Microstructural modeling approach applied to rock material

The importance of the microstructural parameters in rock mechanical behavior has been investigated by several authors. Moreover, the Weibull statistical model has been used to characterize the heterogeneity of several materials on the basis of the concept that the microscopic defects within the material determine their mechanical strength. The modeling of different rocks is a topic that is fundamental for the prediction of rock fragmentation. In this article, the analysis of rock microstructure is performed using the microstructural modeling approach, which consists of the simplification, quantification, and modeling of the main properties of rock microstructure. The grain size, grain shape, and microcracks are modeled by means of statistical density functions, namely, Cauchy, chi-squared, exponential, extreme value, gamma, Laplace, normal, uniform, and Weibull. It is found that the Weibull distribution is the most appropriate statistical model of the grain size and grain shape, when compared with the other eight statistical models. Regarding microcracks, the results show that the gamma distribution is the most appropriate model. The Weibull and gamma distributions are then used to analyze the heterogeneity of the microstructure. This is done by comparison of the statistical models of each microstructural property evaluated in several thin sections of the same rock. It is found that with respect to grain size and grain shape, the rock is homogeneous, while the size distribution of the microcracks shows a clear trend toward less homogeneity. The microstructural modeling approach is important for modeling, characterizing, and analyzing the microstructure of rock material. Among other applications, it can be used to explain differences in the mechanical behavior obtained in testing several specimens.     

Adaptive control optimization in end milling using neural networks

In this paper, we propose an architecture with two different kinds of neural networks for on-line determination of optimal cutting conditions. A back-propagation network with three inputs and four outputs is used to model the cutting process. A second network, which parallelizes the augmented Lagrange multiplier algorithm, determines the corresponding optimal cutting parameters by maximizing the material removal rate according to appropriate operating constraints. Due to its parallelism, this architecture can greatly reduce processing time and make real-time control possible. Numerical simulations and a series of experiments are conducted on end milling to confirm the feasibility of this architecture.     

Properties of Co-doped N-type FeSi2 processed by mechanical alloying

Iron-silicide was produced with a mechanical alloying process and consolidated through vacuum hot pressing. The as-milled powders were of metastable state and fully transformed into the ß-FeSi₂ phase through subsequent isothermal annealing. The as-consolidated iron silicides consisted of an untransformed mixture of α-Fe₂Si₅ and ?-FeSi phases and a partially transformed β-FeSi₂ phase was found in the low density compact. Isothermal annealing was carried out to induce transformation into a thermoelectric semiconducting β-FeSi₂ phase. The transformation behavior of the β-FeSi₂ was investigated utilizing DTA, SEM, and XRD analyses. Isothermal annealing at 830°C in vacuum led to a thermoelectric semiconducting β-FeSi₂ phase transformation, but some residual metallic α and ?-phases were unavoidable even after 96 hours of annealing. The iron silicide microstructures were investigated using SEM and TEM. The mechanical and thermoelectric properties of the β-FeSi₂ materials before and after isothermal annealing are characterized in this study.     

A study of the corrosion properties of plasma nitrocarburized and oxidized AISI 1020 steels

Plasma nitrocarburized AISI 1020 steels were oxidized for 15, 30 and 60 min to evaluate their corrosion and microstructural properties. After plasma nitrocarburizing for 3 h at 570°C in a gas mixture comprising 85 vol.% N₂, 12vol.% H₂ and 3 vol.% CH₄, the compound layer composed of ɛ-Fe_2–3(N,C) and γ’-Fe₄(N,C) phases and the diffusion layer above the matrix were observed. The top oxide layer, consisting mainly of magnetite (Fe₂O₄) and hematite (Fe₂O₃) phases, forms after post-oxidation treatment at 500°C. However, the oxide layer was severely degraded by spallation as a result of increases in post-oxidizing time. The difference in corrosion resistance should be attributed to the thickness of the top oxide layer, which was governed by post-oxidizing time.     

镁基复合材料微区力学状态的有限元分析

弹性变形范围内,在采用三维有限元模型分析了颗粒增强Mg基复合材料(PRMMCs)中,颗粒的分布形态对材料微区力学状态的影响。结果表明,在保持颗粒长径比(2:1)和颗粒间距(d)不变的情况下,随着θ的变化,不存在颗粒断裂的危险,材料的主要失效方式为界面脱离和基体开裂。增强体相对夹角θ=15o时的结果优于其它情况,这更有利于充分发挥材料的性能。     

