高性能表面层制造:基于可控表面完整性的精密制造

高性能表面层制造是具有特殊功能性表面层结构零件的精密制造,体现了高性能零件性能与几何参数一体化制造的特点。依据功能性表面层结构零件的性能要求所设计的几何参数和材料特性,选择表面层加工制造方法,确定加工工艺载荷的物质与能量输入条件,通过减控加工工艺的几何、结构、物理、化学等多源耦合约束,构建主动协调的材料加工载荷的应力场、温度场和化学位场等(多)场环境,相应地揭示零件表面完整性变化关系内禀的加工过程印记,利用可控的表面完整性与高性能零件性能的关联模型,实现具有特殊功能性表面层的精密制造。高性能表面层加工制造原理的核心是表面完整性的形成机制、评价方法和调控作用,所提出的高性能表面层精密制造的体系框架,以基于知识方法取代实验迭代的试错法,可解决高性能制造的加工制造反问题。     

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Rapid prototyping (RP) or layered manufacturing (LM) technologies have been extensively used to manufacture prototypes composed mainly of plastics, polymers, paper, and wax due to the short product development time and low costs of these technologies. However, such technologies, with the exception of selective laser melting and sintering, are not used to fabricate metallic products because of the resulting poor life, short cycle, poor surface finish, and low structural integrity of the fabricated parts. The properties endowed by these parts do not match those of functional parts. Therefore, extensive research has been conducted to develop new additive manufacturing (AM) technologies by extending existing RP technologies. Several AM technologies have been developed for the fabrication of metallic objects. These technologies utilize materials, such as Ni-, Al-, and Ti-based alloys and stainless steel powders, to fabricate high-quality functional components. The present work reviews the type of materials used in laser-based AM processes for the manufacture of metallic products. The advantages and disadvantages of processes and different materials are summarized, and future research directions are discussed in the final section. This review can help experts select the ideal type of process or technology for the manufacturing of elements composed of a given alloy or material (Ni, Ti, Al, Pb, and stainless steel).     

Rapid prototyping fabrication and finite element evaluation of the three-dimensional medical pelvic model

This paper presents a non-uniform, periodic closed B-spline approximation algorithm for the fabrication of a medical pelvic model, based on rapid prototyping, and also gives the finite element evaluation of the pelvic model. Rapid prototyping (RP), when used in fabricating medical prosthesis, has a strict requirement for closeness and impermeability of STL files. Incorrect data structure in STL files will cause the subsequent slicing process not to proceed. The non-uniform periodic closed B-spline curve approximation method was applied to processing CT data. The precision and size of STL files was improved to optimize the RP model of the pelvis. Finally, the model of the pelvis was evaluated with the finite element method. Results suggest that a high similarity has been achieved in terms of shape, size and biomechanical properties of the pelvic model and the normal one, which validates our argument that rapid prototyping with non-uniform, periodic closed B-spline algorithm is suitable for the fabrication of a pelvic model, which will prove to be significant in the design of pelvic prostheses .     

The effect of socket design, materials and liner thickness on the wear of the porous coated anatomic total hip replacement.

The wear of joint replacement prostheses represents the greatest challenge to their continued development. Parameters such as polyethylene quality, liner thickness and metal backing have all been implicated as potential detractors in the search for the lowest-wearing socket. This study examined the effect of these parameters through an extensive study of the two versions of the porous coated anatomic (PCA) hip prosthesis (one-piece socket and snaplock socket). For the whole cohort the wear rate was found to be 88 (SE 10) mm3/year and the clinical wear factor was 2.00 (SE 0.28) x 10(-6) mm3/N m. When the two socket types were investigated individually, the wear factors found were 2.39 (SE 0.44) x 10(-6)mm3/N m and 0.99 (SE 0.25) x 10(-6) mm3/N m for the one-piece and snaplock, respectively. This illustrates that the metal backing per se does not predispose these sockets to rapid wear. The good wear performance of the snaplock liner may be attributed to the high quality of the ultra-high molecular weight polyethylene (UHMWPE) used and the shorter implantation period compared to that for the one-piece design. No correlation was found between the thickness of the liner and the clinical wear factor. Within the range of thicknesses tested here, UHMWPE thickness is not an influential parameter for the hip prosthesis and this is confirmed     

