Importance of optical homogeneity for high-quality transparent ceramics

Two types of transparent Y₂O₃ ceramics without including large scattering sources such as residual pores, one with very high optical homogeneity (type A) and another one with slightly insufficient optical homogeneity (type B), are purposely prepared, and their optical properties are investigated and compared qualitatively and quantitatively. Type A ceramic exhibits transmittance characteristics with very low internal loss in the visible to infrared wavelength region, while type B ceramic is inferior in various optical performances especially in the short (visible) wavelength region. In type B ceramic, birefringence occurs due to optical inhomogeneity in the visible region, resulting in a decrease in the extinction ratio. Non-uniform refractive index distribution is also observed in the Schlieren image of type B ceramic, hence the laser beam quality through that material is degraded. This study proved the importance of optical homogeneity of transparent ceramics and clarified the problems in actual applications.     

Cognitive and metabolic workload assessment techniques: A review in automotive manufacturing context

Ergonomics assessment in the automotive industry has, to date, focused mainly on physical ergonomics, for example, manual handling and posture. However, workload and, in particular, metabolic and cognitive workload, contributes to worker efficiency but has not received sufficient attention to yield practical guidance for industry. Successful workload assessment requires in-depth understanding of the context in which it will be conducted and of the various assessment techniques which will be applied, with consideration given to factors such as feasibility, resources, and skill of the assessor. These requirements are met with challenges within large and complex organizations and are often dealt with in a piecemeal and isolated matter (i.e., reactive workload assessment). The present paper explores these challenges within the automotive manufacturing industry and aims to develop a decision matrix to guide effective selection of workload assessment techniques focused on metabolic and cognitive demands. It also presents the requirements for time, equipment, and knowledge to implement these techniques as part of a participatory ergonomics approach. Early findings suggest that most assessment techniques reviewed require further development, for example, to establish the acceptance criteria for the specific workload scenario. However, five methods (Garg, Borg RPE, IPAQ, SWAT, and NASA-TLX) are ready to use in certain applications. Ultimately, the findings suggest that it is possible to implement a participatory workload evaluation program within large and complex manufacturing plants.     

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.     

模具设计与制造专业群虚拟仿真实训基地建设路径研究

针对模具设计与制造专业群实训教学开展过程中存在的问题,开展专业群虚拟仿真实训基地的建设,通过精密模具智能制造生产线仿真实训工厂、模具数字化设计及智能成型单元综合应用平台、开放共享课程资源等3个方面内容的建设,引入行业新技术、新工艺、新标准,确保虚拟仿真教学资源与学生职业能力培养相一致。基地建设依托智能制造新技术,以培养高层次复合型技术技能人才为主线,满足实训教学为核心,多方共享为目标,助力区域经济发展,服务"鲁班工坊"国际化建设,最终实现虚拟仿真实训基地区域示范性效果。     

Laser damage resistance of plasma-sprayed alumina and honeycomb skeleton/alumina composite ceramic coatings

Al₂O₃ and honeycomb skeleton-Al₂O₃ composite coatings on Titanium alloy (Ti–6Al–4V) were prepared by atmospheric plasma spraying. A laser ablation experiment on as-sprayed coatings was performed. In this paper, the laser damage resistance, microstructure, phase composition of Al₂O₃ coatings were examined. 3D Dimensional Confocal Microscopy, Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Energy Dispersive Spectrometry (EDS) characterized the laser damage morphology, microstructure, phase composition, and element analysis, respectively. The influence of the honeycomb skeleton on the laser ablation damage on as-sprayed coatings was investigated by a comparative analysis of the laser damage morphology with different laser ablation times and gas flow. The results show that the honeycomb skeleton raises thermal conductivity and thermal diffusivity. Moreover, a “tower”-like dendrite was generated during the laser irradiation of the composite coating. The honeycomb skeleton refined the structure, suppressed crack propagation, and reduced the influence of gas flow on cracks. Under the same experimental laser ablation parameters, the laser damage area of the honeycomb skeleton-Al₂O₃ composite coating was smaller than that of the Al₂O₃ coating. It was demonstrated that the laser damage resistance of the honeycomb skeleton-Al₂O₃ composite coating was superior to that of the Al₂O₃ coating.     

Phase constitution,microstructure and mechanical properties of a Ni-based superalloy specially designed for additive manufacturing

In this study, a kind of Ni-based superalloy specially designed for additive manufacturing (AM) was investigated. Thermo-Calc simulation and differential scanning calorimetry (DSC) analysis were used to determine phases and their transformation temperature. Experimental specimens were prepared by laser metal deposition (LMD) and traditional casting method. Microstructure, phase constitution and mechanical properties of the alloy were characterized by scanning electron microscopy (SEM), transmission scanning electron microscopy (TEM), X-ray diffraction (XRD) and tensile tests. The results show that this alloy contains two basic phases, γ/γ', in addition to these phases, at least two secondary phases may be present, such as MC carbides and Laves phases. Furthermore, the as-deposited alloy has finer dendrite, its mean primary dendrite arm space (PDAS) is about 30-45 μm, and the average size of γ' particles is 100-150 nm. However, the dendrite size of the as-cast alloy is much larger and its PDAS is 300-500 μm with secondary and even third dendrite arms. Correspondingly, the alloy displays different tensile behavior with different processing methods, and the as-deposited specimen shows better ultimate tensile stress (1,085.7±51.7 MPa), yield stress (697±19.5 MPa) and elongation (25.8%±2.2%) than that of the as-cast specimen. The differences in mechanical properties of the alloy are due to the different morphology and size of dendrites, γ', and Laves phase, and the segregation of elements, etc. Such important information would be helpful for alloy application as well as new alloy development.     

