in modern industry for their excellent physical and mechanical properties, and they are difficult to machine owing to their high hardness and brittleness. Electrical discharge machining (EDM) is the appropriate process for machining engineering ceramics provided they are electrically conducting. However, the electrical resistivity of the popular engineering ceramics is higher, and there has been no research on the relationship between the EDM parameters and the electrical resistivity of the engineering ceramics. This paper investigates the effects of the electrical resistivity and EDM parameters such as tool polarity, pulse interval, and electrode material, on the ZnO/Al2O3 ceramic's EDM performance, in terms of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The results show that the electrical resistivity and the EDM parameters have the great influence on the EDM performance. The ZnO/Al2O3 ceramic with the electrical resistivity up to 3410 Ω·cm can be effectively machined by EDM with the copper electrode, the negative tool polarity, and the shorter pulse interval. Under most machining conditions, the MRR increases, and the SR decreases with the decrease of electrical resistivity. Moreover, the tool polarity, and pulse interval affect the EWR, respectively, and the electrical resistivity and electrode material have a combined effect on the EWR. Furthermore, the EDM performance of ZnO/Al2O3 ceramic with the electrical resistivity higher than 687 Ω·cm is obviously different from that with the electrical resistivity lower than 687 Ω·cm, when the electrode material changes. The microstructure character analysis of the machined ZnO/Al2O3 ceramic surface shows that the ZnO/Al2O3 ceramic is removed by melting, evaporation and thermal spalling, and the material from the working fluid and the graphite electrode can transfer to the workpiece surface during electrical discharge machining ZnO/Al2O3 ceramic. PMID:25364912

Effects of Laser Treatment on the Bond Strength of Differently Sintered Zirconia Ceramics.

PubMed

Dede, Doğu Ömür; Yenisey, Murat; Rona, Nergiz; Öngöz Dede, Figen

2016-07-01

The purpose of this study was to investigate the effects of carbon dioxide (CO2) and Erbium-doped yttrium aluminum garnet (Er:YAG) laser irradiations on the shear bond strength (SBS) of differently sintered zirconia ceramics to resin cement. Eighty zirconia specimens were prepared, sintered in two different periods (short = Ss, long = Ls), and divided into four treatment groups (n = 10 each). These groups were (a) untreated (control), (b) Er:YAG laser irradiated with 6 W power for 5 sec, (c) CO2 laser with 2 W power for 10 sec, (d) CO2 laser with 4 W power for 10 sec. Scanning electron microscope (SEM) images were recorded for each of the eight groups. Eighty composite resin discs (3 × 3 mm) were fabricated and cemented with an adhesive resin cement to ceramic specimens. The SBS test was performed after specimens were stored in water for 24 h by an universal testing machine at a crosshead speed of 1 mm/min. Data were statistically analyzed with two way analysis of variance (ANOVA) and Tukey honest significant difference (HSD) test (α = 0.05). According to the ANOVA, the sintering time, surface treatments and their interaction were statistically significant (p < 0.05). Although each of the laser-irradiated groups were significantly higher than the control groups, there was no statistically significant difference among them (p > 0.05). Variation in sintering time from 2.5 to 5.0 h may have influenced the SBS of Yttrium-stabilized tetragonal zirconia polycrystalline (Y-TZP) ceramics. Although CO2 and Er:YAG laser irradiation techniques may increase the SBS values of both tested zirconia ceramics, they are recommended for clinicians as an alternative pretreatment method.

Vertical misfit of laser-sintered and vacuum-cast implant-supported crown copings luted with definitive and temporary luting agents.

PubMed

Castillo-de-Oyagüe, Raquel; Sánchez-Turrión, Andrés; López-Lozano, José-Francisco; Albaladejo, Alberto; Torres-Lagares, Daniel; Montero, Javier; Suárez-García, Maria-Jesús

2012-07-01

This study aimed to evaluate the vertical discrepancy of implant-supported crown structures constructed with vacuum-casting and Direct Metal Laser Sintering (DMLS) technologies, and luted with different cement types. Crown copings were fabricated using: (1) direct metal laser sintered Co-Cr (LS); (2) vacuum-cast Co-Cr (CC); and (3) vacuum-cast Ti (CT). Frameworks were luted onto machined implant abutments under constant seating pressure. Each alloy group was randomly divided into 5 subgroups (n = 10 each) according to the cement system utilized: Subgroup 1 (KC) used resin-modified glass-ionomer Ketac Cem Plus; Subgroup 2 (PF) used Panavia F 2.0 dual-cure resin cement; Subgroup 3 (RXU) used RelyX Unicem 2 Automix self-adhesive dual-cure resin cement; Subgroup 4 (PIC) used acrylic/urethane-based temporary Premier Implant Cement; and Subgroup 5 (DT) used acrylic/urethane-based temporary DentoTemp cement. Vertical misfit was measured by scanning electron microscopy (SEM). Two-way ANOVA and Student-Newman-Keuls tests were run to investigate the effect of alloy/fabrication technique, and cement type on vertical misfit. The statistical significance was set at α = 0.05. The alloy/manufacturing technique and the luting cement affected the vertical discrepancy (p < 0.001). For each cement type, LS samples exhibited the best fit (p < 0.01) whereas CC and CT frames were statistically similar. Within each alloy group, PF and RXU provided comparably greater discrepancies than KC, PIC, and DT, which showed no differences. Laser sintering may be an alternative to vacuum-casting of base metals to obtain passive-fitting implant-supported crown copings. The best marginal adaptation corresponded to laser sintered structures luted with glass-ionomer KC, or temporary PIC or DT cements. The highest discrepancies were recorded for Co-Cr and Ti cast frameworks bonded with PF or RXU resinous agents. All groups were within the clinically acceptable misfit range.

ENVIRONMENTALLY CONSCIOUS ELECTROCHEMICAL MACHINING FOR ZERO DISCHARGE AND METAL RECYCLING - PHASE I

EPA Science Inventory

Seminar for High School Students “Practice on Manufacturing Technology by Advanced Machine Tools”

NASA Astrophysics Data System (ADS)

Marui, Etsuo; Yamawaki, Masao; Taga, Yuken; Omoto, Ken'ichi; Miyaji, Reiji; Ogura, Takahiro; Tsubata, Yoko; Sakai, Toshimasa

The seminar ‘Practice on Manufacturing Technology by Advanced Machine Tools’ for high school students was held at the supporting center for technology education of Gifu University, under the sponsorship of the Japan Society of Mechanical Engineers. This seminar was held, hoping that many students become interested in manufacturing through the experience of the seminar. Operating CNC milling machine and CNC wire-cut electric discharge machine, they made original nameplates. Participants made the program to control CNC machine tools themselves. In this report, some valuable results obtained through such experience are explained.

Optical-Fiber-Welding Machine

NASA Technical Reports Server (NTRS)

Goss, W. C.; Mann, W. A.; Goldstein, R.

1985-01-01

Technique yields joints with average transmissivity of 91.6 percent. Electric arc passed over butted fiber ends to melt them together. Maximum optical transmissivity of joint achieved with optimum choice of discharge current, translation speed, and axial compression of fibers. Practical welding machine enables delicate and tedious joining operation performed routinely.

Electric current activated/assisted sintering (ECAS): a review of patents 1906–2008

PubMed Central

Grasso, Salvatore; Sakka, Yoshio; Maizza, Giovanni

2009-01-01

The electric current activated/assisted sintering (ECAS) is an ever growing class of versatile techniques for sintering particulate materials. Despite the tremendous advances over the last two decades in ECASed materials and products there is a lack of comprehensive reviews on ECAS apparatuses and methods. This paper fills the gap by tracing the progress of ECAS technology from 1906 to 2008 and surveys 642 ECAS patents published over more than a century. It is found that the ECAS technology was pioneered by Bloxam (1906 GB Patent No. 9020) who developed the first resistive sintering apparatus. The patents were searched by keywords or by cross-links and were withdrawn from the Japanese Patent Office (342 patents), the United States Patent and Trademark Office (175 patents), the Chinese State Intellectual Property Office of P.R.C. (69 patents) and the World Intellectual Property Organization (12 patents). A subset of 119 (out of 642) ECAS patents on methods and apparatuses was selected and described in detail with respect to their fundamental concepts, physical principles and importance in either present ECAS apparatuses or future ECAS technologies for enhancing efficiency, reliability, repeatability, controllability and productivity. The paper is divided into two parts, the first deals with the basic concepts, features and definitions of basic ECAS and the second analyzes the auxiliary devices/peripherals. The basic ECAS is classified with reference to discharge time (fast and ultrafast ECAS). The fundamental principles and definitions of ECAS are outlined in accordance with the scientific and patent literature. PMID:27877308

Conductive ink print on PA66 gear for manufacturing condition monitoring sensors

NASA Astrophysics Data System (ADS)

Futagawa, Shintaro; Iba, Daisuke; Kamimoto, Takahiro; Nakamura, Morimasa; Miura, Nanako; Iizuka, Takashi; Masuda, Arata; Sone, Akira; Moriwaki, Ichiro

2018-03-01

Failures detection of rotating machine elements, such as gears, is an important issue. The purpose of this study was to try to solve this issue by printing conductive ink on gears to manufacture condition-monitoring sensors. In this work, three types of crack detection sensor were designed and the sprayed conductive ink was directly sintered on polyimide (PI) - coated polyamide (PA) 66 gears by laser. The result showed that it was possible to produce narrow circuit lines of the conductive ink including Ag by laser sintering technique and the complex shape sensors on the lateral side of the PA66 gears, module 1.0 mm and tooth number 48. A preliminary operation test was carried out for investigation of the function of the sensors. As a result of the test, the sensors printed in this work should be effective for detecting cracks at tooth root of the gears and will allow for the development of better equipment and detection techniques for health monitoring of gears.

Mercury mass flow in iron and steel production process and its implications for mercury emission control.

PubMed

Wang, Fengyang; Wang, Shuxiao; Zhang, Lei; Yang, Hai; Gao, Wei; Wu, Qingru; Hao, Jiming

2016-05-01

The iron and steel production process is one of the predominant anthropogenic sources of atmospheric mercury emissions worldwide. In this study, field tests were conducted to study mercury emission characteristics and mass flows at two iron and steel plants in China. It was found that low-sulfur flue gas from sintering machines could contribute up to 41% of the total atmospheric mercury emissions, and desulfurization devices could remarkably help reduce the emissions. Coal gas burning accounted for 17%-49% of the total mercury emissions, and therefore the mercury control of coal gas burning, specifically for the power plant burning coal gas to generate electricity, was significantly important. The emissions from limestone and dolomite production and electric furnaces can contribute 29.3% and 4.2% of the total mercury emissions from iron and steel production. More attention should be paid to mercury emissions from these two processes. Blast furnace dust accounted for 27%-36% of the total mercury output for the whole iron and steel production process. The recycling of blast furnace dust could greatly increase the atmospheric mercury emissions and should not be conducted. The mercury emission factors for the coke oven, sintering machine and blast furnace were 0.039-0.047gHg/ton steel, and for the electric furnace it was 0.021gHg/ton steel. The predominant emission species was oxidized mercury, accounting for 59%-73% of total mercury emissions to air. Copyright © 2016. Published by Elsevier B.V.

Drilling Precise Orifices and Slots

NASA Technical Reports Server (NTRS)

Richards, C. W.; Seidler, J. E.

1983-01-01

Reaction control thrustor injector requires precisely machined orifices and slots. Tooling setup consists of rotary table, numerical control system and torque sensitive drill press. Components used to drill oxidizer orifices. Electric discharge machine drills fuel-feed orifices. Device automates production of identical parts so several are completed in less time than previously.

Additive manufacturing technology (direct metal laser sintering) as a novel approach to fabricate functionally graded titanium implants: preliminary investigation of fabrication parameters.

PubMed

Lin, Wei-Shao; Starr, Thomas L; Harris, Bryan T; Zandinejad, Amirali; Morton, Dean

2013-01-01

This article describes the preliminary findings of the mechanical properties of functionally graded titanium with controlled distribution of porosity and a reduced Young's modulus on the basis of a computeraided design (CAD) file, using the rapid-prototyping, direct metal laser sintering (DMLS) technique. Sixty specimens of Ti-6Al-4V were created using a DMLS machine (M270) following the standard for tensile testing of metals. One group was fabricated with only 170 W of laser energy to create fully dense specimens (control group). The remaining specimens all featured an outer fully dense "skin" layer and a partially sintered porous inner "core" region. The outer "skin" of each specimen was scanned at 170 W and set at a thickness of 0.35, 1.00, or 1.50 mm for different specimen groups. The inner "core" of each specimen was scanned at a lower laser power (43 or 85 W). The partially sintered core was clearly visible in all specimens, with somewhat greater porosity with the lower laser power. However, the amount of porosity in the core region was not related to the laser power alone; thinner skin layers resulted in higher porosity for the same power values in the core structure. The lowest Young's modulus achieved, 35 GPa, is close to that of bone and was achieved with a laser power of 43 W and a skin thickness of 0.35 mm, producing a core that comprised 74% of the total volume. Additive manufacturing technology may provide an efficient alternative way to fabricate customized dental implants based on a CAD file with a functionally graded structure that may minimize stress shielding and improve the long-term performance of dental implants.

Novel hydrophilic nanostructured microtexture on direct metal laser sintered Ti-6Al-4V surfaces enhances osteoblast response in vitro and osseointegration in a rabbit model.

PubMed

Hyzy, Sharon L; Cheng, Alice; Cohen, David J; Yatzkaier, Gustavo; Whitehead, Alexander J; Clohessy, Ryan M; Gittens, Rolando A; Boyan, Barbara D; Schwartz, Zvi

2016-08-01

The purpose of this study was to compare the biological effects in vivo of hierarchical surface roughness on laser sintered titanium-aluminum-vanadium (Ti-6Al-4V) implants to those of conventionally machined implants on osteoblast response in vitro and osseointegration. Laser sintered disks were fabricated to have micro-/nano-roughness and wettability. Control disks were computer numerical control (CNC) milled and then polished to be smooth (CNC-M). Laser sintered disks were polished smooth (LST-M), grit blasted (LST-B), or blasted and acid etched (LST-BE). LST-BE implants or implants manufactured by CNC milling and grit blasted (CNC-B) were implanted in the femurs of male New Zealand white rabbits. Most osteoblast differentiation markers and local factors were enhanced on rough LST-B and LST-BE surfaces in comparison to smooth CNC-M or LST-M surfaces for MG63 and normal human osteoblast cells. To determine if LST-BE implants were osteogenic in vivo, we compared them to implant surfaces used clinically. LST-BE implants had a unique surface with combined micro-/nano-roughness and higher wettability than conventional CNC-B implants. Histomorphometric analysis demonstrated a significant improvement in cortical bone-implant contact of LST-BE implants compared to CNC-B implants after 3 and 6 weeks. However, mechanical testing revealed no differences between implant pullout forces at those time points. LST surfaces enhanced osteoblast differentiation and production of local factors in vitro and improved the osseointegration process in vivo. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 104A: 2086-2098, 2016. © 2016 Wiley Periodicals, Inc.

Effect of fabrication process on physical and mechanical properties of tungsten carbide - cobalt composite: A review

NASA Astrophysics Data System (ADS)

Mahaidin, Ahmad Aswad; Jaafar, Talib Ria; Selamat, Mohd Asri; Budin, Salina; Sulaiman, Zaim Syazwan; Hamid, Mohamad Hasnan Abdul

2017-12-01

WC-Co, which is also known as cemented carbide, is widely used in metal cutting industry and wear related application due to their excellent mechanical properties. Manufacturing industries are focusing on improving productivity and reducing operational cost with machining operation is considered as one of the factors. Thus, machining conditions are becoming more severe and required better cutting tool bit with improved mechanical properties to withstand high temperature operation. Numerous studies have been made over the generation for further improvement of cemented carbide properties to meet the constant increase in demand. However, the results of these studies vary due to different process parameters and manufacturing technology. This paper summarizes the studies to improve the properties of WC-Co composite using different consolidation (powder size, mixing method, formulation, etc) and sintering parameters (temperature, time, atmosphere, etc).

Hollow - cathode electrode for high-power, high-pressure discharge devices

DOEpatents

Chang, Jim J.; Alger, Terry W.

1995-01-01

Several different cold cathode configurations for a gas discharge device each having a plurality of grooves of selected spacing, depth and width to improve the emission of electrons in a gas discharge device. Each of the cold cathode configurations can be machined from a single piece of a selected material. Several of the configurations can be assembled with individual elements which is easily seen from the various figures.

Carbon Coating Of Copper By Arc-Discharge Pyrolysis

NASA Technical Reports Server (NTRS)

Ebihara, Ben T.; Jopek, Stanley

1988-01-01

Adherent, abrasion-resistant coat deposited with existing equipment. Carbon formed and deposited as coating on copper substrate by pyrolysis of hydrocarbon oil in electrical-arc discharges. Technique for producing carbon deposits on copper accomplished with electrical-discharge-machining equipment used for cutting metals. Applications for new coating technique include the following: solar-energy-collecting devices, coating of metals other than copper with carbon, and carburization of metal surfaces.

Powder bed binder jet 3D printing of Inconel 718: Densification, microstructural evolution and challenges

DOE PAGES

Nandwana, Peeyush; Elliott, Amy M.; Siddel, Derek; ...

2017-01-03

Traditional manufacturing of Inconel 718 components from castings and thermomechanical processing routes involve extensive post processing and machining to attain the desired geometry. Additive manufacturing (AM) technologies including direct energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM) and binder jet 3D printing (BJ3DP) can minimize scrap generation and reduce lead times. While there is extensive literature on the use of melting and solidification based AM technologies, there has been limited research on the use of binder jet 3D printing. In this paper, a brief review on binder jet additive manufacturing of Inconel 718 is presented. In addition,more » existing knowledge on sintering of Inconel 718 has been extended to binder jet 3D printing. We found that supersolidus liquid phase sintering (SLPS) is necessary to achieve full densification of Inconel 718. SLPS is sensitive to the feedstock chemistry that has a strong influence on the liquid volume fraction at the processing temperature. Based on these results, we discuss an empirical framework to determine the role of powder particle size and liquid volume fraction on sintering kinetics. In conclusion, the role of powder packing factor and binder saturation on microstructural evolution is discussed. The current challenges in the use of BJ3DP for fabrication of Inconel 718, as well as, extension to other metal systems, are presented.« less

Dense garnet-like Li5La3Nb2O12 solid electrolyte prepared by self-consolidation method

NASA Astrophysics Data System (ADS)

Zhao, Pengcheng; Xiang, Yu; Xu, Yan; Wen, Yuehua; Zhang, Wenfeng; Zhu, Xiayu; Li, Meng; Zhang, Sontong; Ming, Hai; Jin, Zhaoqing; Cao, Gaoping

2018-06-01

Li5La3Nb2O12 (LLNO) is a typical garnet-like solid electrolyte with solitary cubic structure. However, its ionic conductivity is relatively low due to the low relative density when prepared by cold isostatic pressing method, which usually involves high-pressure machines, poor productivity, tedious pressing operations, and low density. In this paper, self-consolidation method is developed to sinter dense LLNO electrolyte. Although not any pressing operations are employed in the entire process, the relative density of LLNO is promoted up to 95%, which is much higher than the reported values of 45-80%. SEM images reveal that the sample is built by huge particles in size of 80 μm indicating that there are few boundaries in the sample. Moreover, a rich content of Li-Al-O compounds is detected out in the boundary areas, which may act as sintering aids for the sample to consolidate automatically. According to the highest density, the bulk ionic conductivity of LLNO sample reaches up to 1.61 × 10-4 S cm-1 at 30 °C, which is in the same order of magnitude as the value of cubic Li7La3Zr2O12 electrolyte. This work verifies the self-consolidation mechanism for the sintering of ceramic electrolytes and could significantly facilitate the development of LLNO membrane technology.

Microstructure and Mechanical Behaviors of Titanium Matrix Composites Containing In Situ Whiskers Synthesized via Plasma Activated Sintering.

PubMed

Sun, Yi; Zhang, Jian; Luo, Guoqiang; Shen, Qiang; Zhang, Lianmeng

2018-04-02

In this paper, titanium matrix composites with in situ TiB whiskers were synthesized by the plasma activated sintering technique; crystalline boron and amorphous boron were used as reactants for in situ reactions, respectively. The influence of the sintering process and the crystallography type of boron on the microstructure and mechanical properties of composites were studied and compared. The densities were evaluated using Archimedes' principle. The microstructure and mechanical properties were characterized by SEM, XRD, EBSD, TEM, a universal testing machine, and a Vickers hardness tester. The prepared composite material showed a high density and excellent comprehensive performance under the PAS condition of 20 MPa at 1000 °C for 3 min. Amorphous boron had a higher reaction efficiency than crystalline boron, and it completely reacted with the titanium matrix to generate TiB whiskers, while there was still a certain amount of residual crystalline boron combining well with the titanium matrix at 1100 °C. The composite samples with a relative density of 98.33%, Vickers hardness of 389.75 HV, compression yield strength of up to 1190 MPa, and an ultimate compressive strength of up to 1710 MPa were obtained. Compared with the matrix material, the compressive strength of TC4 titanium alloy containing crystalline boron and amorphous boron was increased by 7.64% and 15.50%, respectively.

Microstructure and Mechanical Behaviors of Titanium Matrix Composites Containing In Situ Whiskers Synthesized via Plasma Activated Sintering

PubMed Central

Luo, Guoqiang; Shen, Qiang; Zhang, Lianmeng

2018-01-01

In this paper, titanium matrix composites with in situ TiB whiskers were synthesized by the plasma activated sintering technique; crystalline boron and amorphous boron were used as reactants for in situ reactions, respectively. The influence of the sintering process and the crystallography type of boron on the microstructure and mechanical properties of composites were studied and compared. The densities were evaluated using Archimedes’ principle. The microstructure and mechanical properties were characterized by SEM, XRD, EBSD, TEM, a universal testing machine, and a Vickers hardness tester. The prepared composite material showed a high density and excellent comprehensive performance under the PAS condition of 20 MPa at 1000 °C for 3 min. Amorphous boron had a higher reaction efficiency than crystalline boron, and it completely reacted with the titanium matrix to generate TiB whiskers, while there was still a certain amount of residual crystalline boron combining well with the titanium matrix at 1100 °C. The composite samples with a relative density of 98.33%, Vickers hardness of 389.75 HV, compression yield strength of up to 1190 MPa, and an ultimate compressive strength of up to 1710 MPa were obtained. Compared with the matrix material, the compressive strength of TC4 titanium alloy containing crystalline boron and amorphous boron was increased by 7.64% and 15.50%, respectively. PMID:29614842

Dispensing of high concentration Ag nano-particles ink for ultra-low resistivity paper-based writing electronics.

PubMed

Wang, Fuliang; Mao, Peng; He, Hu

2016-02-17

Paper-based writing electronics has received a lot of interest recently due to its potential applications in flexible electronics. To obtain ultra-low resistivity paper-based writing electronics, we developed a kind of ink with high concentration of Ag Nano-particles (up to 80 wt%), as well as a related dispensing writing system consisting an air compressor machine and a dispenser. Additionally, we also demonstrated the writability and practical application of our proposed ink and writing system. Based on the study on the effect of sintering time and pressure, we found the optimal sintering time and pressure to obtain high quality Ag NPs wires. The electrical conductivity of nano-silver paper-based electronics has been tested using the calculated resistivity. After hot-pressure sintering at 120 °C, 25 MPa pressure for 20 minutes, the resistivity of silver NPs conductive tracks was 3.92 × 10(-8) (Ωm), only 2.45 times of bulk silver. The mechanical flexibility of nano-silver paper-based electronics also has been tested. After 1000 bending cycles, the resistivity slightly increased from the initial 4.01 × 10(-8) to 5.08 × 10(-8) (Ωm). With this proposed ink preparation and writing system, a kind of paper-based writing electronics with ultra-low resistivity and good mechanical flexibility was achieved.

Biocompatibility assessment of spark plasma-sintered alumina-titanium cermets.

PubMed

Guzman, Rodrigo; Fernandez-García, Elisa; Gutierrez-Gonzalez, Carlos F; Fernandez, Adolfo; Lopez-Lacomba, Jose Luis; Lopez-Esteban, Sonia

2016-01-01

Alumina-titanium materials (cermets) of enhanced mechanical properties have been lately developed. In this work, physical properties such as electrical conductivity and the crystalline phases in the bulk material are evaluated. As these new cermets manufactured by spark plasma sintering may have potential application for hard tissue replacements, their biocompatibility needs to be evaluated. Thus, this research aims to study the cytocompatibility of a novel alumina-titanium (25 vol. % Ti) cermet compared to its pure counterpart, the spark plasma sintered alumina. The influence of the particular surface properties (chemical composition, roughness and wettability) on the pre-osteoblastic cell response is also analyzed. The material electrical resistance revealed that this cermet may be machined to any shape by electroerosion. The investigated specimens had a slightly undulated topography, with a roughness pattern that had similar morphology in all orientations (isotropic roughness) and a sub-micrometric average roughness. Differences in skewness that implied valley-like structures in the cermet and predominance of peaks in alumina were found. The cermet presented a higher surface hydrophilicity than alumina. Any cytotoxicity risk associated with the new materials or with the innovative manufacturing methodology was rejected. Proliferation and early-differentiation stages of osteoblasts were statistically improved on the composite. Thus, our results suggest that this new multifunctional cermet could improve current alumina-based biomedical devices for applications such as hip joint replacements. © The Author(s) 2015.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining.

PubMed

Ramulu, M; Spaulding, Mathew

2016-09-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application.

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

PubMed Central

Ramulu, M.; Spaulding, Mathew

2016-01-01

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application. PMID:28773866

Development of Experimental Setup of Metal Rapid Prototyping Machine using Selective Laser Sintering Technique

NASA Astrophysics Data System (ADS)

Patil, S. N.; Mulay, A. V.; Ahuja, B. B.

2018-04-01

Unlike in the traditional manufacturing processes, additive manufacturing as rapid prototyping, allows designers to produce parts that were previously considered too complex to make economically. The shift is taking place from plastic prototype to fully functional metallic parts by direct deposition of metallic powders as produced parts can be directly used for desired purpose. This work is directed towards the development of experimental setup of metal rapid prototyping machine using selective laser sintering and studies the various parameters, which plays important role in the metal rapid prototyping using SLS technique. The machine structure in mainly divided into three main categories namely, (1) Z-movement of bed and table, (2) X-Y movement arrangement for LASER movements and (3) feeder mechanism. Z-movement of bed is controlled by using lead screw, bevel gear pair and stepper motor, which will maintain the accuracy of layer thickness. X-Y movements are controlled using timing belt and stepper motors for precise movements of LASER source. Feeder mechanism is then developed to control uniformity of layer thickness metal powder. Simultaneously, the study is carried out for selection of material. Various types of metal powders can be used for metal RP as Single metal powder, mixture of two metals powder, and combination of metal and polymer powder. Conclusion leads to use of mixture of two metals powder to minimize the problems such as, balling effect and porosity. Developed System can be validated by conducting various experiments on manufactured part to check mechanical and metallurgical properties. After studying the results of these experiments, various process parameters as LASER properties (as power, speed etc.), and material properties (as grain size and structure etc.) will be optimized. This work is mainly focused on the design and development of cost effective experimental setup of metal rapid prototyping using SLS technique which will gives the feel of metal rapid prototyping process and its important parameters.

Synthesizing Aluminum Particles Towards Controlling Electrostatic Discharge Ignition Sensitivity

DTIC Science & Technology

2014-01-01

composite energetic materials, Combust. Flame 160 (May 2013) 2279 2281. [10] J. Granier, M. Pantoya, Laser ignition of nanocomposite thermites , Combust...Reactive sintering: an important component in the combustion of nanocomposite thermites , Combust. Flame 159 (1) (Jan. 2012) 2 15. [12] B. Dikici, M.L...Pantoya, V. Levitas, The effect of pre-heating on flame propa- gation behavior in nanocomposite thermites , Combust. Flame 157 (8) (2010) 1581 1585. E.S. Collins et al. / Journal of Electrostatics 72 (2014) 28 3232

Development of a lightweight nickel electrode

NASA Technical Reports Server (NTRS)

Britton, D. L.; Reid, M. A.

1984-01-01

Nickel electrodes made using lightweight plastic plaque are about half the weight of electrodes made from state of the art sintered nickel plaque. This weight reduction would result in a significant improvement in the energy density of batteries using nickel electrodes (nickel hydrogen, nickel cadmium and nickel zinc). These lightweight electrodes are suitably conductive and yield comparable capacities (as high as 0.25 AH/gm (0.048 AH/sq cm)) after formation. These lightweight electrodes also show excellent discharge performance at high rates.

Apparatus and process for controlling fluidized beds

DOEpatents

Rehmat, Amirali G.; Patel, Jitendra G.

1985-10-01

An apparatus and process for control and maintenance of fluidized beds under non-steady state conditions. An ash removal conduit is provided for removing solid particulates from a fluidized bed separate from an ash discharge conduit in the lower portion of the grate supporting such a bed. The apparatus and process of this invention is particularly suitable for use in ash agglomerating fluidized beds and provides control of the fluidized bed before ash agglomeration is initiated and during upset conditions resulting in stable, sinter-free fluidized bed maintenance.

Apparatus for controlling fluidized beds

DOEpatents

Rehmat, Amirali G.; Patel, Jitendra G.

1987-05-12

An apparatus and process for control and maintenance of fluidized beds under non-steady state conditions. An ash removal conduit is provided for removing solid particulates from a fluidized bed separate from an ash discharge conduit in the lower portion of the grate supporting such a bed. The apparatus and process of this invention is particularly suitable for use in ash agglomerating fluidized beds and provides control of the fluidized bed before ash agglomeration is initiated and during upset conditions resulting in stable, sinter-free fluidized bed maintenance.

The influence of Span-20 surfactant and micro-/nano-Chromium (Cr) Powder Mixed Electrical Discharge Machining (PMEDM) on the surface characteristics of AISI D2 hardened steel

NASA Astrophysics Data System (ADS)

Hosni, N. A. J.; Lajis, M. A.

2018-04-01

The application of powder mixed dielectric to improve the efficiency of electrical discharge machining (EDM) has been extensively studied. Therefore, PMEDM have attracted the attention of many researchers since last few decades. Improvement in EDM process has resulted in the use of span-20 surfactant and Cr powder mixed in dielectric fluid, which results in increasing machiniability, better surface quality and faster machining time. However, the study of powder suspension size of surface charateristics in EDM field is still limited. This paper presents the improvement of micro-/nano- Cr powder size on the surface characteristics of the AISI D2 hardened steels in PMEDM. It has found that the reacst layer in PMEDM improved by as high as 41-53 % compared to conventional EDM. Also notably, the combination of added Cr powder and span-20 surfactant reduced the recast layer thickness significantly especially in nano-Cr size. This improvement was great potential adding nano-size Cr powder to dielectric for machining performance.

Suspensions on the basis of stabilised zirconium oxide for three-dimensional printing

NASA Astrophysics Data System (ADS)

Sokolov, P. S.; Komissarenko, D. A.; Shmeleva, I. A.; Slyusar, I. V.; Dosovitskiy, G. A.; Evdokimov, P. V.; Putlyaev, V. I.; Dosovitskiy, A. E.

2018-04-01

Present work considers the first results on rheological and photo-curing behaviour of suspension consisting of nanocrystalline stabilised zirconium dioxide powders (19 - 27 vol. %) and a liquid UV-photosensitive organic monomer. At ambient temperature compositions showed a viscosity of 2.5 and 0.8 Pa×s at 10 and 100 s-1 shear rates, respectively. Printability of these compositions was subsequently investigated by using an stereolithography machine Ember (Autodesk). 3D objects were later sintered in a separate furnace into dense translucent ZrO2 ceramics.

Uranium nitride fuel fabrication for SP-100 reactors

NASA Technical Reports Server (NTRS)

Mason, Richard E.; Chidester, Kenneth M.; Hoth, Carl W.; Matthews, Bruce R.

1987-01-01

Fuel pins of uranium mononitride clad in Nb-1 percent Zr were fabricated for irradiation tests in EBR-II. Laboratory scale process parameters to synthesize UN powders and fabricate UN pellets were developed. Uranium mononitride was prepared by converting UO2 to UN. Fuel pellets were prepared by communition of UN briquettes, uniaxial pressing, and high temperature sintering. Techniques for machining, cleaning, and welding Nb-1 percent Zr cladding components were developed. End caps were electron beam welded to the tubing. Helium back-fill holes were sealed with a laser weld.

Study on brush of moving electrode type electrostatic precipitator (MEEP)

NASA Astrophysics Data System (ADS)

Zhao, Haibao; He, Yuzhong; Yao, Yuping

2018-02-01

MEEP was an efficient particle removal technology for coal plant and sintering machine. As the stability of brush in MEEP was relatively poor, the experiments was designed for the brush which was made by 0Cr18Ni9 stainless steel wire to find the failure mode and cause. Combining the results of the experiments, the failure models of brushes were different under different conditions and the brushes were suitable for being used in the condition of small diameter particles. And the life span of brushes can be more than 6 years.

Uranium nitride fuel fabrication for SP-100 reactors

NASA Astrophysics Data System (ADS)

Mason, Richard E.; Chidester, Kenneth M.; Hoth, Carl W.; Matthews, Bruce R.

Fuel pins of uranium mononitride clad in Nb-1 percent Zr were fabricated for irradiation tests in EBR-II. Laboratory scale process parameters to synthesize UN powders and fabricate UN pellets were developed. Uranium mononitride was prepared by converting UO2 to UN. Fuel pellets were prepared by communition of UN briquettes, uniaxial pressing, and high temperature sintering. Techniques for machining, cleaning, and welding Nb-1 percent Zr cladding components were developed. End caps were electron beam welded to the tubing. Helium back-fill holes were sealed with a laser weld.

Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes

PubMed Central

Hsu, Wei-Hsuan; Chien, Wan-Ting

2016-01-01

Titanium alloys have several advantages, such as a high strength-to-weight ratio. However, the machinability of titanium alloys is not as good as its mechanical properties. Many machining processes have been used to fabricate titanium alloys. Among these machining processes, electrical discharge machining (EDM) has the advantage of processing efficiency. EDM is based on thermoelectric energy between a workpiece and an electrode. A pulse discharge occurs in a small gap between the workpiece and electrode. Then, the material from the workpiece is removed through melting and vaporization. However, defects such as cracks and notches are often detected at the boundary of holes fabricated using EDM and the irregular profile of EDM holes reduces product quality. In this study, an innovative method was proposed to estimate the effect of EDM parameters on the surface quality of the holes. The method combining the finite element method and image processing can rapidly evaluate the stress concentration factor of a workpiece. The stress concentration factor was assumed as an index of EDM process performance for estimating the surface quality of EDM holes. In EDM manufacturing processes, Ti-6Al-4V was used as an experimental material and, as process parameters, pulse current and pulse on-time were taken into account. The results showed that finite element simulations can effectively analyze stress concentration in EDM holes. Using high energy during EDM leads to poor hole quality, and the stress concentration factor of a workpiece is correlated to hole quality. The maximum stress concentration factor for an EDM hole was more than four times that for the same diameter of the undamaged hole. PMID:28774078

Effect of Electrical Discharge Machining on Stress Concentration in Titanium Alloy Holes.

PubMed

Hsu, Wei-Hsuan; Chien, Wan-Ting

2016-11-24

Titanium alloys have several advantages, such as a high strength-to-weight ratio. However, the machinability of titanium alloys is not as good as its mechanical properties. Many machining processes have been used to fabricate titanium alloys. Among these machining processes, electrical discharge machining (EDM) has the advantage of processing efficiency. EDM is based on thermoelectric energy between a workpiece and an electrode. A pulse discharge occurs in a small gap between the workpiece and electrode. Then, the material from the workpiece is removed through melting and vaporization. However, defects such as cracks and notches are often detected at the boundary of holes fabricated using EDM and the irregular profile of EDM holes reduces product quality. In this study, an innovative method was proposed to estimate the effect of EDM parameters on the surface quality of the holes. The method combining the finite element method and image processing can rapidly evaluate the stress concentration factor of a workpiece. The stress concentration factor was assumed as an index of EDM process performance for estimating the surface quality of EDM holes. In EDM manufacturing processes, Ti-6Al-4V was used as an experimental material and, as process parameters, pulse current and pulse on-time were taken into account. The results showed that finite element simulations can effectively analyze stress concentration in EDM holes. Using high energy during EDM leads to poor hole quality, and the stress concentration factor of a workpiece is correlated to hole quality. The maximum stress concentration factor for an EDM hole was more than four times that for the same diameter of the undamaged hole.

Lightweight fibrous nickel electrodes for nickel-hydrogen batteries

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1989-01-01

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art sintered nickel electrodes. Lightweight fibrous materials or plaques are used as conductive supports for the nickel hydroxide active material. These materials are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes that pass the initial tests are life cycle-tested in a low Earth orbit regime at 80 percent depth of discharge.

Hollow-cathode electrode for high-power, high-pressure discharge devices

DOEpatents

Chang, J.J.; Alger, T.W.

1995-08-22

Several different cold cathode configurations are disclosed for a gas discharge device each having a plurality of grooves of selected spacing, depth and width to improve the emission of electrons in a gas discharge device. Each of the cold cathode configurations can be machined from a single piece of a selected material. Several of the configurations can be assembled with individual elements which is easily seen from the various figures. 8 figs.

Additive Manufacturing in Production: A Study Case Applying Technical Requirements

NASA Astrophysics Data System (ADS)

Ituarte, Iñigo Flores; Coatanea, Eric; Salmi, Mika; Tuomi, Jukka; Partanen, Jouni

Additive manufacturing (AM) is expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters. The variability of these parameters affects the manufacturing drastically and therefore standardized processes and harmonized methodologies need to be developed to characterize the technology for end use applications and enable the technology for manufacturing. This research proposes a composite methodology integrating Taguchi Design of Experiments, multi-objective optimization and statistical process control, to optimize the manufacturing process and fulfil multiple requirements imposed to an arbitrary geometry. The proposed methodology aims to characterize AM technology depending upon manufacturing process variables as well as to perform a comparative assessment of three AM technologies (Selective Laser Sintering, Laser Stereolithography and Polyjet). Results indicate that only one machine, laser-based Stereolithography, was feasible to fulfil simultaneously macro and micro level geometrical requirements but mechanical properties were not at required level. Future research will study a single AM system at the time to characterize AM machine technical capabilities and stimulate pre-normative initiatives of the technology for end use applications.

