Microstructural and hardness investigation of tool steel D2 processed by laser surface melting and alloying

Several techniques can be used to improve surface properties of metals. These can involve changes on the surface chemical composition such as alloying or on the surface microstructure, such as hardening. In the present work, melting of the surface by a 9 kW CO₂ CW laser of wavelength 10.6 μm was used to alter surface features of D2 tool steel. Carbon powder and nitrogen gas were used as sources of alloying elements during laser processing. The effect of various laser parameters (power and speed) on the microstructure and hardness of D2 tool steel was investigated. Laser powers from 1 to 8 kW and laser speeds from 5 to 15 mm/s were employed. It was found that as the laser power increases, the hardness of the melted zone decreases while that of the heat-affected zone increases. On the other hand, the depth of both of melted and heat-affected zones increases with power.     

An investigation of the effect of laser deposition parameters on characteristics of multilayered 316 L deposits

A potential problem in applying the direct laser deposition (DLD) technique to material fabrication is the effect that subsequent deposited layers have on reheating previous laser deposition layers. Most of the previous investigations examined the effect of the laser deposition parameters on the microstructure and mechanical properties of a single layer. This work focused on the effect of the laser parameters of subsequent layers on the microstructure and mechanical properties of the deposited layers to select proper parameters and characterize the effect. The microstructure morphology and property values are affected by the varied parameters. This leads to some tempering and aging effects in the steels. The microstructure of the top layer was equiaxed, while the near substrate region was fine dendritic. Typically, both of the travel speed and power of the laser show the significant effects on microstructure and hardness.     

Software compensation of rapid prototyping machines

This paper addresses accuracy improvement of rapid prototyping (RP) machines by parametric error modeling and software error compensation. This approach is inspired by the techniques developed over the years for the parametric evaluation of coordinate measuring machines (CMM) and machine tool systems. The confounded effects of all errors in a RP machine are mapped into a “virtual” parametric machine error model. A generic artifact is built on the RP machine and measured by a master CMM. Measurement results are then used to develop a machine error function and error compensation is applied to the files which drive the build tool. The method is applied to three test parts and the results show a significant improvement in dimensional accuracy of built parts.     

Eddy Current Detection of Retained Austenite in Ni-Hard4 Cast Iron

In this article, the nondestructive eddy current (EC) method was used for microstructural evaluation of Ni-hard4 cast iron (NiHCI). Different destabilizing heat treatments were used to produce different microstructures and hardness. The microstructural analysis and hardness measurement were done for conventional characterization of the reference blocks. Then, the EC techniques were applied to evaluate the hardness and microstructural changes by the detection of EC parameters at different frequencies. Metallurgical investigations showed that increasing the destabilizing soaking time and temperature decreases the amount of retained austenite in NiHCIs. The nondestructive evaluation method (NDT) revealed that it can be good correlated between retained austenite amount and hardness with EC parameters. This shows that the EC technique can detect NiHCIs products according to the metallurgical characterization with good accuracy.     

Effect of silicon content in steel and oxidation temperature on scale growth and morphology

The effect of high silicon content in steel, 1.6 wt.%Si and 3.2 wt.%Si, and high oxidation temperatures (850–1200 °C) on scale growth rate and morphology were investigated. The steels were oxidized in a 15% humid air with short isothermal oxidation times (15 min). The scale growth rate of the non-alloyed steel follows a parabolic law with time; it is an iron diffusion controlled oxidation. The presence of silicon delays scale growth by forming a silica SiO₂ barrier layer at the scale/metal interface, this effect is more important for the steel containing 3.2 wt.%Si and induces a discontinuous scale. Silicon oxides are concentrated at the scale/metal interface; their morphology depends on the oxidation temperature. For temperatures lower than 950 °C, silica is formed. Between 950 °C and 1150 °C, fayalite (Fe₂SiO₄) grains appear in the wüstite matrix close to the scale/metal interface. For temperatures higher than 1177 °C, a fayalite–wüstite eutectic is formed; this molten phase favours iron diffusion leading to high scale growth. After cooling, a continuous fayalite layer with small wüstite grains is obtained at the scale/steel interface.     

A comparative evaluation of sequential set point adjustment procedures for tolerance control

The machining of complex parts typically involves a logical and chronological sequence of n operations on m machine tools. Because manufacturing datums cannot always match design datums, some of the design specifications imposed on the part are usually satisfied by distinct subsets of the n operations prescribed in the process plan. Conventional tolerance control specifies a fixed set point for each operation and permissible variation about this set point to insure compliance with the specifications. Sequential tolerance control (STC) uses real-time measurement information at the completion of one stage to exploit the available space inside a dynamic feasible zone and reposition the set point for subsequent operations. This paper introduces an extension of STC that utilizes the variability of the operations to scale the problem data and further enhance the ability of STC to optimize the production of an acceptable part.     

Optimizing Concentration of Drag Reducing Polymer in Case of One- and Two-Phase Flow in 90° Copper Elbow

Journal of Failure Analysis and Prevention - The rate of diffusion-controlled corrosion of 90° Copper Elbow by acidified dichromate has been investigated in relation to the following...     

Construction and analytical characterization of Prussian-Blue-based carbon paste electrodes and their assembly as oxidase enzyme sensors

This paper reports on the development and characterization of Prussian Blue-modified carbon paste electrodes. New methods of matrix modification with Prussian Blue are reported. Two different carbon pastes have been prepared, using mineral oil or solid paraffin, thus obtaining different types of sensors whose behavior toward the electrochemical reduction of hydrogen peroxide has been fully characterized. Results obtained with Prussian Blue-modified electrodes showed a long operational lifetime, an excellent stability in a wide range of pH (3-9), a high sensitivity, and a fast response time. In addition, the coupling of solid carbon paste modified with Prussian Blue and the enzymes glucose oxidase and choline oxidase led to the assembling of biosensors that showed an optimum working range at alkaline pH.     

Developing pressure sensors from impregnated textile sandwiched in inkjet-printed electrodes

Journal of Materials Science: Materials in Electronics - This work presents an interesting fabrication route toward development of pressure sensing patch by utilizing electrically conductive cotton...