Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. The predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.     

TiI4-doping induced bulk defects passivation in halide perovskites for high efficient photovoltaic devices

Power conversion efficiency (PCE) and stability are two important properties of perovskite solar cells (PSCs). Particularly, defects in the perovskite films could cause the generation of trap states, thereby increasing the nonradiative recombination. To address this issue, suitable dopants can be incorporated to react with non-bonded atoms or surface dangling bonds to passivate the defects. Herein, we introduced TiI₄ into CH₃NH₃PbI₃ (MAPbI₃) film and obtained a dense and uniform morphology with large crystal grains and low defect density. The champion cell based on 0.5% TiI₄-doped MAPbI₃ achieved a PCE as high as 20.55%, which is superior to those based on pristine MAPbI₃ (17.64%). Moreover, the optimal solar cell showed remarkable stability without encapsulation. It retained 88.03% of its initial PCE after 300 h of storage in ambient. This work demonstrates TiI₄ as a new and effective passivator for MAPbI₃ film.     

Growth mechanism and gas-sensing characteristics of organic-additive-free zinc oxide of various shapes

Zinc oxide is widely used in gas sensors, solar cells, and photocatalysts because of its wide bandgap and exciton binding energy of 60 meV in various metal oxides. To use ZnO as a gas sensor, it is necessary to synthesize it with surface defects and a large specific surface area. In this study, hydrothermal synthesis without surfactants was employed to obtain organic-additive-free ZnO. For morphology control, we varied the ratio of the hydroxide ion concentration to the zinc ion concentration. To confirm the growth mechanism of ZnO, we performed X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses. Raman spectroscopy and photoluminescence measurements were performed to analyze the surface properties. The Brunauer–Emmett–Teller method and probe stations were used to measure the specific surface area and sensitivity of the gas sensor, respectively. The results confirmed that flower-shaped ZnO is the most suitable gas-sensing material.     

An enhancement algorithm based on adaptive updating template with Gaussian model for Si3N4 ceramic bearing roller surface defects detection

The method based on machine vision image processing is used to detect the surface defects of Si₃N₄ bearing roller. Owing to the variety of defects, small area and low contrast, it is easy to miss or error detection. In this paper, an adaptive update template defect enhancement algorithm based on Gaussian model is proposed. First, a large number of surface images of Si₃N₄ bearing roller are collected to obtain the non-defect background statistical feature, and the background characteristic curve is fitted by Gaussian model. Further, the initial background template is gained according to the Gaussian curve. Then, combined with the gray distribute of defect images and initial background template, unique adaptive update template can be established. Finally, subtraction operation and nonlinear enhancement are used to improve the comparison of defect information and background. Through inverse sorting, adaptive threshold segmentation and Canny operation, the precise positioning of defects is realized. The enhancement algorithm can effectively enhance the contrast and eliminate the influence of noise. The average detection time is 0.84s, and the detection accuracy is 96.2%.     

Effect of inter-ply sliding on the quality of multilayer interlock dry fabric preforms

Forming thick, complex shapes with several layers is needed in high technology fields. During forming, defects can occur and have to be taken into account because they can significantly affect the mechanical performance of the part. This experimental study shows that, when working with dry fabric forming, the type and number of defects is a function of the punch geometry, the process parameters, the orientation of the fabric with respect to the punch and the inter-ply friction. Inter-ply friction has a huge effect on the quality of the preform when inter-ply sliding occurs. This inter-ply friction leads to several overhanging yarn shocks that generate high tangential forces, which inhibit the relative sliding of plies. In addition, to reduce the number and amplitude of defects, the layers subjected to severe defects can be placed in the inner position where they are subjected to the compression applied by the upper layers.     