Impact of machining on the flexural fatigue strength of glass and polycrystalline CAD/CAM ceramics.

PubMed

Fraga, Sara; Amaral, Marina; Bottino, Marco Antônio; Valandro, Luiz Felipe; Kleverlaan, Cornelis Johannes; May, Liliana Gressler

2017-11-01

To assess the effect of machining on the flexural fatigue strength and on the surface roughness of different computer-aided design, computer-aided manufacturing (CAD/CAM) ceramics by comparing machined and polished after machining specimens. Disc-shaped specimens of yttria-stabilized polycrystalline tetragonal zirconia (Y-TZP), leucite-, and lithium disilicate-based glass ceramics were prepared by CAD/CAM machining, and divided into two groups: machining (M) and machining followed by polishing (MP). The surface roughness was measured and the flexural fatigue strength was evaluated by the step-test method (n=20). The initial load and the load increment for each ceramic material were based on a monotonic test (n=5). A maximum of 10,000 cycles was applied in each load step, at 1.4Hz. Weibull probability statistics was used for the analysis of the flexural fatigue strength, and Mann-Whitney test (α=5%) to compare roughness between the M and MP conditions. Machining resulted in lower values of characteristic flexural fatigue strength than machining followed by polishing. The greatest reduction in flexural fatigue strength from MP to M was observed for Y-TZP (40%; M=536.48MPa; MP=894.50MPa), followed by lithium disilicate (33%; M=187.71MPa; MP=278.93MPa) and leucite (29%; M=72.61MPa; MP=102.55MPa). Significantly higher values of roughness (Ra) were observed for M compared to MP (leucite: M=1.59μm and MP=0.08μm; lithium disilicate: M=1.84μm and MP=0.13μm; Y-TZP: M=1.79μm and MP=0.18μm). Machining negatively affected the flexural fatigue strength of CAD/CAM ceramics, indicating that machining of partially or fully sintered ceramics is deleterious to fatigue strength. Copyright © 2017 The Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Machining of a bioactive nanocomposite orthopedic fixation device.

PubMed

Sparnell, Amie; Aniket; El-Ghannam, Ahmed

2012-08-01

Bioactive ceramics bond to bone and enhance bone formation. However, they have poor mechanical properties which restrict their machinability as well as their application as load bearing implants. The goal of this study was to machine bioactive fixation screws using a silica-calcium phosphate nanocomposite (SCPC50). The effect of compact pressure, holding time, and thermal treatment on the microstructure, machinability, and mechanical properties of SCPC50 cylinders were investigated. Samples prepared by powder metallurgy technique at compact pressure range of 100-300 MPa and treated at 900°C/1 h scored a poor machinability rating of (1/5) due to the significant formation of amorphous silicate phase at the grain boundaries. On the other hand, lowering of compact pressure and sintering temperature to 30 MPa/3 h and 700°C/2 h, respectively, minimized the formation of the amorphous phase and raised the machinability rating to (5/5). The modulus of elasticity and ultimate strength of machinable SCPC50 were 10.8 ± 2.0 GPa and 72.8 ± 22.8 MPa, respectively, which are comparable to the corresponding values for adult human cortical bone. qRT-PCR analyses showed that bone cells attached to SCPC50 significantly upregulated osteocalcin mRNA expression as compared to the cells on Ti-6Al-4V. Moreover, cells attached to SCPC50 produced mineralized bone-like tissue within 8 days. On the other hand, cells attached to Ti-6Al-4V failed to produce bone mineral under the same experimental conditions. Results of the study suggest that machinable SCPC50 has the potential to serve as an attractive new material for orthopedic fixation devices. Copyright © 2012 Wiley Periodicals, Inc.

Engineered Surface Properties of Porous Tungsten from Cryogenic Machining

NASA Astrophysics Data System (ADS)

Schoop, Julius Malte

Porous tungsten is used to manufacture dispenser cathodes due to it refractory properties. Surface porosity is critical to functional performance of dispenser cathodes because it allows for an impregnated ceramic compound to migrate to the emitting surface, lowering its work function. Likewise, surface roughness is important because it is necessary to ensure uniform wetting of the molten impregnate during high temperature service. Current industry practice to achieve surface roughness and surface porosity requirements involves the use of a plastic infiltrant during machining. After machining, the infiltrant is baked and the cathode pellet is impregnated. In this context, cryogenic machining is investigated as a substitutionary process for the current plastic infiltration process. Along with significant reductions in cycle time and resource use, surface quality of cryogenically machined un-infiltrated (as-sintered) porous tungsten has been shown to significantly outperform dry machining. The present study is focused on examining the relationship between machining parameters and cooling condition on the as-machined surface integrity of porous tungsten. The effects of cryogenic pre-cooling, rake angle, cutting speed, depth of cut and feed are all taken into consideration with respect to machining-induced surface morphology. Cermet and Polycrystalline diamond (PCD) cutting tools are used to develop high performance cryogenic machining of porous tungsten. Dry and pre-heated machining were investigated as a means to allow for ductile mode machining, yet severe tool-wear and undesirable smearing limited the feasibility of these approaches. By using modified PCD cutting tools, high speed machining of porous tungsten at cutting speeds up to 400 m/min is achieved for the first time. Beyond a critical speed, brittle fracture and built-up edge are eliminated as the result of a brittle to ductile transition. A model of critical chip thickness ( hc ) effects based on cutting force, temperature and surface roughness data is developed and used to study the deformation mechanisms of porous tungsten under different machining conditions. It is found that when hmax = hc, ductile mode machining of otherwise highly brittle porous tungsten is possible. The value of hc is approximately the same as the average ligament size of the 80% density porous tungsten workpiece.

Life cycle of a geyser discharge apron: Evidence from Waikite Geyser, Whakarewarewa geothermal area, North Island, New Zealand

NASA Astrophysics Data System (ADS)

Jones, Brian; Renaut, Robin W.; Owen, R. Bernhart

2011-05-01

Waikite, a geyser located in the Whakarewarewa geothermal area on the North Island, New Zealand, has a history of eruptive-dormancy cycles that have been attributed to natural and anthropogenic causes. The last cycle involved an active period from ~ 1932 to 1968/69 that was followed by a period of dormancy that continues today. Such cycles are important because they control the temporal development of the discharge apron. When the geyser is active, growth of the discharge apron is dictated by the precipitation of opal-A, which is controlled by factors such as discharge patterns, water chemistry, pH, temperature, rate of cooling, and the resident microbiota. With dormancy, conditions change radically because water no longer flows down the discharge apron. Instead, the discharge apron lapses into a phase of degradation that, on Waikite, is evident from (1) deflation of the apron surface, (2) blocks splaying off the apron margins along margin-parallel fractures, (3) tension fractures, (4) saucer-shaped collapse zones, (5) increasingly unstable surfaces resulting from subsurface opal-A dissolution, (6) fractures, from which steam and other gases emanate, and (7) incursion of native vegetation around the edge of the apron and on the distal parts of the discharge apron. When the geyser becomes active again, silica precipitation will resume and the discharge apron will once again accrete vertically and expand laterally. Analysis of the Waikite system shows that successions that develop on geyser discharge aprons are formed of unconformity-bounded packages of sinter that reflect the eruptive-dormancy history of the parent geyser.

Hard permanent magnet development trends and their application to A.C. machines

NASA Technical Reports Server (NTRS)

Mildrum, H. F.

1981-01-01

The physical and magnetic properties of Mn-Al-C, Fe-Cr-Co, and RE-TM (rare earth-transition metal intermetallics) in polymer and soft metal bonded or sintered form are considered for ac circuit machine usage. The manufacturing processes for the magnetic materials are reviewed, and the mechanical and electrical properties of the magnetic materials are compared, with consideration given to the reference Alnico magnet. The Mn-Al-C magnets have the same magnetic properties and costs as Alnico units, operate well at low temperatures, but have poor high temperature performance. Fe-Cr-Co magnets also have comparable cost to Alnico magnets, and operate at high or low temperature, but are brittle, expensive, and contain Co. RE-Co magnets possess a high energy density, operate well in a wide temperature range, and are expensive. Recommendation for exploring the rare-earth alternatives are offered.

Strain Rate and Stress Triaxiality Effects on Ductile Damage of Additive Manufactured TI-6AL-4V

NASA Astrophysics Data System (ADS)

Iannitti, Gianluca; Bonora, Nicola; Gentile, Domenico; Ruggiero, Andrew; Testa, Gabriel; Gubbioni, Simone

2017-06-01

In this work, the effects of strain rate and stress triaxiality on ductile damage of additive manufactured Ti-6Al-4V, also considering the build direction, were investigated. Raw material was manufactured by means of EOSSINT M2 80 machine, based on Direct Metal Laser Sintering technology, and machined to obtain round notched bar and Rod-on-Rod (RoR) specimens. Tensile tests on round notched bar specimens were performed in a wide range of strain rates. The failure strains at different stress triaxiality were used to calibrate the Bonora Damage Model. In order to design the RoR tests, numerical simulations were performed for assessing velocities at which incipient and fully developed damage occur. Tests at selected velocities were carried out and soft-recovered specimens were sectioning and polishing to observe the developed damage. Nucleated voids maps were compared with numerical simulations results.

Superconductive wire

DOEpatents

Korzekwa, David A.; Bingert, John F.; Peterson, Dean E.; Sheinberg, Haskell

1995-01-01

A superconductive article is made by inserting a rigid mandrel into an internal cavity of a first metallic tube, said tube having an interior surface and an exterior surface, said interior surface defining the interior cavity, forming a layer of a superconductive material or superconductive precursor upon the exterior surface of said first metallic tube, machining the layer of superconductive material or superconductive precursor to a predetermined diameter to form an intermediate article configured for insertion into a second metallic tube having an interior diameter corresponding to the predetermined diameter, inserting the machined intermediate article into a second metallic tube having an internal diameter corresponding to the predetermined diameter of the intermediate article to form a composite intermediate article, reducing or ironing the composite intermediate article to a predetermined cross-sectional diameter, and sintering the reduced or ironed composite intermediate article at temperatures and for time sufficient for the superconductive material or superconductive precursor to exhibit superconductivity.

Superconductive wire

DOEpatents

Korzekwa, D.A.; Bingert, J.F.; Peterson, D.E.; Sheinberg, H.

1995-07-18

A superconductive article is made by inserting a rigid mandrel into an internal cavity of a first metallic tube, said tube having an interior surface and an exterior surface, said interior surface defining the interior cavity, forming a layer of a superconductive material or superconductive precursor upon the exterior surface of said first metallic tube, machining the layer of superconductive material or superconductive precursor to a predetermined diameter to form an intermediate article configured for insertion into a second metallic tube having an interior diameter corresponding to the predetermined diameter, inserting the machined intermediate article into a second metallic tube having an internal diameter corresponding to the predetermined diameter of the intermediate article to form a composite intermediate article, reducing or ironing the composite intermediate article to a predetermined cross-sectional diameter, and sintering the reduced or ironed composite intermediate article at temperatures and for time sufficient for the superconductive material or superconductive precursor to exhibit superconductivity. 2 figs.

Experimental study on Response Parameters of Ni-rich NiTi Shape Memory Alloy during Wire Electric Discharge Machining

NASA Astrophysics Data System (ADS)

Bisaria, Himanshu; Shandilya, Pragya

2018-03-01

Nowadays NiTi SMAs are gaining more prominence due to their unique properties such as superelasticity, shape memory effect, high fatigue strength and many other enriched physical and mechanical properties. The current studies explore the effect of machining parameters namely, peak current (Ip), pulse off time (TOFF), and pulse on time (TON) on wire wear ratio (WWR), and dimensional deviation (DD) in WEDM. It was found that high discharge energy was mainly ascribed to high WWR and DD. The WWR and DD increased with the increase in pulse on time and peak current whereas high pulse off time was favourable for low WWR and DD.

Achieving Small Structures in Thin NiTi Sheets for Medical Applications with Water Jet and Micro Machining: A Comparison

NASA Astrophysics Data System (ADS)

Frotscher, M.; Kahleyss, F.; Simon, T.; Biermann, D.; Eggeler, G.

2011-07-01

NiTi shape memory alloys (SMA) are used for a variety of applications including medical implants and tools as well as actuators, making use of their unique properties. However, due to the hardness and strength, in combination with the high elasticity of the material, the machining of components can be challenging. The most common machining techniques used today are laser cutting and electrical discharge machining (EDM). In this study, we report on the machining of small structures into binary NiTi sheets, applying alternative processing methods being well-established for other metallic materials. Our results indicate that water jet machining and micro milling can be used to machine delicate structures, even in very thin NiTi sheets. Further work is required to optimize the cut quality and the machining speed in order to increase the cost-effectiveness and to make both methods more competitive.

Prototype Development of Remote Operated Hot Uniaxial Press (ROHUP) to Fabricate Advanced Tc-99 Bearing Ceramic Waste Forms - 13381

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

Alaniz, Ariana J.; Delgado, Luc R.; Werbick, Brett M.

The objective of this senior student project is to design and build a prototype construction of a machine that simultaneously provides the proper pressure and temperature parameters to sinter ceramic powders in-situ to create pellets of rather high densities of above 90% (theoretical). This ROHUP (Remote Operated Hot Uniaxial Press) device is designed specifically to fabricate advanced ceramic Tc-99 bearing waste forms and therefore radiological barriers have been included in the system. The HUP features electronic control and feedback systems to set and monitor pressure, load, and temperature parameters. This device operates wirelessly via portable computer using Bluetooth{sup R} technology.more » The HUP device is designed to fit in a standard atmosphere controlled glove box to further allow sintering under inert conditions (e.g. under Ar, He, N{sub 2}). This will further allow utilizing this HUP for other potential applications, including radioactive samples, novel ceramic waste forms, advanced oxide fuels, air-sensitive samples, metallic systems, advanced powder metallurgy, diffusion experiments and more. (authors)« less

Friction behaviour of aluminium composites mixed with carbon fibers with different orientations

NASA Astrophysics Data System (ADS)

Caliman, R.

2016-08-01

The primary goal of this study work it was to distinguish a mixture of materials with enhanced friction and wearing behaviour. The composite materials may be differentiated from alloys; which can contain two more components but are formed naturally through different processes such as casting. The load applied on the specimen during the tests, is playing a very important role regarding friction coefficient and also the wearing speed. Sintered composites are gaining importance because the reinforcement serves to reduce the coefficient of thermal expansion and increase the strength and modulus. The friction tests are carried out, at the room temperature in dry condition, on a pin-on-disc machine. The exponentially decreasing areas form graphs, represented to the curves coefficient of friction, are attributed to the formation of lubricant transfer film and initial polishing surface samples. The influence of the orientation of the carbon fibers on the friction properties in the sintered polymer composites may be studied by the use of both mechanical wear tests by microscopy and through the use of phenomenological models.

Dispensing of high concentration Ag nano-particles ink for ultra-low resistivity paper-based writing electronics

PubMed Central

Wang, Fuliang; Mao, Peng; He, Hu

2016-01-01

Paper-based writing electronics has received a lot of interest recently due to its potential applications in flexible electronics. To obtain ultra-low resistivity paper-based writing electronics, we developed a kind of ink with high concentration of Ag Nano-particles (up to 80 wt%), as well as a related dispensing writing system consisting an air compressor machine and a dispenser. Additionally, we also demonstrated the writability and practical application of our proposed ink and writing system. Based on the study on the effect of sintering time and pressure, we found the optimal sintering time and pressure to obtain high quality Ag NPs wires. The electrical conductivity of nano-silver paper-based electronics has been tested using the calculated resistivity. After hot-pressure sintering at 120 °C, 25 MPa pressure for 20 minutes, the resistivity of silver NPs conductive tracks was 3.92 × 10−8 (Ωm), only 2.45 times of bulk silver. The mechanical flexibility of nano-silver paper-based electronics also has been tested. After 1000 bending cycles, the resistivity slightly increased from the initial 4.01 × 10−8 to 5.08 × 10−8 (Ωm). With this proposed ink preparation and writing system, a kind of paper-based writing electronics with ultra-low resistivity and good mechanical flexibility was achieved. PMID:26883558

Spark Plasma Sintering As a Solid-State Recycling Technique: The Case of Aluminum Alloy Scrap Consolidation

PubMed Central

Paraskevas, Dimos; Vanmeensel, Kim; Vleugels, Jef; Dewulf, Wim; Deng, Yelin; Duflou, Joost R.

2014-01-01

Recently, “meltless” recycling techniques have been presented for the light metals category, targeting both energy and material savings by bypassing the final recycling step of remelting. In this context, the use of spark plasma sintering (SPS) is proposed in this paper as a novel solid-state recycling technique. The objective is two-fold: (I) to prove the technical feasibility of this approach; and (II) to characterize the recycled samples. Aluminum (Al) alloy scrap was selected to demonstrate the SPS effectiveness in producing fully-dense samples. For this purpose, Al alloy scrap in the form of machining chips was cold pre-compacted and sintered bellow the solidus temperature at 490 °C, under elevated pressure of 200 MPa. The dynamic scrap compaction, combined with electric current-based joule heating, achieved partial fracture of the stable surface oxides, desorption of the entrapped gases and activated the metallic surfaces, resulting in efficient solid-state chip welding eliminating residual porosity. The microhardness, the texture, the mechanical properties, the microstructure and the density of the recycled specimens have been investigated. An X-ray computed tomography (CT) analysis confirmed the density measurements, revealing a void-less bulk material with homogeneously distributed intermetallic compounds and oxides. The oxide content of the chips incorporated within the recycled material slightly increases its elastic properties. Finally, a thermal distribution simulation of the process in different segments illustrates the improved energy efficiency of this approach. PMID:28788153

New nano-sized Al2O3-BN coating 3Y-TZP ceramic composites for CAD/CAM-produced all-ceramic dental restorations. Part I. Fabrication of powders.

PubMed

Yang, Se Fei; Yang, Li Qiang; Jin, Zhi Hao; Guo, Tian Wen; Wang, Lei; Liu, Hong Chen

2009-06-01

Partially sintered 3 mol % yttria-stabilized tetragonal zirconium dioxide (ZrO(2), zirconia) polycrystal (3Y-TZP) ceramics are used in dental posterior restorations with computer-aided design-computer-aided manufacturing (CAD/CAM) techniques. High strength is acquired after sintering, but shape distortion of preshaped compacts during their sintering is inevitable. The aim of this study is to fabricate new machinable ceramic composites with strong mechanical properties that are fit for all-ceramic dental restorations. Aluminum oxide (Al(2)O(3))-coated 3Y-TZP powders were first prepared by the heterogeneous precipitation method starting with 3Y-TZP, Al(NO(3))(3) . 9H(2)O, and ammonia, then amorphous boron nitride (BN) was produced and the as-received composite powders were coated via in situ reaction with boric acid and urea. Transmission electron microscopy (TEM) and X-ray diffraction (XRD) were used to analyze the status of Al(2)O(3)-BN on the surface of the 3Y-TZP particles. TEM micrographs show an abundance of Al(2)O(3) particles and amorphous BN appearing uniformly on the surface of the 3Y-TZP particles after the coating process. The size of the Al(2)O(3) particles is about 20 nm. The XRD pattern shows clearly the peak of amorphous BN among the peaks of ZrO(2).

Spark Plasma Sintering As a Solid-State Recycling Technique: The Case of Aluminum Alloy Scrap Consolidation.

PubMed

Paraskevas, Dimos; Vanmeensel, Kim; Vleugels, Jef; Dewulf, Wim; Deng, Yelin; Duflou, Joost R

2014-08-06

Recently, "meltless" recycling techniques have been presented for the light metals category, targeting both energy and material savings by bypassing the final recycling step of remelting. In this context, the use of spark plasma sintering (SPS) is proposed in this paper as a novel solid-state recycling technique. The objective is two-fold: (I) to prove the technical feasibility of this approach; and (II) to characterize the recycled samples. Aluminum (Al) alloy scrap was selected to demonstrate the SPS effectiveness in producing fully-dense samples. For this purpose, Al alloy scrap in the form of machining chips was cold pre-compacted and sintered bellow the solidus temperature at 490 °C, under elevated pressure of 200 MPa. The dynamic scrap compaction, combined with electric current-based joule heating, achieved partial fracture of the stable surface oxides, desorption of the entrapped gases and activated the metallic surfaces, resulting in efficient solid-state chip welding eliminating residual porosity. The microhardness, the texture, the mechanical properties, the microstructure and the density of the recycled specimens have been investigated. An X-ray computed tomography (CT) analysis confirmed the density measurements, revealing a void-less bulk material with homogeneously distributed intermetallic compounds and oxides. The oxide content of the chips incorporated within the recycled material slightly increases its elastic properties. Finally, a thermal distribution simulation of the process in different segments illustrates the improved energy efficiency of this approach.

Plasma Methods of Obtainment of Multifunctional Composite Materials, Dispersion-Hardened by Nanoparticles

NASA Astrophysics Data System (ADS)

Sizonenko, O. N.; Grigoryev, E. G.; Pristash, N. S.; Zaichenko, A. D.; Torpakov, A. S.; Lypian, Ye. V.; Tregub, V. A.; Zholnin, A. G.; Yudin, A. V.; Kovalenko, A. A.

2017-09-01

High voltage electric discharge (HVED) in disperse system "hydrocarbon liquid - powder" due to impact of plasma discharge channel, electromagnetic fields, shock waves mechanical impact, hydro flows and volume microcavitation leads to synthesis of nanocarbon, metal powders dispersion and synthesis of micro- (from 10-6 to 10-7 m) and nanosized (from 10-7 to 10-9 m) composite powders of hardening phases. Spark plasma sintering (SPS) of powder mixtures allows targeted control of grain growth rate and thus allows obtainment of multifunctional composite materials dispersion hardened by nanoparticles. Processes of HVED synthesis of micro- and nanosized powders of new compositions from elemental metal powders and their mixtures with the subsequent application of high-speed SPS of obtained powders create conditions for increase of strength (by 10-20 %), hardness and wear-resistance (by 30-60 %) of obtained materials.

Diamond Smoothing Tools

NASA Technical Reports Server (NTRS)

Voronov, Oleg

2007-01-01

Diamond smoothing tools have been proposed for use in conjunction with diamond cutting tools that are used in many finish-machining operations. Diamond machining (including finishing) is often used, for example, in fabrication of precise metal mirrors. A diamond smoothing tool according to the proposal would have a smooth spherical surface. For a given finish machining operation, the smoothing tool would be mounted next to the cutting tool. The smoothing tool would slide on the machined surface left behind by the cutting tool, plastically deforming the surface material and thereby reducing the roughness of the surface, closing microcracks and otherwise generally reducing or eliminating microscopic surface and subsurface defects, and increasing the microhardness of the surface layer. It has been estimated that if smoothing tools of this type were used in conjunction with cutting tools on sufficiently precise lathes, it would be possible to reduce the roughness of machined surfaces to as little as 3 nm. A tool according to the proposal would consist of a smoothing insert in a metal holder. The smoothing insert would be made from a diamond/metal functionally graded composite rod preform, which, in turn, would be made by sintering together a bulk single-crystal or polycrystalline diamond, a diamond powder, and a metallic alloy at high pressure. To form the spherical smoothing tip, the diamond end of the preform would be subjected to flat grinding, conical grinding, spherical grinding using diamond wheels, and finally spherical polishing and/or buffing using diamond powders. If the diamond were a single crystal, then it would be crystallographically oriented, relative to the machining motion, to minimize its wear and maximize its hardness. Spherically polished diamonds could also be useful for purposes other than smoothing in finish machining: They would likely also be suitable for use as heat-resistant, wear-resistant, unlubricated sliding-fit bearing inserts.

Final Report on Initial Samples Supplied by LLNL for Task 3.3 Binder Burnout and Sintering Schedule Optimisation

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

Walls, P

Sixteen of the twenty-one samples have been investigated using the scanning laser dilatometer. This includes all three types of samples with different preparation routes and organic content. Cracks were observed in all samples, even those only heated to 300 C. It was concluded that the cracking was occurring in the early part of the heat treatment before the samples reached 300 C. Increase in the rate of dilation of the samples occurred above 170 C which coincided with the decomposition of the binder/wax additives as determined by differential thermal analysis. A comparison was made with SYNROC C material (Powder Runmore » 143), samples of which had been CIPed and green machined to a similar diameter and thickness as the 089mm SRTC pucks. These samples contained neither binder nor other organic processing aids and had been kept in the same desiccator as the SRTC samples. The CIPed Synroc C samples sintered to high density with zero cracks. As the cracks made up only a small contribution to the change in diameter of the sample compared to the sintering shrinkage, useful information could still be gained from the runs. The sintering curves showed that there was much greater shrinkage of the Type III samples containing only the 5% PEG binder compared to the Type I which contained polyolefin wax as processing aid. Slight changes in gradient of the sintering curve were observed, however, due to the masking effect of the cracking, full analysis of the sintering kinetics cannot be conducted. Even heating the samples to 300 C at 1.0 or 0.5 C/min could not prevent crack formation. This indicated that heating rate was not the critical parameter causing cracking of the samples. Sectioning of green bodies revealed the inhomogeneous nature of the binder/lubricant distribution in the samples. Increased homogeneity would reduce the amount of binder/lubricant required, which should in turn, reduce the degree of cracking observed during heating to the binder burnout temperature. A combination of: (1) use of a higher forming pressure, (2) reduction of organics content, (3) improvement in the distribution of the organic wax and binder components throughout the green body, could possibly alleviate cracking. Ultrasonic emulsification of the binder and wax with a small quantity of water prior to adding to the ball or attrition mill is advised to ensure more even distribution of the wax/binder system. This would also reduce the proportion of organic additives required. The binder burnout stage of the operation must first be optimized (i.e. production of pucks with no cracks) prior to optimization of the sintering stage.« less

Apparatus for controlling fluidized beds

DOEpatents

Rehmat, A.G.; Patel, J.G.

1987-05-12

An apparatus and process are disclosed for control and maintenance of fluidized beds under non-steady state conditions. An ash removal conduit is provided for removing solid particulates from a fluidized bed separate from an ash discharge conduit in the lower portion of the grate supporting such a bed. The apparatus and process of this invention is particularly suitable for use in ash agglomerating fluidized beds and provides control of the fluidized bed before ash agglomeration is initiated and during upset conditions resulting in stable, sinter-free fluidized bed maintenance. 2 figs.

Deposition and micro electrical discharge machining of CVD-diamond layers incorporated with silicon

NASA Astrophysics Data System (ADS)

Kühn, R.; Berger, T.; Prieske, M.; Börner, R.; Hackert-Oschätzchen, M.; Zeidler, H.; Schubert, A.

2017-10-01

In metal forming, lubricants have to be used to prevent corrosion or to reduce friction and tool wear. From an economical and ecological point of view, the aim is to avoid the usage of lubricants. For dry deep drawing of aluminum sheets it is intended to apply locally micro-structured wear-resistant carbon based coatings onto steel tools. One type of these coatings are diamond layers prepared by chemical vapor deposition (CVD). Due to the high strength of diamond, milling processes are unsuitable for micro-structuring of these layers. In contrast to this, micro electrical discharge machining (micro EDM) is a suitable process for micro-structuring CVD-diamond layers. Due to its non-contact nature and its process principle of ablating material by melting and evaporating, it is independent of the hardness, brittleness or toughness of the workpiece material. In this study the deposition and micro electrical discharge machining of silicon incorporated CVD-diamond (Si-CVD-diamond) layers were presented. For this, 10 µm thick layers were deposited on molybdenum plates by a laser-induced plasma CVD process (LaPlas-CVD). For the characterization of the coatings RAMAN- and EDX-analyses were conducted. Experiments in EDM were carried out with a tungsten carbide tool electrode with a diameter of 90 µm to investigate the micro-structuring of Si-CVD-diamond. The impact of voltage, discharge energy and tool polarity on process speed and resulting erosion geometry were analyzed. The results show that micro EDM is a suitable technology for micro-structuring of silicon incorporated CVD-diamond layers.

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

Hill, Mary Ann; Dombrowski, David E.; Clarke, Kester Diederik

U-10 wt. % Mo (U-10Mo) alloys are being developed as low enrichment monolithic fuel for the CONVERT program. Optimization of processing for the monolithic fuel is being pursued with the use of electrical discharge machining (EDM) under CONVERT HPRR WBS 1.2.4.5 Optimization of Coupon Preparation. The process is applicable to manufacturing experimental fuel plate specimens for the Mini-Plate-1 (MP-1) irradiation campaign. The benefits of EDM are reduced machining costs, ability to achieve higher tolerances, stress-free, burr-free surfaces eliminating the need for milling, and the ability to machine complex shapes. Kerf losses are much smaller with EDM (tenths of mm) comparedmore » to conventional machining (mm). Reliable repeatability is achievable with EDM due to its computer-generated machining programs.« less

Lanthanum-hexaboride carbon composition for use in corrosive hydrogen-fluorine environments

DOEpatents

Holcombe, C.E. Jr.; Kovach, L.; Taylor, A.J.

1980-01-22

The present invention relates to a structural composition useful in corrosive hydrogen-fluorine environments at temperatures in excess of 1400/sup 0/K. The composition is formed of a isostatically pressed and sintered or a hot-pressed mixture of lanthanum hexaboride particles and about 10 to 30 vol% carbon. The lanthanum-hexaboride reacts with the high-temperature fluorine-containing gases to form an adherent layer of corrosion-inhibiting lanthanum trifluoride on exposed surfaces of the composition. The carbon in the composite significantly strengthens the composite, enhances thermal shock resistance, and significantly facilitates the machining of the composition.

Assessing dust exposure in an integrated iron and steel manufacturing plant in South India.

PubMed

Ravichandran, B; Krishnamurthy, V; Ravibabu, K; Raghavan, S; Rajan, B K; Rajmohan, H R

2008-01-01

A study to monitor and estimate respirable particulate matter (RPM), toxic trace metal concentrations in the work environment was carried out in different sections of an integrated steel manufacturing industry. The average RPM concentration observed varied according to the section blast furnace was 2.41 mg/m;{3}; energy optimization furnace, 1.87 mg/m;{3}; sintering plant, 0.98 mg/m;{3}; continuous casting machine, 1.93 mg/m;{3}. The average trace metal concentration estimated from the RPM samples like iron, manganese, lead and chromium did not exceed ACGIH prescribed levels.

Lanthanum-hexaboride carbon composition for use in corrosive hydrogen-fluorine environments

DOEpatents

Holcombe, Cressie E.; Kovach, Louis; Taylor, Albert J.

1981-01-01

The present invention relates to a structural composition useful in corrosive hydrogen-fluorine environments at temperatures in excess of 1400.degree. K. The composition is formed of a isostatically pressed and sintered or a hot-pressed mixture of lanthanum hexaboride particles and about 10-30 vol. % carbon. The lanthanum-hexaboride reacts with the high-temperature fluorine-containing bases to form an adherent layer of corrosion-inhibiting lanthanum trifluoride on exposed surfaces of the composition. The carbon in the composite significantly strengthens the composite, enhances thermal shock resistance, and significantly facilitates the machining of the composition.

The advances and characteristics of high-power diode laser materials processing

NASA Astrophysics Data System (ADS)

Li, Lin

2000-10-01

This paper presents a review of the direct applications of high-power diode lasers for materials processing including soldering, surface modification (hardening, cladding, glazing and wetting modifications), welding, scribing, sheet metal bending, marking, engraving, paint stripping, powder sintering, synthesis, brazing and machining. The specific advantages and disadvantages of diode laser materials processing are compared with CO 2, Nd:YAG and excimer lasers. An effort is made to identify the fundamental differences in their beam/material interaction characteristics and materials behaviour. Also an appraisal of the future prospects of the high-power diode lasers for materials processing is given.

Harmony search optimization in dimensional accuracy of die sinking EDM process using SS316L stainless steel

NASA Astrophysics Data System (ADS)

Deris, A. M.; Zain, A. M.; Sallehuddin, R.; Sharif, S.

2017-09-01

Electric discharge machine (EDM) is one of the widely used nonconventional machining processes for hard and difficult to machine materials. Due to the large number of machining parameters in EDM and its complicated structural, the selection of the optimal solution of machining parameters for obtaining minimum machining performance is remain as a challenging task to the researchers. This paper proposed experimental investigation and optimization of machining parameters for EDM process on stainless steel 316L work piece using Harmony Search (HS) algorithm. The mathematical model was developed based on regression approach with four input parameters which are pulse on time, peak current, servo voltage and servo speed to the output response which is dimensional accuracy (DA). The optimal result of HS approach was compared with regression analysis and it was found HS gave better result y giving the most minimum DA value compared with regression approach.

Utilizing residues from in-woods flail processing

Treesearch

Ronald K. Baughman; Bryce J. Stokes; William F. Watson

1990-01-01

A Barkbuster 1100 tub grinder has been employed to process debris discharged by a Manitowoc VFDD-1642. The machine successfully passed the material through a 7.62 cm screen and discharged the reduced debris into a chip van for transport. Fuel production is directly dependent upon the production of clean chips by the flail/chipper portion of the system and the available...

Experimental study of electrical discharge drilling of stainless steel UNS S30400

NASA Astrophysics Data System (ADS)

Hanash, E. A. H.; Ali, M. Y.

2018-01-01

In this study, overcut and taper angle were investigated in machining of stainless steel UNS S30400 against three different electrical discharge machining parameters which are electric current (Ip), pulse on-time (Ton) and pulse off-time (Toff). The electrode used was of 1 mm diameter with aspect ratio of 10. Dimensional accuracy was measured by evaluating overcut and taper angle. Those two measurements were performed using optical microscope model (Olympus BX41M, Japan). The experimentation planning, evaluation, analysis and optimization have been carried out using DOE software version 10.0.3 RSM based method with total number of twenty experiments. The research reveals that, discharge current was found to have the most significant effect on overcut and taper angle followed by pulse on-time and pulse off-time. As the discharge current and pulse on-time increase, overcut and taper angle are increased. However, when pulse off-time increases, overcut and taper angle decrease. The outcome result of this study will be very useful in the manufacturing industry to select the appropriate parameters for the selected work material. The model has shown a great accuracy with percentage error of less than 5%.

Classification and machine recognition of severe weather patterns

NASA Technical Reports Server (NTRS)

Wang, P. P.; Burns, R. C.

1976-01-01

Forecasting and warning of severe weather conditions are treated from the vantage point of pattern recognition by machine. Pictorial patterns and waveform patterns are distinguished. Time series data on sferics are dealt with by considering waveform patterns. A severe storm patterns recognition machine is described, along with schemes for detection via cross-correlation of time series (same channel or different channels). Syntactic and decision-theoretic approaches to feature extraction are discussed. Active and decayed tornados and thunderstorms, lightning discharges, and funnels and their related time series data are studied.

Heart pacemaker - discharge

MedlinePlus

... table saws) Electric lawnmowers and leaf blowers Slot machines Stereo speakers Tell all providers that you have a pacemaker before any tests are done. Some medical equipment may interfere with ...

Direct laser metal sintering as a new approach to fabrication of an isoelastic functionally graded material for manufacture of porous titanium dental implants.

PubMed

Traini, T; Mangano, C; Sammons, R L; Mangano, F; Macchi, A; Piattelli, A

2008-11-01

This work focuses on a titanium alloy implants incorporating a gradient of porosity, from the inner core to the outer surface, obtained by laser sintering of metal powder. Surface appearance, microstructure, composition, mechanical properties and fractography were evaluated. All the specimens were prepared by a selective laser sintering procedure using a Ti-6Al-4V alloy powder with a particle size of 1-10 microm. The morphological and chemical analyses were performed by SEM and energy dispersive X-ray spectroscopy. The flexure strength was determined by a three-point bend test using a universal testing machine. The surface roughness was investigated using a confocal scanning laser microscope. The surface roughness variation was statistically evaluated by use of a Chi square test. A p value of <0.05 was considered statistically significant. The original surface microstructure consisted of roughly spherical particles, diameter range 5-50 microm. After exposure to hydrofluoric acid some of these were removed and the microsphere diameter then ranged from 5.1 microm to 26.8 microm. Following an organic acid treatment, particles were replaced by grooves 14.6-152.5 microm in width and 21.4-102.4 microm depth. The metal core consisted of columnar beta grains with alpha and beta laths within the grains. The alloy was composed of 90.08% Ti, 5.67% Al and 4.25% V. The Young's modulus of the inner core material was 104+/-7.7 GPa; while that of the outer porous material was 77+/-3.5 GPa. The fracture face showed a dimpled appearance typical of ductile fracture. In conclusion, laser metal sintering proved to be an efficient means of construction of dental implants with a functionally graded material which is better adapted to the elastic properties of the bone. Such implants should minimize stress shielding effects and improve long-term performance.

Plastic superconductor bearings any size-any shape: 77 K and up

NASA Technical Reports Server (NTRS)

Reick, Franklin G.

1991-01-01

'Friction free' bearings at 77 K or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape, and postforming machining. The material is hard and abrasive. It is possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas, and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feed for LN2 is used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material is molded with the internal surfaces shielded by the Meissner effect. It can be thought of as the DC magnetic analog of the Faraday cage and the inside is the 'Meissner space'. It is selective. The AC fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.

Parameters for Fabricating Nano-Au Colloids through the Electric Spark Discharge Method with Micro-Electrical Discharge Machining.

PubMed

Tseng, Kuo-Hsiung; Chung, Meng-Yun; Chang, Chaur-Yang

2017-06-02

In this study, the Electric Spark Discharge Method (ESDM) was employed with micro-electrical discharge machining (m-EDM) to create an electric arc that melted two electrodes in deionized water (DW) and fabricated nano-Au colloids through pulse discharges with a controlled on-off duration (T ON -T OFF ) and a total fabrication time of 1 min. A total of six on-off settings were tested under normal experimental conditions and without the addition of any chemical substances. Ultraviolet-visible spectroscopy (UV-Vis), Zetasizer Nano measurements, and scanning electron microscopy-energy dispersive X-ray (SEM-EDX) analyses suggested that the nano-Au colloid fabricated at 10-10 µs (10 µs on, 10 µs off) had higher concentration and suspension stability than products made at other T ON -T OFF settings. The surface plasmon resonance (SPR) of the colloid was 549 nm on the first day of fabrication and stabilized at 532 nm on the third day. As the T ON -T OFF period increased, the absorbance (i.e., concentration) of all nano-Au colloids decreased. Absorbance was highest at 10-10 µs. The SPR peaks stabilized at 532 nm across all T ON -T OFF periods. The Zeta potential at 10-10 µs was -36.6 mV, indicating that no nano-Au agglomeration occurred and that the particles had high suspension stability.