TXRF法测定聚丙烯材料中有害元素的含量

本文建立微波消解-全反射X荧光法(TXRF)测定聚丙烯材料中的铅、镉、汞含量的方法。基于全反射X荧光分析技术,利用微波消解技术对聚丙烯材料进行消解,从而同时进行铅、镉、汞等有毒有害元素的检测,大大提高检测速度,方法的精密度均小于6%,回收率在88.0%~103.7%之间,完全可以应用于RoHS指令规定的有毒有害元素的检测。     

基于STM8单片机的智能电源插座

针对普通插座在应用中存在的一些安全隐患问题,设计了一个无人在场时定时自动断电的智能插座。该智能插座通过实时监测人体感应传感器发出的信号,可以实时监测插座附近是否有人员在场,如果无人在场,在设定的定时时间到时自动切断插座电源,从而有效防止了一些发热设备因忘记断电而引发的电火灾的发生。经实际测试,本系统具有很高的可靠性和安全性,具有很好的市场推广应用前景,并且已经申请并获得专利。     

随机载荷下材料疲劳寿命可靠性分析的智能仿真系统

将疲劳累积损伤看作是非稳态过程,摒弃了能量均匀耗散及线性累积损伤理论假设,采用神经网络技术准确描述其与材料性能、载荷应力间复杂的非线性映射关系,真实描述了材料疲劳损伤过程;建立了疲劳失效动态准则,综合考虑了材料疲劳性能及载荷的随机性,能够正确反映两者的个体性能及相互关系。并运用离散事件仿真原因,构造了材料疲劳可靠性分析的智能仿真系统,用以准确地进行疲劳可靠性分析。经正火35钢随机载荷疲劳试验验证,其可靠性分析精度较高。     

Effects of temperature on mechanical properties of SU-8 photoresist material

A representative fabrication processing of SU-8 photoresist, Ultraviolet (UV) lithography is usually composed of spin coat, soft bake, UV exposure, post exposure bake (PEB), development and optional hard bake, etc. The exposed region of SU-8 is crosslinked during the PEB process and its physical properties highly depend on UV exposure and PEB condition. This work was initiated to investigate if thermal baking after fabrication can affect the mechanical properties of SU-8 photoresist material because SU-8 is trying to be used as a structural material for MEMS operated at high temperature. Since a temperature of 95°C is normally recommended for PEB process, elevated temperatures up to 200°C were considered for the optional hard bake process. The viscoelastic material properties were measured by dynamic mechanical analyses (DMA). Also, pulling tests were performed to obtain Young’s modulus and Poisson’s ratio as a function of strain rate in a wide temperature range. From this study, the effects of temperature on the elastic and viscoelastic material properties of SU-8 were obtained.     

热老化对主泵泵壳材料失效评定曲线的影响研究

主要研究了热老化对主泵泵壳材料CF8在室温和350℃温度下拉伸性能以及失效评定曲线的影响。对经历不同老化时间的试样进行恒应变速率下的拉伸试验,采用Ramberg-Osgood （R-O）模型对拉伸真应力-真应变曲线进行分析,并将分析结果用于失效评定曲线的计算。结果表明,随热老化时间延长,室温和350℃温度下材料的抗拉强度均不断提高,断后延伸率有所下降;在小应变范围内,R-O模型能够较准确预测材料的真应力-真应变曲线;采用英国R6标准方法二得到不同老化阶段材料的失效评定曲线,结果显示在部分区域,如采用未老化材料的失效评定曲线,则评定结果将偏于不安全。     

某660 MW超超临界机组热段疏水管道接管座的开裂原因

某火电厂660 MW超超临界机组投运不久,其热段疏水管道接管座开裂,导致蒸汽泄漏.对该接管座进行了化学成分、硬度和显微组织分析,并根据管道实际布置情况建立三维实体模型,采用热固耦合有限元方法对该结构受力进行仿真分析.结果表明:该接座管化学成分、硬度、显微组织满足要求,有限元仿真得到最大应力位于接管座与主管连接焊缝下边缘...     

