Laser pressure welding of aluminium and galvannealed steel

Dissimilar metal joints of galvannealed steel and commercially available pure aluminium (A1050) sheets were produced by changing the laser power and the roller pressure by the laser pressure welding method. In this method, the YAG laser beam was irradiated into a flare groove made by these dissimilar metal sheets. In addition, the laser beam was scanned at various frequencies and patterns through the fθ lens using two-dimensional scanning mirrors. Then the sheets were pressed by the pressure rolls to be joined. The compound layers in the weld interface were observed by optical microscope, and the layer thicknesses were measured. The thicknesses were in the range of 7–20 μm. The mechanical properties of welded joints were evaluated by the tensile shear test and the peel test. In the tensile shear test, the strengths of the joints produced under the most welding conditions were so high that the fracture occurred through the base aluminium sheet. In the peel test of the specimens subjected to the laser beam of 1200–1400 W power under the roller pressure of 2.94 kN, the specimen fracture took place in the base aluminium sheet. Even if the compound layer was thick, high joint strength was obtained. In order to know the reason for such high strength of joints with thick compound layers and the joining mechanism, the compound layer was observed by the HR-TEM. The TEM observation results revealed that the main phase in the compound layer was the solid solution of Al + Zn. Moreover, the intermetallic compound was identified as FeAl, Fe₂Al₅, Fe₄Al₁₃, and Fe₂Al₅Zn_0.4 phase by electron diffraction. The Fe₃Zn₁₀ (Γ phase) of Fe–Zn intermetallic compound was confirmed on a Fe base material. It is assumed that the joining areas were heated in a range of 782°C more than 665°C, a melting point of Al, by laser irradiation because the δ_lk phase aspect was not confirmed. Because the surfaces of A1050 and Zn plated layer were melted thinly, the layer was over 10 μm thicker. The reason for the production of high strength joints with the relatively thick intermetallic compound layer was attributed to the formation of (Al + Zn) phase with finely dispersed intermetallic compounds.     

HR-TEM observation of laser pressure weld of galvannealed steel and pure aluminium

Laser pressure welding was conducted by changing the laser power and the roller pressure in the previous experiment. It was revealed that dissimilar metal welding of galvannealed steel and pure aluminium was feasible in a wide range of welding conditions. When the roller pressure was more than 1.96 kN at the laser powers equal to or less than 1400 W, the joint strengths were so high that the specimens in the tensile shear and the peel tests fractured in the A1050 parent metal.

In order to know the reason for such high strengths of joints with thick compound layers and the joining mechanism, the compound layer was observed by HR-transmission electron microscopy (TEM). The TEM observation results revealed that the main phase in the compound layer was the solid solution of Al + Zn. Moreover, the intermetallic compound was identified as FeAl, Fe₂Al₅, Fe₄Al₁₃ and Fe₂Al₅Zn_0.4 phase by electron diffraction. The Fe₃Zn₁₀ (Γ phase) of Fe–Zn intermetallic compound was confirmed on a Fe base material. It is guessed that the joining areas were heated at a range of 782°C more than 665°C, a melting point of Al, by laser irradiation because the δ_lk phase aspect was not confirmed. Because the surfaces of A1050 and Zn plated layer were melted thinly, the layer was over 10 μm thicker. The reason for the production of high-strength joints with a relatively thick intermetallic compound layer was attributed to the formation of (Al + Zn) phase with finely dispersed intermetallic compounds.     

High permittivity BaTiO3 and BaTiO3-polymer nanocomposites enabled by cold sintering with a new transient chemistry: Ba(OH)2∙8H2O

Cold sintering process (CSP) offers a promising strategy for the fabrication of innovative and advanced high permittivity dielectric nanocomposite materials. Here, we introduce Ba(OH)₂?8H₂O hydrated flux as a new transient chemistry that enables the densification of BaTiO₃ in a single step at a temperature as low as 150 °C. This remarkably low temperature is near its Curie transition of 125 °C, associated with a displacive phase transition. The cold sintered BaTiO₃ shows a relative density of 95 % and a room temperature relative permittivity over 1000. This new hydrated flux permits the fabrication of a unique dense BaTiO₃-polymer nanocomposite with a high volume fraction of ceramics ((1-x) BaTiO₃ – x PTFE, with x = 0.05). The composite exhibits a relative permittivity of approximately 800, at least an order of magnitude higher than previous reports on polymer composites with BaTiO₃ nanoparticle fillers that are typically well below 100. Unique high permittivity dielectric nanocomposites with enhanced resistivities can now be designed using polymers to engineer grain boundaries and CSP as a processing method opening up new possibilities in dielectric materials design.     

AC side harmonic and phenomena accompanying DC-injection of utility-interactive PV system

The experiments investigated phenomena related to direct contact between the DC output of a PV array and the AC power from the utility grid. The results show that the DC power flows through the distribution transformers (DC-injection) saturating their magnetic circuits. The saturation of magnetic circuits makes peak currents, incorporating a large portion of even harmonics, flow through the high-voltage side of the distribution transformer, adding the level of harmonic distortion of its exciting current. With the increase of injecting DC-current to the utility grid, peak currents at the primary side of distribution transformer increases the most, and even among the same effective (rms) values, the increase of primary side current is larger than that of the secondary side current.     

