Experimental Assessment of High Heating Rates in Induction Heating with Temperature-Sensitive Lacquers

The fast evolving temperature fields at the surface of induction-heated parts were measured by a contactless, optical method based on temperature-sensitive lacquers recorded with a high-speed imaging system. The positions of specific isotherms over time were precisely measured by image analysis. A 4340 steel cylinder and two spur gears of the same material were investigated. One spur gear was treated at high frequency, and the other one at simultaneous dual frequency. In both cases, the temperature started to rise at the root of the teeth and then expanded along the flanks. The heating rates were higher at the tips than at the roots for both treatments, with higher values for the dual-frequency treatment. The layer of transformed material was similar for both treatments, but the transformation temperature varied greatly. It was found to be 50-100 °C higher than the equilibrium values, depending on the local heating rate.     

Method for Accurate Surface Temperature Measurements During Fast Induction Heating

A robust method is proposed for the measurement of surface temperature fields during induction heating. It is based on the original coupling of temperature-indicating lacquers and a high-speed camera system. Image analysis tools have been implemented to automatically extract the temporal evolution of isotherms. This method was applied to the fast induction treatment of a 4340 steel spur gear, allowing the full history of surface isotherms to be accurately documented for a sequential heating, i.e., a medium frequency preheating followed by a high frequency final heating. Three isotherms, i.e., 704, 816, and 927°C, were acquired every 0.3 ms with a spatial resolution of 0.04 mm per pixel. The information provided by the method is described and discussed. Finally, the transformation temperature Ac1 is linked to the temperature on specific locations of the gear tooth.     

Distortion and residual stress measurements of induction hardened AISI 4340 discs

10 Induction hardened discs with two initial hardness levels were used for exploring the influences of the variation of initial hardness as well as induction hardening (IH) recipes on the heat treatment distortions and hardening depth. The results show that for the same initial hardness, the larger the energy input, the higher the distortion size as well as the hardening depth. For a given induction hardening recipe, the increase in initial hardness leads to a deeper hardening depth but a smaller distortion. One disc was selected for the residual stress investigation in three orthogonal directions by neutron diffraction (ND). The corresponding stress-free lattice spacing d₀ was measured from the same material using both ND and X-ray diffraction (XRD) methods. The ND results show that the variation of d₀ in the hardened layer is significant and should be taken into account for stress calculation. However, regarding the core region, the d₀ value measured by XRD is more reliable. Accordingly, a combination of the ND-measured d₀ profiles in the hardened layer and the XRD-measured d₀ value in the core was adopted for the determination of residual stress distributions.     

Thermomechanical Characterization of Mg-9Al-1Zn Alloy Using Power Dissipation Maps

A processing map is developed on the basis of the Dynamic Material Model for Mg-9Al-1Zn. The model considers the work piece as a dissipator of power and power loss variation with temperature and strain rate constitutes the power dissipation map. To this end, the thermomechanical (i.e., hot compression) characteristics of a Mg-9Al-1Zn alloy was studied in the temperature range of 250-425 °C and strain rates of 0.001-1 s^?1. The strain rate sensitivity (m), power dissipation efficiency (η), and instability parameter (ξ) are computed based on the experimental hot compression data. The deformation mechanisms of different regions in the maps are analyzed and corresponding microstructures are investigated. The processing map of Mg-9Al-1Zn alloy exhibits five workability domains. Dynamic recrystallization (DRX) was observed in three of the domains, while in the two other domains grain boundary sliding, twining, and precipitation are the dominant mechanisms. The optimum hot working conditions of Mg-9Al-1Zn alloy are located in the two domains where DRX takes place. They correspond to 375 °C/0.001 s^?1 and 380 °C/1 s^?1 with peak efficiency of 42 and 36%, respectively.     

Predictive analytical modeling of cutting forces generated by high-speed machining of ductile and hard metals

This paper proposes an analytical cutting forces model based on an extension of the Oxley's machining theory (OMT) to high-speed machining of ductile and hard metals. In this model, the materials' behavior was modeled using the Marusich's constitutive equation (MCE). Furthermore, The OMT was modified to be able to capture the effects of the cutting tool edge radius and the burnishing phenomenon by implementing a variable rake angle equation and the Briks criterion, respectively. The predictive model was validated using experimental data obtained during the orthogonal machining of two aluminum alloys (AA6061-T6 and AA7075-T651) and induction-hardened AISI4340 steel (58-60 HRC). The results showed that the predicted and experimental cutting forces were in reasonable agreement for all tested materials. The strain rate constant in the primary shear zone (C₀) was found to be significantly sensitive to the cutting conditions and work material, and its effect on the predicted data was highlighted and discussed in depth. On one hand, it was found that AA6061-T6 is less sensitive to the strain rate compared to the AA7075-T651. On the other hand, all tested materials were found to be more sensitive to the strain rate at low cutting speeds and/or cutting feeds.     