多晶硅微机械构件损伤的表面效应

利用电磁力驱动微拉伸装置，考察多晶硅微构件表面粗糙度和施加表面分子自组装膜(octadecyltrichlorosilane，简称OTS)对抗拉强度及断裂损伤的影响。结果表明，微构件的抗拉强度表现出依赖表面性质的表面效应。抗拉强度随表面粗糙度的增加而降低，并受环境气氛的影响。当构件表面施加表面分子自组装膜后，在以上两因素的作用下．多晶硅微构件的抗拉强度提高了32．46％。研究结果可用于微机械构件的材料表面改性设计。     

基于RP的人工骨骼制造方法探索

针对目前基于快速成形的人工骨骼制作方法中存在的问题,提出基于快速在成形的人工骨烧结制造工艺方法,研制了气压式熔融沉积快速成形系统（AJS）,该方法达到材料、成形、生物活性的统一。其特点是人工骨肉部微孔的数量、大小,分布及形状可人工影响和控制。     

A preliminary hip joint simulator study of the migration of a cemented femoral stem

A hip joint simulator that can be used to evaluate the outcome of the cemented total hip replacement has been designed, manufactured and evaluated. The simulator produces motion of a cemented hip construct in the extension/flexion plane, with a socket to rotate internal/externally. At the same time a dynamic loading cycle is applied to the construct. A validation test was performed on a cemented femoral stem within a novel composite femur. The study demonstrates the value of using a hip joint simulator to evaluate the outcome of the cemented hip construct. A complex migration pattern of the cemented hip prosthesis with respect to load cycling was observed, demonstrated in vitro comparable prosthesis migration behaviour, both the stem migration and migration patterns, to that found clinically.     

Fatigue of bitumen and bituminous mixes

This paper gives details of an investigation into the fundamental fatigue properties of bitumen and bituminous mixes. Fatigue tests carried out under constant bending stress, at varying temperatures between −13·5°C and +25°C, show that the material exhibits fatigue properties over wide ranges of stress and that for a particular temperature and speed of loading the log stress-log number of cycles to failure relationship is linear between 10⁴ and 10⁸ cycles. The life under constant stress is highly dependent on the temperature of the test, a low temperature giving a longer life at a particular stress; it is also dependent to some extent on the speed of loading, but taking into account the stiffness of the material which depends on temperature, speed of loading, rheological characteristics and composition of the mix, it has been found that when the logarithm of the strain is plotted against the logarithm of the number of cycles to failure all experimental results at different speeds and temperatures for one mix lie with a certain amount of scatter about a straight line. It appears therefore that the factor affecting the fatigue life is one of strain rather than stress, and the effects of temperature and speed can be accounted for by their effect on the stiffness of the specimen. This has been confirmed by tests under constant torsional strain at different temperatures between −20°C and +40°C, but at the higher temperatures under this type of loading the fatigue life includes a considerable crack-propagation time. Similar results have been obtained from mixes containing different amounts of aggregate, but as the quantity of aggregate in the mix is reduced so the life for a given strain increases, suggesting that the criterion of failure may be one of tensile strain in the bitumen present in the mix. Some tests have also been carried out on pure bitumen specimens at different temperatures.

Careful examination of the fatigue cracks and failure surfaces shows that in nearly all cases failure originates on the principal tensile plane. The effects of such factors as surface conditions, void content and rest periods have also been studied.     

Emerging challenges to structural integrity technology for high-temperature applications

Structural integrity technology has been widely used with great success for the design, manufacture and failure prevention of modern constructions such as chemical and petrochemical plants, power generation and energy conversion systems, as well as space and oceanic exploration. The modern needs of structural integrity technology are largely attributed to the increase of service temperature of the structures that results in the efficiency improvement in energy conversion and chemical processing technologies. Besides the needs arising from large-scale high-temperature plants, the high tech developments, such as micro chemo-mechanical systems and high-power electronics, provide new challenges to structural integrity technology. The present paper summarizes the recent technical progresses in large process plants and the aviation industry, micro chemo-mechanical systems, fuel cells, high-temperature electronics, and packaging and coating technologies. The state-of-the-art of structural integrity technology for high temperature applications is reviewed. Suggestions are provided for the improvement of current design and assessment methods.     

