Feasibility study of the ultrasonic vibration assisted drilling of Inconel superalloy

The ultrasonic vibration assisted drilling of Inconel 718 superalloy is studied in this paper. The tool holder of a machining center is retrofitted so that axial resonant vibration can be provided. Experimental results show that the chip size is reduced, and the variation of torque in drilling becomes smaller. These phenomena are particularly apparent at the final stage of a drill's usable life. It is also found that there is little improvement in drilling performance when the frequency of the ultrasonic vibration is varied. On the contrary, a drill's life is greatly increased when the vibration with a smaller amplitude is applied. But too large a vibration amplitude, such as over 12 μm in this study, could lead to negative effects. For the testing conditions, the frequency of 31.8 kHz and the amplitude of 4 μm result in the best drill life and quality of the drilled hole in this study. Under this condition a drill's life is prolonged by as much as 2.7 times of that without vibration assisted drilling process. Concerning drilling efficiency, it is found that by applying ultrasonic vibration assisted drilling, lifting of the drill for chip removal as commonly employed in conventional drilling of a high aspect ratio hole is not necessary, and saving of the working time is obtained.     

淬硬工具钢内圆表面磁性研磨加工实践与研究

磁性磨料研磨是一种较新的光整加工的方法，它是在S、N两极之间加入磁性磨料，磁性磨料吸附在磁极和工件表面上，并沿磁力线方向排列成有一定柔性的“磨料刷”，工件一边旋转，一边做轴向振动，以达到去除表层金属的目的，使工件表面粗糙度大大下降。本文介绍了磁性磨料研磨的加工原理，对工件在磁场中的受力情况进行理论分析。对淬硬工具钢(T8A)工件内圆表面进行磁性磨料研磨的加工试验．得出了不同的磁感应强度，不同加工间隙，以及不同研磨时间对加工表面粗糙度和研磨量的影响；从而得出了优化的磁性磨料研磨的加工参数：磁感应强度B=1．0—1．2T；加工间隙△=1-3mm；研磨时间t=4—5min。     

Nitrogen removal using recycled polystyrene bottles as biofilm media

The performance of an attached growth wastewater treatment process was investigated in an effort to improve nitrogen removal efficiency. Recycled Yakult (lactic acid fermentation drink) bottles made of polystyrene were used as a biofilm media. The use of Yakult bottles as a biofilm media has been attempted by numerous researchers in Japan for the removal of solids and organics. However, these studies focused only on the removal of solids and organics. This study extended their application to the removal of nitrogen for domestic sewage treatment. Yakult media was placed in a reactor with 70% apparent reactor volume in a conventional A/O process. The bottom of the Yakult media was removed, and randomly filled Yakult media were effectively able to reduce the flow in tanks, resulting in an increase in the contact time between pollutants and microorganisms. With higher HRT, the nitrogen removal efficiency was increased by up to 83% with 12 hr of HRT. Nitrification appeared to be the limiting factor of nitrogen removal at an HRT that is less than 12 hr, indicating that the Yakult process requires more retention time to achieve nitrification compared to other biofilm processes. The removal efficiencies of organics and solids were high regardless of the change of operational parameters. This article is based on a presentation in “The 7th Korea-China Workshop On Advanced Materials” organized by the Korea-China Advanced Materials Cooperation Center and the China-Korea Advanced Materials Cooperation Center, held at Ramada Plaza Jeju Hotel, Jeju Island, Korea on August 24–27, 2003.     

Thermal spray vitrification process for the removal of lead-based paint from steel structures: An applications note

Lead-based paints and primers have long been used to protect steel structures from corrosion, but are now recognized as environmental hazards. During lead-based paint removal via abrasive blasting, federal, state and local environmental requirements mandate the use of containment structures to prevent contamination of air, soil, or water. The thermal spray vitrification (TSV) process was developed and optimized in laboratory experiments to remove hazardous lead-based paint. TSV consists of thermal spraying a molten glass onto the painted surface. As the glass strikes the substrate, it reacts with the paint, and organic components are pyrolyzed, while lead ions are trapped on the glass surface. Quenching stresses in the glass cause it to crack and spall off the substrate. The resulting glass fragments are collected, and further remelted to completely immobilize lead (Pb) ions in the glassy iron (Fe) silicate matrix. The glass waste is thus rendered non-hazardous, as determined by the Toxicity Characteristic Leaching Procedure (TCLP). The TSV process was field tested on a fire hydrant, using minimal personal protective equipment and without using a containment structure. The lead-containing paint was removed, without producing hazardous waste, leaving de-painted surfaces suitable for repainting.     

High-throughput drilling of titanium alloys

Experiments of high-throughput drilling of Ti–6Al–4V at 183 m/min cutting speed and 156 mm³/s material removal rate (MRR) using a 4 mm diameter WC–Co spiral point drill were conducted. The tool material and geometry and drilling process parameters, including cutting speed, feed, and fluid supply, were studied to evaluate the effect on drill life, thrust force, torque, energy, and burr formation. The tool wear mechanism, hole surface roughness, and chip light emission and morphology for high-throughput drilling were investigated. Supplying the cutting fluid via through-the-drill holes has proven to be a critical factor for drill life, which can be increased by 10 times compared to that of dry drilling at 183 m/min cutting speed and 0.051 mm/rev feed. Under the same MRR of 156 mm³/s with a doubled feed of 0.102 mm/rev (91 m/min cutting speed), over 200 holes can be drilled. The balance of cutting speed and feed is essential to achieve long drill life and good hole surface roughness. This study demonstrates that, using proper drilling process parameters, spiral point drill geometry, and fine-grained WC–Co tool material, the high-throughput drilling of Ti alloy is technically feasible.     

