Fatigue assessment of cut edges in high strength steel – Influence of surface quality

The influence of surface roughness on the fatigue strength in high strength steels and different cutting processes are studied. Fatigue testing is conducted on S700 and S960 material for different plate thicknesses cut in dog bone specimens using oxygen, plasma, laser and waterjet cutting. The surface roughness is measured for all specimens and residual stress measurements are carried out. Estimations of the fatigue strength are made based on the measured surface roughness and the ISO 9013:2002 standard for thermal cutting quality tolerances. The testing shows a 15–70 % increase in the fatigue strength compared to the estimation, proving a weak connection between the surface quality levels in ISO 9013:2002 and the fatigue test results. Different codes and design recommendations (IIW, EC3 and EN 13001) for fatigue strength of cut surfaces are compared with the fatigue test results which clearly shows an increased fatigue strength with enhanced quality and steel grades. However, the codes and design recommendations do not allow for any fatigue strength improvement with improved quality and increased yield strength.     

Analysis of the drude model in metallic films

A method, believed to be new, to simulate Drude parameters for collective oscillation of the free carriers in metallic films is proposed. Plasma resonance frequency and relaxation were simulated simultaneously from both the real and the imaginary parts of the dielectric function of a metallic film after consideration of their correlation in the Drude model. As examples, the contributions of the electrons in Ag films and of the free carriers in metallic silicide, NbSi(2) and TaSi(2), films have been studied.     

Corrosion susceptibilities of various metals and alloys in synthetic geothermal brines

The corrosion susceptibilities of various pure metals and alloys were investigated in synthetic geothermal fluids. Rates of corrosion of AISI 1010 steel, types 304 and 316 stainless steels, Monel 400 and nickel were determined at three temperatures (296, 333 and 368 K); and those of the molybdenum, niobium and titanium were determined at 368 K only. Type 304 stainless steel appears to undergo an active-passive transition at a temperature range between 333 and 368 K. In the passive state type 304 steel has essentially the same corrosion rate as type 316. At 368 K the corrosion rate of pure nickel was approximately 2.5 times that of Monel, which in turn was twice that of type 316 stainless steel. The corrosion rates of Mo, Nb and Ti were less than one mdd at the highest experimental temperature.     

Properties of shrinkage-reducing admixture-modified pastes and mortar

A comprehensive study on the influence of a shrinkage-reducing admixture (SRA) on properties of ordinary Portland cement and shrinkage-compensating cement has been conducted. The properties investigated include: electrical resistivity, hydration heat rate, free shrinkage and restrained shrinkage cracking. It is found that the shrinkage-reducing admixture (SRA) can reduce the free shrinkage and postpone the occurrence of shrinkage crack significantly. The SRA has also an effect to retard the hydration process of Portland cement under normal condition. However, under semi adiabatic condition, it seems that SRA accelerates the hydration process. A new concept of the hardening ratio, ρ _H , is proposed in the study. It is indicated that the hardening ratio, ρ _H , and compressive strength development have very good linear relationship.     

Al2O3 and TiO2 atomic layer deposition on copper for water corrosion resistance

Al(2)O(3) and TiO(2) atomic layer deposition (ALD) were employed to develop an ultrathin barrier film on copper to prevent water corrosion. The strategy was to utilize Al(2)O(3) ALD as a pinhole-free barrier and to protect the Al(2)O(3) ALD using TiO(2) ALD. An initial set of experiments was performed at 177 °C to establish that Al(2)O(3) ALD could nucleate on copper and produce a high-quality Al(2)O(3) film. In situ quartz crystal microbalance (QCM) measurements verified that Al(2)O(3) ALD nucleated and grew efficiently on copper-plated quartz crystals at 177 °C using trimethylaluminum (TMA) and water as the reactants. An electroplating technique also established that the Al(2)O(3) ALD films had a low defect density. A second set of experiments was performed for ALD at 120 °C to study the ability of ALD films to prevent copper corrosion. These experiments revealed that an Al(2)O(3) ALD film alone was insufficient to prevent copper corrosion because of the dissolution of the Al(2)O(3) film in water. Subsequently, TiO(2) ALD was explored on copper at 120 °C using TiCl(4) and water as the reactants. The resulting TiO(2) films also did not prevent the water corrosion of copper. Fortunately, Al(2)O(3) films with a TiO(2) capping layer were much more resilient to dissolution in water and prevented the water corrosion of copper. Optical microscopy images revealed that TiO(2) capping layers as thin as 200 ? on Al(2)O(3) adhesion layers could prevent copper corrosion in water at 90 °C for ~80 days. In contrast, the copper corroded almost immediately in water at 90 °C for Al(2)O(3) and ZnO films by themselves on copper. Ellipsometer measurements revealed that Al(2)O(3) films with a thickness of ~200 ? and ZnO films with a thickness of ~250 ? dissolved in water at 90 °C in ~10 days. In contrast, the ellipsometer measurements confirmed that the TiO(2) capping layers with thicknesses of ~200 ? on the Al(2)O(3) adhesion layers protected the copper for ~80 days in water at 90 °C. The TiO(2) ALD coatings were also hydrophilic and facilitated H(2)O wetting to copper wire mesh substrates.     

