HR-TEM observation of laser pressure weld of galvannealed steel and pure aluminium

Laser pressure welding was conducted by changing the laser power and the roller pressure in the previous experiment. It was revealed that dissimilar metal welding of galvannealed steel and pure aluminium was feasible in a wide range of welding conditions. When the roller pressure was more than 1.96 kN at the laser powers equal to or less than 1400 W, the joint strengths were so high that the specimens in the tensile shear and the peel tests fractured in the A1050 parent metal.

In order to know the reason for such high strengths of joints with thick compound layers and the joining mechanism, the compound layer was observed by HR-transmission electron microscopy (TEM). The TEM observation results revealed that the main phase in the compound layer was the solid solution of Al + Zn. Moreover, the intermetallic compound was identified as FeAl, Fe₂Al₅, Fe₄Al₁₃ and Fe₂Al₅Zn_0.4 phase by electron diffraction. The Fe₃Zn₁₀ (Γ phase) of Fe–Zn intermetallic compound was confirmed on a Fe base material. It is guessed that the joining areas were heated at a range of 782°C more than 665°C, a melting point of Al, by laser irradiation because the δ_lk phase aspect was not confirmed. Because the surfaces of A1050 and Zn plated layer were melted thinly, the layer was over 10 μm thicker. The reason for the production of high-strength joints with a relatively thick intermetallic compound layer was attributed to the formation of (Al + Zn) phase with finely dispersed intermetallic compounds.     

Surface Waves on Superfluid <Superscript>4</Superscript>He Under Reduced Gravity

Superfluid ⁴He was produced on a small jet plane for the first time using a small GM-refrigerator to condense the liquid and a scroll pump to get the superfluid by evaporation. The surface wave on superfluid under 0.5g _E, 0.1g _E and 0.05g _E, together with 2g _E and 1g _E, was successfully examined by an optical method utilizing parabolic flight. Here, g _E is the gravitational constant on the ground. Assuming that only the fundamental mode was excited as determined by the sample cell width, the resonance peak in the frequency domain was well reproduced by the gravity wave with corresponding gravity constant.     

Mixing speed-controlled gold nanoparticle synthesis with pulsed mixing microfluidic system

Gold nanoparticles with diameters of a few tens of nanometer and a narrow size distribution were synthesized using a pulsed mixing method with a microfluidic system which consists of a Y-shaped mixing microchannel and two piezoelectric valveless micropumps. This mixing method enables control of the mixing speed of gold salts and reducing agent by changing the switching frequency of the micropumps, which was our focus to improve the particle size distribution, which is an essential parameter in gold nanoparticle synthesis. In the proposed method, the mixing time was inversely proportional to the switching frequency and the minimum mixing time was 95 ms at a switching frequency of 200 Hz. During synthesis experiments, the mean diameter of the synthesized gold nanoparticles was found to increase, and the coefficient of variation of particle size was found to decrease with decreasing mixing time. We successfully improved the coefficient of variation to less than 10% for a mean diameter of around 40 nm.     

Novel synthesis of branched polystyrenes by quasi‐living radical copolymerization using photofunctional inimer

Branched polystyrenes were prepared by quasi‐living radical copolymerization of N,N‐diethylaminodithiocarbamoylmethylstyrene (inimer: DTCS) with styrene under UV irradiation. DTCS monomers play an important role in this copolymerization system as an inimer capable of initiating living radical polymerization of the vinyl group. Two monomers (DTCS and styrene) showed equal reactivity toward both propagating species, and the copolymer composition was the same as the comonomer feed. This result means that both the branching and chain length of the hyperbranched molecules can be controlled statistically by the feed monomer ratios. The compact nature of the branched macromolecules is demonstrated by viscosity measurements compared to the linear analogues. © 2001 Society of Chemical Industry     

Laser pressure welding of aluminium and galvannealed steel

Dissimilar metal joints of galvannealed steel and commercially available pure aluminium (A1050) sheets were produced by changing the laser power and the roller pressure by the laser pressure welding method. In this method, the YAG laser beam was irradiated into a flare groove made by these dissimilar metal sheets. In addition, the laser beam was scanned at various frequencies and patterns through the fθ lens using two-dimensional scanning mirrors. Then the sheets were pressed by the pressure rolls to be joined. The compound layers in the weld interface were observed by optical microscope, and the layer thicknesses were measured. The thicknesses were in the range of 7–20 μm. The mechanical properties of welded joints were evaluated by the tensile shear test and the peel test. In the tensile shear test, the strengths of the joints produced under the most welding conditions were so high that the fracture occurred through the base aluminium sheet. In the peel test of the specimens subjected to the laser beam of 1200–1400 W power under the roller pressure of 2.94 kN, the specimen fracture took place in the base aluminium sheet. Even if the compound layer was thick, high joint strength was obtained. In order to know the reason for such high strength of joints with thick compound layers and the joining mechanism, the compound layer was observed by the HR-TEM. The TEM observation results revealed that the main phase in the compound layer was the solid solution of Al + Zn. Moreover, the intermetallic compound was identified as FeAl, Fe₂Al₅, Fe₄Al₁₃, and Fe₂Al₅Zn_0.4 phase by electron diffraction. The Fe₃Zn₁₀ (Γ phase) of Fe–Zn intermetallic compound was confirmed on a Fe base material. It is assumed that the joining areas were heated in a range of 782°C more than 665°C, a melting point of Al, by laser irradiation because the δ_lk phase aspect was not confirmed. Because the surfaces of A1050 and Zn plated layer were melted thinly, the layer was over 10 μm thicker. The reason for the production of high strength joints with the relatively thick intermetallic compound layer was attributed to the formation of (Al + Zn) phase with finely dispersed intermetallic compounds.     

