Structural characteristics and catalytic activities of nanocrystalline Ni-Mo-B coatings obtained by catalytic electroless reduction

The structures, chemical states of elements, and catalytic activities of Ni-Mo-B alloys with different molybdenum contents, which were obtained by catalytic electroless reduction of metal ions, were studied. The rates of the partial reactions (heterogeneous hydrolysis of dimethylamine borane, reduction of nickel ions, and evolution of molecular hydrogen) were found to make a bell-shaped curve when plotted versus the concentration of molybdate ions in solution. Original Russian Text ? V.M. Krutskikh, M.V. Ivanov, A.B. Drovosekov, E.N. Lubnin, B.F. Lyakhov, Yu.M. Polukarov, 2007, published in Zashchita Metallov, 2007, Vol. 43, No. 6, pp. 619–625.     

Deformation Mechanisms of Ti-6Al-4V During Tensile Behavior at Low Strain Rate

A superplastic Ti-6Al-4V grade has been deformed at a strain rate of 5 × 10⁻⁴ s⁻¹ and at temperatures up to 1050 °C. Structural mechanisms like grain boundary sliding, dynamic recrystallization, and dynamic grain growth, occurring during deformation, have been investigated and mechanical properties such as flow stress, strain hardening, and strain at rupture have been determined. Dynamic recrystallization (DRX) brings on a decrease in the grain size. This could be of great interest because a smaller grain size allows a decrease in temperature for superplastic forming. For DRX, the driving force present in the deformed microstructure must be high enough. This means the temperature must be sufficiently low to ensure storing of enough dislocation energy but must also be high enough to provide the activation energy needed for DRX and to allow superplastic deformation. The best compromise for the temperature was found to be situated at about 800 °C; this is quite a bit lower than the 925 °C referenced in the literature as the optimum for the superplastic deformation. At this medium temperature the engineering strain that could be reached exceeds 400%, a value high enough to ensure the industrial production of complex parts by the way of the superplastic forming. Microstructural, EBSD, and mechanical investigations were used to describe the observed mechanisms, some of which are concurrent. This article was presented at the AeroMat Conference, International Symposium on Superplasticity and Superplastic Forming (SPF) held in Seattle, WA, June 6-9, 2005.     

On the concentration maxima of nonequilibrium point defects in irradiated copper with an impurity of gold

Results of a numerical solution based on a model that describes the process of accumulation of radiation-induced point defects in metals with impurities are presented. It has been established that a twofold increase in the energy of migration of interstitial atoms in copper with an impurity of gold results in a 40-fold increase in the excess concentration of interstitial atoms.     

Simulation of various possible cementite structures

The simulation of the cementite structure has been performed without resorting to any preliminary assumptions. The spheres simulating the Fe and C atoms are closely packed in accordance with the rules of pair interpenetration. The maximum depth of the interpenetration in the Fe-C pair was accepted to be intermediate between the maximum depths of the penetration in the Fe-Fe and C-C pairs in ferrite and diamond, respectively. Under such conditions, six iron atoms penetrate into a carbon atom. The carbon atom turns out to be located inside octahedra, which can be of various shapes, while the centers of iron atoms occupy the vertices of these octahedra. The translation of the octahedra leads to the formation of orthorhombic cementite structures with identical or close parameters, but with different relative positions of carbon and iron atoms.     

Fast Modeling of Phase Changes in a Particle Injected Within a d.c Plasma Jet

When spraying ceramic particles with a low thermal conductivity such as zirconia using Ar-H₂ direct-current (d.c.) plasma jets where the heat transfer is important, heat transfer phenomena take place with the propagation of melting, evaporation and even afterwards solidification fronts. Most models neglect these heat transfer phenomena assuming the particle as a lumped media. This work is aimed at developing a model coupling the effect of heat propagation within the particle along its trajectory. It uses an adaptative grid in which the coordinates of the phase change fronts are fixed. It allows minimizing the calculation costs (approximately 10 s on PC under Windows XP against 1 h with an enthalpy model). Such calculations are illustrated in an Ar-H₂ (25 vol.%) for dense and porous agglomerated zirconia (low thermal conductivity) as well as iron particles with a much higher thermal conductivity and drastic evaporation. This article was originally published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 14-16, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, 2007.     