低锡青铜镀层电解退除工艺

介绍低锡青铜镀层电解退除工艺及应用情况,并对影响因素和退镀机理进行探讨。工艺成分简单,溶液稳定,使用寿命长,底层不易腐蚀,退镀溶液可直接加入镀液使用。     

Finishing effects of spiral polishing method on micro lapping surface

This study presents a spiral polishing method and a device for micro-finishing purposes. This novel finishing process has wider application than traditional processes. This offers both automation and flexibility in final machining operations for deburring, polishing, and removing recast layers, thereby producing compressive residual stresses even in difficult to reach areas. Applying of this method can obtain a fine polished surface by removing tiny fragments via a micro lapping generated by transmission of an abrasive medium through a screw rod. The effect of the removal of the tiny fragments can be achieved due to the function of micro lapping. The method is not dependent on the size of the work-piece's application area in order to carry out the ultra precise process. The application of this research can be extended to various products of precision ball-bearing lead screw. The proposed method produces products with greater precision and more efficiently than traditional processes, in terms of processing precisions and the surface quality of products. These parameters used in achieving maximum material removal rate (MRR) and the lowest surface roughness (SR) are abrasive particle size, abrasive concentration, gap, revolution speed and machining time.     

钨合金的磨削加工去除机理

目的 解决钨合金磨削加工去除机理不明晰的问题。方法 基于单磨粒刻划有限元仿真、单磨粒刻划和磨削加工实验，探究钨合金的磨削加工去除机理。结果 在刻划过程中，划痕的不同位置材料的去除特性存在显著差异。在单颗粒刻划切入端，材料依次发生了塑性变形、隆起、微裂纹，再到钨相与黏结相的混杂交融。在划痕中段以材料去除为主，出现了材料微卷起和材料卷起现象，沿着刻划方向卷起现象越来越严重。在划痕切出端，划痕边缘和尾部均出现了“飞边”现象，且相较于切入端，切出端的形貌较差，实验与仿真吻合。此外，在不同相位处，材料的去除特性也存在一定不同。在钨相区域，同时存在脆性特征和塑性特征。在黏结相区域，刻划深度较浅时主要呈现塑性变形、塑性流动等特征，刻划中端深度较大时主要呈现与钨相的混杂和交融。在钨相与黏结相的相界处，相邻钨颗粒呈现不同的损伤或去除特征，且相界会阻断特征形貌的传递。最后，磨削后的钨合金表面存在单颗粒刻划痕上出现的所有去除特征，与单颗粒划痕的去除特征吻合。不同的是，磨削后划痕底部出现了区域性和放射状的裂纹。结论 钨合金的两相特性使得磨削表面的去除特征较复杂，存在塑性变形、微裂纹、微卷起、卷起、裂纹和两相交...     

Effects of blasting parameters on removability of residual grit

This article shows the quantitative evaluation of the residual grit on a blasted substrate, and the removability of the residual grit is examined. Carbon steel plates were blasted by white alumina grit with mean diameters of 338 to 1106 μm. The velocity and the number of grit particles were measured during blasting. The residual grit was removed from a substrate surface by the dissolution of the blasted substrate surface. A mixed acid solution was used as the dissolution solution. The residual grit weight was 7 to 17 g/m². The amount of the residual grit and the penetration depth of the embedded grit increased with increasing grit size. The penetration depth was 5 to 9% of the mean diameter of the grit. The residual grit weight and the penetration depth increased with the increase of the momentum of the grit particle. This article was originally published inBuilding on 100 Years of Success, Proceedings of the 2006 International Thermal Spray Conference (Seattle, WA), May 15–18, 2006, B.R. Marple, M.M. Hyland, Y.-Ch. Lau, R.S. Lima, and J. Voyer, Ed., ASM International, Materials Park, OH, 2006.     

Facile regeneration vitreous microfibrous entrapped supported ZnO sorbent with high contacting efficiency for bulk H2S removal from reformate streams in fuel cell applications

In this study, a microfibrous carrier consisting of 3 vol.% of 8 μm (diameter) glass fibers is used to entrap 45 vol.% of 150 to 250 μm (diameter) SiO₂ support particulates. ZnO is then nanodispersed onto the support by impregnation at the loading of 17 wt.%. At equivalent bed volumes, ZnO/SiO₂-entrapped materials provide twofold longer breakthrough times for H₂S (with a 67% reduction in sorbent loading) compared with packed beds of 1 to 2 mm commercial extrudates. Five-log reductions in H₂S concentration with up to 75% ZnO utilization at breakthrough are achieved. H₂S concentrations from 60 to 2000 parts per million in volume (ppmv) can be reduced to as little as 0.6 ppmv at 400°C in 30% H₂O at a face velocity of 1.7 cm/s for layers as thin as 1.0 mm. At 500 to 600°C, ZnO/SiO₂-entrapped materials provide much higher regenerability in air than do 1 to 2 mm commercial extrudates. The use of glass fibers permits greater than 50 regeneration cycles. This paper was presented at the ASM Materials Solutions Conference & Show held October 18–21, 2004 in Columbus, OH.