Profile error compensation approaches for parallel nanogrinding of aspherical mould inserts

This paper reports a parallel nanogrinding protocol for fabricating aspherical mould inserts. In the protocol, a preliminary grinding cycle was first employed, which significantly reduced the effect of the initial wheel geometry error on the ground profile accuracy. A new compensation approach was developed. The compensation used the ground profile measured from a Talysurf profilometer to modify the NC tool path for the next grinding cycle. The tool path was modified by offsetting the residual profile error along the normal direction of a grinding point, rather than in the horizontal direction commonly used in the conventional method. The performance of the developed method was evaluated by fabricating aspherical mould inserts on cemented tungsten carbide. The result indicated that the residual profile error after two grinding cycles was reduced to approximately 0.4 μm in PV, with average surface roughness of below 10 nm, which is more efficient than the conventional compensation process.     

Microstructural Analysis and Photocatalytic Activity of Plasma-Sprayed Titania-Hydroxyapatite Coatings

Hydroxyapatite (HAp Ca₁₀(PO₄)₆(OH)₂) is known to be a biomaterial and an adsorbent for chromatography. In this study, HAp was agglomerated with anatase TiO₂ to manufacture thermal-spray powders to improve the adsorption activity of TiO₂, and then to improve its photocatalytic activity. The microstructures, compositions and photocatalytic activity of plasma-sprayed TiO₂, TiO₂-10%HAp, TiO₂-30%HAp, and HAp coatings were investigated. Due to the low thermal conductivity of HAp compound, not all HAp particles fully melted even under the arc current of 800 A. The addition of HAp inhibited the phase transformation of anatase TiO₂ to rutile. Under the arc current of 600 A, the anatase content in the TiO₂, TiO₂-10%HAp and TiO₂-30%HAp coatings was 11, 20 and 42%, respectively. With the increasing of the spraying distance from 70 to 110 mm, the anatase content in the TiO₂-30%HAp coatings decreased from 34 to 17% under arc current of 700 A. Furthermore, a slight decomposition of HAp to α-Ca₃(PO₄)₂ was found in the TiO₂-30%HAp coatings, it did not decompose to CaO and P₂O₅ according to the XRD and EDAX analysis. The addition of the secondary gas of helium had no significant influence on the melting state of the TiO₂-HAp feedstock powders. Moreover, the HAp in the TiO₂-10%HAp and TiO₂-30%HAp coatings had adsorption characteristic to acetaldehyde. The photocatalytic activity of TiO₂-10%HAp coating was highest among TiO₂, TiO₂-10%HAp, and TiO₂-30%HAp coatings sprayed under the arc current of 600 A for the optimum adsorption property and anatase content. This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously 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, OH, 2007.     

Microstructures and Mechanical Properties Prediction for Ti-Based Alloys

Titanium alloys have been used in demanding applications such as the chemical industry and aerospace, thanks to their excellent corrosion resistance, low density, and high-mechanical strength. There have been many research activities recently on titanium alloys, mainly focusing on experiments. The kinetics of phase transformations and the relationship between the microstructure and the final mechanical properties has not been widely studied by computer modeling. In this work, a comprehensive finite-element model coupled with thermodynamic calculations has been developed to simulate the microstructure evolution and predict the final mechanical properties resulting from solidification and to solid phase transformation. This model can be applied to casting and heat treatment processes. The predictions are validated by comparison with experimental measurements. The results show that this model can accurately predict the microstructure, volume fraction of different phases, and the final yield strength of titanium alloys.     

Slurry Erosion Studies on Surface Modified 13Cr-4Ni Steels: Effect of Angle of Impingement and Particle Size

Hydroturbine steels, such as 13Cr-4Ni martensitic steels, are generally subjected to heavy-erosive wear and loss of efficiency due to solid particulate entrainment in the water. Surface-modified steels have proven to give better performance in terms of erosive wear resistance. In the present study, an attempt is made to investigate the effect of angle of impingement and particle size on slurry-jet erosion behavior of pulsed plasma nitrided and laser hardened 13Cr-4Ni steels. Laser hardening process has shown good performance at all angles of impingement due to martensitic transformation of retained austenite. Plastic deformation mode of material removal was also an evident feature of all laser-hardened surface damage locations. However, pulsed-plasma nitrided steels have exhibited chip formation and micro-cutting mode of erosive wear. Erosion with 150-300 μm size was twice compared to 150 μm size slurry particulates.     

Life cycle inventory for base metal ingots production in Japan including mining and mineral processing processes by cost estimating system database

CO2 emission levels of copper and zinc mines from which Japanese smelters import ore concentrates into Japan, were estimated by using a database called MLED. Eleven copper mines selected from data availability of mine site covered 84% of the total imported concentrates. Adding inventories of sea transportation and smelting processes to mine development process, total CO2 emission level for copper and zinc ingots produced in Japan were calculated. The results show that the emission share of mining and mineral processing processes for each mine is indicated around 30%-70% of total emission for ingots, which implies the importance of including the mining activities to the inventory of upper stream products.     

An improved cutting force and surface topography prediction model in end milling

During the milling operation, the cutting forces will induce vibration on the cutting tool, the workpiece, and the fixtures, which will affect the surface integrity of the final part and consequently the product's quality. In this paper, a generic and improved model is introduced to simultaneously predict the conventional cutting forces along with 3D surface topography during side milling operation. The model incorporates the effects of tool runout, tool deflection, system dynamics, flank face wear, and the tool tilting on the surface roughness. An improved technique to calculate the instantaneous chip thickness is also presented. The model predictions on cutting forces and surface roughness and topography agreed well with experimental results.     

