Pressure-less joining of alumina ceramics by the reaction-bonded aluminum oxide (RBAO) method

The present work demonstrates a pressure-less and reliable joining technique for alumina ceramics through a reaction-bonded aluminum oxide (RBAO) method. Effective joining relies on the RBAO mechanism, in which Al particles are converted to alumina through oxidation and bond with alumina particles from the parts to be joined upon sintering. Alumina ceramics in a green state were successfully joined with the use of an Al/Al₂O₃ powder mixture as an interlayer. The oxidation behavior of the Al particles was confirmed by thermogravimetry and X-ray diffraction analyses. Joining was performed in ambient air at 1650 °C for 2 h without applying any external pressure. Microstructural observations at the joining interfaces indicated a compact joining. The joining strengths were assessed by determining the biaxial strengths at room temperature, and the joined samples exhibited no fractures at the joining interfaces. Moreover, the joints had a strength of almost 100 % when compared with those of the parent alumina ceramics.     

Ultra-low energy joining: An invisible strong bond at room temperature

We developed Cold Isostatic Joining (CIJ) which is an environmental friendly room temperature joining method. This technique extends cold sintering process to joining of glasses. By optimizing the CIJ conditions a shear stress (18 MPa) comparable to bulk fused silica was achieved. The technique surpasses other joining methods (e.g. adhesive bonding and brazing), because it is insensitive to thermal degradation. Unlike pressure-less silicate bonding, pressure assisted CIJ resulted in a thin joining interlayer (≈27 nm) which maintained its integrity after being heated up to 1000 °C. The in-line transmittance (92%) was identical to un-joined material over the full spectrum making the joining nearly undetectable. The mechanism of CIJ formation and joining were clarified using X-ray diffraction (XRD and pole figure), scanning electron microscopy (SEM) and in line transmittance measurements. The cold joining method could find applications in the field of optics and semiconductors for wafer and lens bonding.     

Joining zirconia with nickel-based superalloys for extreme applications by using a pressure-free high-temperature resistant adhesive

In order to meet the high demand for joining ceramic/superalloy composite structure in extreme environments, a novel high-temperature resistant adhesion technique was developed for joining ZrO₂ and Inconel 625 by applying an aluminum phosphate emulsion/zirconium sol based adhesive. With increasing temperature, a series of reactions occurred in adhesive, and its high-temperature bonding was attributed to the formation of a composite structure containing various ceramics and intermetallics. The adhesive after RT curing could find direct applications in extreme environments, and provide bonding strength no less than 2.5 MPa in the temperature range of RT-1100 °C. The bonding strength was higher than 4 MPa in the temperature range of 800–1000 °C, which was further attributed to the formation of an effective CTE-gradient relationship among ZrO₂, adhesive and Inconel 625, as well as the interfacial reactions between the two substrates. The work broadened the application of adhesion technique and brought new ideas for joining dissimilar engineering materials.     

Fatigue damage study of cold metal transition fusion-brazed aluminium/steel dissimilar joints

ABSTRACT

An aluminium/steel CMT-welded joint is mainly composed of fusion zone (FZ), interfacial intermetallic compound (IMC) zone, and heat-affected zone (HAZ). IMC and FZ are the weakest link in the welded joint. The fatigue fracture indicates that the lattice distortion caused by the lattice mismatch of Fe₂Al₅ and Fe is more likely to engender dislocation slipping and cracks easily nucleate during the fatigue testing. The hysteresis loop is shifted to the right, which indicating that the specimen experiences a ratcheting effect. In the high-stress condition, the cyclic hardening induced by the ratcheting strain is much stronger than that in the lower stress condition, which improves the fatigue life of the materials.     

C/C-SiC component for metallic phase change materials

Thanks to their high energy density and thermal conductivity, metallic Phase Change Materials (mPCM) have shown great potential to improve the performance of thermal energy storage systems. However, the commercial application of mPCM is still limited due to their corrosion behavior with conventional container materials. This work first addresses on a fundamental level, whether carbon-based composite-ceramics are suitable for corrosion critical components in a thermal storage system. The compatibility between the mPCM AlSi₁₂ and the Liquid Silicon Infiltration (LSI)-based carbon fiber reinforced silicon carbide (C/C-SiC) composite is then investigated via contact angle measurements, microstructure analysis, and mechanical testing after exposure. The results reveal that the C/C-SiC composite maintains its mechanical properties and microstructure after exposure in the strongly corrosive mPCM. Based on these results, efforts were made to design and manufacture a container out of C/C-SiC for the housing of mPCM in vehicle application. The stability of the component filled with mPCM was proven nondestructively via computer tomography (CT). Successful thermal input- and output as well as thermal storage ability were demonstrated using a system calorimeter under conditions similar to the application. The investigated C/C-SiC composite has significant application potential as a structural material for thermal energy storage systems with mPCM.     

