EDM of hybrid Al–SiCp–B4Cp and Al–SiCp–Glassp MMCs

Hybrid metal matrix composites are a class of material system, with two or more discrete particulate reinforcement. Notwithstanding their superior properties, their widespread application is constrained by the difficulty in machining them. Non-conventional processes such as electrical discharge machining can be applied to machine such composites. This work reports on the application of EDM to machine cast aluminum–silicon carbide–boron carbide and cast aluminum–silicon carbide–glass hybrid metal matrix composites and how the metal removal rate and surface finish vary in response to the various EDM parameters     

Cavitation erosion of Fe–Mn–Si–Cr shape memory alloys

Cavitation erosion tests of three Fe–Mn–Si–Cr shape memory alloys were carried out at speed 34 and 45 m/s using a rotating disc rig, and their cavitation damage has been investigated by comparison with a referring 13Cr–5Ni–Mo stainless steel used for hydraulic turbine vanes. The research results proved that the cavitation erosion of the Fe–Mn–Si–Cr shape memory alloys is a failure of low cycle fatigue and fracture propagates along grain boundaries. After 48 h cavitation erosion the cumulative mass losses of the studied alloys at speed 45 m/s are more than theirs at speed 34 m/s; however, the effect of velocity on cavitation damage of the Fe–Mn–Si–Cr alloys is much lower than that of 13Cr–5Ni–Mo stainless steel. The cumulative mass loss of the 13Cr–5Ni–Mo stainless steel are 26.3 mg at speed 45 m/s and 3.2 mg at speed 34 m/s, and the mass losses of the Fe–Mn–Si–Cr alloys are within the range of 3.6–7.3 mg at speed 45 m/s and 2.0–4.1 mg at speed 34 m/s. The surface elasticity of the Fe–Mn–Si–Cr shape memory alloys is better than that of the 13Cr–5Ni–Mo stainless steel, and the effect of surface elasticity on cavitation damage increases with velocity. The excellent surface elasticity of the cavitation-induced hexagonal closed-packed (h.c.p.) martensite plays a key role in contribution of phase transformation to the cavitation erosion resistance of the Fe–Mn–Si–Cr shape memory alloys. The cavitation damage of the studied alloys at speed 45 m/s mainly depends on their surface elasticity, and the variation of 48 h cumulative mass loss (Δm) as a function of the elastic depth (h_e) can be expressed as Δm=2.695+[1371.94/(4(h_e−46.83)²+12.751)] with a correlation factor of 0.99345.     

Correlation Between Mechanical Properties and Nanofriction of [Ti–Cr/Ti–Cr–N] n and [Ti–Al/Ti–Al–N] n Multilayers

In this work, thin films deposited by pulsed DC magnetron sputtering of [Ti–Al/Ti–Al–N] _n and [Ti–Cr/Ti–Cr–N] _n multilayers of nanometric periods were analyzed by AFM in contact mode to measure values of lateral and normal forces. From these measurements, the coefficient of friction (COF) of these materials in contact with the AFM tip was calculated. Measurements were made with three types of silicon tips, diamond-coated, Pt–Cr-coated, and bare silicon. Significant differences between the tip materials in contact with the samples, which affected the COF, were observed. The effect of the environmental layer of water covering the surface sample and the tip appears as the most important factor affecting the tribology behavior of the tip-sample contact. For diamond-coated and bare silicon tips there is an additional adherence force increasing the normal load. But for tips platinum–chromium-coated there is a repulsive force due to this water layer, which behaves as a lubricant layer before a threshold load.     

The influence of Cu addition on precipitation in Fe–Cr–Ni–Al–(Cu) model alloys

Precipitation in Fe–Cr–Ni–Al–(Cu) model alloys was investigated after ageing for 0.25, 3, 10 and 100 h at 798 K. Characterization of nanoscale precipitates was performed using three-dimensional atom probe microscopy and transmission electron microscopy. The precipitates are found to be enriched in Ni and Al (Cu) and depleted in Fe and Cr. After 0.25 h of ageing the number density of precipitates is ∼8×10²⁴ m⁻³, their volume fraction is about 15.5% and they are near-spherical with an average diameter of about 2–3 nm. During further ageing the precipitates in the both alloys grow, but the coarsening behaviour is different for both alloys. The precipitates of the Cu-free alloy grow much faster compared with the Cu-containing alloy and their density decreases. Precipitates in Cu-free alloy change to plate shaped even after 10 h of ageing, whereas those of Cu-containing alloy remain spherical up to 10 h of ageing. The influence of Cu addition on precipitation in these model alloys is discussed with respect to the different coarsening mechanisms.     