GS-20Mn5钢非对称循环应力-应变本构模型及其应用

在实际工程中,机械结构件承受反复载荷时,内部往往是非对称的应力应变状态。在非对称循环加载条件下,材料不仅会表现出循环软/硬化特性,还会表现出平均应力松弛行为。这会影响其在循环稳定状态下的力学性能,进而影响结构在相应工况下承载服役的强度安全性。针对大型压机本体结构常用GS-20Mn5钢进行了单向拉伸及应变比R为0.5,应变幅0.20%、0.25%、0.27%、0.30%和0.40%的非对称应变循环加载试验研究,分别构建了基于单向拉伸试验结果的A-F随动硬化模型,以及基于非对称循环加载的Landgraf模型来描述其平均应力松弛特性,将其应用到Ramberg-Osgood公式中,结合A-F非线性随动硬化模型,建立了非对称循环加载条件下对应于循环应力-应变曲线的本构模型,并确定了相应模型参数。针对承受非对称循环载荷的某大型锻造液压机上横梁,应用所建立的本构模型分别进行了安定性数值分析,评估了其在循环载荷下的弹塑性强度安全性。结果显示,与采用单向拉伸条件下的A-F模型时的计算结果相比,采用非对称循环应力-应变本构模型时上横梁的安定极限载荷提高了约7%。     

插座载流件结构对导电性能的影响

为了保证86型插座内部载流体（一般为铜件）的良好导电性和结构稳定性,论文就两种不同品牌的86型插座内部的铜载流件的不同结构进行了分析,并通过对比实验,测量出2种不同结构的铜载流件的电阻大小,进而得出各自导电性能的差异。实验表明：材质相同的铜载流件导体,采用一体成型加工出的载流件相较于采用搭接成型的载流件,导电性能会显著提高。     

Dynamic deformation behavior of aluminum alloys under high strain rate compressive/tensile loading

Mechanical properties of the materials used for transportations and industrial machinery under high strain rate loading conditions such as seismic loading are required to provide appropriate safety assessment to these mechanical structures. The Split Hopkinson Pressure Bar (SHPB) technique with a special experimental apparatus can be used to obtain the material behavior under high strain rate loading conditions. In this paper, dynamic deformation behaviors of the aluminum alloys such as A12024-T4, A16061T-6 and A17075-T6 under both high strain rate compressive and tensile loading conditions are determined using the SHPB technique.     

Fatigue behavior of an austenitic steel of 300-series under non-zero mean loading

Strain-controlled fatigue data of an austenitic stainless steel subjected to uniaxial state at different strain ratios with tensile and compressive mean strain are experimentally investigated to understand the fatigue phenomena when non-zero mean straining is involved. The fatigue test result indicates that mean stresses relax to very low level and the material experiences elastic-plastic response throughout the life. Moreover, the material has higher fatigue resistance under tensile mean strain loading condition than that of completely reversed loading and compressive mean strain cycling at the same strain amplitude which might be attributed to the micro-structural deformation mechanism. The capabilities of several damage parameters to characterize the non-zero mean strain effect on fatigue life are examined based on fatigue data and are found inappropriate for the as-received material. Therefore, a fatigue damage approach with a power law relationship between modified damage parameter and reversals to failure, considering a mean strain function in stress-strain-based fatigue damage module, is introduced to the material which shows better correlation with the uniaxial fatigue data under mean strain loading compared to that of some established fatigue models.     

基于材料非稳态疲劳损伤过程的可靠性分析智能化仿真方法

材料的疲劳损伤受诸多因素的影响 ,是一个非稳态过程 ,其瞬态损伤与材料性能、载荷应力间表现为复杂的非线性映射关系 ,难以用确定性的数学函数准确表达。为此摒弃了能量均匀耗散及线性累积损伤理论假设 ,采用神经网络技术进行描述 ,准确反映了材料疲劳损伤真实演变过程 ;建立了疲劳失效动态准则 ,综合考虑了材料疲劳性能及载荷的随机性 ,能够正确反映两者的个体性能及相互关系 ,并运用离散事件仿真原理 ,构造了材料疲劳可靠性分析和智能化仿真系统 ,用以准确地进行随机载荷的疲劳寿命可靠性分析。经正火 35钢随机载荷疲劳试验验证 ,其可靠性分析精度较高。