Residual toughness of poly(acrylonitrile-butadiene-styrene) (ABS) after fatigue loading—effect of uniaxial fatigue loading

Toughness variation of non-notched poly(acrylonitrile-butadiene-styrene) (ABS) subjected to uniaxial fatigue loading was investigated. The experiments were conducted by applying fatigue loading to strip specimens first, from which dog-bone specimens were machined. The dog-bone specimens were tested to measure the strain for the on-set of fracture, named cracking strain here, thus to monitor the toughness change due to the fatigue loading.The test results showed that the fatigue loading caused the toughness drop in ABS, even before any visible crack was developed. Damage development and fracture behavior were then analyzed using scanning electron microscopy (SEM). The SEM analysis revealed that damage zones, not cracks, were initiated during the fatigue loading, and were the main cause of the toughness drop. Mechanisms for the damage initiation include matrix crazing and debonding of small rubber particles; however, large rubber particles remained intact. Based on the results, a deformation model is proposed for the damage zone initiation, which provides an explanation for the toughness change under the fatigue loading.     

Structural characterisation of apatite coatings

The current, most frequently employed, commercial route to produce hydroxyapatite prosthetic coatings is plasma spraying. However, this has several important limitations especially for textured surfaces. Low temperature methods of coating fabrication such as cathodic electrodeposition are attractive alternatives. However, quantitative characterisation of the phase composition of thin electrodeposited coatings can be problematic. An X-ray diffraction method, which provides quantitative compositional information without reference to external or internal standards, is introduced and validated. The method can also be applied when Bragg peaks from the supporting substrate are apparent within the data and preferred orientation can be tolerated. This method has been used to examine in detail the microstructure of electrodeposited coatings which are compared directly with those formed by a commercial plasma spraying process.We show that, unlike the plasma sprayed coatings, the electrodeposited material consists of a single crystalline phase (hydroxyapatite) and a significantly reduced amorphous phase. The electrodeposited coatings also possess significantly more microstrain and a smaller crystallite size than the corresponding plasma sprayed material.     

On the stabilizing behavior of zirconia: A Combined experimental and theoretical study

Reactive zirconia powder was synthesized by the complexation of zirconium metal from zirconium hydroxide using a solution of 8-hydroxiquinoline. The kinetics of zirconia crystallization was followed by X-ray diffraction, scanning electron microscopy and surface area measured by the nitrogen adsorption/desorption technique. The results indicated that zirconia with a surface area as high as 100 m²/g can be obtained by this method after calcination at 500°C. Zirconia presents three polymorphic phases (monoclinic, tetragonal and cubic), which are reversibly interconversible. The cluster model Zr₄O₈ and Zr₄O₇ ⁺² was used for a theoretical study of the stabilization process. The ab initio RHF method was employed with the Gaussian94 program and the total energies and the energy gap of the different phases were calculated and compared with the experimental energy gap. The theoretical results show good reproducibility of the energy gap for zirconia.     

A demonstration of melt rate control during VAR of “Cracked” electrodes

A particularly challenging problem associated with vacuum arc remelting occurs when trying to maintain accurate control of electrode melt rate as the melt zone passes through a transverse crack in the electrode. As the melt zone approaches the crack, poor heat conduction across the crack drives the local temperature in the electrode tip above its steady-state value, causing the controller to cut back on melting current in response to an increase in melting efficiency. The difficulty arises when the melt zone passes through the crack and encounters the relatively cold metal on the other side, giving rise to an abrupt drop in melt rate. This extremely dynamic melting situation is very difficult to handle using standard load-cell based melt rate control, resulting in large melt rate excursions. We have designed and tested a new generation melt rate controller that is capable of controlling melt rate through crack events. The controller is designed around an accurate dynamic melting model that uses four process variables: electrode tip thermal boundary layer, electrode gap, electrode mass and melting efficiency. Tests, jointly sponsored by the Specialty Metals Processing Consortium and Sandia National Laboratories, were performed at Carpenter Technology Corporation wherein two 0.43 m diameter Pyromet® 718 electrodes were melted into 0.51 m diameter ingots. Each electrode was cut approximately halfway through its diameter with an abrasive saw to simulate an electrode crack. Relatively accurate melt rate control through the cuts was demonstrated despite the observation of severe arc disturbances and loss of electrode gap control. Subsequent to remelting, one ingot was sectioned in the “as cast” condition, whereas the other was forged to 0.20 m diameter billet. Macrostructural characterization showed solidification white spots in regions affected by the cut in the electrode.     

The hypersonic environment: Required operating conditions and design challenges

Hypersonic flight powered by airbreathing engines offers the potential for faster response time at long ranges, and reduced cost for access-to-space. In the present paper the operating environment of typical hypersonic vehicles are discussed, including results for the radiation equilibrium wall temperature of external vehicle surfaces and the flow properties through three sample engines spanning the range of hydrocarbon-fueled Mach 4-8 flight and hydrogen-fueled flight at speeds up to Mach 17. Flow conditions at several locations through the sample engines were calculated to provide indications of the required operating flow environment. Additional system consideration such a seals, joints, vehicle integration and in-service engineering are addressed.     

Microscale wear of vitrified abrasive materials

The study of bonding hard materials such as aluminium oxide and cubic boron nitride (cBN) and the nature of interfacial cohesion between these materials and glass is very important from the perspective of high precision grinding. Vitrified grinding wheels are typically used to remove large volumes of metal and to produce components with very high tolerances. It is expected that the same grinding wheel be used for both rough and finish machining operations. Therefore, the grinding wheel, and in particular its bonding system, is expected to react differently to a variety of machining operations. In order to maintain the integrity of the grinding wheel, the bonding system that is used to hold abrasive grains in place will react differently to forces that are placed on individual bonding bridges. This paper examines the role of vitrification heat treatment on the development of strength between abrasive grains and bonding bridges, and the nature of fracture and wear in vitrified grinding wheels that are used for precision grinding applications.