Parameters for Fabricating Nano-Au Colloids through the Electric Spark Discharge Method with Micro-Electrical Discharge Machining

PubMed Central

Tseng, Kuo-Hsiung; Chung, Meng-Yun; Chang, Chaur-Yang

2017-01-01

In this study, the Electric Spark Discharge Method (ESDM) was employed with micro-electrical discharge machining (m-EDM) to create an electric arc that melted two electrodes in deionized water (DW) and fabricated nano-Au colloids through pulse discharges with a controlled on–off duration (TON–TOFF) and a total fabrication time of 1 min. A total of six on–off settings were tested under normal experimental conditions and without the addition of any chemical substances. Ultraviolet–visible spectroscopy (UV–Vis), Zetasizer Nano measurements, and scanning electron microscopy–energy dispersive X-ray (SEM–EDX) analyses suggested that the nano-Au colloid fabricated at 10–10 µs (10 µs on, 10 µs off) had higher concentration and suspension stability than products made at other TON–TOFF settings. The surface plasmon resonance (SPR) of the colloid was 549 nm on the first day of fabrication and stabilized at 532 nm on the third day. As the TON–TOFF period increased, the absorbance (i.e., concentration) of all nano-Au colloids decreased. Absorbance was highest at 10–10 µs. The SPR peaks stabilized at 532 nm across all TON–TOFF periods. The Zeta potential at 10–10 µs was −36.6 mV, indicating that no nano-Au agglomeration occurred and that the particles had high suspension stability. PMID:28574476

Effect of KOH concentration and anions on the performance of an NiH 2 battery positive plate

NASA Astrophysics Data System (ADS)

Vaidyanathan, Hari; Robbins, Kathleen; Rao, Gopalakrishna M.

The capacity and voltage behavior of electrochemically impregnated sintered nickel positive plates was examined by galvanostatic charging and discharging in a flooded electrolyte cell. Three different concentrations of potassium hydroxide (KOH) (40%,31% and 26%) and 31% KOH containing dissolved nitrate, sulfate, or silicate were investigated. The end-of-charge voltage at {C}/{10} charge and at 10°C showed the following order: 40% KOH > 31 % KOH alone, and in the presence of the anions > 26% KOH. The mid-discharge voltage at {C}/{2} discharge was higher in 26% KOH, almost the same for 31%Ao KOH with and without the added contaminants, and much lower for 40% KOH. The plate capacity was marginally affected by cycling in all cases except for 40% KOH, where the capacity declined after 1000 cycles at 80% depth-of-discharge (DOD). At the end of cycling all the plates tested experienced a weight loss, except in the case of 31% KOH, as a result of active material extrusion. Cyclic voltammetry of miniature electrodes in 31% KOH showed that the cathodic peak potentials are less polarized at -5 °C (compared to 25 °C) in the presence and absence of silicate. This indicates a slightly higher voltage during discharge in an NiH 2 battery. Furthermore, the features of the current-potential profile were practically unchanged in the presence of silicate.

Effective Information Extraction Framework for Heterogeneous Clinical Reports Using Online Machine Learning and Controlled Vocabularies

PubMed Central

Zheng, Shuai; Ghasemzadeh, Nima; Hayek, Salim S; Quyyumi, Arshed A

2017-01-01

Background Extracting structured data from narrated medical reports is challenged by the complexity of heterogeneous structures and vocabularies and often requires significant manual effort. Traditional machine-based approaches lack the capability to take user feedbacks for improving the extraction algorithm in real time. Objective Our goal was to provide a generic information extraction framework that can support diverse clinical reports and enables a dynamic interaction between a human and a machine that produces highly accurate results. Methods A clinical information extraction system IDEAL-X has been built on top of online machine learning. It processes one document at a time, and user interactions are recorded as feedbacks to update the learning model in real time. The updated model is used to predict values for extraction in subsequent documents. Once prediction accuracy reaches a user-acceptable threshold, the remaining documents may be batch processed. A customizable controlled vocabulary may be used to support extraction. Results Three datasets were used for experiments based on report styles: 100 cardiac catheterization procedure reports, 100 coronary angiographic reports, and 100 integrated reports—each combines history and physical report, discharge summary, outpatient clinic notes, outpatient clinic letter, and inpatient discharge medication report. Data extraction was performed by 3 methods: online machine learning, controlled vocabularies, and a combination of these. The system delivers results with F1 scores greater than 95%. Conclusions IDEAL-X adopts a unique online machine learning–based approach combined with controlled vocabularies to support data extraction for clinical reports. The system can quickly learn and improve, thus it is highly adaptable. PMID:28487265

Exploration on Wire Discharge Machining Added Powder for Metal-Based Diamond Grinding Wheel on Wire EDM Dressing and Truing of Grinding Tungsten Carbide Material

NASA Astrophysics Data System (ADS)

Chow, H. M.; Yang, L. D.; Lin, Y. C.; Lin, C. L.

2017-12-01

In this paper, the effects of material removal rate and abrasive grain protrusion on the metal-based diamond grinding wheel were studied to find the optimal parameters for adding powder and wire discharge. In addition, this kind of electric discharge method to add powder on the metal-based diamond grinding wheel on line after dressing and truing will be applied on tungsten carbide to study the grinding material removal rate, grinding wheel wear, surface roughness, and surface micro-hardness.

Improving the Thermochemical Energy Storage Performance of the Mn2 O3 /Mn3 O4 Redox Couple by the Incorporation of Iron.

PubMed

Carrillo, Alfonso J; Serrano, David P; Pizarro, Patricia; Coronado, Juan M

2015-06-08

Redox cycles of manganese oxides (Mn2 O3 /Mn3 O4 ) are a promising alternative for thermochemical heat storage systems coupled to concentrated solar power plants as manganese oxides are abundant and inexpensive materials. Although their cyclability for such a purpose has been proved, sintering processes, related to the high-temperature conditions at which charge-discharge cycles are performed, generally cause a cycle-to-cycle decrease in the oxidation rate of Mn3 O4 . To guarantee proper operation, both reactions should present stable reaction rates. In this study, it has been demonstrated that the incorporation of Fe, which is also an abundant material, into the manganese oxides improves the redox performance of this system by increasing the heat storage density, narrowing the redox thermal hysteresis, and, above all, stabilizing and enhancing the oxidation rate over long-term operation, which counteracts the negative effects caused by sintering, although its presence is not avoided. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Study on the influences of reduction temperature on nickel-yttria-stabilized zirconia solid oxide fuel cell anode using nickel oxide-film electrode

NASA Astrophysics Data System (ADS)

Jiao, Zhenjun; Ueno, Ai; Suzuki, Yuji; Shikazono, Naoki

2016-10-01

In this study, the reduction processes of nickel oxide at different temperatures were investigated using nickel-film anode to study the influences of reduction temperature on the initial performances and stability of nickel-yttria-stabilized zirconia anode. Compared to conventional nickel-yttria-stabilized zirconia composite cermet anode, nickel-film anode has the advantage of direct observation at nickel-yttria-stabilized zirconia interface. The microstructural changes were characterized by scanning electron microscopy. The reduction process of nickel oxide is considered to be determined by the competition between the mechanisms of volume reduction in nickel oxide-nickel reaction and nickel sintering. Electrochemical impedance spectroscopy was applied to analyze the time variation of the nickel-film anode electrochemical characteristics. The anode performances and microstructural changes before and after 100 hours discharging and open circuit operations were analyzed. The degradation of nickel-film anode is considered to be determined by the co-effect between the nickel sintering and the change of nickel-yttria-stabilized zirconia interface bonding condition.

Wire EDM for Refractory Materials

NASA Technical Reports Server (NTRS)

Zellars, G. R.; Harris, F. E.; Lowell, C. E.; Pollman, W. M.; Rys, V. J.; Wills, R. J.

1982-01-01

In an attempt to reduce fabrication time and costs, Wire Electrical Discharge Machine (Wire EDM) method was investigated as tool for fabricating matched blade roots and disk slots. Eight high-strength nickel-base superalloys were used. Computer-controlled Wire EDM technique provided high quality surfaces with excellent dimensional tolerances. Wire EDM method offers potential for substantial reductions in fabrication costs for "hard to machine" alloys and electrically conductive materials in specific high-precision applications.

Effect of Carbon in the Dielectric Fluid and Workpieces on the Characteristics of Recast Layers Machined by Electrical Discharge Machining

NASA Astrophysics Data System (ADS)

Muttamara, Apiwat; Kanchanomai, Chaosuan

2016-06-01

Electrical discharge machining (EDM) is a popular non-traditional machining technique that is usually performed in kerosene. Carbon from the kerosene is mixed into the recast layer during EDM, increasing its hardness. EDM can be performed in deionized water, which causes decarburization. We studied the effects of carbon in the dielectric fluid and workpiece on the characteristics of recast layers. Experiments were conducted using gray cast iron and mild steel workpieces in deionized water or kerosene under identical operating conditions. Scanning electron microscopy revealed that the recast layer formed on gray iron was rougher than that produced on mild steel. Moreover, the dispersion of graphite flakes in the gray iron seemed to cause subsurface cracks, even when EDM was performed in deionized water. Dendritic structures and iron carbides were found in the recast layer of gray iron treated in deionized water. Kerosene caused more microcracks to form and increased surface roughness compared with deionized water. The microcrack length per unit area of mild steel treated in deionized water was greater than that treated in kerosene, but the cracks formed in kerosene were wider. The effect of the diffusion of carbon during cooling on the characteristics of the recast layer was discussed.

Influence of cold isostatic pressing on the magnetic properties of Ni-Zn-Cu ferrite

NASA Astrophysics Data System (ADS)

Le, Trong Trung; Valdez-Nava, Zarel; Lebey, Thierry; Mazaleyrat, Frédéric

2018-04-01

In power electronics, there is the need to develop solutions to increase the power density of converters. Interleaved multicellular transformers allow interleaving many switching cells and, as a result, a possible increase in the power density. This converter is often composed of a magnetic core having the function of an intercell transformer (ICT) and, depending on the complexity of the designed architecture, its shape could be extremely complex. The switching frequencies (1-10 MHz) for the new wide band gap semiconductors (SiC, GaN) allow to interleave switching cell at higher frequencies than silicon-based semiconductors (<1 MHz). Intercell transformers must follow this increase in frequency times-fold the number of switching cells. Current applications for ICT transformers use Mn-Zn based materials, but their limit in frequency drive raises the need of higher frequency magnetic materials, such Ni-Zn ferrites. These materials can operate in medium and high power converters up to 10 MHz. We propose to use Ni0,30Zn0,57Cu0,15Fe2O4 ferrite and to compress it by cold isostatic pressing (CIP) into a a green ceramic block and to machine it to obtain the desired ICT of complex shape prior sintering. We compare the magnetic permeability spectra and hysteresis loops the CIP and uniaxially pressed ferrites. The effect of temperature and sintering time as well as high-pressure on properties will be presented in detail. The magnetic properties of the sintered cores are strongly dependent on the microstructure obtained.

Experiments for practical education in process parameter optimization for selective laser sintering to increase workpiece quality

NASA Astrophysics Data System (ADS)

Reutterer, Bernd; Traxler, Lukas; Bayer, Natascha; Drauschke, Andreas

2016-04-01

Selective Laser Sintering (SLS) is considered as one of the most important additive manufacturing processes due to component stability and its broad range of usable materials. However the influence of the different process parameters on mechanical workpiece properties is still poorly studied, leading to the fact that further optimization is necessary to increase workpiece quality. In order to investigate the impact of various process parameters, laboratory experiments are implemented to improve the understanding of the SLS limitations and advantages on an educational level. Experiments are based on two different workstations, used to teach students the fundamentals of SLS. First of all a 50 W CO2 laser workstation is used to investigate the interaction of the laser beam with the used material in accordance with varied process parameters to analyze a single-layered test piece. Second of all the FORMIGA P110 laser sintering system from EOS is used to print different 3D test pieces in dependence on various process parameters. Finally quality attributes are tested including warpage, dimension accuracy or tensile strength. For dimension measurements and evaluation of the surface structure a telecentric lens in combination with a camera is used. A tensile test machine allows testing of the tensile strength and the interpreting of stress-strain curves. The developed laboratory experiments are suitable to teach students the influence of processing parameters. In this context they will be able to optimize the input parameters depending on the component which has to be manufactured and to increase the overall quality of the final workpiece.

Effect of the silicone disclosing procedure on the shear bond strength of composite cements to ceramic restorations.

PubMed

Szep, Susanne; Schmid, Claudia; Weigl, Paul; Hahn, Lothar; Heidemann, Detlef

2003-01-01

There is no evidence-based information on how ceramic restorations with an adhesive bond between restoration material and composite cement may be influenced by a silicone disclosing agent. The aim of this study was to determine the effects of the silicone disclosing procedure on the shear bond strength of composite cements in the luting of industrial sintered and laboratory sintered ceramic restorations. Thirty standardized (15 x 10 x 9 mm) prefabricated ceramic specimens (Groups 1, 3, 5) and 30 standardized (15 x10 x 9 mm) conventionally sintered ceramic specimens (Groups 2, 4, 6) were roughened with sandpaper (800-grit). Each group contained 10 specimens. Groups 3 and 4 were conditioned with hydrofluoric acid and primed with silane solution after the use of a silicone disclosing procedure. Groups 1 and 2 served as the control groups, where no silicone disclosing procedure was performed. Groups 5 and 6 were insulated with glycerine before the silicone disclosing procedure. A glass tube (4.5 mm in diameter) was used to apply a cylinder of dual-polymerized composite cement to the conditioned surfaces. All specimens were submitted to 5000 thermocycles (5 degrees to 55 degrees C) to simulate the in vivo situation. The specimens were subjected to a shear-pull test at a constant crosshead speed of 5 mm/min with a universal testing machine. The comparative shear bond strengths were analyzed by use of Duncan's test (alpha=0.05). Shear bond strength values for Groups 1 (9.86 +/- 4.97 MPa) and 2 (9.56 +/- 4.47 Mpa) were obtained with no significant differences. Lower but significantly undifferent values were obtained for Groups 3 (7.49 +/- 4.67 MPa) and 4 (7.62 +/- 3.49 MPa) after the use of a silicone disclosing procedure. In Groups 5 (8.21 +/- 4.75 MPa) and 6 (8.22 +/- 3.59 MPa), including insulation with glycerine before the silicone disclosing procedure, no significant differences were obtained. Within the limitations of this study, the use of silicone disclosing procedures before conditioning the ceramic surface did not lead to a significant reduction of the shear bond strength between ceramic and composite cement. The ceramic materials used (industrial-sintered versus laboratory-sintered ceramic) had no significant influence on adhesion.

Boiling behavior of sodium-potassium alloy in a bench-scale solar receiver

NASA Astrophysics Data System (ADS)

Moreno, J. B.; Andraka, C. E.; Moss, T. A.

During 1989-90, a 75-kW(sub t) sodium reflux pool-boiler solar receiver was successfully demonstrated at Sandia National Laboratories. Significant features of this receiver include the following: (1) boiling sodium as the heat transfer medium, and (2) electric-discharge-machined (EDM) cavities as artificial nucleation sites to stabilize boiling. Since this first demonstration, design of a second-generation pool-boiler receiver that will bring the concept closer to commercialization has begun. For long life, the new receiver uses Haynes Alloy 230. For increased safety factors against film boiling and flooding, it has a refined shape and somewhat larger dimensions. To eliminate the need for trace heating, the receiver will boil the sodium-potassium alloy NaK-78 instead of sodium. To reduce manufacturing costs, it will use one of a number of alternatives to EDM cavities for stabilization of boiling. To control incipient-boiling superheats, especially during hot restarts, it will contain a small amount of inert gas. Before the new receiver design could be finalized, bench-scale tests of some of the proposed changes were necessary. A series of bench-scale pool boilers were built from Haynes Alloy 230 and filled with NaK-78. Various boiling-stabilizer candidates were incorporated into them, including laser-drilled cavities and a number of different sintered-powder-metal coatings. These bench-scale pool boilers have been operated at temperatures up to 750 C, heated by quartz lamps with incident radiant fluxes up to 95 W/sq cm. The effects of various orientations and added gases have been studied. Results of these studies are presented.

Improvement of MRR and surface roughness during electrical discharge machining (EDM) using aluminum oxide powder mixed dielectric fluid

NASA Astrophysics Data System (ADS)

Khan, A. A.; Mohiuddin, A. K. M.; Latif, M. A. A.

2018-01-01

This paper discusses the effect of aluminium oxide (Al203) addition to dielectric fluid during electrical discharge machining (EDM). Aluminium oxide was added to the dielectric used in the EDM process to improve its performance when machining the stainless steel AISI 304, while copper was used as the electrode. Effect of the concentration of Al203 (0.3 mg/L) in dielectric fluid was compared with EDM without any addition of Al203. Surface quality of stainless steel and the material removal rate were investigated. Design of the experiment (DOE) was used for the experimental plan. Statistical analysis was done using ANOVA and then appropriate model was designated. The experimental results show that with dispersing of aluminium oxide in dielectric fluid surface roughness was improved while the material removal rate (MRR) was increased to some extent. These indicate the improvement of EDM performance using aluminium oxide in dielectric fluid. It was also found that with increase in pulse on time both MRR and surface roughness increase sharply.

Oxide-Based Composite Electrolytes Using Na3Zr2Si2PO12/Na3PS4 Interfacial Ion Transfer.

PubMed

Noi, Kousuke; Nagata, Yuka; Hakari, Takashi; Suzuki, Kenji; Yubuchi, So; Ito, Yusuke; Sakuda, Atsushi; Hayashi, Akitoshi; Tatsumisago, Masahiro

2018-05-31

All-solid-state sodium batteries using Na 3 Zr 2 Si 2 PO 12 (NASICON) solid electrolytes are promising candidates for safe and low-cost advanced rechargeable battery systems. Although NASICON electrolytes have intrinsically high sodium-ion conductivities, their high sintering temperatures interfere with the immediate development of high-performance batteries. In this work, sintering-free NASICON-based composites with Na 3 PS 4 (NPS) glass ceramics were prepared to combine the high grain-bulk conductivity of NASICON and the interfacial formation ability of NPS. Before the composite preparation, the NASICON/NPS interfacial resistance was investigated by modeling the interface between the NASICON sintered ceramic and the NPS glass thin film. The interfacial ion-transfer resistance was very small above room temperature; the area-specific resistances at 25 and 100 °C were 15.8 and 0.40 Ω cm 2 , respectively. On the basis of this smooth ion transfer, NASICON-rich (70-90 wt %) NASICON-NPS composite powders were prepared by ball-milling fine powders of each component. The composite powders were well-densified by pressing at room temperature. Scanning electron microscopy observation showed highly dispersed sub-micrometer NASICON grains in a dense NPS matrix to form closed interfaces between the oxide and sulfide solid electrolytes. The composite green (unfired) compacts with 70 and 80 wt % NASICON exhibited high total conductivities at 100 °C of 1.1 × 10 -3 and 6.8 × 10 -4 S cm -1 , respectively. An all-solid-state Na 15 Sn 4 /TiS 2 cell was constructed using the 70 wt % NASICON composite electrolyte by the uniaxial pressing of the powder materials, and its discharge properties were evaluated at 100 °C. The cell showed the reversible capacities of about 120 mAh g -1 under the current density of 640 μA cm -2 . The prepared oxide-based composite electrolytes were thus successfully applied in all-solid-state sodium rechargeable batteries without sintering.

Progress in the development of lightweight nickel electrode

NASA Technical Reports Server (NTRS)

Britton, Doris L.

1992-01-01

The use of the lightweight nickel electrode, in place of the heavy-sintered state-of-the-art nickel electrode, will lead to improvements in specific energy and performance of the nickel-hydrogen cell. Preliminary testing indicates that a nickel fiber mat is a promising support candidate for the nickel hydroxide active material. Nickel electrodes made from fiber mats, with nickel and cobalt powder added to the fiber, were tested at LeRC. To date, over 8000 cycles have been accumulated, at 40 percent depth-of-discharge, using the lightweight fiber electrode, in a boiler plate nickel-hydrogen cell.

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

NASA Technical Reports Server (NTRS)

O'Neal, Derek

2016-01-01

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

Laser-assisted guiding of electric discharges around objects

PubMed Central

Clerici, Matteo; Hu, Yi; Lassonde, Philippe; Milián, Carles; Couairon, Arnaud; Christodoulides, Demetrios N.; Chen, Zhigang; Razzari, Luca; Vidal, François; Légaré, François; Faccio, Daniele; Morandotti, Roberto

2015-01-01

Electric breakdown in air occurs for electric fields exceeding 34 kV/cm and results in a large current surge that propagates along unpredictable trajectories. Guiding such currents across specific paths in a controllable manner could allow protection against lightning strikes and high-voltage capacitor discharges. Such capabilities can be used for delivering charge to specific targets, for electronic jamming, or for applications associated with electric welding and machining. We show that judiciously shaped laser radiation can be effectively used to manipulate the discharge along a complex path and to produce electric discharges that unfold along a predefined trajectory. Remarkably, such laser-induced arcing can even circumvent an object that completely occludes the line of sight. PMID:26601188

Research on electrodischarge drilling of polycrystalline diamond with increased gap voltage

NASA Astrophysics Data System (ADS)

Skoczypiec, Sebastian; Bizoń, Wojciech; Żyra, Agnieszka

2018-05-01

This paper presents an experimental investigation of the machining characteristics of polycrystalline diamond (PCD). Machining of PCD by conventional technologies is not an effective solution. Due to presence of cobalt this material can be machined by application of electrical discharges. On the other side, electrical conductivity of PCD is on the limit of electrodischarge machining (EDM) possibilities. Proposed paper reports experimental investigation on electrodischarge drilling of PCD samples. The test were carried out with application on of high-voltage (up to 550 V) pulse power unit for two kinds of dielectrics: carbon based (Exxsol D80) and de-ionized water. As output parameters machining accuracy (side gap), material removal rate were selected. Also, based on SEM photographs and energy dispersive X-ray spectroscopy (EDS) analysis, a qualitative evaluation of the obtained results was presented.

Optimisation of wire-cut EDM process parameter by Grey-based response surface methodology

NASA Astrophysics Data System (ADS)

Kumar, Amit; Soota, Tarun; Kumar, Jitendra

2018-03-01

Wire electric discharge machining (WEDM) is one of the advanced machining processes. Response surface methodology coupled with Grey relation analysis method has been proposed and used to optimise the machining parameters of WEDM. A face centred cubic design is used for conducting experiments on high speed steel (HSS) M2 grade workpiece material. The regression model of significant factors such as pulse-on time, pulse-off time, peak current, and wire feed is considered for optimising the responses variables material removal rate (MRR), surface roughness and Kerf width. The optimal condition of the machining parameter was obtained using the Grey relation grade. ANOVA is applied to determine significance of the input parameters for optimising the Grey relation grade.

Biocompatibility and compressive properties of Ti-6Al-4V scaffolds having Mg element.

PubMed

Kalantari, Seyed Mohammad; Arabi, Hossein; Mirdamadi, Shamsodin; Mirsalehi, Seyed Ali

2015-08-01

Porous scaffolds of Ti-6Al-4V were produced by mixing of this alloy with different amount of magnesium (Mg) powders. The mixtures were compacted in steel die by applying uniaxial pressure of 500 MPa before sintering the compacts in sealed quartz tubes at 900 °C for 2 h. Employing Archimedes׳ principle and Image Tool software, the total and open volume percentages of porosities within the scaffolds were found to be in the range of 47-64% and 41-47%, respectively. XRD results of titanium before and after sintering showed that no contamination, neither oxides nor nitrides formed during processes. Compressive properties of the scaffolds were studied using an Instron machine. The observed compressive strength and Young׳s module of the scaffolds were in the range of 72-132 MPa, and 37-47 GPa, respectively. Cell attachment and proliferation rate of MG-63 on porous samples were investigated. The results showed that proliferation rate increased with increasing Mg content. However no clear differences were observed between samples regarding cell attachment, so that bridges were observed in all cell gaps within the scaffolds. Copyright © 2015 Elsevier Ltd. All rights reserved.

Controlling corrosion rate of Magnesium alloy using powder mixed electrical discharge machining

NASA Astrophysics Data System (ADS)

Razak, M. A.; Rani, A. M. A.; Saad, N. M.; Littlefair, G.; Aliyu, A. A.

2018-04-01

Biomedical implant can be divided into permanent and temporary employment. The duration of a temporary implant applied to children and adult is different due to different bone healing rate among the children and adult. Magnesium and its alloys are compatible for the biodegradable implanting application. Nevertheless, it is difficult to control the degradation rate of magnesium alloy to suit the application on both the children and adult. Powder mixed electrical discharge machining (PM-EDM) method, a modified EDM process, has high capability to improve the EDM process efficiency and machined surface quality. The objective of this paper is to establish a formula to control the degradation rate of magnesium alloy using the PM-EDM method. The different corrosion rate of machined surface is hypothesized to be obtained by having different combinations of PM-EDM operation inputs. PM-EDM experiments are conducted using an opened-loop PM-EDM system and the in-vitro corrosion tests are carried out on the machined surface of each specimen. There are four operation inputs investigated in this study which are zinc powder concentration, peak current, pulse on-time and pulse off-time. The results indicate that zinc powder concentration is significantly affecting the response with 2 g/l of zinc powder concentration obtaining the lowest corrosion rate. The high localized temperature at the cutting zone in spark erosion process causes some of the zinc particles get deposited on the machined surface, hence improving the surface characteristics. The suspended zinc particles in the dielectric fluid have also improve the sparking efficiency and the uniformity of sparks distribution. From the statistical analysis, a formula was developed to control the corrosion rate of magnesium alloy within the range from 0.000183 mm/year to 0.001528 mm/year.

Effective Information Extraction Framework for Heterogeneous Clinical Reports Using Online Machine Learning and Controlled Vocabularies.

PubMed

Zheng, Shuai; Lu, James J; Ghasemzadeh, Nima; Hayek, Salim S; Quyyumi, Arshed A; Wang, Fusheng

2017-05-09

Extracting structured data from narrated medical reports is challenged by the complexity of heterogeneous structures and vocabularies and often requires significant manual effort. Traditional machine-based approaches lack the capability to take user feedbacks for improving the extraction algorithm in real time. Our goal was to provide a generic information extraction framework that can support diverse clinical reports and enables a dynamic interaction between a human and a machine that produces highly accurate results. A clinical information extraction system IDEAL-X has been built on top of online machine learning. It processes one document at a time, and user interactions are recorded as feedbacks to update the learning model in real time. The updated model is used to predict values for extraction in subsequent documents. Once prediction accuracy reaches a user-acceptable threshold, the remaining documents may be batch processed. A customizable controlled vocabulary may be used to support extraction. Three datasets were used for experiments based on report styles: 100 cardiac catheterization procedure reports, 100 coronary angiographic reports, and 100 integrated reports-each combines history and physical report, discharge summary, outpatient clinic notes, outpatient clinic letter, and inpatient discharge medication report. Data extraction was performed by 3 methods: online machine learning, controlled vocabularies, and a combination of these. The system delivers results with F1 scores greater than 95%. IDEAL-X adopts a unique online machine learning-based approach combined with controlled vocabularies to support data extraction for clinical reports. The system can quickly learn and improve, thus it is highly adaptable. ©Shuai Zheng, James J Lu, Nima Ghasemzadeh, Salim S Hayek, Arshed A Quyyumi, Fusheng Wang. Originally published in JMIR Medical Informatics (http://medinform.jmir.org), 09.05.2017.

Predicting discharge mortality after acute ischemic stroke using balanced data.

PubMed

Ho, King Chung; Speier, William; El-Saden, Suzie; Liebeskind, David S; Saver, Jeffery L; Bui, Alex A T; Arnold, Corey W

2014-01-01

Several models have been developed to predict stroke outcomes (e.g., stroke mortality, patient dependence, etc.) in recent decades. However, there is little discussion regarding the problem of between-class imbalance in stroke datasets, which leads to prediction bias and decreased performance. In this paper, we demonstrate the use of the Synthetic Minority Over-sampling Technique to overcome such problems. We also compare state of the art machine learning methods and construct a six-variable support vector machine (SVM) model to predict stroke mortality at discharge. Finally, we discuss how the identification of a reduced feature set allowed us to identify additional cases in our research database for validation testing. Our classifier achieved a c-statistic of 0.865 on the cross-validated dataset, demonstrating good classification performance using a reduced set of variables.

Effect of KOH Concentration and Anions on the Performance of a Ni-H2 Battery Positive Plate

NASA Technical Reports Server (NTRS)

Vaidyanathan, Hari; Robbins, Kathleen; Gopalakrishna, M. Rao

1996-01-01

The capacity and voltage behavior of electrochemically impregnated sintered nickel positive plates was examined by galvanostatic charging and discharging in a flooded electrolyte cell. Three different concentrations of potassium hydroxide (KOH) (40, 31, and 26 percent) and 31 percent KOH containing dissolved nitrate, sulfate, or silicate were investigated. The end-of-charge voltage at C/10 charge and at 10 degrees C showed the following order: 40 percent KOH greater than 31 percent KOH alone and in the presence of the anions greater than 26 percent KOH. The mid discharge voltage at C/2 discharge was higher in 26 percent KOH, almost the same for 31 percent KOH with and without added contaminants, and much lower for 40 percent KOH. The plate capacity was marginally affected by cycling in all cases except for 40 percent KOH, where the capacity declined after 1,000 cycles at 80 percent depth of discharge (DOD). At the end of cycling, all the plates tested experienced a weight loss, except in the case of 31 percent KOH, as a result of active material extrusion. Cyclic voltammetry of miniature electrodes in 31 percent KOH showed that the cathodic peak potentials are less polarized in the presence and absence of silicate at -5 degrees C compared to 25 degrees C indicating a slightly higher voltage during discharge in a Ni-H2 battery. Futhermore, the features of the current-potential profile were practically unchanged in the presence of silicate.

Biocompatibility of hydroxyapatite scaffolds processed by lithography-based additive manufacturing.

PubMed

Tesavibul, Passakorn; Chantaweroad, Surapol; Laohaprapanon, Apinya; Channasanon, Somruethai; Uppanan, Paweena; Tanodekaew, Siriporn; Chalermkarnnon, Prasert; Sitthiseripratip, Kriskrai

2015-01-01

The fabrication of hydroxyapatite scaffolds for bone tissue engineering applications by using lithography-based additive manufacturing techniques has been introduced due to the abilities to control porous structures with suitable resolutions. In this research, the use of hydroxyapatite cellular structures, which are processed by lithography-based additive manufacturing machine, as a bone tissue engineering scaffold was investigated. The utilization of digital light processing system for additive manufacturing machine in laboratory scale was performed in order to fabricate the hydroxyapatite scaffold, of which biocompatibilities were eventually evaluated by direct contact and cell-culturing tests. In addition, the density and compressive strength of the scaffolds were also characterized. The results show that the hydroxyapatite scaffold at 77% of porosity with 91% of theoretical density and 0.36 MPa of the compressive strength are able to be processed. In comparison with a conventionally sintered hydroxyapatite, the scaffold did not present any cytotoxic signs while the viability of cells at 95.1% was reported. After 14 days of cell-culturing tests, the scaffold was able to be attached by pre-osteoblasts (MC3T3-E1) leading to cell proliferation and differentiation. The hydroxyapatite scaffold for bone tissue engineering was able to be processed by the lithography-based additive manufacturing machine while the biocompatibilities were also confirmed.

Preliminary Investigation on Life Cycle Inventory of Powder Bed Fusion of Stainless Steel

NASA Astrophysics Data System (ADS)

Nyamekye, Patricia; Piili, Heidi; Leino, Maija; Salminen, Antti

Manufacturing of work pieces from stainless steel with laser additive manufacturing, known also as laser sintering or 3D printing may increase energy and material efficiency. The use of powder bed fusion offers advantages to make parts for dynamic applications of light weight and near-net-shape products. Due to these advantages among others, PBF may also reduce emissions and operational cost in various applications. However, there are only few life cycle assessment studies examining this subject despite its prospect to business opportunity. The application of Life Cycle Inventory (LCI) in Powder Bed Fusion (PBF) provides a distinct evaluation of material and energy consumption. LCI offers a possibility to improve knowledge of process efficiency. This study investigates effect of process sustainability in terms of raw material, energy and time consumption with PBF and CNC machining. The results of the experimental study indicated lower energy efficiency in the production process with PBF. This study revealed that specific energy consumption in PBF decreased when several components are built simultaneously than if they would be built individually. This is due to fact that energy consumption per part is lower. On the contrary, amount of energy needed to machine on part in case of CNC machining is lower when parts are done separately.

Plastic superconductor bearings any size, any shape, 77 k and up

NASA Technical Reports Server (NTRS)

Reick, Franklin G.

1990-01-01

Friction free bearings at 77 k or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape and postforming machining. The material is hard and abrasive. It's possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feel for LN2 can be used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material can be molded with the internal surfaces shielded by the Meissner effect. It might be thought of as the dc magnetic analogue of the Faraday cage and the inside can be called the Meissner space. It's selective. The ac fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.

Hybrid micromachining using a nanosecond pulsed laser and micro EDM

NASA Astrophysics Data System (ADS)

Kim, Sanha; Kim, Bo Hyun; Chung, Do Kwan; Shin, Hong Shik; Chu, Chong Nam

2010-01-01

Micro electrical discharge machining (micro EDM) is a well-known precise machining process that achieves micro structures of excellent quality for any conductive material. However, the slow machining speed and high tool wear are main drawbacks of this process. Though the use of deionized water instead of kerosene as a dielectric fluid can reduce the tool wear and increase the machine speed, the material removal rate (MRR) is still low. In contrast, laser ablation using a nanosecond pulsed laser is a fast and non-wear machining process but achieves micro figures of rather low quality. Therefore, the integration of these two processes can overcome the respective disadvantages. This paper reports a hybrid process of a nanosecond pulsed laser and micro EDM for micromachining. A novel hybrid micromachining system that combines the two discrete machining processes is introduced. Then, the feasibility and characteristics of the hybrid machining process are investigated compared to conventional EDM and laser ablation. It is verified experimentally that the machining time can be effectively reduced in both EDM drilling and milling by rapid laser pre-machining prior to micro EDM. Finally, some examples of complicated 3D micro structures fabricated by the hybrid process are shown.

Surface integrity and fatigue behaviour of electric discharged machined and milled austenitic stainless steel

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

Lundberg, Mattias, E-mail: mattias.lundberg@liu.se

Machining of austenitic stainless steels can result in different surface integrities and different machining process parameters will have a great impact on the component fatigue life. Understanding how machining processes affect the cyclic behaviour and microstructure are of outmost importance in order to improve existing and new life estimation models. Milling and electrical discharge machining (EDM) have been used to manufacture rectangular four-point bend fatigue test samples; subjected to high cycle fatigue. Before fatigue testing, surface integrity characterisation of the two surface conditions was conducted using scanning electron microscopy, surface roughness, residual stress profiles, and hardness profiles. Differences in cyclicmore » behaviour were observed between the two surface conditions by the fatigue testing. The milled samples exhibited a fatigue limit. EDM samples did not show the same behaviour due to ratcheting. Recrystallized nano sized grains were identified at the severely plastically deformed surface of the milled samples. Large amounts of bent mechanical twins were observed ~ 5 μm below the surface. Grain shearing and subsequent grain rotation from milling bent the mechanical twins. EDM samples showed much less plastic deformation at the surface. Surface tensile residual stresses of ~ 500 MPa and ~ 200 MPa for the milled and EDM samples respectively were measured. - Highlights: •Milled samples exhibit fatigue behaviour, but not EDM samples. •Four-point bending is not suitable for materials exhibiting pronounced ratcheting. •LAGB density can be used to quantitatively measure plastic deformation. •Grain shearing and rotation result in bent mechanical twins. •Nano sized grains evolve due to the heat of the operation.« less

Business Case Analysis of Prototype Fabrication Division Recapitalization Plan. Summary

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

Booth, Steven Richard; Benson, Faith Ann; Dinehart, Timothy Grant

Business case studies were completed to support procurement of new machines and capital equipment in the Prototype Fabrication (PF) Division SM-39 and TA-03-0102 machine shops. Economic analysis was conducted for replacing the Mazak 30Y Mill-Turn Machine in SM-39, the Haas Vertical CNC Mill in Building 102, and the Hardinge Q10/65-SP Lathe in SM-39. Analysis was also conducted for adding a NanoTech Lathe in Building 102 and a new electrical discharge machine (EDM) in SM-39 to augment current capabilities. To determine the value of switching machinery, a baseline scenario was compared with a future scenario where new machinery was purchased andmore » installed. Costs and benefits were defined via interviews with subject matter experts.« less

In-situ resource utilization in the design of advanced lunar facilities

NASA Technical Reports Server (NTRS)

1990-01-01

Resource utilization will play an important role in the establishment and support of a permanently manned lunar base. At the University of Houston - College of Architecture and the Sasakawa International Center for Space Architecture, a study team recently investigated the potential use of lunar in-situ materials in the design of lunar facilities. The team identified seven potential lunar construction materials; concrete, sulfur concrete, cast basalt, sintered basalt, glass, fiberglass, and metals. Analysis and evaluation of these materials with respect to their physical properties, processes, energy requirements, resource efficiency, and overall advantages and disadvantages lead to the selection of basalt materials as the more likely construction material for initial use on a lunar base. Basalt materials can be formed out of in-situ lunar regolith, with minor material beneficiation, by a simple process of heating and controlled cooling. The team then conceptualized a construction system that combines lunar regolith sintering and casting to make pressurized structures out of lunar resources. The design uses a machine that simultaneously excavates and sinters the lunar regolith to create a cylindrical hole, which is then enclosed with cast basalt slabs, allowing the volume to be pressurized for use as a living or work environment. Cylinder depths of up to 4 to 6 m in the lunar mare or 10 to 12 m in the lunar highlands are possible. Advantages of this construction system include maximum resource utilization, relatively large habitable volumes, interior flexibility, and minimal construction equipment needs. Conclusions of this study indicate that there is significant potential for the use of basalt, a lunar resource derived construction material, as a low cost alternative to Earth-based materials. It remains to be determined when in lunar base phasing this construction method should be implemented.