Tilt angle dependence of output power in an 80 kWp hybrid PV system installed at Shiga in Japan

One-year field experience of an 80 kW PV system on a rooftop of the ROHM Memorial VLSI Research Center at the Ritsumeikan University is reported. All kinds of live technology available materials, c-Si, poly Si and a-Si solar cells are installed on the three tilt angles of 26.5° south, horizontal and north 26.5°. Systematic PV performances have been measured from the beginning of June 2000 to the end of May 2001. Measurements were made mainly on DC output power from four kinds of PV arrays; c-Si south side, a-Si of horizontal and poly Si, a-Si north side. It has been shown from analyses of monthly data on each material that almost 70% of with that in the south side in the annual average. In summer a-Si module yields the maximum output power normalized to 1 kWp. On the contrary c-Si module shows larger output in winter. Some other unique results are demonstrated and discussed.     

Molecular dynamics simulation of dislocation nucleation and motion at γ/γ′ interface in Ni-based superalloy

Molecular dynamics simulations are conducted on the dislocation behavior at the apices and edges of cuboidal Ni₃Al precipitate in a pure Ni matrix, or the idealized γ/γ′ microstructure in a Ni-based superalloy. A tensile simulation of the [001] direction is implemented with a periodic cell that has eight cubic precipitates in order to investigate the nucleation site of dislocation in the idealized microstructure with no defects other than the γ/γ′ interfaces. The effect of residual internal stresses on the stability of the interfaces is also discussed. Other simulations are conducted on the behavior of edge dislocations nucleated from a free surface and proceeding in the γ matrix toward γ′ precipitates under shear force. Dislocation pinning at γ′ precipitates, bowing-out in the γ channel, pile-up and nucleation of superdislocation in the γ′ precipitate are simulated and inspected in detail. Discussions on the size of the γ/γ′ microstructure and the sharpness of the edge of the γ′ precipitate are also presented.     

Optimization of heat sink geometries for impingement air-cooling of LSI packages

This paper describes the use of our previous study's prediction procedures for calculating thermal resistance and pressure drop. The procedures are used in the optimization of heat sink geometries for impingement air-cooling of LSI packages. Two types of heat sinks are considered: ones with longitudinal fins and ones with pin fins. We optimized the heat sink geometries by evaluating 16 parameters simultaneously. The parameters included fin thickness, spacing, and height. For the longitudinal fins, the optimal fin thicknesses were found to be between 0.12 and 0.15 mm, depending on which of the four types of fans were used. For pin fins, the optimal pin diameters were between 0.39 and 0.40 mm. Under constant pumping power, the optimal thermal resistance of the longitudinal fins was about 60% that of the pin fins. For both types of heat sinks, the optimal thermal resistance for four off-the-shelf fans was only slightly (maximum about 1%) higher than the theoretical optimum for the same pumping power. When manufacturing cost performance is considered, the most economical fin thickness and diameter are about 5 to 10 times higher than the optimal values calculated without respect for manufacturing costs. These values almost correspond to the actual limits of extrusion and press heat-sink manufacturing processes. © 1999 Scripta Technica, Heat Trans Asian Res, 28(2): 138–151, 1999     

THERMALLY INDUCED STRESS WAVES IN FUNCTIONALLY GRADED MATERIALS WITH TEMPERATURE-DEPENDENT MATERIAL PROPERTIES

This article is concerned with the dynamic treatment of thermally induced stress waves in an infinite elastic plate subjected to impulsive electromagnetic radiation. The plate is assumed to be a functionally graded material (FGM), meaning that the material is composed of multiconstituents in ceramics and metals, the volume fractions of which distribute continuously inside the material. The mathematical problem is one of wave propagation in a typical nonhomogeneous material The radiation absorption is assumed to occur at a constant rate for the duration of the pulse and to diminish exponentially with distance from the surface of the plate, assuming negligible heat conduction. In treating problems, the nature of the stress-wave buildup in the plate is studied for the case of a temperature-dependent solid, that is, when material properties vary with temperature. The numerical procedure employs the characteristic method based on the integration of the governing equations along the characteristics. Numerical calculations are carried out for ceramic-metal FGM plates showing the influences of the temperature-dependent material properties and the volume fractions of the phases composing the FGM on the magnitude of the dynamic thermal stresses.     

OPTIMIZATION OF MATERIAL COMPOSITION OF FUNCTIONALLY GRADED PLATE FOR THERMAL STRESS RELAXATION USING A GENETIC ALGORITHM

In this article, a genetic algorithm is applied to an optimization problem of material composition for a plate of step-formed functionally graded materials. The step-formed functionally graded plate is analyzed as a laminated composite plate made of numerous layers with homogeneous and different isotropic material properties. First, the onedimensional transient temperature distribution for a laminated plate is analyzed theoret ically. In addition, the thermal stress components for such an infinitely long plate are formulated under the mechanical condition of being traction-free. As a numerical example, a plate composed of zirconium oxide and titanium alloy is considered. In addition, for the optimization problem of minimizing the thermal stress distribution, the numerical calculations are made using a genetic algorithm without supposing a distribution function of material composition and the optimal material composition of each layer is determined taking into account the effect of the temperature dependency of material properties. Furthermore, the results obtained when a distribution function isn't specified and the results found when a distribution function is specified are compared.     

A demonstrative study for the wind and solar hybrid power system

In March 1995, a small scale wind and solar hybrid power system was installed at Ashikaga Institute of Technology. Until now, the authors have acquired the data of the output of the hybrid power plant along with wind speed, wind direction, and the solar radiation, in order to demonstrate a complementary relationship between solar energy and wind energy.After nine months operation of the system, the authors confirmed that there exists a complementary relationship between solar energy and wind energy. We also found, however, that the power output by wind does not have much prospect compared to that by solar cell especially in summer season in Ashikaga area.