Comparative study of the tribological behavior of self-lubricating W–S–C and Mo–Se–C sputtered coatings

Transition metal dichalcogenides (TMD) have been one of the best alternatives as low friction coatings for tribological applications, particularly in dry and vacuum environments. However, besides their deficient behavior in humid containing atmospheres, their extensive application has also been restricted due to their low load-bearing capacity. In order to overcome these problems, recently the alloying with C has been tried with the expectation of simultaneously improving the coatings hardness and reaching sliding contacting phases more convenient for achieving low friction in humid environments.The practical application of this concept was extensively studied with the W–S–C system, with the C addition being achieved either by reactive or co-sputtering processes. The best tribological results were obtained by co-sputtering from a C target embedded with an increasing number of WS₂ pellets. Excellent results were reached from the more than one order of magnitude increase in the coatings hardness up to friction coefficients which are close to those of the references of self-lubricating coatings: TMD for dry or vacuum atmospheres or C-based coatings for terrestrial sliding conditions.Following the good results achieved with W–S–C system, other TMDs systems have been envisaged to be studied. The main focus was placed on the Mo–Se–C system.In this paper, the general comparison between W–S–C and Mo–Se–C coatings is presented. The main effort is pointed on the tribological behavior of both systems when tested by pin-on-disk against steel counterpart balls under different testing conditions: applied normal loads, temperatures and relative humidity of the atmospheres. Both coatings were deposited by co-sputtering from a C target with a varying number of TMD pellets which could lead to C contents in the films in the range from 30  up to 70 at.%. A Ti interlayer was interposed between the films and the substrates for improving the adhesion.Typically, W–S–C films are harder than Mo–Se–C films. From the tribological point of view, W–S–C films are more thermally stable than Mo–Se–C films although the friction coefficients of these last ones are lower when tested in humid containing atmospheres.     

Erosion-oxidation of uncoated,aluminized and chromized-aluminized 9Cr–1Mo steels under fluidized-bed conditions at 550–700 °C

Protective coatings, deposited mainly by thermal spraying and diffusion techniques, are considered a solution to extend the lifetime of many components in the energy production sector, such as heat exchangers. In this paper, some results are presented for uncoated, aluminized and chromized-aluminized 9Cr–1Mo steel, subjected to air and to impacts by 200 μm silica particles at angles of 30° and 90° and speeds of 7.0–9.2 m s^?1 at 550 –700 °C, in a laboratory fluidized-bed rig, to determine whether or not aluminized and chromized-aluminized diffusion coatings could protect the steel under such conditions. Erosion-oxidation damage was characterized by measurement of the mean thickness changes using a micrometer and examination of worn surfaces by scanning electron microscopy.Under most conditions, the coatings provided some protection to the substrate: under 30° impacts, up to 650 °C, and under 90° impacts, at 700 °C, both coatings were effective, whereas under 90° impacts, up to 650 °C, only the chromized-aluminized coating gave significant protection. However, for 30° at 700 °C, the oxide scale on the substrate was protective and the coatings were not needed. Explanations for these observations are presented in this paper, in terms of interactions between the erosion and oxidation processes for the materials.     

Desulfurization process using Takagi–Sugeno–Kang fuzzy modeling

Two Takagi–Sugeno–Kang fuzzy models for the prediction of the amount of reagents for desulfurization in steel processing are developed from experimental data. For the design of the models, an algorithm was proposed to be used in the procedures of the two phases: structure building and parametric identification. In the first phase, the Gustafson–Kessel clustering algorithm with the cluster validity index was proposed to find the number of fuzzy rules and an initial fuzzy model. In the second phase, a gradient-descent-based approach was developed and used for optimized tuning of membership functions of the fuzzy model. The numerical results were compared with a conventional statistical model and neural networks and adaptive network-based fuzzy inference system.     

Multi-response optimization of EDM with Al–Cu–Si–TiC P/M composite electrode

The present study investigates the relationship of process parameters in electro-discharge of CK45 steel with novel tool electrode material such as Al–Cu–Si–TiC composite produced using powder metallurgy (P/M) technique. The central composite second-order rotatable design had been utilized to plan the experiments, and response surface methodology (RSM) was employed for developing experimental models. Analysis on machining characteristics of electrical discharge machining (EDM) die sinking was made based on the developed models. In this study, titanium carbide percent (TiC%), peak current, dielectric flushing pressure, and pulse on-time are considered as input process parameters. The process performances such as material removal rate (MRR) and tool wear rate (TWR) were evaluated. Analysis of variance test had also been carried out to check the adequacy of the developed regression models. Al–Cu–Si–TiC P/M electrodes are found to be more sensitive to peak current and pulse on-time than conventional electrodes. The observed optimal process parameter settings based on composite desirability are TiC percent of 18%, peak current of 6 A, flushing pressure of 1.2 MPa, and pulse on-time of 182 μs for achieving maximum MRR and minimum TWR; finally, the results were experimentally verified. A good agreement is observed between the results based on the RSM model and the actual experimental observations. The error between experimental and predicted values at the optimal combination of parameter settings for MRR and TWR lie within 7.2% and 4.74%, respectively.     

A Magnetically Controlled p–i–n Diode Microwave Switch

An inverse microwave switch with a magnetically controlled operating frequency is described. If the magnetic induction varies from 0 to 8000 G, the change in the operating frequency of the Ka-band switch reaches 800 MHz.     