Development of thermoelectric oxides for renewable energy conversion technologies

Geothermal and solar heat can be directly converted into electricity by using thermoelectric generators. Perovskite-type metal oxides are potential materials to improve the efficiency of these devices. Cobaltates with p-type conductivity and n-type manganates are considered for the development of a ceramic thermoelectric converter.Sintered pellets and thin PLD films with the composition La_1−xCa_xMO_3−δ (x=0, 0.3, 0.4) (M = Co, Mn) were synthesised and characterised concerning their thermoelectric properties in a broad temperature range. It was found that similar to polycrystalline samples the electrical conductivity of LaCoO₃ increases significantly with 40% Ca-substitution due to the formation of Co⁴⁺ ions while the thermopower decreases. The thermopower values of the La_0.8Ca_0.2MnO_3−δ films have a negative sign, but become large and positive at temperatures of 1000 K.     

On the effect of the orientation of sheet rolling direction in shot peen forming

Peen forming is commonly used in the aerospace industry to shape large and thin panels, such as wing skins. This manufacturing process uses shot peening to introduce unbalanced compressive stresses near the surface of the component. These stresses tend to bend the panel and, when optimized, lead to the desired contour. Sheet materials often exhibit both elastic and plastic anisotropy, which can alter the development of curvatures. Since peen forming relies on compressive stresses to upset equilibrium, resulting curvatures may also be affected by initial stresses in the part. In this work, the influence of the rolling direction orientation with respect to the sample was investigated experimentally and numerically for the first time for aluminium alloy 2024-T3 specimens. Although maximum deflections were only slightly dependent on the rolling direction orientation, it was found that radii of curvature varied by as much as 10% with respect to this parameter. Finite element simulations allowed quantification of the individual effects of non-equibiaxial initial stresses and elastic orthotropy. It was found that these factors can significantly influence curvature development. Comparison of experimental and numerical results suggested that plastic anisotropy should also be taken into account in future studies. The tools developed in this study show promises for the accurate prediction of peen forming process for large scale components.     

Lab Scale Fixed-Bed Reactor for Operando X-Ray Absorption Spectroscopy for Structure Activity Studies of Supported Metal Oxide Catalysts

Lab scale fixed-bed reactor is applied for operando transmission X-ray absorption spectroscopy (XAS) for structure–activity studies of supported metal oxide catalysts under real reaction conditions. This setup includes many properties of an optimal fixed-bed reactor for operando transmission XAS studies. For instance, it is usable in a wide range of temperature (up to 1,000 °C), pressure and space velocity. Besides, this operando setup can be used for transmission XAS measurements in a wide edge energy range. The potential of this reactor for operando transmission XAS is demonstrated by, as examples, the three-way catalytic performance of Pd/Al₂O₃/CeZrO₂ and Rh/Al₂O₃.     

Dynamic Recrystallization and Precipitation in 13Cr Super-Martensitic Stainless Steels

The influence of precipitation on the kinetics of static and dynamic recrystallization (DRX) was investigated in AISI 403 and 403Nb martensitic stainless steels. Hot compression tests were performed in the temperature range of 1073 K to 1473 K (800 °C to 1200 °C) and strain rates of 0.001 and 0.1 s^?1 to study DRX and precipitation behaviors. In parallel, stress relaxation tests were conducted with pre-strains of 0.1, 0.15, 0.2, and 0.25, a strain rate of 0.1 s^?1, and in the 1073 K to 1473 K (800 °C to 1200 °C) temperature range to study the kinetics of precipitation and recrystallization. Samples of hot compression and stress relaxation tests were quenched and the evolution of the microstructure was examined using optical and scanning electron microscopy. The results indicated that DRX interacts with dynamic precipitation (DP) over the temperature range of 1173 K to 1273 K (900 °C to 1000 °C). Hot compression testing results, confirmed by EBSD analysis, indicated that partial DRX occurs before precipitation in 403Nb, at 1073 K (800 °C). By contrast, no DRX was observed in 403 steel. At higher temperatures, i.e., over 1273 K (1000 °C), DRX preceded DP in both steels. Increasing the strain rate raised the temperature range of interaction between DRX and DP up to 1373 K (1100 °C). Strain-induced precipitation (SIP) was observed over the entire range of investigated test temperatures. Static recrystallization (SRX) took place predominantly in the temperature range of 1173 K to 1373 K (900 °C to 1100 °C), at which SIP significantly delayed the SRX finishing time. The results are analyzed in the framework of the classical nucleation theory and the underlying mechanisms are identified.     

Structure and Luminescence in Long Persistence Eu,Dy, and B Codoped Strontium Aluminate Phosphors: The Boron Effect

Long persistence phosphors are promising materials for energy‐saving applications, due to their ability to temporarily store and release light. While boron is known to dramatically extend the afterglow persistence to longer than 8 h in strontium aluminates, previous attempts to understand the role of boron neglected any nanoscale‐related effects and have been inconclusive. Herein, nanoscale‐resolved cathodoluminescence mapping is correlated with selected area electron diffraction and with energy dispersive x‐ray spectroscopy analysis using a 2 Å‐diameter probe. The salient aspect of this unique approach is that one can not only determine the elemental distribution in the phosphor microstructure, but more importantly, one can discriminate between the distributions of different divalent and trivalent luminescing ions. We demonstrate that the extremely long afterglow is due to the boron dopant via two key roles: (1) facilitating dominance of the long persistence phase during the microstructural evolution and (2) promoting more uniform distribution of the optically active, Eu²⁺ ion in the Sr²⁺ cation sublattice.