Proposal for a benchmark model of a laminated iron core and a large‐scale and highly accurate magnetic analysis

This paper describes a benchmark model proposed for the clarification of the characteristic of various methods for modeling the laminated iron core. In order to obtain a reference solution of the benchmark model, a large‐scale nonlinear magnetostatic field analysis with a mesh fine enough to represent the microscopic structure of the laminated iron core is carried out by using the hybrid finite element–boundary element (FE‐BE) method combined with the fast multipole method (FMM) based on diagonal forms for translation operators. The computational costs and accuracy of two kinds of homogenization methods are discussed, comparing them with the reference solution. As a consequence, it is verified that the homogenization methods can analyze magnetic fields in laminated iron core within acceptable computational costs. © 2009 Wiley Periodicals, Inc. Electr Eng Jpn, 170(1): 26–35, 2010; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20809     

Functional binders for reversible lithium intercalation into graphite in propylene carbonate and ionic liquid media

Poly(acrylic acid) (PAA), poly(methacrylic acid) (PMA), and poly(vinyl alcohol) (PVA), which have oxygen species as functional groups, were utilized as a binder for graphite electrodes, and the electrochemical reversibility of lithium intercalation was examined in PC medium and ionic liquid electrolyte, lithium bis(trifluoromethanesulfonyl)amide dissolved in 1-butyl-1-methylpyrrolidinium bis(trifluoromethanesulfonyl)amide (BMP-TFSA). Columbic efficiency of 75–80% with more than 300 mAh g^?1 was achieved upon first reduction/oxidation cycle in both electrolytes using these binding polymers, which were significantly improved in comparison to a conventional PVdF binder (less than 45% of columbic efficiency for the first cycle). For the graphite-PVdF electrode, co-intercalation and/or decomposition of PC molecules solvating to Li ions were observed by the electrochemical reduction, resulting in the cracking of graphite particles. In contrast, the co-intercalation and decomposition of PC molecules and BMP cations for the first reduction process were completely suppressed for the graphite electrodes prepared with the polymers containing oxygen atoms. It was proposed that the selective permeability of lithium ions was attained by the uniform coating of the graphite particles with PAA, PMA, and PVA polymers, because the electrostatic interaction between the positively charged lithium ions and negatively charged oxygen atom in the polymer should modulate the desolvation process of lithium ions during the lithium intercalation into graphite, showing the similar functions like artificial solid-electrolyte interphase.     

Eddy current analysis of thin metal container in induction heating by line integral equations

In recent years, induction‐heating cookers have spread rapidly. It is desirable to commercialize flexible and disposable food containers that are suitable for induction heating. In order to develop a good‐quality food container for moderate heating, the eddy currents induced in a thin metal plate must be accurately analyzed. The integral equation method is widely used for solving induction‐heating problems. If the plate thickness approaches zero, the surface integral equations on the upper and lower plate surfaces tend to become the same and the equations become ill‐conditioned. In this paper, we first derive line integral equations from the boundary integral equations under the assumption that the electromagnetic fields in the metal are attenuated more rapidly than those along the metal surface. Next, to test the validity of the line integral equations, we solve for the eddy current induced in a thin metal container in induction heating and obtain the power density imparted to the container and the impedance characteristics of the heating coil. We then compare the computed results with those obtained by the FEM. © 2009 Wiley Periodicals, Inc. Electr Eng Jpn, 168(2): 20–27, 2009; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/eej.20813     

TEM/STEM Observation of ZrC Coating Layer for Advanced High-Temperature Gas-Cooled Reactor Fuel, Part II

The Japan Atomic Energy Agency (JAEA) has started to study and develop zirconium carbide (ZrC)-coated fuel particles for advanced high-temperature gas-cooled reactors. The ZrC coating layer has been fabricated at JAEA by chemical vapor deposition using a pyrolytic reaction of zirconium bromide. The microstructures of the ZrC layers, whose nominal deposition temperatures could be measured and controlled during the deposition process, were characterized by means of TEM and STEM. In the present study, three batches were prepared and compared with each other as well as the previous batches. The crystallographic orientation of ZrC with regard to the growth direction in the ZrC layers deposited at a constant temperature of 1630 K was different from that deposited at varying temperatures in the 1493–1823 K range. A thin layer of turbostratic carbon was observed at the boundary between pyrolytic carbon and ZrC in particles deposited at the highest temperature among those used in this study (the nominal temperature was 1769 K); no such structure was found in a batch deposited at a lower temperature (the nominal temperature was 1632 K). Therefore, precise control of temperature is shown to be critical to the formation of good ZrC coatings.