Microstructure and mechanical behavior of laser aided additive manufactured low carbon interstitial Fe49.5Mn30Co10Cr10C0.5 multicomponent alloy

Laser aided additive manufacturing(LAAM)was used to fabricate bulk Fe49.5Mn30Co10Cr10C0.5 interstitial multicomponent alloy using pre-alloyed powder.The room temperature yield strength(σy),ultimate tensile strength(σUTS)and elongation(εUST)were 645 MPa,917 MPa and 27.0％respectively.The as-built sample consisted of equiaxed and dendritic cellular structures formed by elemental segregation.These cellular structures together with oxide particle inclusions were deemed to strengthen the material.The other contributing components include dislocation strengthening,friction stress and grain bound-ary strengthening.The high εUTS was attributed to dislocation motion and activation of both twinning and transformation-induced plasticity(TWIP and TRIP).Tensile tests performed at-40℃and-130℃demonstrated superior tensile strength of 1041 MPa and 1267 MPa respectively.However,almost no twinning was observed in the fractured sample tested at-40℃and-130℃.Instead,higher fraction of strain-induced hexagonal close-packed(HCP)ε phase transformation of 21.2％were observed for fractured sample tested at-40℃,compared with 6.3％in fractured room temperature sample.     

Effect of Cu-Rich Phase Precipitation on the Microstructure and Mechanical Properties of CoCrNiCux Medium-Entropy Alloys Prepared via Laser Directed Energy Deposition

CoCrNiCux (x=0.16,0.33,0.75,and 1) without macro-segregation medium-entropy alloys (MEAs) was prepared using laser directed energy deposition (LDED).The microstructure and mechanical properties of CoCrNiCux alloys with increas-ing Cu content were investigated.The results indicate that a single matrix phase changes into a dual-phase structure and the tensile fracture behaviors convert from brittle to plastic pattern with increasing Cu content in CoCrNiCux alloys.In addi-tion,the tensile strength of CoCrNiCux alloys increased from 148 to 820 MPa,and the ductility increased from 1 to 11％with increasing Cu content.The nano-precipitated particles had a mean size of approximately 20 nm in the Cu-rich phase area,and a large number of neatly arranged misfit dislocations were observed at the interface between the two phases due to Cu-rich phase precipitation in the CoCrNiCu alloy.These misfit dislocations hinder the movement of dislocations during tensile deformation,as observed through transmission electron microscopy.This allows the CoCrNiCu alloy to reach the largest tensile strength and plasticity,and a new strengthening mechanism was achieved for the CoCrNiCu alloy.Moreover,twins were observed in the matrix phase after tensile fracture.Simultaneously,the dual-phase structure with different elastic moduli coordinated with each other during the deformation process,significantly improving the plasticity and strength of the CoCrNiCu alloy.     

Direct writing of textured ceramics using anisotropic nozzles

Direct writing is a unique means to align anisotropic particles for the fabrication of textured ceramics by templated grain growth (TGG). We show that alignment of tabular barium titanate (BT) template particles (20–40 μm width and 0.5–2 μm thickness) in a PIN-PMN-PT matrix powder (d₅₀ = 280 nm) is significantly improved during direct writing using anisotropic nozzles at high printing rates. The particle orientation distribution in as-printed filaments, and the texture orientation distribution in sintered ceramic filaments are shown to directly correlate with COMSOL Multiphysics-predicted torque distributions for direct writing with aspect ratio 2, 3 and 5 oval nozzles. Electromechanical strain properties of the textured piezoelectric ceramics significantly improved relative to random ceramics when printed with anisotropic nozzles. Simulations of aspect ratio 20 nozzles and nozzles with interior baffles demonstrate significantly increased torque and near elimination of constant shear stress cores (i.e. plug flow).     

Additive Manufacturing of Stable Energy Storage Devices Using a Multinozzle Printing System

The development of the Internet of things has prompted an exponential increase in the demand for flexible, wearable devices, thereby posing new challenges to their integration and conformalization. Additive manufacturing facilitates the fabrication of complex parts via a single integrated process. Herein, the development of a multinozzle, multimaterial printing device is reported. This device accommodates the various characteristics of printing materials, ensures high-capacity printing, and can accommodate a wide range of material viscosities from 0 to 1000 Cp. Complete capacitors, inclusive of the current collector, electrode, and electrolyte, can be printed without repeated clamping to complete the preheating, printing, and sintering processes. This method addresses the poor stability issue associated with printed electrode materials. Furthermore, after the intercalation of LiFePO₄ with Na ions, X-ray photoelectron spectroscopy and X-ray diffraction results reveal that the Na ions permeate the interlayer structure of LiFePO₄, enhancing the ion migration channels by increasing the ion transmission rate. A current rate of 2.5 mAh ensures >2000 charge/discharge cycles, while retaining a charge/discharge efficiency of 96% and a discharge capacity of 91.3 mAh g⁻¹. This manufacturing process can provide conformal power modules for a diverse range of portable devices with various shapes, improving space utilization.