Investigation on material mixing during FSW of AA7475 to AISI304

AA7xxx and AISI304 stainless steel (SS) are employed in promising applications. Al alloy-to-SS dissimilar joining is difficult and challenging. Major challenge in the joining of these alloys is the difficulty in mixing of these materials which possess exotic and widely distant properties. AA7475-T761 is a high strength aluminum alloy which is used in key aircraft components. Maiden AA7475-T761 and AISI304 dissimilar joints were fabricated using friction stir welding. Welding was performed with tool having pin diameter of 4 mm and offset of 1.25 mm on Aluminum side. Tool rotational speed, traverse speed and shoulder diameter were varied in the range of 450–560 rpm, 50–63 mm/min, and 12–14 mm, respectively. Mechanical tests showed that joint formed with 14 mm diameter, 560 rpm and 50 mm/min gave the best joint efficiency of 71% of Al-alloy at 7.31% elongation. The materials mixing issues during processing were analyzed with SEM mircrostructure and fractography. Metallography also revealed that offset is critical to the success of joint as it controlled effective mixing of SS and Al in 15 and 85 vol.%, respectively. SS fragments from thermo-mechanically affected zone of SS were found to be partially sheared forming layer of thickness equal to tool traverse/revolution ratio.     

Analysis of adhesively bonded CFRE composite scarf joints modified with MWCNTs

The main objective of the present work is to improve the performance of bonded joints in carbon fiber composite structures through introducing Multi-Walled Carbon Nanotubes (MWCNTs) into Epocast 50-A1/946 epoxy, which was primarily developed for joining and repairing of composite aircraft structures. Results from tension characterizations of structural adhesive joints (SAJs) with different scarf angles (5–45°) showed improvement up to 40% compared to neat epoxy (NE)–SAJs. Special attention was considered to investigate the performance of SAJs with 5° scarf angle under different environments. The tensile strength and stiffness of both NE-SAJs and MWCNT/E-SAJs were dramatically decreased at elevated temperature. Water absorption showed a marginal drop of about 2.0% in the tensile strength of the moist SAJs compared to the dry one. Cracks initiation and propagation were detected effectively using instrumented-SAJs with eight strain gauges. The experimental results agree well with the predicted using three-dimensional finite element analysis model.     

Characteristics and formation mechanism of porosities in CFRP during laser joining of CFRP and steel

An experimental investigation on the mechanism of porosity formation during the laser joining of carbon fiber reinforced polymer (CFRP) and steel is presented. The porosity morphology and distribution were characterized by optical and scanning electron microscopy, and the thermal pyrolysis behaviors were investigated by thermal analysis and designed back-side cooling experiments. The results show that there are two types of porosities in CFRP. Porosity I only appears when the heat input is more than 77.8 J/mm. It has a smooth inner wall and distributes near the bonding interface between CFRP and steel at the central area of melted zone, which is caused by gaseous products such as CO₂, NH₃, H₂O, and hydrocarbons produced by the pyrolysis of CFRP. Porosity II can be seen under all joining conditions. It has a rough inner wall and distributes far away from the bonding interface, concentrating at the final solidification locations. Porosity II is caused by the shrinkage of melted CFRP during solidification stage.     

核屏蔽用中子吸收材料研究现状与展望

镉(Cd)、硼(B)和一些稀有元素具有较大的热中子吸收截面，在核屏蔽吸收中子领域具有较广泛的应用前景。本文概述了用于核电站乏燃料“湿法”贮存用中子吸收材料的种类，论述了各种中子吸收材料的优点和不足。阐述了铝基碳化硼(B4C/Al)中子吸收材料的研究进展以及不同制备方法的优点和不足，进一步介绍了搅拌摩擦焊方法和扩散焊方法在连接B4C/Al中子吸收材料过程中的优势。在此基础上，对新型中子吸收材料在成分、结构设计方面进行了分析，对未来核屏蔽用中子吸收材料进行了展望。     

RB Regulates DNA Double Strand Break Repair Pathway Choice by Mediating CtIP Dependent End Resection

Inactivation of the retinoblastoma tumor suppressor gene (RB1) leads to genome instability, and can be detected in retinoblastoma and other cancers. One damaging effect is causing DNA double strand breaks (DSB), which, however, can be repaired by homologous recombination (HR), classical non-homologous end joining (C-NHEJ), and micro-homology mediated end joining (MMEJ). We aimed to study the mechanistic roles of RB in regulating multiple DSB repair pathways. Here we show that HR and C-NHEJ are decreased, but MMEJ is elevated in RB-depleted cells. After inducing DSB by camptothecin, RB co-localizes with CtIP, which regulates DSB end resection. RB depletion leads to less RPA and native BrdU foci, which implies less end resection. In RB-depleted cells, less CtIP foci, and a lack of phosphorylation on CtIP Thr847, are observed. According to the synthetic lethality principle, based on the altered DSB repair pathway choice, after inducing DSBs by camptothecin, RB depleted cells are more sensitive to co-treatment with camptothecin and MMEJ blocker poly-ADP ribose polymerase 1 (PARP1) inhibitor. We propose a model whereby RB can regulate DSB repair pathway choice by mediating the CtIP dependent DNA end resection. The use of PARP1 inhibitor could potentially improve treatment outcomes for RB-deficient cancers.