Nanostructured component fabrication by electron beam-physical vapor deposition

Fabrication of cost-effective, nano-grained net-shaped components has brought considerable interest to Department of Defense, National Aeronautics and Space Administration, and Department of Energy. The objective of this paper is to demonstrate the versatility of electron beam-physical vapor deposition (EB-PVD) technology in engineering new nanostructured materials with controlled microstructure and microchemistry in the form of coatings and net-shaped components for many applications including the space, turbine, optical, biomedical, and auto industries. Coatings are often applied on components to extent their performance and life under severe environmental conditions including thermal, corrosion, wear, and oxidation. Performance and properties of the coatings depend upon their composition, microstructure, and deposition condition. Simultaneous co-evaporation of multiple ingots of different compositions in the high energy EB-PVD chamber has brought considerable interest in the architecture of functional graded coatings, nano-laminated coatings, and design of new structural materials that could not be produced economically by conventional methods. In addition, high evaporation and condensate rates allowed fabricating precision net-shaped components with nanograined microstructure for various applications. Using EB-PVD, nano-grained rhenium (Re) coatings and net-shaped components with tailored microstructure and properties were fabricated in the form of tubes, plates, and Re-coated spherical graphite cores. This paper will also present the results of various metallic and ceramic coatings including chromium, titanium carbide (TiC), titanium diboride (TiB₂), hafnium nitride (HfN), titanium-boron-carbonitride (TiBCN), and partially yttria stabilized zirconia (YSZ) TBC coatings deposited by EB-PVD for various applications. This paper was presented at the International Symposium on Manufacturing, Properties, and Applications of Nanocrystalline Materials sponsored by the ASM International Nanotechnology Task Force and TMS Powder Materials Committee, October 18–20, 2004, Columbus, OH.     

The assessment of thermal history in pressure vessel steel

A component of the present work involves attempts to simulate the microstructures of 1Cr-0.5Mo steel sample removed from service after extended exposure to elevated temperatures (10⁵ h at 535°C). The aim is to establish a basis for assessing the thermal history of service components and service weldments. Previous work has established that it is not possible to adequately simulate service microstructures using accelerated isothermal heat treatments alone. A selective mechanical testing program at elevated temperature has thus been investigated to superimpose the effect of stress on heat treatment. Qualitative comparison within each of these sets of micrographs suggests that the intraferritic precipitation in the creep samples is in each case refined and of a higher density compared to the sample subjected to isothermal heat treatments. It has been suggested that a comparison of the composition of the pearlitic M₃C in creep test samples with the empirical relationship may provide a means of assessing the average thermal history of the ex-service sample.     

Sampling strategy design for dimensional measurement of geometric features using coordinate measuring machine

Dimensional measurement using a coordinate measuring machine (CMM) has been commonly adapted in advanced manufacturing environments to ensure that manufacturing products have high quality and reliability. To conduct dimensional inspection effectively in a computer-integrated manufacturing (CIM) environment, there is an urgent need to derive a sampling strategy which can be used to specify a set of measuring points that lead to accurate sampling while minimizing the sampling time and cost. Owing to the variations in characteristics of geometric features and manufacturing processes, different feature surfaces on a workpiece usually have different variations in their dimensional accuracy and surface finish. The variations may differ considerably from one surface to another, even though those surfaces may share the same feature. Therefore, the variation in dimensional accuracy and surface finish should be considered in determining the proper sampling size for each geometric feature generated by various processes with different production parameters. In this paper, a feature-based methodology which integrates the Hammersley sequence and a stratified sampling method are developed to derive the sampling strategy for various geometric features which have specified measuring points. Case studies are used to compare the effectiveness of Hammersley sequence sampling, uniform (systematic) sampling and random sampling. The results show that the derived sampling strategy based on the Hammersley sequence leads to a nearly quadratic reduction in the number of samples compared with the uniform sampling method, and hence units of time and cost, while maintaining the same level of accuracy. The derived sampling strategy also shows a better performance when compared with the random sampling method.     

The distribution of grain boundary planes in polycrystals

During the last ten years, techniques have been developed to measure the distribution of grain boundaries in polycrystals as a function of both lattice misorientation and grain boundary plane orientation. This paper presents a brief overview of the techniques used for these measurements and the principle findings of studies implementing these techniques. The most significant findings are that grain boundary plane distributions are anisotropic, that they are scale invariant during normal grain growth, that the most common grain boundary planes are those with low surface energies, that the grain boundary populations are inversely correlated with the grain boundary energy, and that the coincident site lattice number is a poor predictor of the grain boundary energy and population.     

The atomic age challenge to steel

Some months ago the submarine Nautilus was in dock for refueling. It had traveled 60,000 miles, but the total uranium used would make a lump smaller than a light bulb. This is only one example that the Atomic Age is here with us, now! How and where does this incredible Atomic Age challenge the first and greatest of America’s basic industries?