A Brain-Machine-Brain Interface for Rewiring of Cortical Circuitry after Traumatic Brain Injury

DTIC Science & Technology

2015-11-01

or asymmetric biphasic current pulses up to ~100 A with passive discharge , and W-level digital signal processing 6 (DSP) unit for real-time SAR...voltage compliance of 4.68 V with a 5 V supply, when configured for monophasic stimulation with passive discharge . The programmable microstimulator...superficial aspects of the corona radiate was evident. In the full study, impact parameters will be altered slightly (somewhat larger impact tip, slightly

Using a Guided Machine Learning Ensemble Model to Predict Discharge Disposition following Meningioma Resection.

PubMed

Muhlestein, Whitney E; Akagi, Dallin S; Kallos, Justiss A; Morone, Peter J; Weaver, Kyle D; Thompson, Reid C; Chambless, Lola B

2018-04-01

Objective  Machine learning (ML) algorithms are powerful tools for predicting patient outcomes. This study pilots a novel approach to algorithm selection and model creation using prediction of discharge disposition following meningioma resection as a proof of concept. Materials and Methods  A diversity of ML algorithms were trained on a single-institution database of meningioma patients to predict discharge disposition. Algorithms were ranked by predictive power and top performers were combined to create an ensemble model. The final ensemble was internally validated on never-before-seen data to demonstrate generalizability. The predictive power of the ensemble was compared with a logistic regression. Further analyses were performed to identify how important variables impact the ensemble. Results  Our ensemble model predicted disposition significantly better than a logistic regression (area under the curve of 0.78 and 0.71, respectively, p  = 0.01). Tumor size, presentation at the emergency department, body mass index, convexity location, and preoperative motor deficit most strongly influence the model, though the independent impact of individual variables is nuanced. Conclusion  Using a novel ML technique, we built a guided ML ensemble model that predicts discharge destination following meningioma resection with greater predictive power than a logistic regression, and that provides greater clinical insight than a univariate analysis. These techniques can be extended to predict many other patient outcomes of interest.

Near-Net-Shape Processing of Sintered Fibrous Ceramics Achieved

NASA Technical Reports Server (NTRS)

Angel, Paul W.

2000-01-01

A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.

CNC water-jet machining and cutting center

NASA Astrophysics Data System (ADS)

Bartlett, D. C.

1991-09-01

Computer Numerical Control (CNC) water-jet machining was investigated to determine the potential applications and cost-effectiveness that would result by establishing this capability in the engineering shops of Allied-Signal Inc., Kansas City Division (KCD). Both conductive and nonconductive samples were machined at KCD on conventional machining equipment (a three-axis conversational programmed mill and a wire electrical discharge machine) and on two current-technology water-jet machines at outside vendors. These samples were then inspected, photographed, and evaluated. The current-technology water-jet machines were not as accurate as the conventional equipment. The resolution of the water-jet equipment was only +/- 0.005 inch, as compared to +/- 0.0002 inch for the conventional equipment. The principal use for CNC water-jet machining would be as follows: Contouring to near finished shape those items made from 300 and 400 series stainless steels, titanium, Inconel, aluminum, glass, or any material whose fabrication tolerance is less than the machine resolution of +/- 0.005 inch; and contouring to finished shape those items made from Kevlar, rubber, fiberglass, foam, aluminum, or any material whose fabrication specifications allow the use of a machine with +/- 0.005 inch tolerance. Additional applications are possible because there is minimal force generated on the material being cut and because the water-jet cuts without generating dust.

Advancements in Binder Systems for Solid Freeform Fabrication

NASA Technical Reports Server (NTRS)

Cooper, Ken; Munafo, Paul (Technical Monitor)

2002-01-01

Paper will present recent developments in advanced material binder systems for solid freeform fabrication (SFF) technologies. The advantage of SFF is the capability to custom fabricate complex geometries directly from computer aided design data in layer- by-layer fashion, eliminated the need for traditional fixturing and tooling. Binders allow for the low temperature processing of 'green' structural materials, either metal, ceramic or composite, in traditional rapid prototyping machines. The greatest obstacle comes when green parts must then go through a sintering or burnout process to remove the binders and fully densify the parent material, without damaging or distorting the original part geometry. Critical issues and up-to-date assessments will be delivered on various material systems.

KOH concentration effect on the cycle life of nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Lim, H. S.; Verzwyvelt, S. A.

1985-01-01

Effects of KOH concentration on the cycle life of a sintered-type nickel electrode were studied in a boiler plate nickel-hydrogen cell at 23 C using an accelerated 45-min cycle regime at 80 percent depth of discharge. The cycle life improved greatly as the KOH concentration decreased, although the initial capacity of the cell decreased slightly. The cycle life improved by a factor of two or more when the KOH concentration was reduced from 36 to 31 percent and by a similar factor from reductions of 31 to 26 percent. For many applications, this life improvement may outweigh the initial capacity decrease.

Sintering behavior of U 80 at.%Zr powder compacts in a vacuum environment

NASA Astrophysics Data System (ADS)

Kim, Tae-Kyu; Lee, Chong-Tak; Sohn, Dong-Seong

2008-01-01

Sintering behavior of U-80 at.%Zr powder compacts in a temperature range from 1100 to 1500 °C in a vacuum of 1 × 10 -4 Pa was evaluated. The sintered density depended more on the sintering temperature than on the sintering time. The sintered specimens consisted of the δ-UZr 2 matrix with acicular α-Zr precipitates, but it still had un-reacted zirconium when the sintering temperature was 1100 °C. The uranium depletion near the surface of the specimens sintered at temperatures above 1300 °C was detected. Massive Zr(O) grains in the sintered specimen were found, and their formation was restrained when the cooling rate from the sintering temperature was increased.

[Translucency of dental zirconia ceramics sintered in conventional and microwave ovens].

PubMed

Yuemei, Jiang; Ying, Yang; Wenhui, Zhan; Guoxin, Hu; Qiuxia, Yang

2015-12-01

To evaluate the effect of microwave sintering on the translucency of zirconia and to compare these effect with those of conventional sintering. The relationship between the microstructure of specimens and translucency was investigated. A total of 10 disc-shaped specimens were fabricated from 2 commercial brands of zirconia, namely, Zenostar and Lava. Each group included 5 discs. Conventional sintering was performed according to the manufacturers' specifications. The maximum temperature for Zenostar was 1,490 °C, whereas that for Lava was 1,500 °C. The dwelling time was 2 h. The sintering temperature for microwave sintering was 1,420 °C, heating rate was 15 °C · min⁻¹, and dwelling time was 30 min. After sintering, the translucency parameter (TP) of the specimens were measured with ShadeEye NCC. The sintered density of the specimens was determined by Archimedes' method. The grain size and microstructure of the specimens were investigated by scanning electron microscopy. Density and translucency slightly increased by microwave sintering, but no significant difference was found between microwave and conventional sintering (P > 0.05). Small and uniform microstructure were obtained from microwave sintering. The mean TP of Lava was significantly higher than that of Zenostar (P < 0.001). The translucency of zirconia sintered by microwave sintering is similar to that of the zirconia sintered by conventional sintering.

[Effect of two-step sintering method on properties of zirconia ceramic].

PubMed

Huang, Hui; Wei, Bin; Zhang, Fu-Qiang; Sun, Jing; Gao, Lian

2008-04-01

To study the influence of two-step sintering method on the sintering property, mechanical properties and microstructure of zirconia ceramic. The nano-size zirconia powder were compacted and divided into two groups, one group for one-step sintering method, another group for two-step sintering method. All samples sintered at different temperature. The relative density, three-bend strength, HV hardness, fracture toughness and microstructure of sintered block were investigated. Two-step sintering method influenced the sintering property and mechanical properties of zirconia ceramic. The maximal relative density was 98.49% at 900 degrees C/1,450 degrees C sintering temperature. There were significant difference of mechanical properties between one-step sintering and two-step sintering, the three-bend strength and fracture toughness declined, hardness increased at two-step sintering. The three-bend strength, HV hardness and fracture toughness reached to maximum value as 1,059.08 MPa +/- 75.24 MPa, 1,377.00 MPa +/- 16.37 MPa and 5.92 MPa x m1/2 +/- 0.37 MPa x m1/2 at 900 degrees C/1,450 degrees C sintering temperature respectively. Microscopy revealed the relationship between the porosity and shapes of grains was correlated to strength of the zirconia ceramics. Despite of the two-step sintering method influences the properties of zirconia, it also is a promising esthetic all-ceramic dental material.

[Influence on microstructure of dental zirconia ceramics prepared by two-step sintering].

PubMed

Jian, Chao; Li, Ning; Wu, Zhikai; Teng, Jing; Yan, Jiazhen

2013-10-01

To investigate the microstructure of dental zirconia ceramics prepared by two-step sintering. Nanostructured zirconia powder was dry compacted, cold isostatic pressed, and pre-sintered. The pre-sintered discs were cut processed into samples. Conventional sintering, single-step sintering, and two-step sintering were carried out, and density and grain size of the samples were measured. Afterward, T1 and/or T2 of two-step sintering ranges were measured. Effects on microstructure of different routes, which consisted of two-step sintering and conventional sintering were discussed. The influence of T1 and/or T2 on density and grain size were analyzed as well. The range of T1 was between 1450 degrees C and 1550 degrees C, and the range of T2 was between 1250 degrees C and 1350 degrees C. Compared with conventional sintering, finer microstructure of higher density and smaller grain could be obtained by two-step sintering. Grain growth was dependent on T1, whereas density was not much related with T1. However, density was dependent on T2, and grain size was minimally influenced. Two-step sintering could ensure a sintering body with high density and small grain, which is good for optimizing the microstructure of dental zirconia ceramics.

Parametric Optimization of Wire Electrical Discharge Machining of Powder Metallurgical Cold Worked Tool Steel using Taguchi Method

NASA Astrophysics Data System (ADS)

Sudhakara, Dara; Prasanthi, Guvvala

2017-04-01

Wire Cut EDM is an unconventional machining process used to build components of complex shape. The current work mainly deals with optimization of surface roughness while machining P/M CW TOOL STEEL by Wire cut EDM using Taguchi method. The process parameters of the Wire Cut EDM is ON, OFF, IP, SV, WT, and WP. L27 OA is used for to design of the experiments for conducting experimentation. In order to find out the effecting parameters on the surface roughness, ANOVA analysis is engaged. The optimum levels for getting minimum surface roughness is ON = 108 µs, OFF = 63 µs, IP = 11 A, SV = 68 V and WT = 8 g.

Simulation of Flywheel Energy Storage System Controls

NASA Technical Reports Server (NTRS)

Truong, Long V.; Wolff, Frederick J.; Dravid, Narayan

2001-01-01

This paper presents the progress made in the controller design and operation of a flywheel energy storage system. The switching logic for the converter bridge circuit has been redefined to reduce line current harmonics, even at the highest operating speed of the permanent magnet motor-generator. An electromechanical machine model is utilized to simulate charge and discharge operation of the inertial energy in the flywheel. Controlling the magnitude of phase currents regulates the rate of charge and discharge. The resulting improvements are demonstrated by simulation.

A Brain-Machine-Brain Interface for Rewiring of Cortical Circuitry after Traumatic Brain Injury

DTIC Science & Technology

2015-11-01

asymmetric biphasic current pulses up to ~100 A with passive discharge , and W-level digital signal processing 6 (DSP) unit for real-time SAR based on...compliance of 4.68 V with a 5 V supply, when configured for monophasic stimulation with passive discharge . The programmable microstimulator could also...severely disrupted. While the underlying white matter was intact, distortion of the most superficial aspects of the corona radiate was evident. In the

Bench-scale screening tests for a boiling sodium-potassium alloy solar receiver

NASA Astrophysics Data System (ADS)

Moreno, J. B.; Moss, T. A.

1993-06-01

Bench-scale tests were carried out in support of the design of a second-generation 75-kW(sub t) reflux pool-boiler solar receiver. The receiver will be made from Haynes Alloy 230 and will contain the sodium-potassium alloy NaK-78. The bench-scale tests used quartz lamp heated boilers to screen candidate boiling stabilization materials and methods at temperatures up to 750 degree C. Candidates that provided stable boiling were tested for hot-restart behavior. Poor stability was obtained with single 1/4-inch diameter patches of powdered metal hot press sintered onto the wetted side of the heat-input area. Laser-drilled and electric discharge machined cavities in the heated surface also performed poorly. Small additions of xenon, and heated-surface tilt out of the vertical, dramatically improved poor boiling stability; additions of helium or oxygen did not. The most stable boiling was obtained when the entire heat-input area was covered by a powdered-metal coating. The effect of heated-area size was assessed for one coating: at low incident fluxes, when even this coating performed poorly, increasing the heated-area size markedly improved boiling stability. Good hot-restart behavior was not observed with any candidate, although results were significantly better with added xenon in a boiler shortened from 3 to 2 feet. In addition to the screening tests, flash-radiography imaging of metal-vapor bubbles during boiling was attempted. Contrary to the Cole-Rohsenow correlation, these bubble-size estimates did not vary with pressure; instead they were constant, consistent with the only other alkali metal measurements, but about 1/2 their size.

Recent Advances and Research Status in Energy Conservation of Iron Ore Sintering in China

NASA Astrophysics Data System (ADS)

Wang, Yao-Zu; Zhang, Jian-Liang; Liu, Zheng-Jian; Du, Cheng-Bo

2017-11-01

For the ferrous burden of blast furnaces in China, sinter generally accounts for more than 70% and the sintering process accounts for approximately 6-10% of the total energy consumption of the iron and steel enterprise. Therefore, saving energy during the sintering process is important to reduce the energy consumption in the iron and steel industry. This paper aims to illustrate recent advances and the research status of energy conservation of iron ore sintering in China. It focuses on the development and application of energy-saving technologies such as the composite agglomeration process, sintering with high-proportion flue gas recirculation sintering, recovery of sensible heat from the sinter cooling process, homogeneous deep-bed sintering technology, and comprehensive treatment technology of leakage of sintering. Moreover, some suggestions for the future development of energy-saving technologies are put forward.

Properties and Clinical Application of Three Types of Dental Glass-Ceramics and Ceramics for CAD-CAM Technologies

PubMed Central

Ritzberger, Christian; Apel, Elke; Höland, Wolfram; Peschke, Arnd; Rheinberger, Volker M.

2010-01-01

The main properties (mechanical, thermal and chemical) and clinical application for dental restoration are demonstrated for three types of glass-ceramics and sintered polycrystalline ceramic produced by Ivoclar Vivadent AG. Two types of glass-ceramics are derived from the leucite-type and the lithium disilicate-type. The third type of dental materials represents a ZrO2 ceramic. CAD/CAM technology is a procedure to manufacture dental ceramic restoration. Leucite-type glass-ceramics demonstrate high translucency, preferable optical/mechanical properties and an application as dental inlays, onlays and crowns. Based on an improvement of the mechanical parameters, specially the strength and toughness, the lithium disilicate glass-ceramics are used as crowns; applying a procedure to machine an intermediate product and producing the final glass-ceramic by an additional heat treatment. Small dental bridges of lithium disilicate glass-ceramic were fabricated using a molding technology. ZrO2 ceramics show high toughness and strength and were veneered with fluoroapatite glass-ceramic. Machining is possible with a porous intermediate product.

Porous single-phase NiTi processed under Ca reducing vapor for use as a bone graft substitute.

PubMed

Bertheville, Bernard

2006-03-01

Porous nickel-titanium alloys (NiTi, nitinol) have recently attracted attention in clinical surgery because they are a very interesting alternative to the more brittle and less machinable conventional porous Ca-based ceramics. The main remaining limitations come from the chemical homogeneity of the as-processed porous nickel-titanium alloys, which always contain undesired secondary Ti- and Ni-rich phases. These are known to weaken the NiTi products, to favor their cavitation corrosion and to decrease their biocompatibility. Elemental nickel must also be avoided because it could give rise to several adverse tissue reactions. Therefore, the synthesis of porous single-phase NiTi alloys by using a basic single-step sintering procedure is an important step towards the processing of safe implant materials. The sintering process used in this work is based on a vapor phase calciothermic reduction operating during the NiTi compound formation. The as-processed porous nickel-titanium microstructure is single-phase and shows a uniformly open pore distribution with porosity of about 53% and pore diameters in the range 20-100 microm. Furthermore, due to the process, fine CaO layers grow on the NiTi outer and inner surfaces, acting as possible promoting agents for the ingrowth of bone cells at the implantation site.

The effect of alumina particles on the microstructural and mechanical properties of copper foams fabricated by space-holder method

NASA Astrophysics Data System (ADS)

Salvo, C.; Aguilar, C.; Lascano, S.; Pérez, L.; López, M.; Mangalaraja, R. V.

2018-05-01

The copper foam is an interesting field of research because of its several advantages as an engineering material. Powder metallurgy presents an alternative route to obtain a porous structure with high strength to weight ratio and functional properties. The viability of processing copper foam separately with two different space-holders such as ammonium hydrogen carbonate (NH4HCO3) and sodium chloride (NaCl) of 50 vol% was studied. The green compacts obtained under 200 MPa were sintered at different cycles for the complete removal of space-holder. The sintered foams were characterized by optical microscopy (OM), scanning electron microscopy (SEM) and uniaxial testing machine (UTM) to study their structural features and compressive strength, respectively. The results showed that NaCl particles were the best alternative to obtain a porous structure, hence two different sizes (1 and 0.01 μm) of alumina (Al2O3) particles with 2, 4 and 6 vol% were used to fabricate copper foams. As a result, a bimodal structure consisting of macro and micropores with a highly interconnected porosity was achieved. In addition, the smaller size alumina particles promoted a higher density of pores, however, the compressive strength was reduced for the higher volume fraction of alumina particles.

Effects of SiO2 and ZnO doping on mechanical and biological properties of 3D printed TCP scaffolds

PubMed Central

Fielding, Gary A.; Bandyopadhyay, Amit; Bose, Susmita

2011-01-01

Objectives To evaluate the effects of SiO2 (0.5 wt %) and ZnO (0.25 wt %) dopants on the mechanical and biological properties of tricalcium phosphate (TCP) scaffolds with three dimensionally (3D) interconnected pores. Methods Scaffolds were created with a commercial 3D printer. Post sintering phase analysis was determined by x-ray diffraction. Surface morphology of the scaffolds was examined by field emission electron microscopy. Mechanical strength was evaluated with a screw driven universal testing machine. MTT assay was used for cellular proliferation characteristics and cellular morphology was examined by field emission electron microscopy. Results Addition of dopants into TCP increased the average density of pure TCP from 90.8 ± 0.8% to 94.1 ± 1.6% and retarded the β to α phase transformation at high sintering temperatures, which resulted in up to 2.5 fold increase in compressive strength. In vitro cell-materials interaction studies, carried out using hFOB cells, confirmed that the addition of SiO2 and ZnO to the scaffolds facilitates faster cell proliferation when compared to pure TCP scaffolds. Significance Addition of SiO2 and ZnO dopants to the TCP scaffolds showed increased mechanical strength as well as increased cellular proliferation. PMID:22047943

Effect of sintering process on the magnetic and mechanical properties of sintered Nd-Fe-B magnets

NASA Astrophysics Data System (ADS)

Hu, Z. H.; Qu, H. J.; Zhao, J. Q.; Yan, C. J.; Liu, X. M.

2014-11-01

The magnetic and mechanical properties of sintered Nd-Fe-B magnets prepared by different sintering processes were investigated. The results showed that the intrinsic coercivity and fracture toughness of sintered Nd-Fe-B magnets first increased, and then declined with increasing annealing temperature. The optimum magnetic properties and fracture toughness of sintered Nd-Fe-B magnets were obtained at the annealing temperature of 540 °C. Sintering temperature increasing from 1047 °C to 1071 °C had hardly effect on the magnetic properties of sintered Nd-Fe-B magnets. The variation of Vickers hardness and fracture toughness was not the same with increasing sintering temperature, and the effect of sintering temperature on the mechanical properties was complex and irregular. The reasons for the variation on magnetic and mechanical properties were analyzed, and we presumed that the effect of microstructure on the mechanical properties was more sensitive than the magnetic properties through analyzing the microstructure of sintered Nd-Fe-B magnets.

New materials through a variety of sintering methods

NASA Astrophysics Data System (ADS)

Jaworska, L.; Cyboroń, J.; Cygan, S.; Laszkiewicz-Łukasik, J.; Podsiadło, M.; Novak, P.; Holovenko, Y.

2018-03-01

New sintering techniques make it possible to obtain materials with special properties that are impossible to obtain by conventional sintering techniques. This issue is especially important for ceramic materials for application under extreme conditions. Following the tendency to limit critical materials in manufacturing processes, the use of W, Si, B, Co, Cr should be limited, also. One of the cheapest and widely available materials is aluminum oxide, which shows differences in phase composition, grain size, hardness, strain and fracture toughness of the same type of powder, sintered via various methods. In this paper the alumina was sintered using the conventional free sintering process, microwave sintering, Spark Plasma Sintering (SPS), high pressure-high temperature method (HP-HT) and High Pressure Spark Plasma Sintering (HP SPS). Phase composition analysis, by X-ray diffraction of the alumina materials sintered using various methods, was carried out. For the conventional sintering method, compacts are composed of α-Al2O3 and θ-Al2O3. For compacts sintered using SPS, microwave and HP-HT methods, χ-Al2O3 and γ-Al2O3 phases were additionally present. Mechanical and physical properties of the obtained materials were compared between the methods of sintering. On the basis of images from scanning electron microscope quantitative analysis was performed to determine the degree of grain growth of alumina after sintering.

Sintering in Ceramics and Solid Oxide Fuel Cells

NASA Astrophysics Data System (ADS)

Hunt, Clay Dale

Nature's propensity to minimize energy, and the change in energy with respect to position, drives diffusion. Diffusion is a means by which mass transport resulting in the bonding of the particles of a powder compact can be achieved without melting. This phenomenon occurs in powdered materials near their melting temperature, and is referred to as "sintering". Because of the extreme melting temperature of some materials, sintering might be the only practical means of processing. The complexity and subtlety of sintering ceramics motivated the evaluation of empirical data and existing sintering models. This project examined polycrystalline cubic-zirconia sintering with and without transition-metal oxide additions that change sintering behavior. This study was undertaken to determine how sintering aids affect the driving force, and activation energy, the energy barrier that must be overcome in order for an atom or ion to diffuse, of the densification occurring during sintering. Examination of commercially-available cubic-zirconia powder sintering behavior was undertaken with dilatometry, which allows monitoring of the length change a material undergoes as it sinters, and with scanning electron microscopy, which facilitates the study of sintered-sample microstructure. MATLAB algorithms quantifying sintering results were developed. Results from this work include proposed definitions of a 26-year-old undefined function of density factor in a well-accepted mathematical model of sintering. These findings suggest activation energy is not changing with density, as is suggested by recent published results. The first numerical integration of the studied sintering model has been performed. With these tools, a measure of the activation energy of densification of cubic-zirconia with and without the addition of cobalt-oxide as a sintering aid has been performed. The resulting MATLAB algorithms can be used in future sintering studies. It is concluded that sintering enhancement achieved with cobalt-oxide addition comes from reduction in activation energy of densification of cubic-zirconia. Further, it is suggested that the activation energy of densification does not change with material density. This conclusion is supported by the sensitivity of the numerical integration of the aforementioned sintering model to changes in activation energy.

Rare earth elements in sinters from the geothermal waters (hot springs) on the Tibetan Plateau, China

NASA Astrophysics Data System (ADS)

Feng, Jin-Liang; Zhao, Zhen-Hong; Chen, Feng; Hu, Hai-Ping

2014-10-01

The mineralogical and geochemical composition of sinters from the geothermal areas on the Tibetan Plateau was determined. They occur as siliceous, salty and calcareous sinters but biogenic siliceous sinters were also found. The analyses indicate that there are no distinct inter -element relationships between individual rare earth elements (REEs) and other elements. Formed from the same geothermal water, the mineralogical and chemical composition of the sinters is influenced by their genesis and formation conditions. The REE distributions depend on the origin of the sinters. Fe-Mn phases in sinters tend to scavenge more REEs from geothermal water. Neither the REE fractionation nor the Ce anomaly seems to be associated with Fe-Mn phases in the sinters. The fourth tetrads of some sinters display weak W-type (concave) effects. In contrast, the third tetrads present large effects in some sinters due to positive Gd anomalies. The origin of the positive Eu anomalies in some sinters seems to be caused by preferential dissolution of feldspars during water-rock interaction. The complexing ligands in geothermal water may contribute significantly to the fractionation of REEs in sinters. The dominant CO32- and HCO3- complexing in geothermal water favors enrichment of heavy REEs in calcareous sinters.

Ultrasonic Abrasive Removal Of EDM Recast

NASA Technical Reports Server (NTRS)

Mandel, Johnny L.; Jacobson, Marlowe S.

1990-01-01

Ultrasonic abrasive process removes layer of recast material generated during electrical-discharge machining (EDM) of damper pocket on turbine blade. Form-fitted tool vibrated ultrasonically in damper pocket from which material removed. Vibrations activate abrasive in pocket. Amount of material removed controlled precisely.

Feasibility study of a brine boiling machine by solar energy

NASA Astrophysics Data System (ADS)

Phayom, W.

2018-06-01

This study presented the technical and operational feasibility of brine boiling machine by using solar energy instead of firewood or husk for salt production. The solar salt brine boiling machine consisted of a boiling chamber with an enhanced thermal efficiency through use of a solar brine heater. The stainless steel solar salt brine boiling chamber had dimensions of 60 cm x 70 cm x 20 cm. The steel brine heater had dimensions of 70 cm x 80 cm x 20 cm. The tilt angle of both the boiling chamber and brine heater was 20 degrees from horizontal. The brine temperature in the reservoir tank was 42°C with a flow rate of 6.64 L/h discharging into the solar boiling machine. It was found that the thermal efficiency and overall efficiency of the solar salt brine boiling machine were 0.63 and 0.38, respectively at a solar irradiance of 787.6 W/m2. The results shows that the potential of using solar energy for salt production system is feasible.

Artificial Intelligence Learning Semantics via External Resources for Classifying Diagnosis Codes in Discharge Notes.

PubMed

Lin, Chin; Hsu, Chia-Jung; Lou, Yu-Sheng; Yeh, Shih-Jen; Lee, Chia-Cheng; Su, Sui-Lung; Chen, Hsiang-Cheng

2017-11-06

Automated disease code classification using free-text medical information is important for public health surveillance. However, traditional natural language processing (NLP) pipelines are limited, so we propose a method combining word embedding with a convolutional neural network (CNN). Our objective was to compare the performance of traditional pipelines (NLP plus supervised machine learning models) with that of word embedding combined with a CNN in conducting a classification task identifying International Classification of Diseases, Tenth Revision, Clinical Modification (ICD-10-CM) diagnosis codes in discharge notes. We used 2 classification methods: (1) extracting from discharge notes some features (terms, n-gram phrases, and SNOMED CT categories) that we used to train a set of supervised machine learning models (support vector machine, random forests, and gradient boosting machine), and (2) building a feature matrix, by a pretrained word embedding model, that we used to train a CNN. We used these methods to identify the chapter-level ICD-10-CM diagnosis codes in a set of discharge notes. We conducted the evaluation using 103,390 discharge notes covering patients hospitalized from June 1, 2015 to January 31, 2017 in the Tri-Service General Hospital in Taipei, Taiwan. We used the receiver operating characteristic curve as an evaluation measure, and calculated the area under the curve (AUC) and F-measure as the global measure of effectiveness. In 5-fold cross-validation tests, our method had a higher testing accuracy (mean AUC 0.9696; mean F-measure 0.9086) than traditional NLP-based approaches (mean AUC range 0.8183-0.9571; mean F-measure range 0.5050-0.8739). A real-world simulation that split the training sample and the testing sample by date verified this result (mean AUC 0.9645; mean F-measure 0.9003 using the proposed method). Further analysis showed that the convolutional layers of the CNN effectively identified a large number of keywords and automatically extracted enough concepts to predict the diagnosis codes. Word embedding combined with a CNN showed outstanding performance compared with traditional methods, needing very little data preprocessing. This shows that future studies will not be limited by incomplete dictionaries. A large amount of unstructured information from free-text medical writing will be extracted by automated approaches in the future, and we believe that the health care field is about to enter the age of big data. ©Chin Lin, Chia-Jung Hsu, Yu-Sheng Lou, Shih-Jen Yeh, Chia-Cheng Lee, Sui-Lung Su, Hsiang-Cheng Chen. Originally published in the Journal of Medical Internet Research (http://www.jmir.org), 06.11.2017.

[Interface bond and compatibility between Mark II machining ceramic and vita VM9 veneering porcelain].

PubMed

Liu, Tian-Shuang; Li, Zhen-Chun; Chen, Xiao-Dong

2009-04-01

To investigate the interface bond and thermal compatibility between Mark II machining ceramic and Vita VM9 veneering porcelain. A bar shaped specimen (30 mm x 15 mm x 1 mm in size) of Mark II block was prepared, with 0.5 mm-deep notch (vertical to the long axis of specimen) at the middle of the bottom surface. The upper surface was veneered with 0.3 mm VM9 dentin base porcelain. Then the specimen was fractured from the notching site and the fracture surface was examined under scanning electron microscope (SEM) and electron microprobe analyzer (EMPA) with electron beam of 1 microm in diameter. Another ten specimens (30 mm x 15 mm x 1.5 mm in size) were fabricated and the temperature of thermal shock resistance were tested. SEM observation showed tight bond between these two materials and EMPA results showed penetration of Al element from Mark II block into veneering porcelain and Ca element from veneering porcelain into Mark II block occurred after sintering baking. The average temperature of thermal shock resistance for specimens in this study was (194.0+/-10.3) degrees C. Cracks were mainly distributed in veneering porcelain. Chemical bond exists between the Mark II machining ceramic and Vita VM9 veneering porcelain, and there is good thermal compatibility between them.

Flash sintering of stoichiometric and hyper-stoichiometric urania

DOE PAGES

Valdez, James Anthony; Byler, Darrin David; Kardoulaki, Erofili; ...

2018-03-29

Flash sintering (FS), a novel fabrication technique belonging to the family of field assisted sintering (FAS) techniques, has been utilized in this study to fabricate uranium dioxide (UO 2) pellets. Stoichiometric (UO 2.00) and hyper-stoichiometric (UO 2.16) pellets were flash sintered at 600 °C within a few (2–3) minutes. This is in sharp contrast to conventional sintering where temperatures hundreds of degrees higher are necessary and the sintering time extends to hours. Relating this in terms of the homologous temperature ratio (T H) for both conditions shows that in the case of flash sintering at 600 °C, T H =more » 0.3 versus T H = 0.6 for conventional sintering at 1600 °C. The highest density achieved for a UO 2.00 pellet was 81% theoretical density (TD) when flash sintered at 600 °C for 184 s at a field of 188 V/cm and a current density of 442 mA/mm 2. For the UO 2.16 pellet, the highest achieved density was 92% TD when flash sintered at 600 °C for 140 s at a field of 188 V/cm and a current density of 632 mA/mm 2. X-ray diffraction (XRD) characterization of the sintered pellets showed the final sintered material to be single cubic fluorite phase. Scanning electron microscopy (SEM) of longitudinal sections revealed non-uniform microstructures with regions of high density where the grain size ranged from 1 to 15 μm. Comparisons between conventionally and flash sintered pellets that achieved equivalent shrinkage strains were also conducted. Lastly, in all cases, the flash sintered pellets achieved similar densification to the conventionally sintered pellets at much lower furnace temperatures and shorter times.« less

Flash sintering of stoichiometric and hyper-stoichiometric urania

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

Valdez, James Anthony; Byler, Darrin David; Kardoulaki, Erofili

Flash sintering (FS), a novel fabrication technique belonging to the family of field assisted sintering (FAS) techniques, has been utilized in this study to fabricate uranium dioxide (UO 2) pellets. Stoichiometric (UO 2.00) and hyper-stoichiometric (UO 2.16) pellets were flash sintered at 600 °C within a few (2–3) minutes. This is in sharp contrast to conventional sintering where temperatures hundreds of degrees higher are necessary and the sintering time extends to hours. Relating this in terms of the homologous temperature ratio (T H) for both conditions shows that in the case of flash sintering at 600 °C, T H =more » 0.3 versus T H = 0.6 for conventional sintering at 1600 °C. The highest density achieved for a UO 2.00 pellet was 81% theoretical density (TD) when flash sintered at 600 °C for 184 s at a field of 188 V/cm and a current density of 442 mA/mm 2. For the UO 2.16 pellet, the highest achieved density was 92% TD when flash sintered at 600 °C for 140 s at a field of 188 V/cm and a current density of 632 mA/mm 2. X-ray diffraction (XRD) characterization of the sintered pellets showed the final sintered material to be single cubic fluorite phase. Scanning electron microscopy (SEM) of longitudinal sections revealed non-uniform microstructures with regions of high density where the grain size ranged from 1 to 15 μm. Comparisons between conventionally and flash sintered pellets that achieved equivalent shrinkage strains were also conducted. Lastly, in all cases, the flash sintered pellets achieved similar densification to the conventionally sintered pellets at much lower furnace temperatures and shorter times.« less

Flash sintering of stoichiometric and hyper-stoichiometric urania

NASA Astrophysics Data System (ADS)

Valdez, J. A.; Byler, D. D.; Kardoulaki, E.; Francis, J. S. C.; McClellan, K. J.

2018-07-01

Flash sintering (FS), a novel fabrication technique belonging to the family of field assisted sintering (FAS) techniques, has been utilized in this study to fabricate uranium dioxide (UO2) pellets. Stoichiometric (UO2.00) and hyper-stoichiometric (UO2.16) pellets were flash sintered at 600 °C within a few (2-3) minutes. This is in sharp contrast to conventional sintering where temperatures hundreds of degrees higher are necessary and the sintering time extends to hours. Relating this in terms of the homologous temperature ratio (TH) for both conditions shows that in the case of flash sintering at 600 °C, TH = 0.3 versus TH = 0.6 for conventional sintering at 1600 °C. The highest density achieved for a UO2.00 pellet was 81% theoretical density (TD) when flash sintered at 600 °C for 185 s at a field of 188 V/cm and a current density of 442 mA/mm2. For the UO2.16 pellet, the highest achieved density was 91% TD when flash sintered at 600 °C for 123 s at a field of 188 V/cm and a current density of 632 mA/mm2. X-ray diffraction (XRD) characterization of the sintered pellets showed the final sintered material to be single cubic fluorite phase. Scanning electron microscopy (SEM) of longitudinal sections revealed non-uniform microstructures with regions of high density where the grain size ranged from 1 to 15 μm. Comparisons between conventionally and flash sintered pellets that achieved equivalent shrinkage strains were also conducted. In all cases, the flash sintered pellets achieved similar densification to the conventionally sintered pellets at much lower furnace temperatures and shorter times.

Parallel Large-Scale Molecular Dynamics Simulation Opens New Perspective to Clarify the Effect of a Porous Structure on the Sintering Process of Ni/YSZ Multiparticles.

PubMed

Xu, Jingxiang; Higuchi, Yuji; Ozawa, Nobuki; Sato, Kazuhisa; Hashida, Toshiyuki; Kubo, Momoji

2017-09-20

Ni sintering in the Ni/YSZ porous anode of a solid oxide fuel cell changes the porous structure, leading to degradation. Preventing sintering and degradation during operation is a great challenge. Usually, a sintering molecular dynamics (MD) simulation model consisting of two particles on a substrate is used; however, the model cannot reflect the porous structure effect on sintering. In our previous study, a multi-nanoparticle sintering modeling method with tens of thousands of atoms revealed the effect of the particle framework and porosity on sintering. However, the method cannot reveal the effect of the particle size on sintering and the effect of sintering on the change in the porous structure. In the present study, we report a strategy to reveal them in the porous structure by using our multi-nanoparticle modeling method and a parallel large-scale multimillion-atom MD simulator. We used this method to investigate the effect of YSZ particle size and tortuosity on sintering and degradation in the Ni/YSZ anodes. Our parallel large-scale MD simulation showed that the sintering degree decreased as the YSZ particle size decreased. The gas fuel diffusion path, which reflects the overpotential, was blocked by pore coalescence during sintering. The degradation of gas diffusion performance increased as the YSZ particle size increased. Furthermore, the gas diffusion performance was quantified by a tortuosity parameter and an optimal YSZ particle size, which is equal to that of Ni, was found for good diffusion after sintering. These findings cannot be obtained by previous MD sintering studies with tens of thousands of atoms. The present parallel large-scale multimillion-atom MD simulation makes it possible to clarify the effects of the particle size and tortuosity on sintering and degradation.

49 CFR 571.224 - Standard No. 224; Rear impact protection.

Code of Federal Regulations, 2010 CFR

2010-10-01

... trailers, pulpwood trailers, road construction controlled horizontal discharge trailers, special purpose... latches are excluded from the determination of the rearmost point. Road construction controlled horizontal... machine or paving equipment for road construction and paving operations. Rounded corner means a guard's...

Preparation of Ti3Al intermetallic compound by spark plasma sintering

NASA Astrophysics Data System (ADS)

Ito, Tsutomu; Fukui, Takahiro

2018-04-01

Sintered compacts of single phase Ti3Al intermetallic compound, which have excellent potential as refractory materials, were prepared by spark plasma sintering (SPS). A raw powder of Ti3Al intermetallic compound with an average powder diameter of 176 ± 56 μm was used in this study; this large powder diameter is disadvantageous for sintering because of the small surface area. The samples were prepared at sintering temperatures (Ts) of 1088, 1203, and 1323 K, sintering stresses (σs) of 16, 32, and 48 MPa, and a sintering time (ts) of 10 min. The calculated relative densities based on the apparent density of Ti3Al provided by the supplier were approximately 100% under all sintering conditions. From the experimental results, it was evident that SPS is an effective technique for dense sintering of Ti3Al intermetallic compounds in a short time interval. In this report, the sintering characteristics of Ti3Al intermetallic compacts are briefly discussed and compared with those of pure titanium compacts.

KOH concentration effect on cycle life of nickel-hydrogen cells

NASA Technical Reports Server (NTRS)

Lim, Hong S.; Verzwyvelt, S. A.