Modified diffraction theory of Kirchhoff

The diffraction theory of Kirchhoff is reinterpreted and a new form of a surface diffraction integral is developed by using the axioms of the modified theory of physical optics, which leads to the exact scattered fields by conducting bodies. The new integral is arranged according to the interpretation of Young, and the diffracted waves are expressed in terms of a line integral. The method is applied to the diffraction problem by a semi-infinite edge contour.     

Investigation of small fatigue crack initiation and growth behaviour of nickel base superalloy GH4169

Surface replication method was utilized to monitor the small fatigue crack initiation and growth process of single‐edge‐notch tension specimens fabricated by nickel base superalloy GH4169. Three different stress levels were selected. Results showed that small fatigue cracks of nickel base superalloy GH4169 initiated from grain boundaries or surface inclusions. The small fatigue crack initiation and growth stages took up about 80–90% of the total fatigue life. Multiple major cracks were observed in the notch root, and specimen with more major cracks seemed to have smaller fatigue life under the same test conditions. At the early growth stage, small crack behaviour might be strongly influenced by microstructures; thus, the crack growth rates had high fluctuations. However, the stress level effect on the small fatigue crack growth rates was not distinguishable for the three different stress levels. And no clear differences were found among the crack initiation lives by using replication technique.     

Writer pole tip remanence in perpendicular recording

We studied the remanent field from perpendicular writer pole tips by micromagnetic modeling. The pole tip remanence has two causes: 1) the residual flux from the yoke due to undesirable material properties and/or yoke design and 2) the geometry of the pole tip. An optimal yoke design for low remanence includes a wide and short yoke with relatively shallow yoke flare angle around 30/spl deg/ that favors transverse major domains. Horizontal anisotropy in the yoke and the pole tip also helps suppress the vertical magnetization, mainly in the yoke, which yields less residual flux into the pole tip, hence lower remanence. The remanent field is also a strong function of the throat height, i.e., the pole tip length, due to the shape anisotropy effect. Micromagnetic modeling shows that multilayer lamination, both in the yoke and in the pole tip, is an effective way to achieve low remanence. It also eliminates the sensitivity of remanence to the throat height. To improve the robustness of the remanence against the stray field, an antiferromagnetic coupling (AFC) between the lamination layers may also be necessary. Our results apply to both single pole heads and shielded pole heads.     

A prediction method for fatigue life of large moving components as function of scale factor: A case of motor‐generator rotor

With the development of science and technology, more and more large moving components have been used in industry, and their service lives have become an important issue. After analysis of the previous results, considering the scale factor, a prediction method for fatigue life of large moving components based on the Basquin relation was proposed at first, and then the magnet pole part of motor‐generator rotor was chosen to make simulation parts with different scale factors mainly in terms of their S‐N curves and fractographies. It was found that with the change of specimen scale factor, the stress concentration factor at transition arc is almost unchanged as well as the fatigue strength exponent, and the fatigue strength coefficient changes linearly. Based on those results, a life prediction method was validated, and the results show that this method is a simple but more precise relation. After fatigue fracture surface and crack growth angle observations and quantitative analyses, the fatigue damage mechanisms associated with the relation among fatigue strength exponent and coefficient and scale factors were explained well. Those studies will provide a new clue to the prediction of the service life for those large moving components.