A new cladding technology to bond aluminium on magnesium

ABSTRACT

An in situ hot press bonding technology has been developed to clad aluminium on magnesium. Followed by regular hot rolling, magnesium sheets, covered by ductile and corrosion-resistant aluminium without detectable oxides in the interface, are produced. The new technology requires no welding, vacuum, protective atmosphere or barrier layer, and it makes good interfacial strength and rollability. Aluminium–magnesium intermetallic phases are formed along the clad–core interface at elevated temperatures. They are not detrimental under compression but may cause clad-core delamination in tensile strain. However, the tensile failure is more dependent on the formability of magnesium core than on the strength of interface.     

Microstructure and Wear Behaviors of Plasma-Sprayed FeCrNiMoCBSi Coating with Nano-Grain Dispersed Amorphous Phase in Reciprocating Sliding Contact

A novel FeCrNiMoCBSi amorphous/nanocrystalline coating was fabricated using a plasma spraying process. The coating was dense with a low porosity of approximately 0.99%. The coating consisted of a 67.8 vol% amorphous phase coupled with many nanocrystalline grains that were approximately 5?nm in diameter. The mechanical properties of the as-sprayed coating were determined by nanoindentation measurement, and the tribological behaviors were systematically investigated in a reciprocating sliding contact. The results show that FeCrNiMoCBSi coatings possess superior wear resistance compared to other typically similar Fe-based amorphous coatings. The tribological behaviors evolve with the combination of normal load and sliding velocity. Herein, the dominant wear mechanisms are delamination wear and oxidation wear. With an increase in normal load and sliding velocity, the abrasive wear is gradually weakened, the formation of oxide films on the worn surfaces is facilitated, and wear debris is ground to powder. The oxide films suffer from fatigue wear with induced cracks undergoing reciprocating sliding effects.     

The unlubricated wear of sintered steels

The unlubricated wear of 10.3% porosity sintered medium-carbon and 12.8% porosity sintered low-alloy steels was investigated under different sliding conditions. Their wear characteristics were found to be similar to their non-sintered counterparts. Within this range of sliding conditions, both mild-oxidational and delamination wear took place, with the former dominating the wear processes. The oxide debris produced changed with the applied load: switching from a low-temperature oxide to a high-temperature one at higher loads. The wear rates agreed reasonably well with Archard's law and with data from other sources, suggesting that Archard's law can account for the wear rates produced by both mild-oxidational wear and delamination wear. This agreement also suggests that within the range of porosites investigated an overall framework can be established in the unlubricated wear of both sintered and non-sintered steels.     

Delamination‐Free Functional Graphene Surface by Multiscale,Conformal Wrinkling

Obtaining a delamination‐free wrinkled functional graphene surface in layered systems is an interesting challenge because the interface is usually too weak to withstand interfacial stress mismatch, which can trigger mechanical instability. In this paper, a general strategy is proposed toward addressing the delamination limitation imposed by fabricating conformal graphene wrinkles with bilayer systems of poly(methyl methacrylate) (PMMA) and polydimethylsiloxane (PDMS). To improve the interfacial strength, a postcuring transfer process is introduced to form a gradient interface layer without interfacial liquid between the PMMA and PDMS by entanglement of polymer chains during high‐temperature curing. Compared to the conventional wet transfer of graphene,the transfer method can greatly enhance the interfacial strength. The chemical and mechanical mechanisms underlying the enhancement are revealed both experimentally and theoretically in terms of the transition from the buckled‐induced delamination state to the delamination‐free wrinkled state. Moreover, the light diffraction behaviors of multiscale graphene wrinkles are initially demonstrated to be an interesting continuous pattern induced by overlapping. The delamination‐free conformal wrinkled functional graphene surface can provide valuable insight and design guidelines for the fundamental problems of deformed graphene and its applications in flexible functional devices.     

Eddy Current Testing of Delamination in Carbon Fiber Reinforced Polymer (CFRP): A Finite Element Analysis

Carbon fiber reinforced polymer (CFRP) is widely used thanks to its excellent material properties. However, damages, especially delamination, can cause significant reduction in strength of CFRP structures. This article attempts to study the nondestructive testing of delamination using eddy current (EC) method. To this end, we design a novel probe consisting of dual coplanar rectangular coils placed perpendicular to sample surface, and make use of the vertical sections of the coils to induce vertical EC in the test sample. Perturbation of the vertical EC by delamination gives us a chance to detect delamination. Simulation results by the finite element method demonstrate the feasibility of the proposed method.     