1987-01-01

A cycle life test of Ni/H2 cells containing electrolytes of various KOH concentrations and a sintered type nickel electrode was carried out at 23 C using a 45 min accelerated low Earth orbit (LEO) cycle regime at 80 percent depth of discharge. One of three cells containing 26 percent KOH has achieved over 28,000 cycles, and the other two 19,000 cycles, without a sign of failure. Two other cells containing 31 percent KOH electrolyte, which is the concentration presently used in aerospace cells, failed after 2,979 and 3,620 cycles. This result indicates that the cycle life of the present type of Ni/H2 cells may be extended by a factor of 5 to 10 simply by lowering the KOH concentration. Long cycle life of a Ni/H2 battery at high depth-of-discharge operation is desired, particularly for an LEO spacecraft application. Typically, battery life of about 30,000 cycles is required for a five year mission in an LEO. Such a cycle life with presently available cells can be assured only at a very low depth-of-discharge operation. Results of testing already show that the cycle life of an Ni/H2 cell is tremendously improved by simply using an electrolyte of low KOH concentration.

Properties of ceramics prepared using dry discharged waste to energy bottom ash dust.

PubMed

Bourtsalas, Athanasios; Vandeperre, Luc; Grimes, Sue; Themelis, Nicolas; Koralewska, Ralf; Cheeseman, Chris

2015-09-01

The fine dust of incinerator bottom ash generated from dry discharge systems can be transformed into an inert material suitable for the production of hard, dense ceramics. Processing involves the addition of glass, ball milling and calcining to remove volatile components from the incinerator bottom ash. This transforms the major crystalline phases present in fine incinerator bottom ash dust from quartz (SiO(2)), calcite (CaCO(3)), gehlenite (Ca(2)Al(2)SiO(7)) and hematite (Fe(2)O(3)), to the pyroxene group minerals diopside (CaMgSi(2)O(6)), clinoenstatite (MgSi(2)O(6)), wollastonite (CaSiO(3)) together with some albite (NaAlSi(3)O(8)) and andradite (Ca(3)Fe(2)Si(3)O(12)). Processed powders show minimal leaching and can be pressed and sintered to form dense (>2.5 g cm(-3)), hard ceramics that exhibit low firing shrinkage (<7%) and zero water absorption. The research demonstrates the potential to beneficially up-cycle the fine incinerator bottom ash dust from dry discharge technology into a raw material suitable for the production of ceramic tiles that have potential for use in a range of industrial applications. © The Author(s) 2015.

Preliminary study on zinc-air battery using zinc regeneration electrolysis with propanol oxidation as a counter electrode reaction

NASA Astrophysics Data System (ADS)

Wen, Yue-Hua; Cheng, Jie; Ning, Shang-Qi; Yang, Yu-Sheng

A zinc-air battery using zinc regeneration electrolysis with propanol oxidation as a counter electrode reaction is reported in this paper. It possesses functions of both zincate reduction and electrochemical preparation, showing the potential for increasing the electronic energy utilization. Charge/discharge tests and scanning electron microscopy (SEM) micrographs reveal that when a nickel sheet plated with the high-H 2-overpotential metal, cadmium, was used as the negative substrate electrode, the dendritic formation and hydrogen evolution are suppressed effectively, and granular zinc deposits become larger but relatively dense with the increase of charge time. The performance of batteries is favorable even if the charge time is as long as 5 h at the current density of 20 mA cm -2. Better discharge performance is achieved using a 'cavity-opening' configuration for the discharge cell rather than a 'gas-introducing' configuration. The highest energy efficiency is up to 59.2%. That is, the energy consumed by organic electro-synthesis can be recovered by 59.2%. Cyclic voltammograms show that the sintered nickel electrode exhibits a good electro-catalysis activity for the propanol oxidation. The increase of propanol concentration conduces to an enhancement in the organic electro-synthesis efficiency. The organic electro-synthesis current efficiency of 82% can be obtained.

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision

PubMed Central

Wu, Dung-Sheng

2018-01-01

Spark-assisted chemical engraving (SACE) is a non-traditional machining technology that is used to machine electrically non-conducting materials including glass, ceramics, and quartz. The processing accuracy, machining efficiency, and reproducibility are the key factors in the SACE process. In the present study, a machine vision method is applied to monitor and estimate the status of a SACE-drilled hole in quartz glass. During the machining of quartz glass, the spring-fed tool electrode was pre-pressured on the quartz glass surface to feed the electrode that was in contact with the machining surface of the quartz glass. In situ image acquisition and analysis of the SACE drilling processes were used to analyze the captured image of the state of the spark discharge at the tip and sidewall of the electrode. The results indicated an association between the accumulative size of the SACE-induced spark area and deepness of the hole. The results indicated that the evaluated depths of the SACE-machined holes were a proportional function of the accumulative spark size with a high degree of correlation. The study proposes an innovative computer vision-based method to estimate the deepness and status of SACE-drilled holes in real time. PMID:29565303

Characteristics of the Arcing Plasma Formation Effect in Spark-Assisted Chemical Engraving of Glass, Based on Machine Vision.

PubMed

Ho, Chao-Ching; Wu, Dung-Sheng

2018-03-22

Spark-assisted chemical engraving (SACE) is a non-traditional machining technology that is used to machine electrically non-conducting materials including glass, ceramics, and quartz. The processing accuracy, machining efficiency, and reproducibility are the key factors in the SACE process. In the present study, a machine vision method is applied to monitor and estimate the status of a SACE-drilled hole in quartz glass. During the machining of quartz glass, the spring-fed tool electrode was pre-pressured on the quartz glass surface to feed the electrode that was in contact with the machining surface of the quartz glass. In situ image acquisition and analysis of the SACE drilling processes were used to analyze the captured image of the state of the spark discharge at the tip and sidewall of the electrode. The results indicated an association between the accumulative size of the SACE-induced spark area and deepness of the hole. The results indicated that the evaluated depths of the SACE-machined holes were a proportional function of the accumulative spark size with a high degree of correlation. The study proposes an innovative computer vision-based method to estimate the deepness and status of SACE-drilled holes in real time.

Mineral Phases and Release Behaviors of As in the Process of Sintering Residues Containing As at High Temperature

PubMed Central

Wang, Xingrun; Zhang, Fengsong; Nong, Zexi

2014-01-01

To investigate the effect of sintering temperature and sintering time on arsenic volatility and arsenic leaching in the sinter, we carried out experimental works and studied the structural changes of mineral phases and microstructure observation of the sinter at different sintering temperatures. Raw materials were shaped under the pressure of 10 MPa and sintered at 1000~1350°C for 45 min with air flow rate of 2000 mL/min. The results showed that different sintering temperatures and different sintering times had little impact on the volatilization of arsenic, and the arsenic fixed rate remained above 90%; however, both factors greatly influenced the leaching concentration of arsenic. Considering the product's environmental safety, the best sintering temperature was 1200°C and the best sintering time was 45 min. When sintering temperature was lower than 1000°C, FeAsS was oxidized into calcium, aluminum, and iron arsenide, mainly Ca3(AsO4)2 and AlAsO4, and the arsenic leaching was high. When it increased to 1200°C, arsenic was surrounded by a glass matrix and became chemically bonded inside the matrix, which lead to significantly lower arsenic leaching. PMID:24723798

Sintering and microstructure of silicon carbide ceramic with Y3Al5O12 added by sol-gel method*

PubMed Central

Guo, Xing-zhong; Yang, Hui

2005-01-01

Silicon carbide (SiC) ceramic with YAG (Y3Al5O12) additive added by sol-gel method was liquid-phase sintered at different sintering temperatures, and the sintering mechanism and microstructural characteristics of resulting silicon carbide ceramics were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM) and elemental distribution of surface (EDS). YAG (yttrium aluminum garnet) phase formed before the sintering and its uniform distribution in the SiC/YAG composite powder decreased the sintering temperature and improved the densification of SiC ceramic. The suitable sintering temperature was 1860 °C with the specimen sintered at this temperature having superior sintering and mechanical properties, smaller crystal size and fewer microstructure defects. Three characteristics of improved toughness of SiC ceramic with YAG added by sol-gel method were microstructural densification, main-crack deflection and crystal ‘bridging’. PMID:15682507

Effect of Process Parameter on Barium Titanate Stannate (BTS) Materials Sintered at Low Sintering

NASA Astrophysics Data System (ADS)

Shukla, Alok; Bajpai, P. K.

2011-11-01

Ba(Ti1-xSnx)O3 solid solutions with (x = 0.15, 0.20, 0.30 and 0.40) are synthesized using conventional solid state reaction method. Formation of solid solutions in the range 0 ≤ x ≤0.40 is confirmed using X-ray diffraction technique. Single phase solid solutions with homogeneous grain distribution are observed at relatively low sintering by controlling process parameters viz. sintering time. Composition at optimized temperature (1150 °C) sintered by varying the sintering time, stabilize in cubic perovskite phase. The % experimental density increase with increasing the time of sintering instead of increasing sintering temperature. The lattice parameter increases by increasing the tin composition in the material. This demonstrates that process parameter optimization can lead to single phase at relatively lower sintering-a major advantage for the materials used as capacitor element in MLCC.

Fast sintering of silver nanoparticle and flake layers by infrared module assistance in large area roll-to-roll gravure printing system

PubMed Central

Park, Janghoon; Kang, Hyi Jae; Shin, Kee-Hyun; Kang, Hyunkyoo

2016-01-01

We present fast sintering for silver (Ag) nanoparticle (NP) and flake layers printed using roll-to-roll (R2R) gravure printing. An infrared (IR) sintering module was applied to an R2R system to shorten the sintering duration of an R2R gravure-printed Ag layer. IR sintering of the conductive layer was improved by optimising the process condition. After printing of the Ag NP and Ag flake layers, additional IR sintering was performed in the R2R system. The lowest sheet resistance obtained in the Ag NP layer was 0.294 Ω/□, the distance between the substrate and lamp was 50-mm long, the IR lamp power was 500 W, and the sintering time was 5.4 s. The fastest sintering of 0.34 Ω/□ was achieved with 50-mm distance, 1,000-W IR lamp power, and 1.08-s sintering time. In the Ag flake layer, the lowest sheet resistance obtained was 0.288 Ω/□ with a 20-mm distance, 1,000-W IR lamp power, and 10.8-s sintering time. Meanwhile, the fastest sintering was obtained with a 3.83 Ω/□ sheet resistance, 20-mm distance, 1000-W IR lamp, and 1.08-s sintering time. Thus, the IR sintering module can easily be employed in an R2R system to obtain excellent layer sheet resistance. PMID:27713469

Sintering behavior and mechanical properties of zirconia compacts fabricated by uniaxial press forming.

PubMed

Oh, Gye-Jeong; Yun, Kwi-Dug; Lee, Kwang-Min; Lim, Hyun-Pil; Park, Sang-Won

2010-09-01

The purpose of this study was to compare the linear sintering behavior of presintered zirconia blocks of various densities. The mechanical properties of the resulting sintered zirconia blocks were then analyzed. Three experimental groups of dental zirconia blocks, with a different presintering density each, were designed in the present study. Kavo Everest® ZS blanks (Kavo, Biberach, Germany) were used as a control group. The experimental group blocks were fabricated from commercial yttria-stabilized tetragonal zirconia powder (KZ-3YF (SD) Type A, KCM. Corporation, Nagoya, Japan). The biaxial flexural strengths, microhardnesses, and microstructures of the sintered blocks were then investigated. The linear sintering shrinkages of blocks were calculated and compared. Despite their different presintered densities, the sintered blocks of the control and experimental groups showed similar mechanical properties. However, the sintered block had different linear sintering shrinkage rate depending on the density of the presintered block. As the density of the presintered block increased, the linear sintering shrinkage decreased. In the experimental blocks, the three sectioned pieces of each block showed the different linear shrinkage depending on the area. The tops of the experimental blocks showed the lowest linear sintering shrinkage, whereas the bottoms of the experimental blocks showed the highest linear sintering shrinkage. Within the limitations of this study, the density difference of the presintered zirconia block did not affect the mechanical properties of the sintered zirconia block, but affected the linear sintering shrinkage of the zirconia block.

Sintering behavior and mechanical properties of zirconia compacts fabricated by uniaxial press forming

PubMed Central

Oh, Gye-Jeong; Yun, Kwi-Dug; Lee, Kwang-Min; Lim, Hyun-Pil

2010-01-01

PURPOSE The purpose of this study was to compare the linear sintering behavior of presintered zirconia blocks of various densities. The mechanical properties of the resulting sintered zirconia blocks were then analyzed. MATERIALS AND METHODS Three experimental groups of dental zirconia blocks, with a different presintering density each, were designed in the present study. Kavo Everest® ZS blanks (Kavo, Biberach, Germany) were used as a control group. The experimental group blocks were fabricated from commercial yttria-stabilized tetragonal zirconia powder (KZ-3YF (SD) Type A, KCM. Corporation, Nagoya, Japan). The biaxial flexural strengths, microhardnesses, and microstructures of the sintered blocks were then investigated. The linear sintering shrinkages of blocks were calculated and compared. RESULTS Despite their different presintered densities, the sintered blocks of the control and experimental groups showed similar mechanical properties. However, the sintered block had different linear sintering shrinkage rate depending on the density of the presintered block. As the density of the presintered block increased, the linear sintering shrinkage decreased. In the experimental blocks, the three sectioned pieces of each block showed the different linear shrinkage depending on the area. The tops of the experimental blocks showed the lowest linear sintering shrinkage, whereas the bottoms of the experimental blocks showed the highest linear sintering shrinkage. CONCLUSION Within the limitations of this study, the density difference of the presintered zirconia block did not affect the mechanical properties of the sintered zirconia block, but affected the linear sintering shrinkage of the zirconia block. PMID:21165274

Sintering of MSW fly ash for reuse as a concrete aggregate.

PubMed

Mangialardi, T

2001-10-12

The sintering process of municipal solid waste (MSW) fly ash was investigated in order to manufacture sintered products for reuse as concrete aggregates. Four types of fly ash resulting from different Italian MSW incineration plants were tested in this study. A modification of the chemical composition of MSW fly ash--through a preliminary four-stage washing treatment of this material with water--was attempted to improve the chemical and mechanical characteristics of sintered products.The sintering treatment of untreated or washed fly ash was performed on cylindrical compact specimens (15 mm in diameter and 20mm in height) at different compact pressures, sintering temperatures and times.The sintering process of untreated MSW fly ashes proved to be ineffective for manufacturing sintered products for reuse as a construction material, because of the adverse chemical characteristics of these fly ashes in terms of sulfate, chloride, and vitrifying oxide contents.A preliminary washing treatment of MSW fly ash with water greatly improved the chemical and mechanical characteristics of sintered products and, for all the types of fly ash tested, the sintered products satisfied the Italian requirements for normal weight aggregates for use in concretes having a specified strength not greater than 12 and 15N/mm(2), when measured on cylindrical and cubic specimens, respectively.A compact pressure of 28 N/mm(2), a sintering temperature of 1140 degrees C, and a sintering time of 60 min were the best operating conditions for manufacturing sintered products of washed MSW fly ash.

Multi-Thruster Propulsion Apparatus

NASA Technical Reports Server (NTRS)

Patterson, Michael J. (Inventor)

2016-01-01

An electric propulsion machine includes an ion thruster having a discharge chamber housing a large surface area anode. The ion thruster includes flat annular ion optics with a small span to gap ratio. Optionally, at least a second thruster may be disposed radially offset from the ion thruster.

4th level of 1913 elevator indicating sacking scale, part of ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

4th level of 1913 elevator indicating sacking scale, part of the bagging system and nate to the sewing machine. Discharge spout for the grain bin to the left - Stewart Company Grain Elevator, 16 West Carson Street, Pittsburgh, Allegheny County, PA

Effect of the application of surface treatments before and after sintering on the flexural strength, phase transformation and surface topography of zirconia.

PubMed

Kurtulmus-Yilmaz, Sevcan; Aktore, Huseyin

2018-05-01

To evaluate the effects of airborne-particle abrasion (APA) and Er,Cr:YSGG laser irradiation on 4-point-flexural strength, phase transformation and morphologic changes of zirconia ceramics treated at pre-sintered or post-sintered stage. Three hundred and forty-two bar shaped zirconia specimens were milled with different sizes according to the flexural strength test (n = 10), X-ray diffraction (XRD) (n = 4) and field emission scanning electron microscope (FE-SEM) (n = 4) analyses. For each test protocol, specimens were divided into 4 main groups whether the surface treatments applied before or after sintering and whether the specimens received heat treatment or not as pre-sintered, post-sintered no-heat and post-sintered heat-treated groups, and a group was served as control. Main groups were further divided into 6 equal subgroups according to surface treatment method applied (2 W-, 3 W-, 4 W-, 5 W-, 6 W-laser irradiations and APA). Surface treatments were applied to pre-sintered groups before sintering and to post-sintered groups after sintering. Post-sintered heat-treated groups were subjected to veneer ceramic firing simulation after surface treatments. Flexural strength and flexural modulus values were statistically analysed and monoclinic phase content was calculated. Weibull analysis was used to evaluate strength reliability and fractographic analysis was conducted. Highest flexural strength values were detected at post-sintered no-heat APA and 4W-laser groups (P < 0.05). Pre-sintered groups showed statistically lower flexural strength values. Heat treatment decreased the strength of the specimens. Monoclinic phase content was only detected at post-sintered no-heat groups and the highest amount was detected at APA group. Rougher surfaces and deeper irregularities were detected at FE-SEM images pre-sintered groups. Application of surface treatments at pre-sintered stage may be detrimental for zirconia ceramics in terms of flexural strength. Treating the surface of zirconia ceramic before sintering process is not recommended due to significant decrease in flexural strength values. 2 W-4 W Er,Cr:YSGG laser irradiations can be regarded as alternative surface treatment methods when zirconia restoration would be subjected to veneer ceramic firing procedures. Copyright © 2018 Elsevier Ltd. All rights reserved.

A hybrid least squares support vector machines and GMDH approach for river flow forecasting

NASA Astrophysics Data System (ADS)

Samsudin, R.; Saad, P.; Shabri, A.

2010-06-01

This paper proposes a novel hybrid forecasting model, which combines the group method of data handling (GMDH) and the least squares support vector machine (LSSVM), known as GLSSVM. The GMDH is used to determine the useful input variables for LSSVM model and the LSSVM model which works as time series forecasting. In this study the application of GLSSVM for monthly river flow forecasting of Selangor and Bernam River are investigated. The results of the proposed GLSSVM approach are compared with the conventional artificial neural network (ANN) models, Autoregressive Integrated Moving Average (ARIMA) model, GMDH and LSSVM models using the long term observations of monthly river flow discharge. The standard statistical, the root mean square error (RMSE) and coefficient of correlation (R) are employed to evaluate the performance of various models developed. Experiment result indicates that the hybrid model was powerful tools to model discharge time series and can be applied successfully in complex hydrological modeling.

Bearingless AC Homopolar Machine Design and Control for Distributed Flywheel Energy Storage

NASA Astrophysics Data System (ADS)

Severson, Eric Loren

The increasing ownership of electric vehicles, in-home solar and wind generation, and wider penetration of renewable energies onto the power grid has created a need for grid-based energy storage to provide energy-neutral services. These services include frequency regulation, which requires short response-times, high power ramping capabilities, and several charge cycles over the course of one day; and diurnal load-/generation-following services to offset the inherent mismatch between renewable generation and the power grid's load profile, which requires low self-discharge so that a reasonable efficiency is obtained over a 24 hour storage interval. To realize the maximum benefits of energy storage, the technology should be modular and have minimum geographic constraints, so that it is easily scalable according to local demands. Furthermore, the technology must be economically viable to participate in the energy markets. There is currently no storage technology that is able to simultaneously meet all of these needs. This dissertation focuses on developing a new energy storage device based on flywheel technology to meet these needs. It is shown that the bearingless ac homopolar machine can be used to overcome key obstacles in flywheel technology, namely: unacceptable self-discharge and overall system cost and complexity. Bearingless machines combine the functionality of a magnetic bearing and a motor/generator into a single electromechanical device. Design of these machines is particularly challenging due to cross-coupling effects and trade-offs between motor and magnetic bearing capabilities. The bearingless ac homopolar machine adds to these design challenges due to its 3D flux paths requiring computationally expensive 3D finite element analysis. At the time this dissertation was started, bearingless ac homopolar machines were a highly immature technology. This dissertation advances the state-of-the-art of these machines through research contributions in the areas of magnetic modeling, winding design, control, and power-electronic drive implementation. While these contributions are oriented towards facilitating more optimal flywheel designs, they will also be useful in applying the bearingless ac homopolar machine in other applications. Example designs are considered through finite element analysis and experimental validation is provided from a proof-of-concept prototype that has been designed and constructed as a part of this dissertation.

Pressureless sintering of whisker-toughened ceramic composites

DOEpatents

Tiegs, T.N.

1993-05-04

A pressureless sintering method is disclosed for use in the production of whisker-toughened ceramic composites wherein the sintered density of composites containing up to about 20 vol. % SiC whiskers is improved by reducing the average aspect ratio of the whiskers to from about 10 to about 20. Sintering aids further improve the density, permitting the production of composites containing 20 vol. % SiC with sintered densities of 94% or better of theoretical density by a pressureless sintering method.

Pressureless sintering of whiskered-toughened ceramic composites

DOEpatents

Tiegs, Terry N.

1994-01-01

A pressureless sintering method is disclosed for use in the production of whisker-toughened ceramic composites wherein the sintered density of composites containing up to about 20 vol. % SiC whiskers is improved by reducing the average aspect ratio of the whiskers to from about 10 to about 20. Sintering aids further improve the density, permitting the production of composites containing 20 vol. % SiC with sintered densities of 94% or better of theoretical density by a pressureless sintering method.

Pressureless sintering of whisker-toughened ceramic composites

DOEpatents

Tiegs, Terry N.

1993-01-01

A pressureless sintering method is disclosed for use in the production of whisker-toughened ceramic composites wherein the sintered density of composites containing up to about 20 vol. % SiC whiskers is improved by reducing the average aspect ratio of the whiskers to from about 10 to about 20. Sintering aids further improve the density, permitting the production of composites containing 20 vol. % SiC with sintered densities of 94% or better of theoretical density by a pressureless sintering method.

Behavior of New Zealand Ironsand During Iron Ore Sintering

NASA Astrophysics Data System (ADS)

Wang, Zhe; Pinson, David; Chew, Sheng; Rogers, Harold; Monaghan, Brian J.; Pownceby, Mark I.; Webster, Nathan A. S.; Zhang, Guangqing

2016-02-01

A New Zealand ironsand sample was characterized by scanning electron microscopy (SEM), X-ray fluorescence spectroscopy, qualitative and quantitative X-ray diffraction, and electron probe microanalysis. The titanomagnetite-rich ironsand was added into an industrial sinter blend in the proportion of 5 wt pct, and the mixture was uniaxially pressed into cylindrical tablets and sintered in a tube furnace under flowing gas with various oxygen potentials and temperatures to develop knowledge and understanding of the behavior of titanium during sintering. An industrial sinter with the addition of 3 wt pct ironsand was also examined. Both the laboratory and industrial sinters were characterized by optical and SEM. Various morphologies of relict ironsand particles were present in the industrial sinter due to the heterogeneity of sintering conditions, which could be well simulated by the bench-scale sintering experiments. The assimilation of ironsand during sintering in a reducing atmosphere started with the diffusion of calcium into the lattice of the ironsand matrix, and a reaction zone was formed near the boundary within individual ironsand particles where a perovskite phase was generated. With increasing sintering temperature, in a reducing atmosphere, ironsand particles underwent further assimilation and most of the titanium moved from the ironsand particles into a glass phase. In comparison, more titanium remained in the original ironsand particles when sintered in air. Ironsand particles are more resistant to assimilation in an oxidizing atmosphere.

Static capacity model for sealed nickel cadmium cells

NASA Astrophysics Data System (ADS)

Lomaniec, Jacob

1989-04-01

A model was developed for calculating the capacity of nickel cadmium rechargeable sealed cells. The model applies only to the following operating conditions for a cell of capacity C ampere-hours: Temperature of 20 + or - 5 C; charging for 16 hr, at 0.1 C amp; discharging at 0.2 C amp until the terminal voltage falls to 1.0 V. The study considers the dimensional and quantitative relationships among the cell's chemical and mechanical components, and the application of these relationships to optimizing cell design in terms of energy density and electrical performance. The model comprises several components, representing the several stages of the manufacturing process: assembling the electrodes and separator in a cylindrical can; production of porous, sintered nickel plaque on a perforated steel substrate; impregnating the plaque with active material; oxidation of the sintered nickel during impregnation; insertion and concentration of the electrolyte solution. Results from the model were compared with those obtained from cells manufactured during a long period. Good agreement was obtained. The models were used in the plant, to define the operating parameters of various production stages and contributed to a general improvement in product quality. The models were also applied to the optimization of new cell designs, and reduction of development costs by the elimination of much experimental work.

A comparative study of conventionally sintered and microwave sintered nickel zinc ferrite

NASA Astrophysics Data System (ADS)

Rani, Rekha; Juneja, J. K.; Raina, K. K.; Kotnala, R. K.; Prakash, Chandra

2014-04-01

For the present work, nickel zinc ferrite having compositional formula Ni0.8Zn0.2Fe2O4 was synthesized by conventional solid state method and sintered in conventional and microwave furnaces. Pellets were sintered with very short soaking time of 10 min at 1150 °C in microwave furnace whereas 4 hrs of soaking time was selected for conventional sintering at 1200 °C. Phase formation was confirmed by X-ray diffraction analysis technique. Scanning electron micrographs were taken for microstructural study. Dielectric properties were studied as a function of temperature. To study magnetic behavior, M-H hysteresis loops were recorded for both samples. It is observed that microwave sintered sample could obtain comparable properties to the conventionally sintered one in lesser soaking time at lower sintering temperature.

The laser micro-machining system for diamond anvil cell experiments and general precision machining applications at the High Pressure Collaborative Access Team

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

Hrubiak, Rostislav; Sinogeikin, Stanislav; Rod, Eric

We have designed and constructed a new system for micro-machining parts and sample assemblies used for diamond anvil cells and general user operations at the High Pressure Collaborative Access Team, sector 16 of the Advanced Photon Source. The new micro-machining system uses a pulsed laser of 400 ps pulse duration, ablating various materials without thermal melting, thus leaving a clean edge. With optics designed for a tight focus, the system can machine holes any size larger than 3 μm in diameter. Unlike a standard electrical discharge machining drill, the new laser system allows micro-machining of non-conductive materials such as: amorphousmore » boron and silicon carbide gaskets, diamond, oxides, and other materials including organic materials such as polyimide films (i.e., Kapton). An important feature of the new system is the use of gas-tight or gas-flow environmental chambers which allow the laser micro-machining to be done in a controlled (e.g., inert gas) atmosphere to prevent oxidation and other chemical reactions in air sensitive materials. The gas-tight workpiece enclosure is also useful for machining materials with known health risks (e.g., beryllium). Specialized control software with a graphical interface enables micro-machining of custom 2D and 3D shapes. The laser-machining system was designed in a Class 1 laser enclosure, i.e., it includes laser safety interlocks and computer controls and allows for routine operation. Though initially designed mainly for machining of the diamond anvil cell gaskets, the laser-machining system has since found many other micro-machining applications, several of which are presented here.« less

The influence of sintering temperature on the proliferation of fibroblastic cells in contact with HA-bioceramics.

PubMed

Frayssinet, P; Rouquet, N; Fages, J; Durand, M; Vidalain, P O; Bonel, G

1997-06-05

HA-ceramics used in human surgery as osteoconductive surfaces show a great variety of characteristics. Certain characteristics such as grain size, porosity, and surface area, are controlled by the sintering temperature of the slurry. We grew L-929 fibroblast cells on HA-ceramic disks that had been sintered at different temperatures ranging from 850 degrees-1350 degrees C. The cell line growth rate was lower on ceramic disks than on the culture-grade polystyrene used as a negative control. Cell growth correlated with the ceramic sintering temperature although no significant difference in the cell adhesion to the different ceramics was shown. Growth rate on ceramics sintered at low temperatures (850 degrees and 950 degrees C) was negative whereas it was positive on disks sintered at higher temperatures. When the cells were separated from the disks by a polycarbonate membrane, the growth rate was negative on those membranes in contact with low-temperature sintered disks and positive on the high-temperature sintered disks. The calcium and phosphorus concentration in the culture medium in contact with ceramics sintered below 1050 degrees C decreased during the culture period. Ceramics sintered between 1100 degrees and 1250 degrees C brought about an increase in Ca and P concentrations while ceramics sintered at higher temperatures did not induce any changes. SEM examination of the 850 degrees and 1200 degrees C sintered ceramics showed that the 850 degrees C sintered ceramics consisted of small grains with pores between them and the 1200 degrees C sintered ceramics were made of larger grains without any visible pores, thereby decreasing the surface of material in contact with the culture medium. This difference in surface area was confirmed by the fact that the amount of albumin absorbed onto the ceramic was dependent on the sintering temperature. In conclusion, the modification of the culture medium brought about by high-surfaced ceramics could influence the growth of cells with which such ceramics come in contact.

Inductive sensor performance in partial discharges and noise separation by means of spectral power ratios.

PubMed

Ardila-Rey, Jorge Alfredo; Rojas-Moreno, Mónica Victoria; Martínez-Tarifa, Juan Manuel; Robles, Guillermo

2014-02-19

Partial discharge (PD) detection is a standardized technique to qualify electrical insulation in machines and power cables. Several techniques that analyze the waveform of the pulses have been proposed to discriminate noise from PD activity. Among them, spectral power ratio representation shows great flexibility in the separation of the sources of PD. Mapping spectral power ratios in two-dimensional plots leads to clusters of points which group pulses with similar characteristics. The position in the map depends on the nature of the partial discharge, the setup and the frequency response of the sensors. If these clusters are clearly separated, the subsequent task of identifying the source of the discharge is straightforward so the distance between clusters can be a figure of merit to suggest the best option for PD recognition. In this paper, two inductive sensors with different frequency responses to pulsed signals, a high frequency current transformer and an inductive loop sensor, are analyzed to test their performance in detecting and separating the sources of partial discharges.

Array servo scanning micro EDM of 3D micro cavities

NASA Astrophysics Data System (ADS)

Tong, Hao; Li, Yong; Yi, Futing

2011-05-01

Micro electro discharge machining (Micro EDM) is a non-traditional processing technology with the special advantages of low set-up cost and few cutting force in machining any conductive materials regardless of their hardness. As well known, die-sinking EDM is unsuitable for machining the complex 3D micro cavity less than 1mm due to the high-priced fabrication of 3D microelectrode itself and its serous wear during EDM process. In our former study, a servo scanning 3D micro-EDM (3D SSMEDM) method was put forward, and our experiments showed it was available to fabricate complex 3D micro-cavities. In this study, in order to improve machining efficiency and consistency accuracy for array 3D micro-cavities, an array-servo-scanning 3D micro EDM (3D ASSMEDM) method is presented considering the complementary advantages of the 3D SSMEDM and the array micro electrodes with simple cross-section. During 3D ASSMEDM process, the array cavities designed by CAD / CAM system can be batch-manufactured by servo scanning layer by layer using array-rod-like micro tool electrodes, and the axial wear of the array electrodes is compensated in real time by keeping discharge gap. To verify the effectiveness of the 3D ASSMEDM, the array-triangle-micro cavities (side length 630 μm) are batch-manufactured on P-doped silicon by applying the array-micro-electrodes with square-cross-section fabricated by LIGA process. Our exploratory experiment shows that the 3D ASSMEDM provides a feasible approach for the batch-manufacture of 3D array-micro-cavities of conductive materials.

Pressureless sintering of whiskered-toughened ceramic composites

DOEpatents

Tiegs, T.N.

1994-12-27

A pressureless sintering method is disclosed for use in the production of whisker-toughened ceramic composites wherein the sintered density of composites containing up to about 20 vol. % SiC whiskers is improved by reducing the average aspect ratio of the whiskers to from about 10 to about 20. Sintering aids further improve the density, permitting the production of composites containing 20 vol. % SiC with sintered densities of 94% or better of theoretical density by a pressureless sintering method. 6 figures.

A New Method for Low Cost Production of Titanium Alloys for Reducing Energy Consumption of Mechanical Systems

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

Fang, Z. Zak; Chandran, Ravi; Koopman, Mark

This project investigated an innovative manufacturing process intended to minimize the cost of production of titanium materials and components, and increase the adoption of Ti components for energy consuming applications, such as automobiles. A key innovation of the proposed manufacturing approach is a novel Ti powder sintering technology for making titanium materials with ultrafine grain microstructure in the as-sintered state with minimum, or an absence, of post-sintering processes. The new sintering technology is termed Hydrogen Sintering and Phase Transformations (HSPT), and constitutes a promising manufacturing technology that can be used to produce titanium (Ti) materials and components in a near-net-shapemore » form, thus also minimizing machining costs. Our objective was to meet, or possibly surpass, the mechanical property levels for ASTM B348 Grade 5 for wrought Ti-6Al-4V. Although specific applications call for varying mechanical property requirements, ASTM B348 was created for the demanding applications of the aerospace industry, and is the established standard for Ti-6Al-4V. While the primary goal was to meet, or exceed this standard, the team also had the goal of demonstrating this could be done at a significantly lower cost of production. Interim goals of the project were to fully develop this novel sintering process, and provide sufficient baseline testing to make the method practical and attractive to industry. By optimizing the process parameters for the sintering of titanium hydride (TiH 2) powders in a hydrogen atmosphere and controlling the phase transformations during and after sintering, the HSPT process was expected to reduce the energy consumption, and thus cost, of making Ti alloys and fabricating Ti components. The process was designed such that no high temperature melting is required for producing Ti alloys; little or no post-sintering processing is needed for producing desired microstructures (and therefore enhanced mechanical properties), and finally, minimum machining is needed to fabricate finished Ti components. An energy analysis within this report provides more detail, but calculated values indicate that the HSPT process is less than half as energy intensive as conventional wrought processing, while producing mechanical properties that are comparable. In addition to the energy savings anticipated from the industrial production of Ti components, a second prong of energy savings resides in the use phase of components produced, primarily from use in the transportation sector. Titanium has a number of material qualities appropriate for the auto industry, particularly low mass and corrosion resistance. By reducing the weight of automobiles and other vehicles, energy costs and CO 2 production will be reduced over the lifetime of the vehicles, and components in corrosive environments on vehicles, such as exhaust systems and other under carriage parts, may not have to be replaced during a vehicle’s lifetime. Our analysis indicates that by replacing only 5.6 kg of steel parts in an auto with Ti components across the entire US fleet would save approximately 486 million gallons of gasoline per year. This correlates to a reduction of 3.6 million metric tons of CO 2 per year. The potential for replacing many more of the steel parts in automobiles with lighter weight titanium components is clear. The project was very successful overall, meeting all milestones and surpassing project goals in terms of mechanical properties and microstructures produced. In addition to tensile properties, fatigue properties were emphasized in the project work. Powder metallurgy processes often have porosity to some degree in their final microstructure, and porosity is a well-known cause of crack initiation and low fatigue performance. Although many automobile applications do not undergo fatigue stress regimes, many others do encounter cyclic stress, and design criteria in the latter case require good fatigue properties. Production and testing of HSPT parts showed excellent tensile properties and fracture toughness, and fatigue properties that exceeded all previously reported powder metallurgy Ti methods, overlapping with wrought processed values. Fatigue limits exceeded 500 MPa and tensile strength exceeded 1,000 MPa while maintaining good ductility. Microstructures produced during the project period easily surpassed pre-project expectations. In addition to producing very fine grains in the as-sintered state (without post sintered thermo-mechanical work), porosity was reduced and industrially relevant microstructures previously undemonstrated in any other powder metallurgy titanium method were produced using HSPT materials. These microstructures, both bi-modal and globularized, were produced with simple post-sinter heat treatments, but without the need for energy intensive mechanical work. The employed heat treatments expanded the available mechanical property range (tensile strength vs. ductility) of the HSPT system in Ti-6Al-4V. The project has resulted in the publication, thus far, of five refereed journal articles and five conference proceedings papers, as well as a patent application, two dissertations and a master’s thesis. Two additional journal articles are currently under review, and at least three others are currently in preparation, with several additional students anticipated to graduate within the coming year. Presentations and papers were a particular focus of the second half of the project, once significant experimentation had been performed and analyzed. As part of our efforts to disseminate information of our results, the Ti research teams within Prof. Fang’s and Prof. Chandran’s research groups had a strong presence at the 13th World Conference on Ti, August 16-20, 2015, in San Diego. Several research groups in the US and in Europe are now performing experiments using the HSPT process. Accompanying efforts to bring HSPT to the Ti community at large, and industry in particular, work has continued with our partners and with other interested industrial Ti users and producers, including Boeing and GKN (a major powder metallurgy parts manufacturer). Commercialization has been a central focus of the final phase of the project, and Reading Alloys signed a provisional licensing agreement in summer of 2015. They are currently seeking an appropriate customer with which to pursue initial parts manufacturing efforts. Other licensing options and partners are continuing to be pursued. The promise of lightweight, strong and corrosion resistant Ti alloys with long fatigue lifetimes for automobile or transportation applications has been the vision of the metal industry since titanium came to the attention of scientists and engineers. The sole limitation of realizing these goals has been cost, which is primarily a function of energy used in production. The HSPT process was shown through this work to be capable of realizing this goal, and facilitating the practical use of titanium in US automotive and other industries.« less

[Application of sintered Ti powder to dental prostheses].

PubMed

Hikosaka, Tatsuya; Tanaka, Yoshinobu; Hoshiai, Kazumoto; Kanazawa, Takeshi; Nakamura, Yoshinori; Tsuda, Kenji; Ohasi, Hideya

2005-04-01

Powder metallurgy is a metal processing technology. Porous titanium produced from powder is widely used. The method is applied to titanium, which is not easy to cast as it sinters under melting point. In prosthetic dentistry, powder metallurgy can be applied to high fusing metal that is biocompatible. In this study, we examined the mechanical characteristics of the Ti sheet produced by sintering and discussed its application to dental prosthesis manufacturing. Ti sheets of 1-mm thickness, in which a binder was added to spherical Ti powder, were produced with the Doctor Blade Method. The sintering was carried out between 900-1150 degrees C at 6 temperatures. The sintered compact was evaluated by dimensional change rate, hardness test, bending strength, tensile strength and SEM observation. Another compact was sintered on the refractory cast. Mechanical strength significantly increased with sintering temperature. In addition, excellent mechanical strength was acquired by adding crushed powder and performing the de-binder process. In the sintering on the refractory cast, pre-baking for more than 100 minutes and sintering at over 1050 degrees C was needed for practical application. It thus seems possible to apply sintered titanium to dental prostheses. However, it will be necessary to examine the control of the shrinkage of the sintered compact in the future too.