Influence of tool vibration on machining performance in electrochemical micro-machining of copper

Electrochemical micro-machining (EMM) appears to be promising as a future micro-machining technique since in many areas of applications, it offers several advantages, including biomedical and MEMS applications. A suitable micro-tool vibration system has been developed, which consists of tool-holding unit, micro-tool vibrating unit, etc. The developed system was used successfully to control material removal rate (MRR) and machining accuracy to meet the micro-machining requirements. Micro-holes have been produced on thin copper workpiece by EMM with stainless-steel micro-tool. Experiments have been carried out to investigate the most effective values of process parameters such as micro-tool vibration frequency, amplitude and electrolyte concentration for producing micro-hole with high accuracy and appreciable amount of MRR. From the experimental results and SEM micrographs, it is evident that the introduction of micro-tool vibration improves EMM performance characteristics. Lower electrolyte concentration in the range of 15–20 g/l reduces stray current effects. Hertz (Hz) range of tool vibration frequency improves the removal of sludge and precipitates from very small interelectrode gap. The 150–200 Hz range of tool vibration frequency can be recommended for EMM, which provides a better electrochemical machining in the narrow end gap. Compared to kHz range, Hz range micro-tool's vibration improves the MRR and accuracy in EMM.     

Circular tests for HSM machine tools: Bore machining application

Today's High-Speed Machining (HSM) machine tool combines productivity and part quality. The difficulty inherent in HSM operations lies in understanding the impact of machine tool behaviour on machining time and part quality. Analysis of some of the relevant ISO standards [230. Acceptance code for machine tools. Part 4, Circular tests for numerically controlled machine-tools, April 1998, 10791. Test conditions for machining centres. Part 6, Accuracy of feeds, speeds and interpolation, September 1998, 10791. Test conditions for machining centres. Part 7, Accuracy of feeds, speeds and interpolation, September 1998] and a complementary protocol for better understanding HSM technology are presented in the first part of this paper. These ISO standards are devoted to the procedures implemented in order to study the behaviour of machine tool. As these procedures do not integrate HSM technology, the need for HSM machine tool tests becomes critical to improving the trade-off between machining time and part quality. A new protocol for analysing the HSM technology impact during circular interpolation is presented in the second part of the paper. This protocol, which allows evaluating kinematic machine tool behaviour during circular interpolation, was designed from tests without machining. These tests are discussed and their results analysed in the paper. During the circular interpolation, axis capacities (such as acceleration or Jerk) related to certain setting parameters of the numerical control unit have a significant impact on the value of the feed rate. Consequently, a kinematic model for a circular-interpolated trajectory was developed on the basis of these parameters. Moreover, the link between part accuracy and kinematic machine tool behaviour was established. The kinematic model was ultimately validated on a bore machining simulation.     

A local process model for simulation of robotic belt grinding

A local process model to estimate the material removal rate in robotic belt grinding is presented and applied to the process simulation system. It calculate the acting force by incorporating the local geometry information of the workpiece instead of the cutting depth parameter with only one certain value as in a global grinding model. The simulation accuracy can be improved to below 5% even for a non-uniform contact under stable cutting conditions.     

Refrigerated cooling air cutting of difficult-to-cut materials

One approach to enhance machining performance is to apply cutting fluids during cutting process. However, the use of cutting fluids in machining process has caused some problems such as high cost, pollution, and hazards to operator's health. All the problems related to the use of cutting fluids have urged researchers to search for some alternatives to minimize or even avoid the use of cutting fluids in machining operations. Cooling gas cutting is one of these alternatives. This paper investigates the effect of cooling air cutting on tool wear, surface finish and chip shape in finish turning of Inconel 718 nickel-base super alloy and high-speed milling of AISI D2 cold work tool steel. Comparative experiments were conducted under different cooling/lubrication conditions, i.e. dry cutting, minimal quantity lubrication (MQL), cooling air, and cooling air and minimal quantity lubrication (CAMQL). For this research, composite refrigeration method was adopted to develop a new cooling gas equipment which was used to lower the temperature of compressed gas. The significant experimental results were: (i) application of cooing air and CAMQL resulted in drastic reduction in tool wear and surface roughness, and significant improvement in chip shape in finish turning of Inconel 718, (ii) in the high-speed milling of AISI D2, cooling air cutting presented longer tool life and slightly higher surface roughness than dry cutting and MQL. Therefore, it appears that cooling air cutting can provide not only environment friendliness but also great improvement in machinability of difficult-to-cut materials.