A method for measuring the energy spectrum of neutrons with energies of 1–15 MeV

The characteristics of the detector prototype for 1–15 MeV neutrons are described. The prototype is a full absorption detector consisting of interlaced plastic scintillators and ⁶Li doped glasses. A neutron incident on the detector deposits all its energy in the plastic scintillator, is moderated to thermal energies, and detected in the lithium glass. The measured time of complete neutron moderation is ～60 μs. Recording two signals in this time interval from the first event of neutron scattering in the plastic scintillator and from the neutron absorption by a lithium atom in the glass, it is possible to effectively suppress background thermal neutrons and γ rays and, therefore, detect low-intensity neutron sources. Owing to the proposed detector design, the direction toward the neutron source can be determined.     

Influence of matrix hardness on honing engine cylinder liner with Cu–Sn–Fe–Ni diamond stones

In this work, three Cu–Sn–Fe–Ni matrices with different hardness were utilized in the diamond honing stones. Structures of the three matrices were investigated by X-ray diffraction, energy dispersive spectroscopy and scanning electron microscopy, and the results showed that the Cu–Sn–Fe–Ni matrices were composed of the pure copper, pure iron and (Cu, Ni)₄₁Sn₁₁. The wear properties of the matrices were estimated by a pin-on-disk wear machine under dry conditions at room temperature in the air. The influences of hardness on the honing performances were studied in terms of the honed surface aspect, the honing efficiency and the throughput of cylinder liners. Among the three stones, the stone with matrix B (HRB 71) reaches the self-sharpening range in terms of the three aspects mentioned above. Compared this stone with a commercially available product, the former has better honing efficiency.     

Wear analysis of Cu–Al coating on Ti–6Al–4V substrate under fretting condition

Fretting behavior of Cu–Al coating on Ti–6Al–4V substrate was investigated with and without fatigue load. Soft and rough Cu–Al coating resulted in abrasive wear and a large amount of debris remained at the contact surface, which caused an increase in tangential force during the fretting test under gross slip condition. Fretting in the partial slip condition also showed the wear of coating. To characterize wear, dissipated energies during fretting were calculated from fretting loops and wear volumes were obtained from worn surface profiles. Energy approach of wear analysis showed a linear relationship between wear volume and accumulated dissipated energy. This relationship was independent of fatigue loading condition and extended from partial slip to gross slip regimes. As an alternate but simple approach for wear analysis, accumulated relative displacement range was correlated with the wear volume. This also resulted in a linear relationship as in the case of accumulated dissipated energy suggesting that the accumulated relative displacement range can be used as an alternative parameter for dissipated energy to characterize the wear. When the maximum wear depth was equal to the thickness of Cu–Al coating, harder Ti–6Al–4V substrate inhibited further increase in wear depth. Only when a considerable energy was supplied through a large value of the applied displacement, wear in the substrate material could occur beyond the thickness of coating.     

Mechanical and tribological properties of sputtered Mo–Se–C coatings

Transition metal dichalcogenides belong to the more developed class of materials for solid lubrication. However, the main limitation of these materials is the detrimental effect of air humidity causing an increase in the friction. In previous works, molybdenum diselenide has been shown to be a promising coating retaining low friction even in very humid environment. In this study, Mo–Se–C films were deposited by sputtering from a C target with pellets of MoSe₂. Besides the evaluation of the chemical composition, the structure, the morphology, the hardness and the cohesion/adhesion, special attention was paid to the tribological characterization.The C content varied from 29 to 68 at.% which led to a progressive increase of the Se/Mo ratio. As a typical trend, the hardness increases with increasing C content. The coatings were tested at room temperature with different air humidity levels and at temperatures up to 500 °C on a pin-on-disc tribometer. The friction coefficient of Mo–Se–C coatings increased with air humidity from ～0.04 to ～0.12, while it was as low as 0.02 at temperature range 100–250 °C. The coatings were very sensitive to the elevated temperature being worn out at 300 °C due to adhesion problems at coating–titanium interface.     

Seismoacoustic Hydrophysical Complex for Monitoring the Atmosphere–Hydrosphere–Lithosphere System

The seismoacoustic hydrophysical complex intended for investigation of the interaction of geospheres wave fields in a frequency range from 1 Hz to 1 Hz is described. The complex consists of a shore-based system of laser strain meters, laser nanobarograph, bottom station with a hydrophone and a temperature-sensitive element, weather station, and seismoacoustic radiator. The use of modern laser-interferometry methods provided a deformation sensitivity of 10^–10 and an atmospheric-pressure sensitivity of 10 mPa.     

Relations of counterface materials with stability of tribo-oxide layer and wear behavior of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si alloy

Dry sliding wear tests of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si alloy (TC11 alloy) sliding against AISI 52100 and AISI M2 steels were performed under the load of 50–250 N at 25–600 °C. For two kinds of counterface materials, the titanium alloy presented totally different wear behaviours as the function of temperature. The appreciable variations of the titanium alloy sliding against different counterface materials were attributed the fact that a hard counterface caused unstable existence of tribo-layers by its microcutting action, thus resulting in the increase of wear rate. It is suggested that the hard counterface must be avoided as the counterface for the titanium alloy/steel sliding system.