Behavior of oxide film at the interface between particles in sintered Al powders by pulse electric-current sintering

NASA Astrophysics Data System (ADS)

Xie, Guoqiang; Ohashi, Osamu; Song, Minghui; Furuya, Kazuo; Noda, Tetsuji

2003-03-01

The microstructure of the bonding interfaces between particles in aluminum (Al) powder sintered specimens by the pulse electric-current sintering (PECS) process was observed, using conventional transmission electron microscopy (CTEM) and high-resolution transmission electron microscopy (HRTEM). The behavior of oxide film at the interface between Al particles and its effect on properties of the sintered specimens were investigated. The results showed there were two kinds of bonding interfaces in the sintered specimens, namely, the direct metal/metal bonding and the metal/oxide film layer/metal bonding interface. By increasing the fraction of the direct metal/metal bonding interfaces, the tensile strength of the sintered specimens increased, and the electrical resistivity decreased. By increasing the loading pressure at higher sintering temperatures or increasing the sintering temperature under loading pressure, the breakdown of oxide film was promoted. The broken oxide film debris was dispersed in aluminum metal near the bonding interfaces between particles.

Effect of sintering atmosphere on properties of porous stainless steel for biomedical applications.

PubMed

Dudek, Agata; Włodarczyk, Renata

2013-01-01

This study discusses manufacturing of metallic biomaterials by means of powder metallurgy with consideration for their unquestionable advantages, i.e. opportunities of obtaining materials with controllable porosity. The paper focuses on properties of 316 L stainless steel obtained using the method of powder metallurgy with respect to compacting pressure and sintering atmosphere. All the specimens were compacted at 700, 400 and 225 MPa, and sintered at 1250 °C. In order to analyze the sintering atmosphere, three different media were used: dissociated ammonia, hydrogen and vacuum. The study covered sintering density, porosity, microstructure analysis and corrosion resistance. The proposed method of powder metallurgy allowed for obtaining materials with predictable size and distribution of pores, depending on the parameters of sinter preparation (compaction force, sinter atmosphere). High corrosion resistance of the materials (sintering in the atmosphere of hydrogen and in vacuum) and high porosity in the sinters studied offer opportunities for using them for medical purposes. Copyright © 2012 Elsevier B.V. All rights reserved.

Infiltration sintering properties of Ni-4B-4Si(wt.%) alloy powders

NASA Astrophysics Data System (ADS)

Yang, Q.; Zhang, X. C.; Wang, F. L.; Zou, J. T.

2018-01-01

The Ni-4B-4Si(wt.%) alloy powders were infiltrated into the nickel skeletons, the effects of sintering temperatures (1050-1150 °C) and skeletons (loose and compact nickel powders) on the microstructures and hardness of the sintered alloys were investigated. The Ni-B-Si alloy sintered at 1100 °C consisted of γ-Ni and Ni3B, and Si mainly solid soluted in the γ-Ni. The loose nickel powders favored to the infiltration of Ni-B-Si liquid alloy into the nickel skeletons, the sintered alloys exhibited dense microstructures and good interfacial bonding with Ni substrates. The interfacial hardness was equal to that of the sintered alloys and Ni substrates. Loose nickel powders ensured the density and interfacial bonding of the sintered alloys, the infiltration sintering process can be simplified and easily applied to practice.

Characteristics of iron ore sinter with EFB addition

NASA Astrophysics Data System (ADS)

Purwanto, H.; Rozhan, A. N.; Mohamad, A. S.; Zakiyuddin, A.

2018-04-01

Utilization of EFB-derived biochar in sintering of iron ore has been conducted in this work with regards to the porosity of iron sinter. EFB has been heated up in argon atmosphere to 450°C in order to produce biochar. In the present work, the sintering process was conducted at 1150°C with variations of biochar content from 5% to 10%. In this case, the apparent density for iron sinter shows significant decrease as the biochar addition increase. The porosity of iron sinter showed a gradual increment from 5% to 7.5% and escalated at 10% biochar content. The results of porosity and apparent density were in line with the micrograph of iron sinter.

Apparatus and method for direct measurement of coal ash sintering and fusion properties at elevated temperatures and pressures

DOEpatents

Khan, M. Rashid

1990-01-01

A high-pressure microdilatometer is provided for measuring the sintering and fusion properties of various coal ashes under the influence of elevated pressures and temperatures in various atmospheres. Electrical resistivity measurements across a sample of coal ash provide a measurement of the onset of the sintering and fusion of the ash particulates while the contraction of the sample during sintering is measured with a linear variable displacement transducer for detecting the initiation of sintering. These measurements of sintering in coal ash at different pressures provide a mechanism by which deleterious problems due to the sintering and fusion of ash in various combustion systems can be minimized or obviated.

Influence of spark plasma sintering parameters on magnetic properties of FeCo alloy

NASA Astrophysics Data System (ADS)

Albaaji, Amar J.; Castle, Elinor G.; Reece, Mike J.; Hall, Jeremy P.; Evans, Sam L.

2018-04-01

Equiatomic FeCo alloys with average particle size of 24 μm were sintered using spark plasma sintering (SPS) system at sintering temperatures of 1100, 800, and 850 °C for heating rates 50, 100, 300 °C/min by applying pressure of 50 MPa instantly at room temperature for sintering time of 5 and 15 minutes. The highest saturation induction was achieved at SPS conditions of 50 MPa, 50 °C/min, 1100 °C, without dwelling, of value 2.39 T. The saturation induction was improved with extending sintering time, the coercivity was higher in samples sintered at a fast heating rate in comparison to the slowest heating rate.

Sintered Lining for Heat-Pipe Evaporator

NASA Technical Reports Server (NTRS)

Ernst, D. M.; Eastman, G. Y.

1985-01-01

Hotspots eliminated by lining inner wall. Distribution of heat transfer liquid in heat-pipe evaporator improved by lining inner wall with layer of sintered metal. Sintered layer takes place of layer of screen wick formerly sintered or bonded to wall. Since sintered layer always full of liquid, no hotspot of type that previously arose where former screen wick did not fit properly against wall.

Effect of surface oxide films on the properties of pulse electric-current sintered metal powders

NASA Astrophysics Data System (ADS)

Xie, Guoqiang; Ohashi, Osamu; Yamaguchi, Norio; Wang, Airu

2003-11-01

Metallic powders with various thermodynamic stability oxide films (Ag, Cu, and Al powders) were sintered using a pulse electric-current sintering (PECS) process. Behavior of oxide films at powder surfaces and their effect on the sintering properties were investigated. The results showed that the sintering properties of metallic powders in the PECS process were subject to the thermodynamic stability of oxide films at particles surfaces. The oxide films at Ag powder surfaces are decomposed during sintering with the contact region between the particles being metal/metal bond. The oxide films at Cu powder surfaces are mainly broken via loading pressure at a low sintering temperature. At a high sintering temperature, they are mainly dissolved in the parent metal, and the contact regions turn into the direct metal/metal bonding. Excellent sintering properties can be received. The oxide films at Al powder surfaces are very stable, and cannot be decomposed and dissolved, but broken by plastic deformation of particles under loading pressure at experimental temperatures. The interface between particles is partially bonded via the direct metal/metal bonding making it difficult to achieve good sintered properties.

[Influence of manufacture technique on translucency and color of dental porcelain].

PubMed

Xiong, Fang; Chao, Yong-Lie; Zhu, Zhi-Min

2007-12-01

To study the influence of manufacture technique on the translucency and color of dental porcelain. Specimens were made of VITA VMK 95 dentin porcelain and enamel porcelain and divided into 3 groups: Sintering times group (1, 2, 4, 6, 8 and 10 times), sintering temperature group (910, 920, 930, 940 and 950 degrees C), sintering vacuum group (95, 65, 35 and 0 kPa). Transmittance, Y, dominant wavelength and saturation were measured by PR-650 spectra scan spectrocolorimeter. Transmittance of dentin porcelain increased after 6 times repeated sintering. Transmittance of enamel porcelain increased first after the second sintering, and then became decreasing when sintering more than 2 times. Transmittance of enamel porcelain deceased when sintering temperature was lower than standard. Decrease of sintering vacuum caused the transmittance of dentin and enamel porcelain decreased. The changing of value was coordinated with transmittance. Dominant wavelength and saturation had negative correlation with sintering times and temperature, and positive correlation with vacuum. Sintering times, temperature and vacuum all had prominent effects on the translucency and color of dental porcelain. Comparing with dentin porcelain, enamel porcelain was more sensitive with the modification of manufacture technique.

Exothermic low temperature sintering of Cu nanoparticles

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

Mittal, Jagjiwan; Lin, Kwang-Lung, E-mail: matkllin@mail.ncku.edu.tw

2015-11-15

Sintering of the Cu nanoparticle at low temperatures resulted in exothermic behavior after its initiation. The calorimetry study of the heating of a 20 nm copper nanoparticles agglomerate revealed the evolution of 41.17 J/g of heat between 170 °C and 270 °C. High resolution transmission electron microscopy (HRTEM) images indicated that the heat generation was accompanied by sintering. The surface energy of the 20 nm copper nanoparticles was estimated to be 1.23 × 10{sup 3} erg/cm{sup 2} based on the heat released during sintering. The in situ high resolution transmission electron microscope (HRTEM) investigation showed that vigorous sintering occurred betweenmore » 217 and 234 °C, which took place through the dislocation sintering mechanism. - Highlights: • Calorimetry showed exothermic behavior during heating of Cu nanoparticles between 170 and 270 °C. • Heat released due to the sintering of Cu nanoparticles was demonstrated by HRTEM. • Surface energy of 20 nm copper nanoparticles was estimated to be 1.23 × 10{sup 3} erg/cm{sup 2} during sintering. • Growth in crystallite sizes during sintering is disclosed by X-ray diffraction. • In situ HRTEM heating study showed occurrence of sintering through dislocation mechanism.« less

Effect of Sintering Temperature on Magnetic Core-Loss Properties of a NiCuZn Ferrite for High-Frequency Power Converters

NASA Astrophysics Data System (ADS)

Yan, Yi; Ngo, Khai D. T.; Hou, Dongbin; Mu, Mingkai; Mei, Yunhui; Lu, Guo-Quan

2015-10-01

In an effort to find a magnetic material for making low-loss magnetic components for high-power-density converters, we investigated the magnetic core-loss characteristics of a commercial NiCuZn ferrite (LSF 50) at 5 MHz as a function of the sintering temperature of the ferrite powder. The ferrite powder was compacted into toroid cores and then sintered at 850°C, 900°C, 950°C, 1000°C, and 1050°C for 2 h. The sintered densities of the cores increased at higher sintering temperatures. The magnetic properties of the sintered cores—complex permeability and core-loss density—were measured. We found that both the real and imaginary parts of the relative permeability increased with sintering temperature. The core-loss results at 5 MHz showed that the cores sintered at 950°C and 1000°C had the lowest core-loss densities, being two to three times lower than that of a commercial NiZn ferrite (4F1) core. Microstructures of the sintered cores were examined by scanning electron microscopy; the grains grew significantly at higher sintering temperatures.

Enhanced thermal conductivity of uranium dioxide-silicon carbide composite fuel pellets prepared by Spark Plasma Sintering (SPS)

NASA Astrophysics Data System (ADS)

Yeo, S.; Mckenna, E.; Baney, R.; Subhash, G.; Tulenko, J.

2013-02-01

Uranium dioxide (UO2)-10 vol% silicon carbide (SiC) composite fuel pellets were produced by oxidative sintering and Spark Plasma Sintering (SPS) at a range of temperatures from 1400 to 1600 °C. Both SiC whiskers and SiC powder particles were utilized. Oxidative sintering was employed over 4 h and the SPS sintering was employed only for 5 min at the highest hold temperature. It was noted that composite pellets sintered by SPS process revealed smaller grain size, reduced formation of chemical products, higher density, and enhanced interfacial contact compared to the pellets made by oxidative sintering. For given volume of SiC, the pellets with powder particles yielded a smaller grain size than pellets with SiC whiskers. Finally thermal conductivity measurements at 100 °C, 500 °C, and 900 °C revealed that SPS sintered UO2-SiC composites exhibited an increase of up to 62% in thermal conductivity compared to UO2 pellets, while the oxidative sintered composite pellets revealed significantly inferior thermal conductivity values. The current study points to the improved processing capabilities of SPS compared to oxidative sintering of UO2-SiC composites.

On the self-damping nature of densification in photonic sintering of nanoparticles

PubMed Central

MacNeill, William; Choi, Chang-Ho; Chang, Chih-Hung; Malhotra, Rajiv

2015-01-01

Sintering of nanoparticle inks over large area-substrates is a key enabler for scalable fabrication of patterned and continuous films, with multiple emerging applications. The high speed and ambient condition operation of photonic sintering has elicited significant interest for this purpose. In this work, we experimentally characterize the temperature evolution and densification in photonic sintering of silver nanoparticle inks, as a function of nanoparticle size. It is shown that smaller nanoparticles result in faster densification, with lower temperatures during sintering, as compared to larger nanoparticles. Further, high densification can be achieved even without nanoparticle melting. Electromagnetic Finite Element Analysis of photonic heating is coupled to an analytical sintering model, to examine the role of interparticle neck growth in photonic sintering. It is shown that photonic sintering is an inherently self-damping process, i.e., the progress of densification reduces the magnitude of subsequent photonic heating even before full density is reached. By accounting for this phenomenon, the developed coupled model better captures the experimentally observed sintering temperature and densification as compared to conventional photonic sintering models. Further, this model is used to uncover the reason behind the experimentally observed increase in densification with increasing weight ratio of smaller to larger nanoparticles. PMID:26443492

The effect of air-abrasion and heat treatment on the fracture behavior of Y-TZP.

PubMed

Passos, Sheila P; Linke, Bernie; Major, Paul W; Nychka, John A

2015-09-01

This study evaluated how the flexural strength and fracture behavior of a zirconia-based ceramic (Y-TZP) were affected by pre- and post-sintering mechanical and thermal treatments. Treatments included sandblasting with different particle size and type (30μm SiO2; 50 and 110μm Al2O3) and thermal conditioning. Two hundred bar-shaped specimens of pre-sintered Y-TZP ceramic (Lava Frame, 3M) were prepared (specimen dimensions: 25mm length×4mm width×0.7mm thickness) and divided into three groups (before sintering, after sintering and after sintering with heating treatment). The before sintering group specimens were airborne-particle abraded prior to dense sintering. Specimens from the after sintering group were airborne-particle abraded after sintering. The after sintering with heating treatment group specimens were submitted to a heating procedure after airborne-particle abrasion. The controls were the specimens that were sintered and not treated with any conditioning procedures. The specimens from all experimental conditions were analyzed by SEM, CLSM and XRD. All specimens were tested in four-point bending. Data were statistically analyzed using one-way ANOVA and Post Hoc tests (α=0.05). A Weibull analysis was used to analyze the strength reliability. Sandblasting pre-sintered zirconia before sintering significantly decreased the flexural strength, except when the smallest blasting particles were used (30μm SiO2). Phase transformation (t-m) was observed after sandblasting and reverse transformation (m-t) was observed after heating. Sandblasting with 30μm SiO2 and 50μm Al2O3 allowed lower phase transformation. However, 30mm SiO2 presented better reliability. Copyright © 2015 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Determining optimal operation parameters for reducing PCDD/F emissions (I-TEQ values) from the iron ore sintering process by using the Taguchi experimental design.

PubMed

Chen, Yu-Cheng; Tsai, Perng-Jy; Mou, Jin-Luh

2008-07-15

This study is the first one using the Taguchi experimental design to identify the optimal operating condition for reducing polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/ Fs) formations during the iron ore sintering process. Four operating parameters, including the water content (Wc; range = 6.0-7.0 wt %), suction pressure (Ps; range = 1000-1400 mmH2O), bed height (Hb; range = 500-600 mm), and type of hearth layer (including sinter, hematite, and limonite), were selected for conducting experiments in a pilot scale sinter pot to simulate various sintering operating conditions of a real-scale sinter plant We found that the resultant optimal combination (Wc = 6.5 wt%, Hb = 500 mm, Ps = 1000 mmH2O, and hearth layer = hematite) could decrease the emission factor of total PCDD/Fs (total EF(PCDD/Fs)) up to 62.8% by reference to the current operating condition of the real-scale sinter plant (Wc = 6.5 wt %, Hb = 550 mm, Ps = 1200 mmH2O, and hearth layer = sinter). Through the ANOVA analysis, we found that Wc was the most significant parameter in determining total EF(PCDD/Fs (accounting for 74.7% of the total contribution of the four selected parameters). The resultant optimal combination could also enhance slightly in both sinter productivity and sinter strength (30.3 t/m2/day and 72.4%, respectively) by reference to those obtained from the reference operating condition (29.9 t/m (2)/day and 72.2%, respectively). The above results further ensure the applicability of the obtained optimal combination for the real-scale sinter production without interfering its sinter productivity and sinter strength.

Effect on the grain size of single-mode microwave sintered NiCuZn ferrite and zinc titanate dielectric resonator ceramics.

PubMed

Sirugudu, Roopas Kiran; Vemuri, Rama Krishna Murthy; Venkatachalam, Subramanian; Gopalakrishnan, Anisha; Budaraju, Srinivasa Murty

2011-01-01

Microwave sintering of materials significantly depends on dielectric, magnetic and conductive Losses. Samples with high dielectric and magnetic loss such as ferrites could be sintered easily. But low dielectric loss material such as dielectric resonators (paraelectrics) finds difficulty in generation of heat during microwave interaction. Microwave sintering of materials of these two classes helps in understanding the variation in dielectric and magnetic characteristics with respect to the change in grain size. High-energy ball milled Ni0.6Cu0.2Zn0.2Fe1.98O4-delta and ZnTiO3 are sintered in conventional and microwave methods and characterized for respective dielectric and magnetic characteristics. The grain size variation with higher copper content is also observed with conventional and microwave sintering. The grain size in microwave sintered Ni0.6Cu0.2Zn0.2Fe1.98O4-delta is found to be much small and uniform in comparison with conventional sintered sample. However, the grain size of microwave sintered sample is almost equal to that of conventional sintered sample of Ni0.3Cu0.5Zn0.2Fe1.98O4-delta. In contrast to these high dielectric and magnetic loss ferrites, the paraelectric materials are observed to sinter in presence of microwaves. Although microwave sintered zinc titanate sample showed finer and uniform grains with respect to conventional samples, the dielectric characteristics of microwave sintered sample are found to be less than that of conventional sample. Low dielectric constant is attributed to the low density. Smaller grain size is found to be responsible for low quality factor and the presence of small percentage of TiO2 is observed to achieve the temperature stable resonant frequency.

Lightweight nickel electrode for nickel hydrogen cells and batteries

NASA Technical Reports Server (NTRS)

Britton, D. L.

1986-01-01

The nickel electrode was identified as the heaviest component of the nickel hydrogen (NiH2) battery. The NASA Lewis Research Center is developing nickel electrodes for NiH2 battery devices which will be lighter in weight and have higher energy densities when cycled under a low Earth orbit regime at deep depths of discharge. Lightweight plaques are first exposed to 31 percent potassium hydroxide for 3 months to determine their suitability for use as electrode substrates from a chemical corrosion standpoint. Pore size distribution and porosity of the plaques are then measured. The lightweight plaques examined are nickel foam, nickel felt, nickel plastic and nickel plated graphite. Plaques are then electrochemically impregnated in an aqueous solution. Initial characterization tests of the impregnated plaques are performed at five discharge levels, C/2, 1.0 C, 1.37 C, 2.0C, and 2.74 C rates. Electrodes that passed the initial characterization screening test will be life cycle tested. Lightweight electrodes are approximately 30 to 50 percent lighter in weight than the sintered nickel electrode.

Use of CFD to predict trapped gas excitation as source of vibration and noise in screw compressors

NASA Astrophysics Data System (ADS)

Willie, James

2017-08-01

This paper investigates the source of noise in oil free screw compressors mounted on highway trucks and driven by a power take-off (PTO) transmission system. Trapped gas at the discharge side is suggested as possible source of the excitation of low frequency torsional resonance in these compressors that can lead to noise and vibration. Measurements and lumped mass torsional models have shown low frequency torsional resonance in the drive train of these compressors when they are mounted on trucks. This results in high torque peak at the compressor input shaft and in part to pulsating noise inside the machine. The severity of the torque peak depends on the amplitude of the input torque fluctuation from the drive (electric motor or truck engine). This in turn depends on the prop-shaft angle. However, the source of the excitation of this low torsional resonance inside the machine is unknown. Using CFD with mesh motion at every 1° rotation of the rotors, it is shown that the absence of a pressure equalizing chamber at the discharge can lead to trapped gas creation, which can lead to over-compression, over-heating of the rotors, and to high pressure pulsations at the discharge. Over-compression can lead to shock wave generation at the discharge plenum and the pulsation in pressure can lead to noise generation. In addition, if the frequency of the pressure pulsation in the low frequency range coincides with the first torsional frequency of the drive train the first torsional resonance mode can be excited.

Improving detection sensitivity for partial discharge monitoring of high voltage equipment

NASA Astrophysics Data System (ADS)

Hao, L.; Lewin, P. L.; Swingler, S. G.

2008-05-01

Partial discharge (PD) measurements are an important technique for assessing the health of power apparatus. Previous published research by the authors has shown that an electro-optic system can be used for PD measurement of oil-filled power transformers. A PD signal generated within an oil-filled power transformer may reach a winding and then travel along the winding to the bushing core bar. The bushing, acting like a capacitor, can transfer the high frequency components of the partial discharge signal to its earthed tap point. Therefore, an effective PD current measurement can be implemented at the bushing tap by using a radio frequency current transducer around the bushing-tap earth connection. In addition, the use of an optical transmission technique not only improves the electrical noise immunity and provides the possibility of remote measurement but also realizes electrical isolation and enhances safety for operators. However, the bushing core bar can act as an aerial and in addition noise induced by the electro-optic modulation system may influence overall measurement sensitivity. This paper reports on a machine learning technique, namely the use of a support vector machine (SVM), to improve the detection sensitivity of the system. Comparison between the signal extraction performances of a passive hardware filter and the SVM technique has been assessed. The results obtained from the laboratory-based experiment have been analysed and indicate that the SVM approach provides better performance than the passive hardware filter and it can reliably detect discharge signals with apparent charge greater than 30 pC.

Machined Titanium Heat-Pipe Wick Structure

NASA Technical Reports Server (NTRS)

Rosenfeld, John H.; Minnerly, Kenneth G.; Gernert, Nelson J.

2009-01-01

Wick structures fabricated by machining of titanium porous material are essential components of lightweight titanium/ water heat pipes of a type now being developed for operation at temperatures up to 530 K in high-radiation environments. In the fabrication of some prior heat pipes, wicks have been made by extruding axial grooves into aluminum unfortunately, titanium cannot be extruded. In the fabrication of some other prior heat pipes, wicks have been made by in-situ sintering of metal powders shaped by the use of forming mandrels that are subsequently removed, but in the specific application that gave rise to the present fabrication method, the required dimensions and shapes of the heat-pipe structures would make it very difficult if not impossible to remove the mandrels due to the length and the small diameter. In the present method, a wick is made from one or more sections that are fabricated separately and assembled outside the tube that constitutes the outer heat pipe wall. The starting wick material is a slab of porous titanium material. This material is machined in its original flat configuration to form axial grooves. In addition, interlocking features are machined at the mating ends of short wick sections that are to be assembled to make a full-length continuous wick structure. Once the sections have been thus assembled, the resulting full-length flat wick structure is rolled into a cylindrical shape and inserted in the heatpipe tube (see figure). This wick-structure fabrication method is not limited to titanium/water heat pipes: It could be extended to other heat pipe materials and working fluids in which the wicks could be made from materials that could be pre-formed into porous slabs.

Experimental Investigation Nano Particles Influence in NPMEDM to Machine Inconel 800 with Electrolyte Copper Electrode

NASA Astrophysics Data System (ADS)

Karunakaran, K.; Chandrasekaran, M.

2017-05-01

The recent technology of machining hard materials is Powder mix dielectric electrical Discharge Machining (PMEDM). This research investigates nano sized (about 5Nm) powders influence in machining Inconel 800 nickel based super alloy. This work is motivated for a practical need for a manufacturing industry, which processes various kinds of jobs of Inconel 800 material. The conventional EDM machining also considered for investigation for the measure of Nano powders performances. The aluminum, silicon and multi walled Carbon Nano tubes powders were considered in this investigation along with pulse on time, pulse of time and input current to analyze and optimize the responses of Material Removal Rate, Tool Wear Rate and surface roughness. The Taguchi general Full Factorial Design was used to design the experiments. The most advance equipments employed in conducting experiments and measuring equipments to improve the accuracy of the result. The MWCNT powder mix was out performs than other powders which reduce 22% to 50% of the tool wear rate, gives the surface roughness reduction from 29.62% to 41.64% and improved MRR 42.91% to 53.51% than conventional EDM.

Performance and Surface Integrity of Ti6Al4V After Sinking EDM with Special Graphite Electrodes

NASA Astrophysics Data System (ADS)

Amorim, Fred L.; Stedile, Leandro J.; Torres, Ricardo D.; Soares, Paulo C.; Henning Laurindo, Carlos A.

2014-04-01

Titanium and its alloys have high chemical reactivity with most of the cutting tools. This makes it difficult to work with these alloys using conventional machining processes. Electrical discharge machining (EDM) emerges as an alternative technique to machining these materials. In this work, it is investigated the performance of three special grades of graphite as electrodes when ED-Machining Ti6Al4V samples under three different regimes. The main influences of electrical parameters are discussed for the samples material removal rate, volumetric relative wear and surface roughness. The samples surfaces were evaluated using SEM images, microhardness measurements, and x-ray diffraction. It was found that the best results for samples material removal rate, surface roughness, and volumetric relative wear were obtained for the graphite electrode with 10-μm particle size and negative polarity. For all samples machined by EDM and characterized by x-ray (XRD), it was identified the presence of titanium carbides. For the finish EDM regimes, the recast layer presents an increased amount of titanium carbides compared to semi-finish and rough regimes.

Al2O3-TiC Composite Prepared by Spark Plasma Sintering Process: Evaluation of Mechanical and Tribological Properties

NASA Astrophysics Data System (ADS)

Kumar, Rohit; Chaubey, A. K.; Bathula, Sivaiah; Prashanth, K. G.; Dhar, Ajay

2018-03-01

Al2O3-10TiC composites were synthesized by spark plasma sintering (SPS) process. Microstructural and mechanical properties of the composite reveal homogeneous distribution of the fine TiC particles in the matrix. The samples were produced with different sintering temperature, and it shows that the hardness and density gradually increases with increasing sintering temperature. Abrasion wear test result reveals that the composite sintered at 1500 °C shows high abrasion resistance (wt. loss 0.016 g) and the lowest abrasion resistance was observed for the composite sample sintered at 1100 °C (wt. loss 1.459 g). The profilometry surface roughness study shows that sample sintered at 1100 °C shows maximum roughness ( R a = 6.53 µm) compared to the sample sintered at 1500 °C ( R a = 0.66 µm) corroborating the abrasion wear test results.

The effects of surface finish and grain size on the strength of sintered silicon carbide

NASA Technical Reports Server (NTRS)

You, Y. H.; Kim, Y. W.; Lee, J. G.; Kim, C. H.

1985-01-01

The effects of surface treatment and microstructure, especially abnormal grain growth, on the strength of sintered SiC were studied. The surfaces of sintered SiC were treated with 400, 800 and 1200 grit diamond wheels. Grain growth was induced by increasing the sintering times at 2050 C. The beta to alpha transformation occurred during the sintering of beta-phase starting materials and was often accompanied by abnormal grain growth. The overall strength distributions were established using Weibull statistics. The strength of the sintered SiC is limited by extrinsic surface flaws in normal-sintered specimens. The finer the surface finish and grain size, the higher the strength. But the strength of abnormal sintering specimens is limited by the abnormally grown large tabular grains. The Weibull modulus increases with decreasing grain size and decreasing grit size for grinding.

Gravitational Role in Liquid Phase Sintering

NASA Technical Reports Server (NTRS)

Upadhyaya, Anish; Iacocca, Ronald G.; German, Randall M.

1998-01-01

To comprehensively understand the gravitational effects on the evolution of both the microstructure and the macrostructure during liquid phase sintering, W-Ni-Fe alloys with W content varying from 35 to 98 wt.% were sintered in microgravity. Compositions that slump during ground-based sintering also distort when sintered under microgravity. In ground-based sintering, low solid content alloys distort with a typical elephant-foot profile, while in microgravity, the compacts tend to spheroidize. This study shows that microstructural segregation occurs in both ground-based as well as microgravity sintering. In ground-based experiments, because of the density difference between the solid and the liquid phase, the solid content increases from top to the bottom of the sample. In microgravity, the solid content increases from periphery to the center of the samples. This study also shows that the pores during microgravity sintering act as a stable phase and attain anomalous shapes.

An application of powder metallurgy to dentistry.

PubMed

Oda, Y; Ueno, S; Kudoh, Y

1995-11-01

Generally, the dental casting method is used to fabricate dental prostheses made with metal. The method of fabricating dental prostheses from sintered titanium alloy has certain advantages: the elimination of casting defects, a sintering temperature that is lower than the melting point, and a shorter processing time. By examining (1) the properties of green, sintered compacts of titanium powder, (2) the effects of adding aluminum powder on the properties of green, sintered compacts of Ti-Al compound, and (3) the effects of adding copper powder on the properties of green, sintered compacts of Ti-Al-Cu compound, the authors developed a sintered titanium alloy on a trial basis. Because the properties satisfied the requirements of dental restorations, a powder metallurgical method of making dental restorations from this sintered titanium alloy was devised. Applications of such sintered titanium alloys for the metal coping of metal-ceramic crowns and denture base plates were discussed.

Osseointegrated dental implants produced via microwave processing

NASA Astrophysics Data System (ADS)

Kutty, Muralithran G.

This research is a comprehensive effort to develop osseointegrated dental implants via microwave processing. A net-shape microwave sintering procedure was employed to fabricate dental implants. Commercial pure titanium powders (-100, -200 and -325 mesh sizes) were used in this work. This process eliminates the need for machining of implants and prevents contamination. The idea was to take advantage of the peculiar way microwave couple with metallic powders, i.e. generating heat in the interior of the sample and dissipating it away through the surface. The desired features for an implant, a dense core with surface pores, is not possible via conventional sintering. Coating with hydroxyapatite via electrodeposition and chemical combustion vapor deposition was also attempted to further enhance the bioactivity of this layer. Surface roughness and area were measured using a non-contact surface profilometer to further describe the unique surface. In-vitro studies, conducted using osteoblast cells extracted from neonatal rat calvarial, showed improved cell growth on all the uncoated porous samples. However, the highest cell growth was observed on the -200 mesh size samples. The higher surface area of the -200 mesh samples is attributed to this observation. This work was able to identify the processing parameters for titanium in microwave and establishes the importance of surface area as a key parameter for cell growth on porous surfaces as compared to surface roughness.

Composite ceramic superconducting wires for electric motor applications

NASA Astrophysics Data System (ADS)

Halloran, John W.

1990-07-01

Several types of HTSC wire have been produced and two types of HTSC motors are being built. Hundreds of meters of Ag- clad wire were fabricated from YBa2Cu3O(7-x) (Y-123) and Bi2Ca2Sr2Cu3O10 (BiSCCO). The dc homopolar motor coils are not yet completed, but multiple turns of wire have been wound on the coil bobbins to characterize the superconducting properties of coiled wire. Multifilamentary conductors were fabricated as cables and coils. The sintered polycrystalline wire has self-field critical current densities (Jc) as high as 2800 A/sq cm, but the Jc falls rapidly with magnetic field. To improve Jc, sintered YBCO wire is melt textured with a continuous process which has produced textures wire up to 0.5 meters long with 77K transport Jc above 11, 770 A/sq cm2 in self field and 2100 A/sq cm2 at 1 telsa. The Emerson Electric dc homopolar HTSC motor has been fabricated and run with conventional copper coils. A novel class of potential very powerful superconducting motors have been designed to use trapped flux in melt textures Y-123 as magnet replicas in an new type of permanent magnet motor. The stator element and part of the rotor of the first prototype machine exist, and the HTSC magnet replica segments are being fabricated.

Fabrication of High Thermal Conductivity NARloy-Z-Diamond Composite Combustion Chamber Liner for Advanced Rocket Engines

NASA Technical Reports Server (NTRS)

Bhat, Biliyar N.; Greene, Sandra E.; Singh, Jogender

2016-01-01

NARloy-Z alloy (Cu-3 percent, Ag-0.5 percent, Zr) is a state of the art alloy currently used for fabricating rocket engine combustion chamber liners. Research conducted at NASA-MSFC and Penn State – Applied Research Laboratory has shown that thermal conductivity of NARloy-Z can be increased significantly by adding diamonds to form a composite (NARloy-Z-D). NARloy-Z-D is also lighter than NARloy-Z. These attributes make this advanced composite material an ideal candidate for fabricating combustion chamber liner for an advanced rocket engine. Increased thermal conductivity will directly translate into increased turbopump power and increased chamber pressure for improved thrust and specific impulse. This paper describes the process development for fabricating a subscale high thermal conductivity NARloy-Z-D combustion chamber liner using Field Assisted Sintering Technology (FAST). The FAST process uses a mixture of NARloy-Z and diamond powders which is sintered under pressure at elevated temperatures. Several challenges were encountered, i.e., segregation of diamonds, machining the super hard NARloy-Z-D composite, net shape fabrication and nondestructive examination. The paper describes how these challenges were addressed. Diamonds coated with copper (CuD) appear to give the best results. A near net shape subscale combustion chamber liner is being fabricated by diffusion bonding cylindrical rings of NARloy-Z-CuD using the FAST process.

Fracture resistance and marginal discrepancy of porcelain laminate veneers influenced by preparation design and restorative material in vitro.

PubMed

Lin, Tai-Min; Liu, Perng-Ru; Ramp, Lance C; Essig, Milton E; Givan, Daniel A; Pan, Yu-Hwa

2012-03-01

The purpose of this investigation is to evaluate marginal discrepancy and fracture resistance of two veneering materials using two preparation designs. Two veneer preparation designs (full and traditional) were restored with leucite-reinforced ceramic (ProCAD, Ivoclar Vivadent, Amherst, NY) milled by CAD/CAM (Cerec 3D milling system, Serona Dental Systems), and conventional sintered feldspathic porcelain (Noritake Super Porcelain EX3, Noritake Dental Supply Co). Forty-eight specimens were analysed with a sample size of n=12 per group. The thickness of each veneer was measured on four specific surfaces. Marginal discrepancy was evaluated with a replica technique and cross-sectional view using a digital microscope. The fracture resistance of veneers cemented on standardised composite resin dies was evaluated using a universal testing machine. Results were analysed with ANOVA, Tukey-Kramer post hoc testing, and linear regression. The results of this investigation revealed no correlation between the thickness and marginal discrepancy of the veneers. The full preparation design with ProCAD and the traditional preparation design with feldspathic porcelain manifested smaller gap. Fracture resistance was decreased for the full preparation design with feldspathic porcelain. In terms of marginal discrepancy and fracture resistance, the most favourable combination was a traditional veneer preparation design with conventional sintered feldspathic porcelain. For the full veneer preparation, a stronger ceramic material such as ProCAD is suggested. Published by Elsevier Ltd.

Effects of silica and zinc oxide doping on mechanical and biological properties of 3D printed tricalcium phosphate tissue engineering scaffolds.

PubMed

Fielding, Gary A; Bandyopadhyay, Amit; Bose, Susmita

2012-02-01

To evaluate the effects of silica (SiO(2)) (0.5 wt%) and zinc oxide (ZnO) (0.25 wt%) dopants on the mechanical and biological properties of tricalcium phosphate (TCP) scaffolds with three dimensionally (3D) interconnected pores. Scaffolds were created with a commercial 3D printer. Post sintering phase analysis was determined by X-ray diffraction. Surface morphology of the scaffolds was examined by field emission scanning electron microscopy (FESEM). Mechanical strength was evaluated with a screw driven universal testing machine. MTT assay was used for cellular proliferation characteristics and cellular morphology was examined by FESEM. Addition of dopants into TCP increased the average density of pure TCP from 90.8 ± 0.8% to 94.1 ± 1.6% and retarded the β to α phase transformation at high sintering temperatures, which resulted in up to 2.5 fold increase in compressive strength. In vitro cell-materials interaction studies, carried out using hFOB cells, confirmed that the addition of SiO(2) and ZnO to the scaffolds facilitated faster cell proliferation when compared to pure TCP scaffolds. Addition of SiO(2) and ZnO dopants to the TCP scaffolds showed increased mechanical strength as well as increased cellular proliferation. Copyright © 2011 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Free-piston cutting machine

DOEpatents

Ciccarelli, Gaby; Subudhi, Manomohan; Hall, Robert E.

2000-01-01

A cutting machine includes a gun barrel for receiving a projectile. A compression tube is disposed in flow communication with the barrel and includes a piston therein. A reservoir is disposed in flow communication with the tube and receives a first gas under pressure. A second gas fills the compression tube on a front face of the piston. And, the pressurized first gas is discharged into the tube on a back face of the piston to accelerate the piston through the tube for compressing the second gas, and in turn launching the projectile through the barrel to impact a workpiece.

Physics of Self-Field-Dominated Plasmas.

DTIC Science & Technology

1995-03-31

plasma focus machines (APF) for different optimal levels of discharge feeding energy W, in particular for APF-20O (W <or = 200 kJ) and APF-50 (W <or= 50 kJ). The function of these APF systems was to determine, along with the data of smaller machines, the scaling laws of the emission (fluence) of ion and ion cluster beams as a function of W, ejected from the self field dominated plasma of the APF pinch. Typical ion spectra from a Thomson (parabola) spectrometer in the 80 deg direction from the electrode/pinch axis are also included

Electric Propulsion Apparatus

NASA Technical Reports Server (NTRS)

Patterson, Michael J. (Inventor)

2013-01-01

An electric propulsion machine includes an ion thruster having an annular discharge chamber housing an anode having a large surface area. The ion thruster includes flat annular ion optics with a small span to gap ratio. Optionally, a second electric propulsion thruster may be disposed in a cylindrical space disposed within an interior of the annulus.