Numerical Modeling of Exit-Ply Delamination During Drilling of CFRPs Considering Thermal Effects

Abstract

A finite element (FE) model for exit-ply delamination during drilling carbon fiber reinforced polymers (CFRPs) laminates is presented. The current FE model is developed to predict critical thrust force at the onset of delamination for 1 and 2 plies under the twist drill for various cutting temperatures. The interface behavior for delamination onset is modeled using surface based cohesive zone model (CZM). The numerical predictions for critical thrust force are compared with experimental thrust forces for various number of plies under the twist drill over a range of cutting temperature. Thrust force predictions were found to match with experimental data.     

分层对复合材料机械连接结构承载能力的影响

针对含孔边分层复合材料沉头螺栓连接结构,通过挤压试验及有限元仿真,研究了孔边分层对复合材料连接结构力学性能的影响。通过连接孔的挤压试验,得到了不同类型试验件的承载能力与破坏模式。有限元仿真中,基于ABAQUS有限元分析软件建立了复合材料机械连接的三维有限元模型,进行复合材料渐进失效损伤模拟,并采用内聚力单元来模拟预制分层。有限元计算得到载荷-位移曲线和变形模式与试验吻合较好,从而验证了有限元模型的有效性。在此基础上,分析了含孔边分层的复合材料机械连接结构的破坏机制,并研究了分层位置、分层面积大小和分层形状对该结构承载能力的影响。研究表明：复合材料的破坏始于沉头孔中的直孔区域,且当预制分层位于直孔区域时,结构的承载能力最低;分层形状为圆形和正方形时,会严重影响结构的承载能力,分层形状为椭圆形时,对承载能力影响较低。无论分层形状如何变化,分层总是从受挤压的一侧开始,以半圆弧的形状向受挤压方向进行扩展。     

复合材料L型端框的失效行为

本文将某典型复合材料结构舱体的L型端框简化为单点连接的L型端框试件,通过试验和仿真分析,对试件拉伸载荷工况下的失效形式和承载能力进行了研究。结果表明,拉伸载荷工况下,L型端框失效形式以分层和基体破坏为主,试验与仿真分析承载力偏差为10.1%,具有良好的一致性。依据研究结果,对复合材料L型端框设计进行改进,通过试验发现,连接点局部粘接金属垫片可以有效提升复合材料L型端框的拉伸承载能力。本文的研究结果可作为复合材料L型端框设计的参考。     

Investigation of the 2D assumption in the image‐based inertial impact test

The image‐based inertial impact (IBII) test has shown promise for measuring properties of composites at strain rates where existing test methods become unreliable due to inertial effects (> 10² s^?1 ). Typically, the IBII tests are performed with a single camera, and therefore, to use surface measurements for material property identification, it is necessary to assume that the test is two‐dimensional. In this work, synchronised ultra‐high‐speed cameras are used to quantify the relevance of this assumption when nonuniform, through‐the‐thickness loading is applied to interlaminar samples. Initial experiments revealed that an angular misalignment of approximately 1° between the impact faces of the waveguide and projectile created a bending wave that propagated along the sample behind the axial pulse. Even under these conditions, consistent measurements of stiffness were made by assuming a linear distribution of the behaviour through‐the‐thickness. When the misalignment was reduced to 0.2°, the effects on single‐sided measurements were significantly reduced. The two alignment cases were compared to show that three‐dimensional loading had a small effect on stiffness identification (approximately 5% bias) relative to failure stress (approximately 30% bias). This study highlights the importance of impact alignment for reliable characterisation of the interlaminar failure stress and was used to establish guidelines for diagnosing loading issues from single‐sided measurements.     

Experimental investigation and optimization of machining parameters in drilling of fly ash-filled carbon fiber reinforced composites

Particle-filled polymer composites have become attractive because of their wide applications and low cost. Carbon fiber reinforced polymer (CFRP) is well known as a difficult-to-cut material, which has very strong physical and mechanical characteristics. Machining of carbon fiber reinforced composites is essential to have functional upshots, out of which drilling is the key operation needed for fabrication. In this paper Taguchi L₂₇ experimental design is coupled with grey relational analysis (GRA) to optimize the multiple performance characteristics in the drilling of fly ash-filled carbon fiber reinforced composites. Experiments were conducted on a vertical machining center, and Taguchi L₂₇ experimental design was chosen for the experiments. The drilling parameters, namely spindle speed, feed rate, drill diameter and wt% of fly ash, have been optimized based on the multiple performance characteristics including thrust force, surface roughness, and delamination. The GRA with multiple performance characteristics indicates that the wt% of fly ash and drill diameter are the most significant factors that affect the performance. Experimental results have shown that the performance in the drilling process can be improved effectively by using this approach.