Effect of ultrasonic stirring on temperature distribution and grain refinement in Al- 1.65%Si alloy melt

A series of experiments were conducted for Al-1.65%Si （mass fraction） alloy melt to study the formation of grain refining structure with ultrasonic stirring. The cooling curves of ingots with ultrasonic were measured and compared with those without ultrasonic. At the same time, the effect of the time of ultrasonic stirring on solidification structure of ingots was investigated. The influence of ultrasonic on the grain-refining efficiency of ingots was analyzed. In order to well understand the melts behavior under ultrasonic, by using ammonium chloride solution, the simulation experiment was carried out and the temperature distribution in ingot with or without ultrasonic was compared. The results indicate that the ultrasonic reduces the temperature inhomogeneity of melt, i.e. the ultrasonic helps to homogenize the melt temperature. The effect of stirring and heat generation in ingot start to occur with increasing the time of ultrasonic stirring.     

Influence of pH on the passivation behavior of 254SMO stainless steel in 3.5% NaCl solution

The potentiodynamic polarization measurement of 254SMO stainless steel (UNS 31254) was conducted in 3.5% NaCl solutions with pH ranging from 0.1 to 5. The results indicated that this stainless steel offered excellent pitting corrosion resistance in corrosive environments. Further, it also exhibited various features on the polarization curves in different pH solutions. The electrochemical constant-potential passivation treatment performed at different pH followed by XPS analysis revealed that the primary constituents of the outermost layer of the passive films formed in the weak (pH 5) and strong (pH 0.8) acid solutions are iron oxides and Cr₂O₃ and Cr(OH)₃, respectively. Molybdenum oxides, primarily in the six-valence state, existed in the outermost layer of the passive film. Only very weak signals corresponding to that of nickel oxides were detected in the film formed in the weak acid (pH 5) solution. The ICP-MS analyses indicated selective dissolution of a significant amount of Fe and a few Mo and Ni ions during the passivation treatment in the strong acid (pH 0.8) solution. No Cr dissolution was observed; this indicated that the Cr in the film is relatively stable. XPS depth profiling results showed that a similar bilayer-structured film was formed in both the solutions (pH 0.8 and 5); the outer layer of this film is primarily composed of Cr(OH)₃ and Mo(VI), and the inner layer, Cr₂O₃ and Mo(IV). The results of the examinations of passive film formations and dissolution by XPS and ICP-MS were consistent with the polarization curves.     

Effect of the marine environment on reinforced concrete durability in Iberoamerican countries: DURACON project/CYTED

This work presents some of the results from the project: “Effect of the environment on reinforcement durability” (DURACON) in its first two-years period, which investigates the influence of urban and marine meteorochemical parameters on the performance of reinforced concrete structures. The results presented in this investigation are from 21 marine test sites only (no urban environments are included), distributed among 11 countries (Argentina, Bolivia, Brazil, Chile, Colombia, Costa Rica, Mexico, Spain, Uruguay, Portugal and Venezuela). The environment was evaluated using ISO Standard 9223 and the concrete was characterized by measuring compressive strength, elastic modulus, total and effective porosity, chloride permeability according to ASTM standards, as well as the effective porosity and resistance to water absorption using the Fagerlund method. To that effect, concrete specimens (with and without reinforcement) were prepared for electrochemical and physical/mechanical/chemical tests using the existing materials in each participating country, following strict procedures which enabled the preparation of similar concrete samples. Two water/cement (w/c) ratios (0.45 and 0.65) were selected, where the concrete with 0.45 w/c ratio had to have a minimum cement content of 400 kg/m³ and the one with 0.65 w/c ratio a compressive strength of 210 kg/cm². Type I Portland cement, siliceous sand, and crushed rock as coarse aggregates (13-mm maximum nominal size) were used. After a one-year exposure, the results of the corrosion potentiality and probability analysis of the reinforcement in the different test stations showed that, for marine atmospheres, the most aggressive environment to induce steel corrosion was at Portugal’s Cabo Raso station, and the least aggressive one was at Chile’s Valparaíso station. These results are comparable with the ones found using electrochemical measurements, after a two-year exposure.     

Effect of Fe-Zn alloy layer on the corrosion resistance of galvanized steel in chloride containing environments

In this study, the effect of Fe-Zn alloy layer that is formed during galvanizing process on the corrosion behavior of galvanized steel has been investigated. The galvanostatic dissolution of galvanized steel was carried out in 0.5 M NaCl solution to obtain the Fe-Zn alloy layer on the base steel. The alloy layer was characterized to be composed of FeZn₁₃, FeZn₇ and Fe₃Zn₁₀ intermetallic phases, which constitute the zeta, delta1 and gamma layers of galvanized steel, respectively. It was observed that the alloy layer has similar cathodic polarization behavior but different anodic polarization behavior compared to galvanized steel. The anodic current plateau of alloy layer was up to 100 times lower than that of galvanized coating. Corrosion test performed in wet-dry cyclic condition has shown that the alloy layer has lower corrosion rate as compared to galvanized steel. From the results of corrosion test of alloy layer and base steel, it was concluded that Zn²⁺ has positive effect on the protectiveness of the zinc corrosion products. The measurement of surface potential over the alloy/steel galvanic couple has confirmed the galvanic ability of alloy layer to protect both the alloy layer itself and the base iron during initial stage of atmospheric corrosion.