75 FR 17529 - High-Voltage Continuous Mining Machine Standard for Underground Coal Mines

Federal Register 2010, 2011, 2012, 2013, 2014

2010-04-06

..., requires manufacturers to provide safeguards against corona on all 4,160-volt circuits in explosion-proof enclosures. Corona is a luminous discharge that occurs around electric conductors that are subject to high electric stresses. Corona can cause premature breakdown of insulating materials in explosion-proof...

Electromagnetic Machines Which Utilize Microgeometry Field Structures

DTIC Science & Technology

1990-04-01

34Phenomenological Theory of Electret Discharge Including Incomplete Recombination of Ions". Acta Physica Polonica , A50(1)1 1. Mehendru, P.C. (177)(: "Electret...Resonance of Stabilized Electrons in PTFE Coronoelectrets". Physica Status Solidi, (a)90:K71-K74. Lagues, M. (1976): "Les Electrets: des Transducteurs

[Effect of sintering gold paste coating on the bonding strength of pure titanium and three low-fusing porcelains].

PubMed

Zhang, Ya-li; Luo, Xiao-ping; Zhou, Li

2012-05-01

To study the effect of sintering gold paste coating of pure titanium on the adhesion of three porcelains following the protocol ISO 9693, and to investigate the titanium-porcelains interfaces. Sixty machined pure titanium samples were prepared in a rectangular shape according to ISO 9693 and divided equally into six groups. Half of the strips were coated with gold paste (Deckgold) and sintered. Three ultra-low-fusing dental porcelains (I: Initial Ti, S: Super porcelain Ti-22, T: TitanKeramik) were fused onto the titanium surfaces. A thin layer of bonding agent was only applied on the surfaces of uncoated gold specimens. The interface of the porcelain and titanium was observed with a field emission scanning electron microscope (FE-SEM) after metallographic preparation and sputtered with a very thin carbon layer of the embedded titanium-porcelain interface. After three-point bending test was performed, optical stereomicroscope was used to characterize the titanium-porcelains adhesion and determine the mode of failure. FE-SEM illustrated intermetallic compounds of Au-Ti formed with some visible microcracks in the gold layer and the interface of gold layer and ceramic. All the uncoated gold titanium-porcelain system showed predominately adhesive fracture at the titanium oxidation, whereas the failure modes in all gold coated systems were cohesive and adhesive, mainly cohesive. The three-point-bending test showed that the bonding strength of GS and GI groups [(37.08 ± 4.32) and (36.20 ± 2.40) MPa] were higher than those in uncoated groups [(31.56 ± 3.74) and (30.88 ± 2.60) MPa, P < 0.05], while no significant difference was found between T group and GT group (P > 0.05). The gold paste intermediate coatings can improve bond strengths of Super porcelain Ti-22 system and Initial Ti system, which have potential applications in clinical fields.

Comparison of porcelain bond strength of different metal frameworks prepared by using conventional and recently introduced fabrication methods.

PubMed

Kaleli, Necati; Saraç, Duygu

2017-07-01

Most studies evaluating dental laser sintering systems have focused on the marginal accuracy of the restorations. However, the bond strength at the metal-ceramic interface is another important factor that affects the survival of restorations, and currently, few studies focus on this aspect. The purpose of this in vitro study was to compare the porcelain bond strength of cobalt-chromium (Co-Cr) metal frameworks prepared by using the conventional lost-wax technique, milling, direct metal laser sintering (DMLS), and laser cusing, a direct process powder-bed system. A total of 96 metal frameworks (n=24 in each group) were prepared by using conventional lost-wax (group C), milling (group M), DMLS (group LS), and direct process powder-bed (group LC) methods according to International Organization for Standardization standard ISO 9693-1. After porcelain application, a 3-point bend test was applied to each specimen by using a universal testing machine. Data were statistically analyzed using 1-way ANOVA and Tukey honest significant difference tests (α=.05). Failure types at the metal-ceramic interfaces were examined using stereomicroscopy. Additionally, 1 specimen from each group was prepared for scanning electron microscopy analysis to evaluate the surface topography of metal frameworks. The mean bond strength was 38.08 ±3.82 MPa for group C, 39.29 ±3.51 MPa for group M, 40.73 ±3.58 MPa for group LS, and 41.24 ±3.75 MPa for group LC. Statistically significant differences were observed among the 4 groups (P=.016). All groups, except for LS, exhibited adhesive and mixed type bond failure. Both of the laser sintering methods were found to be successful in terms of metal-ceramic bond strength. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Structural and mechanical characterization of boron doped biphasic calcium phosphate produced by wet chemical method and subsequent thermal treatment

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

Albayrak, Onder, E-mail: albayrakonder@mersin.edu.tr

In the current study, boron doped biphasic calcium phosphate bioceramics consisting of a mixture of boron doped hydroxyapatite (BHA) and beta tricalcium phosphate (β-TCP) of varying BHA/β-TCP ratios were obtained after sintering stage. The effects of varying boron contents and different sintering temperatures on the BHA/β-TCP ratios and on the sinterability of the final products were investigated. Particle sizes and morphologies of the obtained precipitates were determined using SEM. XRD and FTIR investigation were conducted to detect the boron formation in the structure of HA and quantitative analysis was performed to determine the BHA/β-TCP ratio before and after sintering stage.more » In order to determine the sinterability of the obtained powders, pellets were prepared and sintered; the rates of densification were calculated and obtained results were correlated by SEM images. Also Vickers microhardness values of the sintered samples were determined. The experimental results verified that boron doped hydroxyapatite powders were obtained after sintering stage and the structure consists of a mixture of BHA and β-TCP. As the boron content used in the precipitation stage increases, β-TCP content of the BHA/β-TCP ratio increases but sinterability, density and microhardness deteriorate. As the sintering temperature increases, β-TCP content, density and microhardness of the samples increase and sinterability improves. - Highlights: • This is the first paper about boron doped biphasic calcium phosphate bioceramics. • Boron doping affects the structural and mechanical properties. • BHA/β-TCP ratio can be adjustable with boron content and sintering temperature.« less

One step sintering of homogenized bauxite raw material and kinetic study

NASA Astrophysics Data System (ADS)

Gao, Chang-he; Jiang, Peng; Li, Yong; Sun, Jia-lin; Zhang, Jun-jie; Yang, Huan-ying

2016-10-01

A one-step sintering process of bauxite raw material from direct mining was completed, and the kinetics of this process was analyzed thoroughly. The results show that the sintering kinetics of bauxite raw material exhibits the liquid-phase sintering behavior. A small portion of impurities existed in the raw material act as a liquid phase. After X-ray diffraction analyses, scanning electron microscopy observations, and kinetics calculations, sintering temperature and heating duration were determined as the two major factors contributing to the sintering process and densification of bauxite ore. An elevated heating temperature and longer duration favor the densification process. The major obstacle for the densification of bauxite material is attributed to the formation of the enclosed blowhole during liquid-phase sintering.

Stress-dislocation interaction mechanism in low-temperature thermo-compression sintering of Ag NPs

NASA Astrophysics Data System (ADS)

Wang, Fuliang; Tang, Zikai; He, Hu

2018-04-01

The sintering of metal nanoparticles (NPs) has been widely studied in the field of nanotechnology, and low-temperature sintering has become the industry standard. In this study, a molecular dynamics (MD) model was established to study the sintering behaviour of silver NPs during low-temperature thermo-compression. Primarily, we studied the sintering process, in which the ratio of neck radius to particle radius (x/r) changes. Under a uniaxial pressure, the maximum ratio in the temperature range 420-425 K was 1. According to the change of x/r, the process can be broken down into three stages: the neck-formation stage, neck-growth stage, and neck-stability stage. In addition, the relationship between potential energy, internal stress, and dislocation density during sintering is discussed. The results showed that cycling internal stress played an important role in sintering. Under the uniaxial pressure, the stress-dislocation interaction was found to be the major mechanism for thermo-compression sintering because the plastic deformation product dislocation intensified the diffusion of atoms. Also, the displacement vector, the mean square displacement, and the changing crystal structure during sintering were studied.

[Study on preparation and physicochemical properties of surface modified sintered bone].

PubMed

Li, Jingfeng; Zheng, Qixin; Guo, Xiaodong

2012-06-01

The aim of this study is to investigate a new method for preparing a biomimetic bone material-surface modified sintered bovine cancellous bone, and to improve its bioactivity as a tissue engineering bone. The prepared sintered bovine cancellous bones with the same size were randomly divided into two groups, immersing in 1 and 1. 5 times simulated body fluid (SBF), respectively. The three time periods of soak time were 7, 14, and 21 days. After sintered bone was dried, the surface morphology of sintered bone and surface mineralization composition were observed under scanning electron microscopy (SEM). By comparing the effect of surface modification of sintered bone materials, we chose the most ideal material and studied its pore size, the rate of the porosity, the compress and bend intensity. And then the material and the sintered bone material without surface modification were compared. The study indicated that sintered bone material immersed in SBF (1.5 times) for 14 days showed the best effect of surface modification, retaining the original physico-chemical properties of sintered bone.

Feasibility of Actively Cooled Silicon Nitride Airfoil for Turbine Applications Demonstrated

NASA Technical Reports Server (NTRS)

Bhatt, Ramakrishna T.

2001-01-01

Nickel-base superalloys currently limit gas turbine engine performance. Active cooling has extended the temperature range of service of nickel-base superalloys in current gas turbine engines, but the margin for further improvement appears modest. Therefore, significant advancements in materials technology are needed to raise turbine inlet temperatures above 2400 F to increase engine specific thrust and operating efficiency. Because of their low density and high-temperature strength and thermal conductivity, in situ toughened silicon nitride ceramics have received a great deal of attention for cooled structures. However, the high processing costs and low impact resistance of silicon nitride ceramics have proven to be major obstacles for widespread applications. Advanced rapid prototyping technology in combination with conventional gel casting and sintering can reduce high processing costs and may offer an affordable manufacturing approach. Researchers at the NASA Glenn Research Center, in cooperation with a local university and an aerospace company, are developing actively cooled and functionally graded ceramic structures. The objective of this program is to develop cost-effective manufacturing technology and experimental and analytical capabilities for environmentally stable, aerodynamically efficient, foreign-object-damage-resistant, in situ toughened silicon nitride turbine nozzle vanes, and to test these vanes under simulated engine conditions. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. Starting with computer aided design (CAD) files of an airfoil and a flat plate with internal cooling passages, the permanent and removable mold components for gel casting ceramic slips were made by stereolithography and Sanders machines, respectively. The gel-cast part was dried and sintered to final shape. Several in situ toughened silicon nitride generic airfoils with internal cooling passages have been fabricated. The uncoated and thermal barrier coated airfoils and flat plates were burner rig tested for 30 min without and with air cooling. Without cooling, the surface temperature of the flat plate reached approximately 2350 F. With cooling, the surface temperature decreased to approximately 1910 F--a drop of approximately 440 F. This preliminary study demonstrates that a near-net-shape silicon nitride airfoil can be fabricated and that silicon nitride can sustain severe thermal shock and the thermal gradients induced by cooling and, thus, is a viable candidate for cooled components.

Sintered rare earth-iron Laves phase magnetostrictive alloy product and preparation thereof

DOEpatents

Malekzadeh, Manoochehr; Pickus, Milton R.

1979-01-01

A sintered rare earth-iron Laves phase magnetostrictive alloy product characterized by a grain oriented morphology. The grain oriented morphology is obtained by magnetically aligning powder particles of the magnetostrictive alloy prior to sintering. Specifically disclosed are grain oriented sintered compacts of Tb.sub.x Dy.sub.1-x Fe.sub.2 and their method of preparation. The present sintered products have enhanced magnetostrictive properties.

Influence of Hydrogen on Atomized Titanium Powders Sintering

NASA Astrophysics Data System (ADS)

Senkevich, K. S.

2018-07-01

The aim of this work is to study the effect of hydrogen reversible alloying (thermohydrogen processing, THP) on low-temperature sintering of atomized titanium powders. It is stated that alloying with 0.2 to 0.8 wt pct of hydrogen beneficially affects titanium powders sintering. The effect is caused by phase transformations occurring upon hydrogen saturation of powders and dehydrogenation, which substantially intensifies sintering at temperatures from 800 °C to 900 °C. The role of certain THP stages (sintering in hydrogenated state and upon dehydrogenation) on formation of sintered contacts in porous materials is shown.

Influence of Hydrogen on Atomized Titanium Powders Sintering

NASA Astrophysics Data System (ADS)

Senkevich, K. S.

2018-05-01

The aim of this work is to study the effect of hydrogen reversible alloying (thermohydrogen processing, THP) on low-temperature sintering of atomized titanium powders. It is stated that alloying with 0.2 to 0.8 wt pct of hydrogen beneficially affects titanium powders sintering. The effect is caused by phase transformations occurring upon hydrogen saturation of powders and dehydrogenation, which substantially intensifies sintering at temperatures from 800 °C to 900 °C. The role of certain THP stages (sintering in hydrogenated state and upon dehydrogenation) on formation of sintered contacts in porous materials is shown.

Sintering Kinetics of Inkjet Printed Conductive Silver Lines on Insulating Plastic Substrate

DOE PAGES

Zhou, Wenchao; List, III, Frederick Alyious; Duty, Chad E; ...

2015-01-24

This paper focuses on sintering kinetics of inkjet printed lines containing silver nanoparticles deposited on a plastic substrate. Upon heat treatment, the change of resistance in the printed lines was measured as a function of time and sintering temperatures from 150 to 200 C. A critical temperature was observed for the sintering process, beyond which there was no further reduction in resistance. Analysis shows the critical temperature correlates to the boiling point of the solvent, which is attributed to a liquid-mediated sintering mechanism. It is demonstrated that the sintering process shuts down after the solvent has completely evaporated.

Effects of the addition of municipal solid waste incineration fly ash on the behavior of polychlorinated dibenzo-p-dioxins and furans in the iron ore sintering process.

PubMed

Min, Yi; Liu, Chengjun; Shi, Peiyang; Qin, Chongda; Feng, Yutao; Liu, Baichen

2018-04-11

Raw materials were co-sintered with municipal solid waste incineration (MSWI) fly ash through iron ore sintering to promote the safe treatment and utilization of MSWI fly ash. To assess the feasibility of this co-sintering method, in this study, the effects of the addition of MSWI fly ash on the formation and emission of polychlorinated dibenzo-p-dioxins and furans (PCDD/Fs) were estimated via iron ore sintering pot experiments. During co-sintering, most of the PCDD/Fs in the added MSWI fly ash were decomposed and transformed into PCDD/Fs associated with iron sintering, and the concentrations of lower- and mid-chlorinated congeners increased. As there was a sufficient chlorine source and the sintering bed permeability was decreased by the addition of MSWI fly ash, the PCDD/F concentration in the exhaust gas increased. The mass emission of PCDD/Fs decreased; however, the emission of toxic PCDD/Fs increased beyond the total emissions from the independent MSW incineration and iron ore sintering processes due to the transformation of PCDD/F congeners. The co-sintering may be an important solution after technological improvements in the flue gas cleaning system and PCDD/F formation inhibition procedures. Copyright © 2018. Published by Elsevier Ltd.

Triphasic Composite And Method Of Making Same

DOEpatents

Kear, Bernard H.; Sadangi, Rajendra K.; McCandlish, Larry E.; Voronov, Oleg

2000-07-18

A method for fabricating a triphasic composite such as a WC/Co/diamond composite with a high volume fraction of diamond in a WC/Co matrix. The method involves sintering of a WC/Co powder compact to develop a porous preform, which displays some rigidity and strength, infiltrating the porous preform with a controlled distribution of carbon, and high pressure/high temperature treatment of the carbon-containing WC/Co preform to transform the carbon to diamond. The distribution of diamond in the composite can be functionally graded to provide a WC/Co core and a diamond-enriched surface, wherein all three phases form an interconnected structure in three dimensions. Such a tricontinuous structure combines high strength and toughness with superior wear resistance, making it attractive for applications in machine tools and drill bits.

Rapid Fabrication of Flat Plate Cavity Phosphor Thermography Test Models for Shuttle Return-to-Flight Aero-Heating

NASA Technical Reports Server (NTRS)

Buck, Gregory M.; Powers, Michael A.; Nevins, Stephen C.; Griffith, Mark S.; Wainwright, Gary A.

2006-01-01

Methods, materials and equipment are documented for fabricating flat plate test models at NASA Langley Research Center for Shuttle return-to-flight aeroheating experiments simulating open and closed cavity interactions in Langley s hypersonic 20-Inch Mach 6 air wind tunnel. Approximately 96 silica ceramic flat plate cavity phosphor thermography test models have been fabricated using these methods. On one model, an additional slot is machined through the back of the plate and into the cavity and vented into an evacuated plenum chamber to simulate a further opening in the cavity. After sintering ceramic to 2150 F, and mounting support hardware, a ceramic-based two-color thermographic phosphor coating is applied for global temperature and heat transfer measurements, with fiducial markings for image registration.

Laser direct writing of micro- and nano-scale medical devices

PubMed Central

Gittard, Shaun D; Narayan, Roger J

2010-01-01

Laser-based direct writing of materials has undergone significant development in recent years. The ability to modify a variety of materials at small length scales and using short production times provides laser direct writing with unique capabilities for fabrication of medical devices. In many laser-based rapid prototyping methods, microscale and submicroscale structuring of materials is controlled by computer-generated models. Various laser-based direct write methods, including selective laser sintering/melting, laser machining, matrix-assisted pulsed-laser evaporation direct write, stereolithography and two-photon polymerization, are described. Their use in fabrication of microstructured and nanostructured medical devices is discussed. Laser direct writing may be used for processing a wide variety of advanced medical devices, including patient-specific prostheses, drug delivery devices, biosensors, stents and tissue-engineering scaffolds. PMID:20420557

[Influence of repeated sintering on the color of two brands of porcelain-fused-to-titanium].

PubMed

Shu, Cheng-jun; Luo, Xiao-ping; Wu, Lie

2007-08-01

To investigate the influence of repeated sintering on the color of two porcelain-fused-to-titanium, and the differences between the two porcelains. Thirty samples were prepared and sintered for 9 times. The color of samples were measured following sintering 1, 3, 5, 7, 9 times by ShadeEye NCC colorimeter according to two brands of porcelains with CIE1976L*a*b* color system, and calculated relevant chrome, chromatism and hue, and statistical analysis. When two brands of porcelains were sintered 5 times, the color parameters had no significant change and sintered continuely, the color parameters of L* and a* had obvious changes, but can't be observed by eyes. The color parameters of titanium-porcelains have no significant change after repeated sintering.

Sub-second carbon-nanotube-mediated microwave sintering for high-conductivity silver patterns on plastic substrates

NASA Astrophysics Data System (ADS)

Jung, Sunshin; Chun, Su Jin; Han, Joong Tark; Woo, Jong Seok; Shon, Cha-Hwa; Lee, Geon-Woong

2016-02-01

A method of microwave sintering that is mediated by carbon nanotubes (CNTs) has been developed to obtain high-conductivity Ag patterns on the top of heat-sensitive plastic substrates within a short time. The Ag patterns are printed on CNTs formed on plastic substrates and rapidly heated to a great extent by the heat transferred from the microwave-heated CNTs. The conductivity of the microwave-sintered Ag patterns reaches ~39% that of bulk Ag within 1 s without substrate deformation. Furthermore, microwave sintering enhances the adhesion of Ag patterns to the thermoplastic substrates because the sintering causes interfacial fusion between the Ag patterns and the substrates, and CNTs physically connect the patterns with the substrates.A method of microwave sintering that is mediated by carbon nanotubes (CNTs) has been developed to obtain high-conductivity Ag patterns on the top of heat-sensitive plastic substrates within a short time. The Ag patterns are printed on CNTs formed on plastic substrates and rapidly heated to a great extent by the heat transferred from the microwave-heated CNTs. The conductivity of the microwave-sintered Ag patterns reaches ~39% that of bulk Ag within 1 s without substrate deformation. Furthermore, microwave sintering enhances the adhesion of Ag patterns to the thermoplastic substrates because the sintering causes interfacial fusion between the Ag patterns and the substrates, and CNTs physically connect the patterns with the substrates. Electronic supplementary information (ESI) available: Temperature difference in Ag/CNT/PC samples; the carbon content and electrical performance after microwave sintering; microwave sintering of Ag/CNT patterns; physical connection between the substrate and sintered Ag lines; touch-piano (figure and movie). See DOI: 10.1039/c5nr08082g

Flash sintering of ceramic materials

NASA Astrophysics Data System (ADS)

Dancer, C. E. J.

2016-10-01

During flash sintering, ceramic materials can sinter to high density in a matter of seconds while subjected to electric field and elevated temperature. This process, which occurs at lower furnace temperatures and in shorter times than both conventional ceramic sintering and field-assisted methods such as spark plasma sintering, has the potential to radically reduce the power consumption required for the densification of ceramic materials. This paper reviews the experimental work on flash sintering methods carried out to date, and compares the properties of the materials obtained to those produced by conventional sintering. The flash sintering process is described for oxides of zirconium, yttrium, aluminium, tin, zinc, and titanium; silicon and boron carbide, zirconium diboride, materials for solid oxide fuel applications, ferroelectric materials, and composite materials. While experimental observations have been made on a wide range of materials, understanding of the underlying mechanisms responsible for the onset and latter stages of flash sintering is still elusive. Elements of the proposed theories to explain the observed behaviour include extensive Joule heating throughout the material causing thermal runaway, arrested by the current limitation in the power supply, and the formation of defect avalanches which rapidly and dramatically increase the sample conductivity. Undoubtedly, the flash sintering process is affected by the electric field strength, furnace temperature and current density limit, but also by microstructural features such as the presence of second phase particles or dopants and the particle size in the starting material. While further experimental work and modelling is still required to attain a full understanding capable of predicting the success of the flash sintering process in different materials, the technique non-etheless holds great potential for exceptional control of the ceramic sintering process.

Continuous pile discharging machine

DOEpatents

Smith, Phillips P.

1976-05-11

A device for discharging cartridges from tubes under fluid pressure includes a cylindrical housing adapted to be seated in a leak-tight manner on the end of one of the tubes, a chute depending from the cylindrical housing near the end seated on the end of the tube, a rotatable piston having a wrench on the forward end thereof disposed in the cylindrical housing and adapted to manipulate a plug in the end of the tube, and a telescopic hydraulic ram adapted to move the piston toward the plug. In addition the wrench contains a magnet which prevents inadvertent uncoupling of the wrench and the plug.

Study on the Fabrication of Paint-Type Si Quantum Dot-Sensitized Solar Cells

NASA Astrophysics Data System (ADS)

Seo, Hyunwoong; Son, Min-Kyu; Kim, Hee-Je; Wang, Yuting; Uchida, Giichiro; Kamataki, Kunihiro; Itagaki, Naho; Koga, Kazunori; Shiratani, Masaharu

2013-10-01

Quantum dots (QDs) have attracted much attention with their quantum characteristics in the research field of photochemical solar cells. Si QD was introduced as one of alternatives to conventional QD materials. However, their large particles could not penetrate inside TiO2 layer. Therefore, this work proposed the paint-type Si QD-sensitized solar cell. Its heat durability was suitable for the fabrication of paint-type solar cell. Si QDs were fabricated by multihollow discharge plasma chemical vapor deposition and characterized. The paste type, sintering temperature, and Si ratio were controlled and analyzed for better performance. Finally, its performance was enhanced by ZnS surface modification and the whole process was much simplified without sensitizing process.

Processing and Characterization of Porous Ti2AlC with Controlled Porosity and Pore Size

DTIC Science & Technology

2012-09-11

fabricated by spark plasma sintering , were also characterized. The effects of porosity and/or pore size on the room temperature elastic moduli...pressureless- sintered without NaCl pore former, or fabricated by spark plasma sintering , were also characterized. The effects of porosity and/or pore size...as well as several samples sintered using spark plasma sintering (SPS). Furthermore, we demon- strate that the developed methodology can be implemented

The effect of impurities elements on titanium alloy (Ti-6Al-4V) MIM sintered part properties

NASA Astrophysics Data System (ADS)

Ahmad, M. Azmirruddin; Jabir, M.; Johari, N.; Ibrahim, R.; Hamidi, N.

2017-12-01

The titanium alloys (Ti-6Al-4V) compact were fabricated by Metal Injection Molding (MIM). However, the real challenge of MIM processing for titanium alloy is its affinity to be contaminated by interstitial light elements such as oxygen and carbon which could degrade the mechanical properties of sintered titanium alloy such as its tensile strength and ductility. The sintering temperature effect on carbon and oxygen content that affects its physical and mechanical properties of the sintered titanium alloy was studied. The titanium MIM brown specimen was sintered at four different sintering temperatures which are 1100 °C, 1150 °C, 1200 °C and 1250 °C for 4 hours under furnace control atmosphere. The experimental result indicated that the specimen which has been made from 100% gas atomized powder have a relative density of 92.2 % - 97.6 %, the range of porosity percent around 2.38 %-3.84 %. Ultimate tensile strength of 873.11 MPa - 1007.19 MPa and ductility percent in range of 1.89 %-3.46 %. The titanium alloy MIM specimen which was sintered at 1150 °C contained 0.145 % of carbon and 0.143 % of oxygen possess the highest value of density and tensile strength, with value of 4.344 gcm-3 and 1007.2 MPa respectively. Meanwhile, the titanium alloy MIM specimen which was sintered at 1200 °C contains 0.130 % of carbon and 0.127 % of oxygen, has the highest percentage of ductility with 3.46 %. The carbon content level increased as the sintering temperature increased due to decomposition of high molecule weight of residue binder system which could not be eliminated during solvent extraction debinding process and sintered at low temperature. Contrarily, the oxygen content level indicates a decrease as the sintering temperature increased. Briefly, the sintering temperature could influence the physical and mechanical properties of titanium alloy MIM sintered specimen as it influences the oxygen and carbon content level in the alloys.

Debinding and Sintering of an Injection-Moulded Hypereutectic Al⁻Si Alloy.

PubMed

Ni, Jiaqi; Yu, Muhuo; Han, Keqing

2018-05-16

Hypereutectic Al⁻Si (20 wt.%) alloy parts were fabricated by employing a powder injection moulding (PIM) technique with a developed multi-component binder system composed of high-density polyethylene (35 wt.%), carnauba wax (62 wt.%) and stearic acid (3 wt.%). The feedstocks contained 83 wt.% metal powders. The debinding process was carried out by a combination of solvent extraction and thermal decomposition. The effects of solvent debinding variables such as kind of solvents, debinding temperatures and time, and the bulk surface area to volume ratios on the debinding process were investigated. Thermal debinding and the subsequent sintering process were carried out in a heating sequence under a nitrogen atmosphere. The influences of sintering temperature and sintering time on the mechanical properties and structure were considered. Under the optimal sintering condition, sintering at 550 °C for 3 h, the final sintering parts were free of distortion and exhibited good mechanical properties. Relative sintered density, Brinell hardness, and tensile strength were ~95.5%, 58 HBW and ~154, respectively.

Effect of starting powders on the sintering of nanostructured ZrO2 ceramics by colloidal processing

NASA Astrophysics Data System (ADS)

Suárez, Gustavo; Sakka, Yoshio; Suzuki, Tohru S.; Uchikoshi, Tetsuo; Zhu, Xinwen; Aglietti, Esteban F.

2009-04-01

The effect of starting powders on the sintering of nanostructured tetragonal zirconia was evaluated. Suspensions were prepared with a concentration of 10 vol.% by mixing a bicomponent mixture of commercial powders (97 mol.% monoclinic zirconia with 3 mol.% yttria) and by dispersing commercially available tetragonal zirconia (3YTZ, Tosoh). The preparation of the slurry by bead-milling was optimized. Colloidal processing using 50 μm zirconia beads at 4000 rpm generated a fully deagglomerated suspension leading to the formation of high-density consolidated compacts (62% of the theoretical density (TD) for the bicomponent suspension). Optimum colloidal processing of the bicomponent suspension followed by the sintering of yttria and zirconia allowed us to obtain nanostructured tetragonal zirconia. Three different sintering techniques were investigated: normal sintering, two-step sintering and spark plasma sintering. The inhibition of grain growth in the bicomponent mixed powders in comparison with 3YTZ was demonstrated. The inhibition of the grain growth may have been caused by inter-diffusion of cations during the sintering.

Chemical Sintering Generates Uniform Porous Hyaluronic Acid Hydrogels

PubMed Central

Cam, Cynthia; Segura, Tatiana

2014-01-01

Implantation of scaffolds for tissue repair has been met with limited success primarily due to the inability to achieve vascularization within the construct. Many strategies have shifted to incorporate pores into these scaffolds to encourage rapid cellular infiltration and subsequent vascular ingrowth. We utilized an efficient chemical sintering technique to create a uniform network of polymethyl methacrylate (PMMA) microspheres for porous hyaluronic acid hydrogel formation. The porous hydrogels generated from chemical sintering possessed comparable pore uniformity and interconnectivity as the commonly used non- and heat sintering techniques. Moreover, similar cell response to the porous hydrogels generated from each sintering approach was observed in cell viability, spreading, proliferation in vitro, as well as, cellular invasion in vivo. We propose chemical sintering of PMMA microspheres using a dilute acetone solution as an alternative method to generating porous hyaluronic acid hydrogels since it requires equal or ten-fold less processing time as the currently used non-sintering or heat sintering technique, respectively. PMID:24120847

Microwave processing of a dental ceramic used in computer-aided design/computer-aided manufacturing.

PubMed

Pendola, Martin; Saha, Subrata

2015-01-01

Because of their favorable mechanical properties and natural esthetics, ceramics are widely used in restorative dentistry. The conventional ceramic sintering process required for their use is usually slow, however, and the equipment has an elevated energy consumption. Sintering processes that use microwaves have several advantages compared to regular sintering: shorter processing times, lower energy consumption, and the capacity for volumetric heating. The objective of this study was to test the mechanical properties of a dental ceramic used in computer-aided design/computer-aided manufacturing (CAD/CAM) after the specimens were processed with microwave hybrid sintering. Density, hardness, and bending strength were measured. When ceramic specimens were sintered with microwaves, the processing times were reduced and protocols were simplified. Hardness was improved almost 20% compared to regular sintering, and flexural strength measurements suggested that specimens were approximately 50% stronger than specimens sintered in a conventional system. Microwave hybrid sintering may preserve or improve the mechanical properties of dental ceramics designed for CAD/CAM processing systems, reducing processing and waiting times.

The Effects of Atmosphere on the Sintering of Ultrafine-Grained Tungsten with Ti

NASA Astrophysics Data System (ADS)

Ren, Chai; Koopman, Mark; Fang, Z. Zak; Zhang, Huan

2016-11-01

Tungsten (W) is a brittle material at room temperature making it very difficult to fabricate. Although the lack of ductility remains a difficult challenge, nano-sized and ultrafine-grained (UFG) structures offer the potential to overcome tungsten's room-temperature brittleness. One way to manufacture UFG W is to compact and sinter nano-sized W powder. It is challenging, however, to control grain growth during sintering. As one method to inhibit grain growth, the effect of Ti-based additives on the densification and grain growth of nano-W powders was investigated in this study. Addition of 1% Ti into tungsten led to more than a 63% decrease in average grain size of sintered samples at comparable density levels. It was found that sintering in Ar yielded a finer grain size than sintering in H2 at similar densities. The active diffusion mechanisms during sintering were different for W-1% Ti nano powders sintered in Ar and H2.

EFFECT OF MICROWAVE SINTERING ON THE STRUCTURAL AND ELECTRICAL PROPERTIES OF Li0.51Zn0.2Ti0.2V0.01Fe2.08O4 FERRITE

NASA Astrophysics Data System (ADS)

Maisnam, Mamata; Phanjoubam, Sumitra

2013-07-01

Effect of microwave sintering on the structural and electrical properties of Li+0.51Zn2+0.2Ti4+0.2V5+0.01Fe3+2.08O2-4 is studied in comparison with that of conventionally sintered one. The technique is advantageous in terms of significantly reduced size of microwave kilns and rapid heating compared to the cumbersome and slow heating of conventional sintering technology. Microwave sintering produced enhanced densification and much finer microstructures. The DC resistivity is markedly increased. Microwave sintering reduces chances of evaporation of lithium and oxygen during sintering of lithium based ferrites resulting in formation of lesser ferrous ions. This has profound effect on the electrical properties of microwave sintered ferrites. The dielectric constant is significantly reduced possibly due to reduced space charge polarization and the temperature dependence of the dielectric properties are also studied.

Improved microstructure and thermoelectric properties of iodine doped indium selenide as a function of sintering temperature

NASA Astrophysics Data System (ADS)

Dhama, Pallavi; Kumar, Aparabal; Banerji, P.

2018-04-01

In this paper, we explored the effect of sintering temperature on the microstructure, thermal and electrical properties of iodine doped indium selenide in the temperature range 300 - 700 K. Samples were prepared by a collaborative process of vacuum melting, ball milling and spark plasma sintering at 570 K, 630 K and 690 K. Single phase samples were obtained at higher sintering temperature as InSe is stable only at lower temperature. With increasing sintering temperature, densities of the samples were found to improve with larger grain size formation. Negative values of Seebeck coefficient were observed which indicates n-type carrier transport. Seebeck coefficient increases with sintering temperature and found to be the highest for the sample sintered at 690 K. Thermal conductivity found to be lower in the samples sintered at lower temperatures. The maximum thermoelectric figure of merit found to be ˜ 1 at 700 K due to the enhanced power factor as a result of improved microstructure.

Reduction of FeO contents in sinter under high bed operation

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

Fujii, K.; Hazama, K.; Hoshikuma, Y.

1996-12-31

High-bed operation (bed height more than 700 mm) is currently being carried out at the Kure No. 1 sintering plant. Before initiating this high-bed operation, the authors conducted sinter pot tests at various bed heights to investigate the effect of bed height on sintering. The following results were obtained from these pot tests: Heightening of the sinter bed increased yield at the upper layer, but at the lower layer, the yield reached a maximum value at a certain bed height. From observation of the sinter cakes, the reduction in yield is attributed to uneven burn caused by surplus heat atmore » the lower layers. Therefore, when high-bed operation is carried out, reduction of the burning energy (reduction of the FeO content in the sinter) is required. This high-bed operation with lower FeO content has enabled the company to reduce fuel consumption and SiO{sub 2} content, while maintaining high yield and high sinter quality.« less

A study of machine-learning-based approaches to extract clinical entities and their assertions from discharge summaries.

PubMed

Jiang, Min; Chen, Yukun; Liu, Mei; Rosenbloom, S Trent; Mani, Subramani; Denny, Joshua C; Xu, Hua

2011-01-01

The authors' goal was to develop and evaluate machine-learning-based approaches to extracting clinical entities-including medical problems, tests, and treatments, as well as their asserted status-from hospital discharge summaries written using natural language. This project was part of the 2010 Center of Informatics for Integrating Biology and the Bedside/Veterans Affairs (VA) natural-language-processing challenge. The authors implemented a machine-learning-based named entity recognition system for clinical text and systematically evaluated the contributions of different types of features and ML algorithms, using a training corpus of 349 annotated notes. Based on the results from training data, the authors developed a novel hybrid clinical entity extraction system, which integrated heuristic rule-based modules with the ML-base named entity recognition module. The authors applied the hybrid system to the concept extraction and assertion classification tasks in the challenge and evaluated its performance using a test data set with 477 annotated notes. Standard measures including precision, recall, and F-measure were calculated using the evaluation script provided by the Center of Informatics for Integrating Biology and the Bedside/VA challenge organizers. The overall performance for all three types of clinical entities and all six types of assertions across 477 annotated notes were considered as the primary metric in the challenge. Systematic evaluation on the training set showed that Conditional Random Fields outperformed Support Vector Machines, and semantic information from existing natural-language-processing systems largely improved performance, although contributions from different types of features varied. The authors' hybrid entity extraction system achieved a maximum overall F-score of 0.8391 for concept extraction (ranked second) and 0.9313 for assertion classification (ranked fourth, but not statistically different than the first three systems) on the test data set in the challenge.

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.

Enhanced Densification and Hardness of Titanium Bodies Sintered by Advanced Hydrogen Sintering Process

NASA Astrophysics Data System (ADS)

Oh, Jung-Min; Koo, Ja-Geon; Lim, Jae-Won

2018-05-01

A new sintering technique for enhancing a densification and hardness of sintered titanium body by supplying hydrogen was developed (Hydrogen Sintering Process, HSP). The HSP was developed by only injecting hydrogen into an argon atmosphere during the core time. As a result, sound titanium sintered bodies with high density and hardness were obtained by the HSP. In addition, a pore size and number of the HSP specimens were smaller than those of the argon atmosphere specimen. It was found that the injecting hydrogen into the argon atmosphere by HSP can prevent the formation of oxide layers, resulting in enhanced densification and hardness.

Rapid sintering of anisotropic, nanograined Nd-Fe-B by flash-spark plasma sintering

NASA Astrophysics Data System (ADS)

Castle, Elinor; Sheridan, Richard; Grasso, Salvatore; Walton, Allan; Reece, Mike

2016-11-01

A Spark Plasma Sintering (SPS) furnace was used to Flash-Sinter (FS) Nd-Fe-Dy-Co-B-Ga melt spun permanent magnetic material. During the 10 s "Flash" process (heating rate 2660 K min-1), sample sintering (to theoretical density) and deformation (54% height reduction) occurred. This produced texturing and significant magnetic anisotropy, comparable to conventional die-upset magnets; yet with much greater coercivities (>1600 kA m-1) due to the nanoscale characteristics of the plate-like sintered grains. These preliminary results suggest that Flash-SPS could provide a new processing route for the mass production of highly anisotropic, nanocrystalline magnetic materials with high coercivity.

Solvent/non-solvent sintering: a novel route to create porous microsphere scaffolds for tissue regeneration.

PubMed

Brown, Justin L; Nair, Lakshmi S; Laurencin, Cato T

2008-08-01

Solvent/non-solvent sintering creates porous polymeric microsphere scaffolds suitable for tissue engineering purposes with control over the resulting porosity, average pore diameter, and mechanical properties. Five different biodegradable biocompatible polyphosphazenes exhibiting glass transition temperatures from -8 to 41 degrees C and poly (lactide-co-glycolide), (PLAGA) a degradable polymer used in a number of biomedical settings, were examined to study the versatility of the process and benchmark the process to heat sintering. Parameters such as: solvent/non-solvent sintering solution composition and submersion time effect the sintering process. PLAGA microsphere scaffolds fabricated with solvent/non-solvent sintering exhibited an interconnected porosity and pore size of 31.9% and 179.1 mum, respectively which was analogous to that of conventional heat sintered PLAGA microsphere scaffolds. Biodegradable polyphosphazene microsphere scaffolds exhibited a maximum interconnected porosity of 37.6% and a maximum compressive modulus of 94.3 MPa. Solvent/non-solvent sintering is an effective strategy for sintering polymeric microspheres, with a broad spectrum of glass transition temperatures, under ambient conditions making it an excellent fabrication route for developing tissue engineering scaffolds and drug delivery vehicles. (c) 2007 Wiley Periodicals, Inc.

