A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing

Simulating the transient temperature field in additive layer manufacturing (ALM) processes has presented a challenge to many researchers in the field. The transient temperature history is vital for determining the thermal stress distribution and residual stress states in ALM-processed parts that utilise a moving laser heat source. The modelling of the problem involving multiple layers is equally of great importance because the thermal interactions of successive layers affect the temperature gradients, which govern the heat transfer and thermal stress development mechanisms. This paper uses an innovative simulation technique known as element birth and death, in modelling the three-dimensional temperature field in multiple layers in a powder bed. The results indicate that the heated regions undergo rapid thermal cycles that could be associated with commensurate thermal stress cycles. Deposition of successive layers and subsequent laser scanning produces temperature spikes in previous layers. The resultant effect is a steady temperature build-up in the lower layers as the number of layers increases.     

Middleware and Metrology for the Pervasive Future

Looks at the data and metrology tools developed by The National Institute of Standards and Technology for the research community, including common middleware for distributed sensor data acquisition and processing.     

Sacrosidase therapy for congenital sucrase-isomaltase deficiency

BACKGROUND: The purpose of this study was to determine if sacrosidase, a liquid produced from Saccharomyces cerevisiae containing 6000 IU of sucrase activity per mg protein, prevented symptoms of diarrhea, abdominal cramps, gas, and bloating in patients with congenital sucrase-isomaltase deficiency (CSID) consuming a normal sucrose and carbohydrate-containing diet. METHODS: Twenty-eight children (aged 5 months to 11 years) underwent a randomized, double-blind trial consisting of two phases: 1) three sucrose breath H2 tests with three single-dose treatments (placebo, sacrosidase, and sacrosidase plus milk), and 2) a dose-response phase consisting of four multidose treatments, each for 10 days of full-strength sacrosidase, 1:10 dilution, 1:100 dilution, and 1:1000 dilution. Patients who weighed less than or equal to 15 kg received a dose of sacrosidase and those who weighed more than 15 kg received 2 ml. For the dose-response phase each patient consumed a normal diet. The number of stools and severity of symptoms were recorded daily for each concentration of sacrosidase administered and compared to a baseline period during which the patient took no sacrosidase and consumed a sucrose/starch-free diet. Data were analyzed using an ANOVA model and the nonparameter Wilcoxon signed-rank test. RESULTS: Breath H2 excretion decreased significantly when patients received sacrosidase or sacrosidase plus milk compared to placebo during sucrose breath tests. During the dose-response phase significant treatment differences were observed between the two higher concentrations and the two lower concentrations of sacrosidase for both total stools (p < 0.001) and total symptom score (p = 0.003). Higher concentrations of sacrosidase were associated with fewer stools and a greater number of formed or hard stools compared to lower concentrations and compared to the baseline period. Higher concentrations were also associated with fewer symptoms of gas, abdominal cramps, or bloating, but no differences in vomiting. The only significant adverse event was wheezing in one child with a history of asthma. CONCLUSIONS: Sacrosidase is a safe, effective, well-accepted treatment to prevent gastrointestinal symptoms in patients with CSID consuming a normal diet.     

The Effect of Nb Micro-alloying on the Bainitic Phase Transformation Under Strip Casting Conditions

The effect of Nb concentration on the transformation from austenite to bainitic ferrite has been examined under simulated strip casting conditions. Nb concentration was found to delay the nucleation of bainite, but accelerated its growth. It is suggested that the delay in nucleation increases the driving force for transformation, which results in an increase in the growth rate of the bainite. The bainite/austenite interfaces are proposed to move too quickly to suffer appreciable solute drag.     

Optimal actuation of nonlinear resonant systems

In this study, we examine a new approach for actuation of dynamical systems with minimum work and maximum amplitude while maintaining constraints on the actuation force. Two methodology issues are addressed in the paper: sensitivity analysis about the nonlinear transient response and exploration of the strongly nonlinear relationship between the two objectives and the actuation design variables. The optimization analysis is carried out on lightly damped Duffing systems. The formulation of the optimization problem is found ideally suited to resolve the difficulty of dependence of response on initial conditions. The tradeoff curve of work and amplitude is computed. The optimal actuation strove to compensate for the limited force amplitude by an abrupt change in the force in time. Finally the optimization procedure is demonstrated on the kinematic design of hovering insect flight. The optimal design gives 50% reduction in power consumption, with a larger cutback for an actuation with high acceleration.     

Effect of NbC and TiC precipitation on shape memory in an iron-based alloy

This paper examines the effects of TiC and NbC precipitation and prior cold rolling on the shape memory behaviour of an iron-based alloy. A precipitate-free alloy was used as a reference to investigate the relative contributions of prior-deformation and precipitation on shape memory. Heat treatment of the Nb- and Ti-containing alloys at 700 °C and 800 °C resulted in carbide precipitates between 120 nm and 220 nm in diameter. Bend testing of these samples showed a marginal increase in shape memory compared to the precipitate-free alloy. Under these conditions TiC precipitation exhibited slightly better shape memory than for NbC. However, this small increase was over-shadowed by the marked increase in shape memory that can be produced by subjecting the alloys to cold rolling followed by recovery annealing. When processed in this way, fine carbides are formed in the Ti- and Nb-containing alloys during the heat treatment. For particles >25 nm in diameter the shape memory is unaffected, but, it was found that small <5 nm particles have a detrimental effect on shape memory due to pinning of the martensite plates, thereby inhibiting their reversion to austenite. The optimum shape memory was observed in the precipitate-free alloy after cold rolling and recovery annealing.     

Effect of particle morphology on flow characteristics of a composite plasma spray powder

The effects of BaF₂-CaF₂ particle morphology on National Aeronautics and Space Administration (NASA) PS304 feedstock powder flowability were investigated, BaF₂-CaF₂ eutectic powders were fabricated by comminution (producing an angular morphology) and by gas atomization (producing a spherical morphology). The fluoride powders were added incrementally to the other powder constituents of the NASA PS304 feedstock, (Ni-Cr, Cr₂O₃, and Ag powders). A linear relationship between flow time and concentration of the BaF₂-CaF₂ powder was found. The flow of the powder blend with spherical BaF₂-CaF₂ was better than that with angular BaF₂-CaF₂. The flowability of the powder blend with angular fluorides decreased linearly with increasing fluoride concentration. However, the flow of the powder blend with spherical fluorides was independent of fluoride concentration. The results suggest that for this material blend, particle morphology plays a significant role in flow behavior, offering potential methods to improve powder flowability and enhance the commercial potential. These findings may be applicable to other difficult-to-flow powders such as cohesive ceramics.