Effect of fibre wrinkling to the spring-in behaviour of L-shaped composite materials

To determine the amount of deformation resulting from fibre wrinkling at corner regions, a set of experiments have been conducted. As known in the conventional lay-up method, the prepregs are laid sequentially layer by layer on the mould surface. At the corner region of a female tool the radius decreases at the inner surface and the amount of wrinkles increase towards the top layer as the layers are laid up. In order to determine how much these wrinkles influence the dimensional stability of the manufactured parts, an alternative lay-up method is used. The amount of the wrinkles can be increased for the parts of same geometry by first stacking prepregs on a flat plate and then bending the whole stack to conform to the surface of the L-shaped mould. In this method, more wrinkling occurs on the inner surface of the corner regions as compared to the conventional lay-up procedure. It was found that fibre wrinkling decreases the spring-in values. The mechanism behind that observation is discussed with the help of a heuristic Finite Element Analysis (FEA). The conformation of the stacked prepregs on the mould was simulated by using FEA.     

The native point defects in C14 Mg2Ca Laves phase: A first-principles study

The native point defects in C14 Mg₂Ca Laves phase are studied from the first-principles density functional theory calculations within GGA approximation. The defect formation energies indicate that anti-site defects are energetically favored over vacancies. Under Mg-rich and even general Ca-rich condition, defect Mg_Ca of Mg anti-site on Ca sublattice is favorable owing to the lowest formation energy. The Ca_Mg2 defect of Ca anti-site on Mg2 sublattice is also likely dominant only under extreme Ca-rich environment. The present results could explain reasonably the asymmetric off-stoichiometry of Mg₂Ca. The effective point defect concentrations of Mg₂Ca as a function of composition and temperature at experimental range are also calculated from a canonical statistical model, and the derived results show a linear relationship between the logarithm of defect concentration and T⁻¹. Geometrical factor is further studied, and it is found that atomic size possesses an obvious influence on the structure of point defect in Mg₂Ca. The electronic feature is further studied to reveal underlying mechanism for formation of point defects.     

Evaluation of gluing of CFRP onto concrete structures by infrared thermography coupled with thermal impedance

Carbon Fiber Reinforced Polymers (CFRPs) have been increasingly employed for structural strengthening, and are attached to structures using bonding adhesives. The aim of this work is to characterize defects in the bond between CFRP and concrete (after they are located by pulse infrared thermography), and assign the defects a “numerical value” (ranging from 0 for a complete air–gap to 1 for a fully glued bond). Quantitative characterization is performed by measuring the thermal impedance, and then identifying the thermophysical parameters of the system through fitting the measured impedance to a theoretical model. An inversion procedure is carried out to estimate the unknown parameters, without prior knowledge of sample properties. In particular, it is possible to estimate more accurately both the amount of glue within a defect and the thermal contact resistance.     

Exploring the Formation Mechanism of Deformation Twins in CrMnFeCoNi High Entropy Alloy

The deformation twins initiated in CrMnFeCoNi high entropy alloy at cryogenic temperature are experimentally studied. Under the external loading, a three-dimensional shear stress concentration originating from dislocation tangling at both the grain boundaries and twin boundaries could be formed, which promotes emission of partial dislocations from the planar defects and is thus considered to be the key factor for twin formation. A sympathetic nucleation mechanism is proposed to describe the nucleation behaviors of twins.     

Thermoluminescence properties of Al doped ZnO nanoparticles

ZnO nanoparticles doped with aluminum (AZO nanoparticles) were investigated using low temperature thermoluminescence (TL) and structural characterization experiments. TL experiments were performed on AZO nanoparticles in the temperature range of 10–300?K. TL curve presented one intensive peak around 123?K and two overlapped peaks to intensive peak around 85 and 150?K for heating rate of 0.1?K/s. Curve fitting and initial rise methods were used to find the activation energies of associated trapping centers. Analyses resulted in the presence of three centers at 0.05, 0.08 and 0.17?eV with peak maximum temperatures (T_m) of 86.2, 121.5 and 147.1?K, respectively. TL experiments were expanded using different heating rates between 0.1?K/s and 0.5?K/s. Behavior of revealed traps was investigated using an experimental technique called as T_m??T_stop method. It was seen that traps are quasi-continuously distributed within the band gap. Structural properties were studied using x-ray diffraction, energy dispersive spectroscopy and scanning electron microscopy experiments.