Solvent/Non-Solvent Sintering: A Novel Route to Create Porous Microsphere Scaffolds For Tissue Regeneration

PubMed Central

Brown, Justin L.; Nair, Lakshmi S.; Laurencin, Cato T.

2009-01-01

Solvent/non-solvent sintering creates porous polymeric microsphere scaffolds suitable for tissue engineering purposes with control over the resulting porosity, average pore diameter and mechanical properties. Five different biodegradable biocompatible polyphosphazenes exhibiting glass transition temperatures from −8°C to 41oC and poly(lactide-co-glycolide), (PLAGA) a degradable polymer used in a number of biomedical settings, were examined to study the versatility of the process and benchmark the process to heat sintering. Parameters such as: solvent/non-solvent sintering solution composition and submersion time effect the sintering process. PLAGA microsphere scaffolds fabricated with solvent/non-solvent sintering exhibited an interconnected porosity and pore size of 31.9% and 179.1µm respectively which was analogous to that of conventional heat sintered PLAGA microsphere scaffolds. Biodegradable polyphosphazene microsphere scaffolds exhibited a maximum interconnected porosity of 37.6% and a maximum compressive modulus of 94.3MPa. Solvent/non-solvent sintering is an effective strategy for sintering polymeric microspheres, with a broad spectrum of glass transition temperatures, under ambient conditions making it an excellent fabrication route for developing tissue engineering scaffolds and drug delivery vehicles. PMID:18161819

An Investigation of Sintering Parameters on Titanium Powder for Electron Beam Melting Processing Optimization.

PubMed

Drescher, Philipp; Sarhan, Mohamed; Seitz, Hermann

2016-12-01

Selective electron beam melting (SEBM) is a relatively new additive manufacturing technology for metallic materials. Specific to this technology is the sintering of the metal powder prior to the melting process. The sintering process has disadvantages for post-processing. The post-processing of parts produced by SEBM typically involves the removal of semi-sintered powder through the use of a powder blasting system. Furthermore, the sintering of large areas before melting decreases productivity. Current investigations are aimed at improving the sintering process in order to achieve better productivity, geometric accuracy, and resolution. In this study, the focus lies on the modification of the sintering process. In order to investigate and improve the sintering process, highly porous titanium test specimens with various scan speeds were built. The aim of this study was to decrease build time with comparable mechanical properties of the components and to remove the residual powder more easily after a build. By only sintering the area in which the melt pool for the components is created, an average productivity improvement of approx. 20% was achieved. Tensile tests were carried out, and the measured mechanical properties show comparatively or slightly improved values compared with the reference.

Influence of Basicity on High-Chromium Vanadium-Titanium Magnetite Sinter Properties, Productivity, and Mineralogy

NASA Astrophysics Data System (ADS)

Zhou, Mi; Yang, Songtao; Jiang, Tao; Xue, Xiangxin

2015-05-01

The effect of basicity on high-chromium vanadium-titanium magnetite (V-Ti-Cr) sintering was studied via sintering pot tests. The sinter rate, yield, and productivity were calculated before determining sinter strength (TI) and reduction degradation index (RDI). Furthermore, the effect of basicity on V-Ti-Cr sinter mineralogy was clarified using metallographic microscopy, x-ray diffraction, and scanning electron microscopy-energy-dispersive x-ray spectroscopy. The results indicate that increasing basicity quickly increases the sintering rate from 25.4 mm min-1 to 28.9 mm min-1, yield from 75.3% to 87.2%, TI from 55.4% to 64.8%, and productivity from 1.83 t (m2 h)-1 to 1.94 t (m2 h)-1 before experiencing a slight drop. The V-Ti-Cr sinter shows complex mineral composition, with main mineral phases such as magnetite, hematite, silicate (dicalcium silicate, Ca-Fe olivine, glass), calcium and aluminum silico-ferrite (SFCA/SFCAI) and perovskite. Perovskite is notable because it lowers the V-Ti sinter strength and RDI. The well intergrowths between magnetite and SFCA/SFCAI, and the decrease in perovskite and secondary skeletal hematite are the key for improving TI and RDI. Finally, a comprehensive index was calculated, and the optimal V-Ti-Cr sinter basicity also for industrial application was 2.55.

An Arrhenius-type viscosity function to model sintering using the Skorohod Olevsky viscous sintering model within a finite element code.

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

Ewsuk, Kevin Gregory; Arguello, Jose Guadalupe, Jr.; Reiterer, Markus W.

2006-02-01

The ease and ability to predict sintering shrinkage and densification with the Skorohod-Olevsky viscous sintering (SOVS) model within a finite-element (FE) code have been improved with the use of an Arrhenius-type viscosity function. The need for a better viscosity function was identified by evaluating SOVS model predictions made using a previously published polynomial viscosity function. Predictions made using the original, polynomial viscosity function do not accurately reflect experimentally observed sintering behavior. To more easily and better predict sintering behavior using FE simulations, a thermally activated viscosity function based on creep theory was used with the SOVS model. In comparison withmore » the polynomial viscosity function, SOVS model predictions made using the Arrhenius-type viscosity function are more representative of experimentally observed viscosity and sintering behavior. Additionally, the effects of changes in heating rate on densification can easily be predicted with the Arrhenius-type viscosity function. Another attribute of the Arrhenius-type viscosity function is that it provides the potential to link different sintering models. For example, the apparent activation energy, Q, for densification used in the construction of the master sintering curve for a low-temperature cofire ceramic dielectric has been used as the apparent activation energy for material flow in the Arrhenius-type viscosity function to predict heating rate-dependent sintering behavior using the SOVS model.« less

SEM and TEM characterization of microstructure of stainless steel composites reinforced with TiB{sub 2}

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

Sulima, Iwona, E-mail: isulima@up.krakow.pl

Steel-8TiB{sub 2} composites were produced by two new sintering techniques, i.e. Spark Plasma Sintering (SPS) and High Pressure-High Temperature (HP-HT) sintering. This study discusses the impact of these sintering methods on the microstructure of steel composites reinforced with TiB{sub 2} particles. Scanning electron microscopy (SEM), wavelength dispersive spectroscopy (WDS), X-ray diffraction, electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were used to analyze the microstructure evolution in steel matrix composites. The results of microscopic examinations revealed a close relationship between the composite microstructure and the methods and conditions of sintering. Substantial differences were observed in the grain size ofmore » materials sintered by HP-HT and SPS. It has been demonstrated that the composites sintered by HP-HT tend to form a chromium-iron-nickel phase in the steel matrix. In contrast, the microstructure of the composites sintered by SPS is characterized by the presence of complex borides and chromium-iron phase. - Highlights: •The steel-8TiB{sub 2} composites were fabricated by Spark Plasma Sintering (SPS) and High Pressure-High Temperature (HP-HT). •Sintering techniques has an important effect on changes in the microstructure of steel-8TiB{sub 2} composites. •New phases of different size and morphology were identified.« less

Sintering of Lead-Free Piezoelectric Sodium Potassium Niobate Ceramics

PubMed Central

Malič, Barbara; Koruza, Jurij; Hreščak, Jitka; Bernard, Janez; Wang, Ke; Fisher, John G.; Benčan, Andreja

2015-01-01

The potassium sodium niobate, K0.5Na0.5NbO3, solid solution (KNN) is considered as one of the most promising, environment-friendly, lead-free candidates to replace highly efficient, lead-based piezoelectrics. Since the first reports of KNN, it has been recognized that obtaining phase-pure materials with a high density and a uniform, fine-grained microstructure is a major challenge. For this reason the present paper reviews the different methods for consolidating KNN ceramics. The difficulties involved in the solid-state synthesis of KNN powder, i.e., obtaining phase purity, the stoichiometry of the perovskite phase, and the chemical homogeneity, are discussed. The solid-state sintering of stoichiometric KNN is characterized by poor densification and an extremely narrow sintering-temperature range, which is close to the solidus temperature. A study of the initial sintering stage revealed that coarsening of the microstructure without densification contributes to a reduction of the driving force for sintering. The influences of the (K + Na)/Nb molar ratio, the presence of a liquid phase, chemical modifications (doping, complex solid solutions) and different atmospheres (i.e., defect chemistry) on the sintering are discussed. Special sintering techniques, such as pressure-assisted sintering and spark-plasma sintering, can be effective methods for enhancing the density of KNN ceramics. The sintering behavior of KNN is compared to that of a representative piezoelectric lead zirconate titanate (PZT). PMID:28793702

Effect of temperature on porosity of iron ore sinter with biochar derived from EFB

NASA Astrophysics Data System (ADS)

Purwanto, H.; Rozhan, A. N.; Zakiyuddin, A.; Mohamad, A. S.

2018-01-01

In this research, the replacement of fossil fuel energy (coke) with oil palm empty fruit bunch as a potential energy in sintering of iron ore was investigated. Carbon derived biomass has been produced by using oil palm empty fruit bunch by heat treatment process. In the present investigation, sintering process was carried out by heating the mixed iron ore and biochar at various temperatures. The apparent density and porosity for iron sinter show a significant increase and gradual decrement as the temperature increase, respectively. The porosity of iron sinter shows a gradual decrement from 950 °C to 1050 °C but up to 1150 °C it shows a significant decrement about 44%. Inferring to the micrograph, the agglomeration and assimilation of sinter at high temperature is better compared with low sintering temperature.

Reflow-oven-processing of pressureless sintered-silver interconnects

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

Wereszczak, Andrew A.; Chen, Branndon R.; Oistad, Brian A.

Here, a method was developed to pressurelessly fabricate strong and consistent sinterable-silver joints or interconnects using reflow oven heating. Circular sinterable-silver interconnects, having nominal diameter of 5 mm and 0.1 mm thickness were stencil printed, contact-dried, and then pressurelessly sinter-bonded to Au-plated direct copper bonded ceramic substrates at 250 °C in ambient air. That sintering was done in either a reflow oven or a convective oven (latter being a conventional heating source for processing sinterable-silver). Consistently strong (>40 MPa) interconnects were produced with reflow oven heating and were as strong as those produced with convective oven heating. This is significantmore » because reflow oven technology affords better potential for continuous mass production and it was shown that strong sintered-silver bonds can indeed be achieved with its use.« less

The physical chemistry and materials science behind sinter-resistant catalysts.

PubMed

Dai, Yunqian; Lu, Ping; Cao, Zhenming; Campbell, Charles T; Xia, Younan

2018-06-18

Catalyst sintering, a main cause of the loss of catalytic activity and/or selectivity at high reaction temperatures, is a major concern and grand challenge in the general area of heterogeneous catalysis. Although all heterogeneous catalysts are inevitably subjected to sintering during their operation, the immediate and drastic consequences can be mitigated by carefully engineering the catalytic particles and their interactions with the supports. In this tutorial review, we highlight recent progress in understanding the physical chemistry and materials science involved in sintering, including the discussion of advanced techniques, such as in situ microscopy and spectroscopy, for investigating the sintering process and its rate. We also discuss strategies for the design and rational fabrication of sinter-resistant catalysts. Finally, we showcase recent success in improving the thermal stability and thus sinter resistance of supported catalytic systems.

Mechanical parameters of strontium doped hydroxyapatite sintered using microwave and conventional methods.

PubMed

Curran, Declan J; Fleming, Thomas J; Towler, Mark R; Hampshire, Stuart

2011-11-01

The effects of ion substitution in hydroxyapatite (HA) on crystal structure and lattice stability is investigated in the green state and post sintering. The effects of ion incorporation on the biaxial flexural strength and hardness are also investigated. Sintering is carried out at 1200 °C using comparative conventional and microwave regimes. Post sintering, the effects of ion incorporation manifest as an increase in the lattice d-spacings and a reduction of the crystallite size. Some HA decomposition occurs with β-TCP stabilisation in conventional sintering (CS), but this phase is destabilised during microwave sintering (MS), generating α-TCP. Conventional sintering (CS) allows higher densification in the undoped samples. Overall, for the Sr-doped compositions, the MS samples retain higher amounts of HA and experience higher density levels compared to the CS samples. Published by Elsevier Ltd.

Lanthanide (Nd, Gd) compounds with garnet and monazite structures. Powders synthesis by "wet" chemistry to sintering ceramics by Spark Plasma Sintering

NASA Astrophysics Data System (ADS)

Potanina, Ekaterina; Golovkina, Ludmila; Orlova, Albina; Nokhrin, Aleksey; Boldin, Maksim; Sakharov, Nikita

2016-05-01

Complex oxide Y2.5Nd0.5Al5O12 with garnet structure and phosphates NdPO4 and GdPO4 with monazite structure were obtained by using precipitation methods. Ceramics Y2.5Nd0.5Al5O12 and NdPO4 were processed by Spark Plasma Sintering (SPS). Relative density more 98%, sintering time did not exceed 8 min, sintering temperature 1330-1390 °C. Leaching rates of elements from ceramics were 10-6-10-7 g/(cm2 d). The process of ceramics sintering has two-stage character: the first step of sintering-compaction process is related to the plastic flow of the material, the second step-to the process of grain boundary diffusion and grain growth.

Reflow-oven-processing of pressureless sintered-silver interconnects

DOE PAGES

Wereszczak, Andrew A.; Chen, Branndon R.; Oistad, Brian A.

2018-01-04

Here, a method was developed to pressurelessly fabricate strong and consistent sinterable-silver joints or interconnects using reflow oven heating. Circular sinterable-silver interconnects, having nominal diameter of 5 mm and 0.1 mm thickness were stencil printed, contact-dried, and then pressurelessly sinter-bonded to Au-plated direct copper bonded ceramic substrates at 250 °C in ambient air. That sintering was done in either a reflow oven or a convective oven (latter being a conventional heating source for processing sinterable-silver). Consistently strong (>40 MPa) interconnects were produced with reflow oven heating and were as strong as those produced with convective oven heating. This is significantmore » because reflow oven technology affords better potential for continuous mass production and it was shown that strong sintered-silver bonds can indeed be achieved with its use.« less

Analysis of copper mixed kerosene servotherm in EDM of Monel 400™

NASA Astrophysics Data System (ADS)

Anandakumar, P. A.; Molla, Baya; Biruke, Fisha; Aravind, S.

2017-05-01

Powder mixed electro discharge machine process (PMEDM) is a hybrid machine process where a conductive powders is mixed to the dielectric fluid to facilitate effective machining of advanced material. This present study focused on performance of copper mixed kerosene servotherm as dielectric medium in EDM of Monel 400TM. The ratio of kerosene sevothermis 75 : 25. The copper powder was mixed with dielectric medium of kerosene servothem of 6g, 8g and 10 g respectively. This mixture was analyzed using different current rate of 8 amps, 10 amps and 12 amps to know the performance characteristics by using material removal rate, tool wear rate, diameter overcut, surface finish and dimensional accuracy. Based on the experimental investigation it is concluded that copper powder of 10g with 10 amps performed well than that of all other parameters.

Sinter-vein correlations at Buckskin Mountain, National district, Humboldt County, Nevada

USGS Publications Warehouse

Vikre, P.G.

2007-01-01

At Buckskin Mountain (elev 2,650 m, 8,743 ft), Humboldt County, Nevada, a hydrothermal system, imposed on a middle Miocene volcanic sequence with contrasting permeabilities and tensile strengths, produced alteration assemblages controlled by elevation, from Hg-mineralized sinter to subjacent precious metal veins over a vertical distance exceeding 790 m. Sinter and epiclastic deposits, interpreted to be remnant paleosurface basinal strata enclosed by 16.6 to 16.1 Ma rhyolites, overlie older volcaniclastic basinal deposits and were part of a regional fluvial-lacustrine system developed among ca. 16 to 12 Ma basalt-rhyolite eruptive centers throughout the northern Great Basin. Because of contrasting erosional resistance among altered and unaltered rocks, Buckskin Mountain represents inverse topography with sinter and silicified epiclastic deposits at the summit. Sinter and veins, correlated by common elements, similar mineralogy, age constraints, textures, S isotope compositions, and fluid inclusion microthermometry, were deposited by sinter-vein fluid, the first of two sequential hydrothermal fluid regimes that evolved in response to magmatism, tectonism, hydrology, and topography. Thermal quenching of distally derived sinter-vein fluid in planar conduits caused deposition of banded quartz-silicate-selenide-sulfide veins ???270 to > 440 m below sinter at 16.1 Ma; vei??ns were initially enveloped by zoned selvages of proximal K-feldspar + K-mica + quartz + pyrite and distal illite + chlorite + calcite + pyrite. Mixing of sinter-vein fluid with local meteoric water in saturated basinal deposits caused deposition of silica, Hg-Se-S-Cl minerals, and precious metals in sinter and epiclastic deposits. Elevated ???Se/???S in sinter-vein fluid, and the relatively large stability fields of reduced aqueous selenide species in the temperature range of 250?? to <100??C, enabled (but was not the cause of) codeposition of selenide-sulfide minerals and common element associations in veins and sinter. Acid-sulfate fluid of the second fluid regime was derived from oxidation of H2S and other volatiles exsolved from sinter-vein fluid. Acid-sulfate fluid produced (1) a subhorizontal zone of partially leached basinal deposits and rhyolite from the paleosurface to a depth of ???60 m, and (2) laterally pervasive zones, ???100 to 200 m thick, of quartz + alunite ?? hematite and quartz + kaolinite + pyrite in volcaniclastic deposits immediately beneath partially leached rocks, but this fluid did not decompose selenide-sulfide-precious metal phases in sinter. Paragenetically late vein and wall-rock assemblages, including marcasite + pyrite, calcite, and kaolinite-replaced K minerals, record deeper transition of sinter-vein fluid into acid-sulfate fluid in vein conduits. This transition occurred as regional subsidence, manifested by the Goosey Lake depression immediately east of Buckskin Mountain, lowered the pieziometric surface at Buckskin Mountain, terminated sinter deposition, and caused boiling and/or degassing of sinter-vein fluid. The timing of subsidence is recorded by a decrease in alunite ages, from ca. 15.8 to 15.6 Ma, with depth below sinter. Lateral replacement of sinter and partially leached epiclastic deposits and rhyolite by opal-A marks the termination of the two hydrothermal regimes that lasted ???0.5 m.y. and followed rhyolitic volcanism of similar duration. Veins and sinter display textures that attest to plastic deformation, spalling, and gravitational settling, and indicate fluid-flow direction, velocity, and density stratification which, with conduit topology, may have influenced precious metal tenor in the veins. Components of sinter and veins were transported as colloids, formed in supersaturated sinter-vein fluid, that aggregated or coagulated as incompetent gelatinous layers in shallow pools and in underlying, near-vertical conduits in rhyolite and initially crystallized as opal and chalcedony. The low thermal conductivity of ho

Inductive Sensor Performance in Partial Discharges and Noise Separation by Means of Spectral Power Ratios

PubMed Central

Ardila-Rey, Jorge Alfredo; Rojas-Moreno, Mónica Victoria; Martínez-Tarifa, Juan Manuel; Robles, Guillermo

2014-01-01

Partial discharge (PD) detection is a standardized technique to qualify electrical insulation in machines and power cables. Several techniques that analyze the waveform of the pulses have been proposed to discriminate noise from PD activity. Among them, spectral power ratio representation shows great flexibility in the separation of the sources of PD. Mapping spectral power ratios in two-dimensional plots leads to clusters of points which group pulses with similar characteristics. The position in the map depends on the nature of the partial discharge, the setup and the frequency response of the sensors. If these clusters are clearly separated, the subsequent task of identifying the source of the discharge is straightforward so the distance between clusters can be a figure of merit to suggest the best option for PD recognition. In this paper, two inductive sensors with different frequency responses to pulsed signals, a high frequency current transformer and an inductive loop sensor, are analyzed to test their performance in detecting and separating the sources of partial discharges. PMID:24556674

Boron ion beam generation utilizing lanthanum hexaboride cathodes: Comparison of vacuum arc and planar magnetron glow

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

Nikolaev, A. G.; Vizir, A. V.; Yushkov, G. Yu., E-mail: gyushkov@mail.ru

Boron ion beams are widely used for semiconductor ion implantation and for surface modification for improving the operating parameters and increasing the lifetime of machine parts and tools. For the latter application, the purity requirements of boron ion beams are not as stringent as for semiconductor technology, and a composite cathode of lanthanum hexaboride may be suitable for the production of boron ions. We have explored the use of two different approaches to boron plasma production: vacuum arc and planar high power impulse magnetron in self-sputtering mode. For the arc discharge, the boron plasma is generated at cathode spots, whereasmore » for the magnetron discharge, the main process is sputtering of cathode material. We present here the results of comparative test experiments for both kinds of discharge, aimed at determining the optimal discharge parameters for maximum yield of boron ions. For both discharges, the extracted ion beam current reaches hundreds of milliamps and the fraction of boron ions in the total extracted ion beam is as high as 80%.« less

Electrical Discharge Machining (EDM) Gun Barrel Bore and Rifling Feasibility Study

DTIC Science & Technology

1974-09-01

11 I + | , + + in cri es sss asa f^piis aisa -^ nro^ HH^ S I I + VD 1X> ^3 Wfl ^mvo ^00...and high erosion rates encountered in high performance gun designs such as the GAU-7/A DD , :°N RM73 1473 EDITION OF 1 NOV 65 IS OBSOLETE

Process for ultra smooth diamond coating on metals and uses thereof

NASA Technical Reports Server (NTRS)

Vohra, Yogesh K. (Inventor); Catledge, Shane A. (Inventor)

2001-01-01

The present invention provides a new process to deposit well adhered ultra smooth diamond films on metals by adding nitrogen gas to the methane/hydrogen plasma created by a microwave discharge. Such diamond coating process is useful in tribological/wear resistant applications in bio-implants, machine tools, and magnetic recording industry.

Microstructure, Morphology, and Nanomechanical Properties Near Fine Holes Produced by Electro-Discharge Machining

NASA Astrophysics Data System (ADS)

Blau, P. J.; Howe, J. Y.; Coffey, D. W.; Trejo, R. M.; Kenik, E. D.; Jolly, B. C.; Yang, N.

2012-08-01

Fine holes in metal alloys are employed for many important technological purposes, including cooling and the precise atomization of liquids. For example, they play an important role in the metering and delivery of fuel to the combustion chambers in energy-efficient, low-emission diesel engines. Electro-discharge machining (EDM) is one process employed to produce such holes. Since the hole shape and bore morphology can affect fluid flow, and holes also represent structural discontinuities in the tips of the spray nozzles, it is important to understand the microstructures adjacent to these holes, the features of the hole walls, and the nanomechanical properties of the material that was in some manner altered by the EDM hole-making process. Several techniques were used to characterize the structure and properties of spray-holes in a commercial injector nozzle. These include scanning electron microscopy, cross sectioning and metallographic etching, bore surface roughness measurements by optical interferometry, scanning electron microscopy, and transmission electron microscopy of recast EDM layers extracted with the help of a focused ion beam.

Teaching High School Students Machine Learning Algorithms to Analyze Flood Risk Factors in River Deltas

NASA Astrophysics Data System (ADS)

Rose, R.; Aizenman, H.; Mei, E.; Choudhury, N.

2013-12-01

High School students interested in the STEM fields benefit most when actively participating, so I created a series of learning modules on how to analyze complex systems using machine-learning that give automated feedback to students. The automated feedbacks give timely responses that will encourage the students to continue testing and enhancing their programs. I have designed my modules to take the tactical learning approach in conveying the concepts behind correlation, linear regression, and vector distance based classification and clustering. On successful completion of these modules, students will learn how to calculate linear regression, Pearson's correlation, and apply classification and clustering techniques to a dataset. Working on these modules will allow the students to take back to the classroom what they've learned and then apply it to the Earth Science curriculum. During my research this summer, we applied these lessons to analyzing river deltas; we looked at trends in the different variables over time, looked for similarities in NDVI, precipitation, inundation, runoff and discharge, and attempted to predict floods based on the precipitation, waves mean, area of discharge, NDVI, and inundation.

Intense X-ray machine for penetrating radiography

NASA Astrophysics Data System (ADS)

Lucht, Roy A.; Eckhouse, Shimon

Penetrating radiography has been used for many years in the nuclear weapons research programs. Infrequently penetrating radiography has been used in conventional weapons research programs. For example the Los Alamos PHERMEX machine was used to view uranium rods penetrating steel for the GAU-8 program, and the Ector machine was used to see low density regions in forming metal jets. The armor/anti-armor program at Los Alamos has created a need for an intense flash X-ray machine that can be dedicated to conventional weapons research. The Balanced Technology Initiative, through DARPA, has funded the design and construction of such a machine at Los Alamos. It will be an 8- to 10-MeV diode machine capable of delivering a dose of 500 R at 1 m with a spot size of less than 5 mm. The machine used an 87.5-stage low inductance Marx generator that charges up a 7.4-(Omega), 32-ns water line. The water line is discharged through a self-breakdown oil switch into a 12.4-(Omega) water line that rings up the voltage into the high impendance X-ray diode. A long (233-cm) vacuum drift tube is used to separate the large diameter oil-insulated diode region from the X-ray source area that may be exposed to high overpressures by the explosive experiments. The electron beam is selffocused at the target area using a low pressure background gas.

Ir-based refractory superalloys by pulse electric current sintering (PECS) process (II prealloyed powder)

NASA Astrophysics Data System (ADS)

Huang, C.; Yamabe-Mitarai, Y.; Harada, H.

2002-02-01

Five prealloyed powder samples prepared from binary Ir-based refractory superalloys were sintered at 1800 °C for 4 h by Pulse Electric Current Sintering (PECS). No metal loss was observed during sintering. The relative densities of the sintered specimens all exceeded 90% T.D. The best one was Ir-13% Hf with the density of 97.82% T.D. Phases detected in sintered samples were in accordance with the phase diagram as expected. Fractured surfaces were observed in two samples (Ir-13% Hf and Ir-15% Zr). Some improvements obtained by using prealloyed powders instead of elemental powders, which were investigated in the previous studies, were presented.

Powder metallurgy: Solid and liquid phase sintering of copper

NASA Technical Reports Server (NTRS)

Sheldon, Rex; Weiser, Martin W.

1993-01-01

Basic powder metallurgy (P/M) principles and techniques are presented in this laboratory experiment. A copper based system is used since it is relatively easy to work with and is commercially important. In addition to standard solid state sintering, small quantities of low melting metals such as tin, zinc, lead, and aluminum can be added to demonstrate liquid phase sintering and alloy formation. The Taguchi Method of experimental design was used to study the effect of particle size, pressing force, sintering temperature, and sintering time. These parameters can be easily changed to incorporate liquid phase sintering effects and some guidelines for such substitutions are presented. The experiment is typically carried out over a period of three weeks.

Densification kinetics of nanocrystalline zirconia powder using microwave and spark plasma sintering--a comparative study.

PubMed

Vasylkiv, Oleg; Demirskyi, Dmytro; Sakka, Yoshio; Ragulya, Andrey; Borodianska, Hanna

2012-06-01

Two-stage densification process of nanosized 3 mol% yttria-stabilized zirconia (3Y-SZ) polycrystalline compacts during consolidation via microwave and spark-plasma sintering have been observed. The values of activation energies obtained for microwave and spark-plasma sintering 260-275 kJ x mol(-1) are quite similar to that of conventional sintering of zirconia, suggesting that densification during initial stage is controlled by the grain-boundary diffusion mechanism. The sintering behavior during microwave sintering was significantly affected by preliminary pressing conditions, as the surface diffusion mechanism (230 kJ x mol(-1)) is active in case of cold-isostatic pressing procedure was applied.

Using machine learning algorithms to guide rehabilitation planning for home care clients.

PubMed

Zhu, Mu; Zhang, Zhanyang; Hirdes, John P; Stolee, Paul

2007-12-20

Targeting older clients for rehabilitation is a clinical challenge and a research priority. We investigate the potential of machine learning algorithms - Support Vector Machine (SVM) and K-Nearest Neighbors (KNN) - to guide rehabilitation planning for home care clients. This study is a secondary analysis of data on 24,724 longer-term clients from eight home care programs in Ontario. Data were collected with the RAI-HC assessment system, in which the Activities of Daily Living Clinical Assessment Protocol (ADLCAP) is used to identify clients with rehabilitation potential. For study purposes, a client is defined as having rehabilitation potential if there was: i) improvement in ADL functioning, or ii) discharge home. SVM and KNN results are compared with those obtained using the ADLCAP. For comparison, the machine learning algorithms use the same functional and health status indicators as the ADLCAP. The KNN and SVM algorithms achieved similar substantially improved performance over the ADLCAP, although false positive and false negative rates were still fairly high (FP > .18, FN > .34 versus FP > .29, FN. > .58 for ADLCAP). Results are used to suggest potential revisions to the ADLCAP. Machine learning algorithms achieved superior predictions than the current protocol. Machine learning results are less readily interpretable, but can also be used to guide development of improved clinical protocols.

Fabrication of Bi2223 bulks with high critical current properties sintered in Ag tubes

NASA Astrophysics Data System (ADS)

Takeda, Yasuaki; Shimoyama, Jun-ichi; Motoki, Takanori; Kishio, Kohji; Nakashima, Takayoshi; Kagiyama, Tomohiro; Kobayashi, Shin-ichi; Hayashi, Kazuhiko

2017-03-01

Randomly grain oriented Bi2223 sintered bulks are one of the representative superconducting materials having weak-link problem due to very short coherence length particularly along the c-axis, resulting in poor intergrain Jc properties. In our previous studies, sintering and/or post-annealing under moderately reducing atmospheres were found to be effective for improving grain coupling in Bi2223 sintered bulks. Further optimizations of the synthesis process for Bi2223 sintered bulks were attempted in the present study to enhance their intergrain Jc. Effects of applied pressure of uniaxial pressing and sintering conditions on microstructure and superconducting properties have been systematically investigated. The best sample showed intergrain Jc of 2.0 kA cm-2 at 77 K and 8.2 kA cm-2 at 20 K, while its relative density was low ∼65%. These values are quite high as for a randomly oriented sintered bulk of cuprate superconductors.

Effects of sintering temperature on electrical properties of sheep enamel hydroxyapatite

NASA Astrophysics Data System (ADS)

Dumludag, F.; Gunduz, O.; Kılıc, O.; Kılıc, B.; Ekren, N.; Kalkandelen, C.; Oktar, F. N.

2017-12-01

Bioceramics, especially calcium phosphate based bioceramics, whose examples are hydroxyapatite, and calcium phosphate powders have been widely used in the biomedical engineering applications. Hydroxyapatite (HA) is one of the most promising biomaterials, which are derived from natural sources, chemical method, animal like dental enamel and corals. The influence of sintering temperature on the electrical properties (i.e. DC conductivity, AC conductivity) of samples of sintered sheep enamel (SSSE) was studied in air and in vacuum ambient at room temperature. The sheep enamel were sintered at varying temperatures between 1000°C and 1300°C. DC conductivity results revealed that while dc conductivity of the SSSE decreases with increasing the sintering temperature in air ambient the values increased with increasing the sintering temperature in vacuum ambient. AC conductivity measurements were performed in the frequency range of 40 Hz - 105 Hz. The results showed that ac conductivity values decrease with increasing the sintering temperature.

Degradation resistance of 3Y-TZP ceramics sintered using spark plasma sintering

NASA Astrophysics Data System (ADS)

Chintapalli, R.; Marro, F. G.; Valle, J. A.; Yan, H.; Reece, M. J.; Anglada, M.

2009-09-01

Commercially available tetragonal zirconia powder doped with 3 mol% of yttria has been sintered using spark plasma sintering (SPS) and has been investigated for its resistance to hydrothermal degradation. Samples were sintered at 1100, 1150, 1175 and 1600 °C at constant pressure of 100 MPa and soaking for 5 minutes, and the grain sizes obtained were 65, 90, 120 and 800 nm, respectively. Samples sintered conventionally with a grain size of 300 nm were also compared with samples sintered using SPS. Finely polished samples were subjected to artificial degradation at 131 °C for 60 hours in vapour in auto clave under a pressure of 2 bars. The XRD studies show no phase transformation in samples with low density and small grain size (<200 nm), but significant phase transformation is seen in dense samples with larger grain size (>300 nm). Results are discussed in terms of present theories of hydrothermal degradation.

Accelerated sintering in phase-separating nanostructured alloys

PubMed Central

Park, Mansoo; Schuh, Christopher A.

2015-01-01

Sintering of powders is a common means of producing bulk materials when melt casting is impossible or does not achieve a desired microstructure, and has long been pursued for nanocrystalline materials in particular. Acceleration of sintering is desirable to lower processing temperatures and times, and thus to limit undesirable microstructure evolution. Here we show that markedly enhanced sintering is possible in some nanocrystalline alloys. In a nanostructured W–Cr alloy, sintering sets on at a very low temperature that is commensurate with phase separation to form a Cr-rich phase with a nanoscale arrangement that supports rapid diffusional transport. The method permits bulk full density specimens with nanoscale grains, produced during a sintering cycle involving no applied stress. We further show that such accelerated sintering can be evoked by design in other nanocrystalline alloys, opening the door to a variety of nanostructured bulk materials processed in arbitrary shapes from powder inputs. PMID:25901420

Microwave sintering of single plate-shaped articles

DOEpatents

Katz, Joel D.; Blake, Rodger D.

1995-01-01

Apparatus and method for high temperature sintering of plate-shaped articles of alumina, magnesia, silica, yttria, zirconia, and mixtures thereof using microwave radiation. An article is placed within a sintering structure located within a sintering container which is placed in a microwave cavity for heating. The rates at which heating and cooling take place is controlled.

77 FR 51046 - Certain Sintered Rare Earth Magnets, Methods of Making Same and Products Containing Same; Notice...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-08-23

... INTERNATIONAL TRADE COMMISSION [Docket No. 2908] Certain Sintered Rare Earth Magnets, Methods of... Certain Sintered Rare Earth Magnets, Methods of Making Same and Products Containing Same, DN 2908; the... importation, and the sale within the United States after importation of certain sintered rare earth magnets...

77 FR 58578 - Certain Sintered Rare Earth Magnets, Methods of Making Same and Products Containing Same...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-09-21

... INTERNATIONAL TRADE COMMISSION [Investigation No. 337-TA-855] Certain Sintered Rare Earth Magnets... importation of certain sintered rare earth magnets, methods of making same and products containing same by... importation of certain sintered rare earth magnets, methods of making same and products containing same that...

Effects of sintering atmosphere on the physical and mechanical properties of modified BOF slag glass

NASA Astrophysics Data System (ADS)

Dai, Wen-bin; Li, Yu; Cang, Da-qiang; Zhou, Yuan-yuan; Fan, Yong

2014-05-01

This study proposes an efficient way to utilize all the chemical components of the basic oxygen furnace (BOF) slag to prepare high value-added glass-ceramics. A molten modified BOF slag was converted from the melting BOF slag by reducing it and separating out iron component in it, and the modified BOF slag was then quenched in water to form glasses with different basicities. The glasses were subsequently sintered in the temperature range of 600-1000°C in air or nitrogen atmosphere for 1 h. The effects of different atmospheres on the physical and mechanical properties of sintered samples were studied by using differential scanning calorimetry (DSC), X-ray diffraction (XRD) and scanning electron microscopy (SEM) and by conducting experiment on evaluating the sintering shrinkage, water absorption and bulk density. It is found that the kinetics of the sintering process is significantly affected by sintering atmosphere. In particular, compared with sintering in air atmosphere, sintering in N2 atmosphere promotes the synergistic growth of pyroxene and melilite crystalline phases, which can contribute to better mechanical properties and denser microstructure.

Evaluation of Sintering Behaviors of Saprolitic Nickeliferous Laterite Based on Quaternary Basicity

NASA Astrophysics Data System (ADS)

Luo, Jun; Li, Guanghui; Rao, Mingjun; Zhang, Yuanbo; Peng, Zhiwei; Zhi, Qian; Jiang, Tao

2015-09-01

The sintering behaviors of saprolitic nickeliferous laterite with various quaternary basicities [(CaO + MgO)/(SiO2 + Al2O3) mass ratio] in a reductive atmosphere are investigated by simulative sintering and validated by sintering pot tests. The simulative sintering results show that the generation of diopside (CaMgSi2O6) with low melting point is the key reason for the decrease in characteristic fusion temperatures when the quaternary basicity increases from 0.5 to 0.8-1.0. Continuous increase of basicity leads to transformation of diopside (CaMgSi2O6) into akermanite (Ca2MgSi2O7), which adversely increases the characteristic fusion temperatures. These findings are confirmed by the sinter pot tests, which demonstrate that the sintering indexes including vertical sintering velocity (VSV), yield ( Y), and productivity ( P), can be improved by optimizing quaternary basicity. At basicity of 1.0, the VSV, Y, P, and ISO tumbling index reach 49.2 mm/min, 80.5%, 1.0 t/(h m2), and 66.5%, respectively.

Sintering Behavior of Spark Plasma Sintered SiC with Si-SiC Composite Nanoparticles Prepared by Thermal DC Plasma Process

NASA Astrophysics Data System (ADS)

Yu, Yeon-Tae; Naik, Gautam Kumar; Lim, Young-Bin; Yoon, Jeong-Mo

2017-11-01

The Si-coated SiC (Si-SiC) composite nanoparticle was prepared by non-transferred arc thermal plasma processing of solid-state synthesized SiC powder and was used as a sintering additive for SiC ceramic formation. Sintered SiC pellet was prepared by spark plasma sintering (SPS) process, and the effect of nano-sized Si-SiC composite particles on the sintering behavior of micron-sized SiC powder was investigated. The mixing ratio of Si-SiC composite nanoparticle to micron-sized SiC was optimized to 10 wt%. Vicker's hardness and relative density was increased with increasing sintering temperature and holding time. The relative density and Vicker's hardness was further increased by reaction bonding using additional activated carbon to the mixture of micron-sized SiC and nano-sized Si-SiC. The maximum relative density (97.1%) and Vicker's hardness (31.4 GPa) were recorded at 1800 °C sintering temperature for 1 min holding time, when 0.2 wt% additional activated carbon was added to the mixture of SiC/Si-SiC.