Abstract: Electron Beam Melting (EBM) is a metal powder bed-based Additive Manufacturing (AM) technology, which uses computer-controlled electron beams to create fully dense three-dimensional near-net-shaped parts from metal powder. It gives the ability to produce any complex parts directly from a computer-aided design (CAD) model without tools and dies, and with a variety of materials. However, the quality of the surface finish in EBM process has limitations to meeting the performance requirements of additively manufactured components. The aim of this study is to investigate the cutting forces induced during milling Ti6Al4V produced by EBM as well as the surface quality of the milled surfaces. The effects of cutting speed and radial depth of cut on the cutting forces, surface roughness, and surface morphology were investigated. The results indicated that the cutting speed was found to be proportional to the resultant cutting force at any cutting conditions while the surface roughness improved significantly with the increase in cutting speed and radial depth of cut.
Abstract: Electron beam melting (EBM) is one of the modern additive manufacturing (AM) technologies. In EBM, the electron beam melts metal powder into a fully solid part layer by layer. Since EBM is a new technology, most designers are unaware of the capabilities and the limitations of EBM technology. Also, many engineers are facing many challenges to utilize the technology because of a lack of design rules for the technology. The aim of this study is to identify the capabilities and the limitations of EBM technology in fabrication of small features and overhang structures and develop a design rules that need to be considered by designers and engineers. In order to achieve this objective, a series of experiments are conducted. Several features having varying sizes were designed, fabricated, and evaluated to determine their manufacturability limits. In general, the results showed the capabilities and limitations of the EBM technology in fabrication of the small size features and the overhang structures. In the end, the results of these investigation experiments are used to develop design rules. Also, the results showed the importance of developing design rules for AM technologies in increasing the utilization of these technologies.
Abstract: In the paper the results of welding of car’s air-conditioning elements are presented. These systems based on, mainly, the environmental unfriendly refrigerants. Thus, the producers of cars will have to stop using traditional refrigerant and to change it to carbon dioxide (R744). This refrigerant is environmental friendly. However, it should be noted that the air condition system working with R744 refrigerant operates at high temperature (up to 150 °C) and high pressure (up to 130 bar). These two parameters are much higher than for other refrigerants. Thus new materials, design as well as joining technologies are strongly needed for these systems. AISI 304 and 316L steels as well as aluminium alloys 5xxx are ranked among the prospective materials. As a joining process laser welding, plasma welding, electron beam welding as well as high rotary friction welding can be applied. In the study, the metallographic examination based on light microscopy as well as SEM was applied to estimate the quality of welded joints. The analysis of welding was supported by numerical modelling based on Sysweld software. The results indicated that using laser, plasma and electron beam welding, it is possible to obtain proper quality of welds in stainless steel. Moreover, high rotary friction welding allows to guarantee the metallic continuity in the aluminium welded area. The metallographic examination revealed that the grain growth in the heat affected zone (HAZ) in laser and electron beam welded joints were not observed. It is due to low heat input and short welding time. The grain growth and subgrains can be observed at room temperature when the solidification mode is austenitic. This caused low microstructural changes during solidification. The columnar grain structure was found in the weld metal. Meanwhile, the equiaxed grains were detected in the interface. The numerical modelling of laser welding process allowed to estimate the temperature profile in the welded joint as well as predicts the dimensions of welds. The agreement between FEM analysis and experimental data was achieved.
Abstract: The goal of the paper is to present the results regarding the influence of the irradiation dose and amount of multifunctional monomer trimethylol-propane trimethacrylate (TMPT) on ethylene-propylene-diene terpolymer rubber (EPDM) mixtures irradiated in electron beam. Blends, molded on an electrically heated laboratory roller mill and compressed in an electrically heated hydraulic press, were irradiated using the ALID 7 of 5.5 MeV linear accelerator in the dose range of 22.6 kGy to 56.5 kGy in atmospheric conditions and at room temperature of 25 °C. The share of cross-linking and degradation reactions was evaluated by means of sol-gel analysis, cross-linking density measurements, FTIR studies and Charlesby-Pinner parameter (p0/q0) calculations. The blends containing different concentrations of TMPT (3 phr and 9 phr) and irradiated with doses in the mentioned range have present the increasing of gel content and cross-linking density. Modified and new bands in FTIR spectra have appeared, because of both cross-linking and chain scission reactions.
Abstract: The ionization yield of ion tracks in polymers and bio-molecular systems reaches a maximum, known as the Bragg peak, close to the end of the ion trajectories. Along the path of the ions through the materials, many electrons are generated, which produce a cascade of further ionizations and, consequently, a shower of secondary electrons. Among these, very low energy secondary electrons can produce damage in the biomolecules by dissociative electron attachment. This work deals with the calculation of the energy distribution of electrons produced by protons in a sample of polymethylmethacrylate (PMMA), a material that is used as a phantom for living tissues in hadron therapy. PMMA is also of relevance for microelectronics in CMOS technologies and as a photoresist mask in electron beam lithography. We present a Monte Carlo code that, starting from a realistic description of the energy distribution of the electrons ejected by protons moving through PMMA, simulates the entire cascade of generated secondary electrons. By following in detail the motion of all these electrons, we find the radial distribution of the energy that they deposit in PMMA for several initial proton energies characteristic of the Bragg peak.
Abstract: This study is concerned with the microstructural analysis and improvement of wear resistance of 356 aluminum alloy by a high energy electron beam. Shock hardening on material by high energy electron beam improved wear resistance. Particularly, in the surface of material by shock hardening, the wear resistance was greatly enhanced to 29% higher than that of the 356 aluminum alloy substrate. These findings suggested that surface shock hardening using high energy electron beam irradiation was economical and useful for the development of surface shock hardening with improved wear resistance.
Abstract: Processing of Al-19.4Si alloy by high intensive
electron beam has been carried out and multiple increases in fatigue
life of the material have been revealed. Investigations of structure and
surface modified layer destruction of Al-19.4Si alloy subjected to
multicycle fatigue tests to fracture have been carried out by methods
of scanning electron microscopy. The factors responsible for the
increase of fatigue life of Al-19.4Si alloy have been revealed and
analyzed.
Abstract: We study the anomalous WWγ and WWZ couplings by
calculating total cross sections of two processes at the LHeC with
electron beam energy Ee=140 GeV and the proton beam energy Ep=7
TeV, and at the FCC-ep collider with the polarized electron beam
energy Ee=80 GeV and the proton beam energy Ep=50 TeV. At the
LHeC with electron beam polarization, we obtain the results for the
difference of upper and lower bounds as (0.975, 0.118) and (0.285,
0.009) for the anomalous (Δκγ, λγ) and (Δκz, λz) couplings,
respectively. As for FCC-ep collider, these bounds are obtained as
(1.101, 0.065) and (0.320, 0.002) at an integrated luminosity of
Lint=100 fb^-1.
Abstract: Electron Beam Melting (EBM) process was used to prepare porous scaffolds with controlled porosity to ensure optimal levels of osteointegration for different trabeculae sizes. Morphological characterization by means of SEM analyses was carried out to assess pore dimensions; tensile, compression and adhesion tests have been carried out to determine the mechanical behavior. The results indicate that EBM process allows the creation of regular and repeatable porous scaffolds. Mechanical properties greatly depend on pore dimension and on bulk-pore ratio. Adhesion resistance meets the normative requirements, and the overall performance of the produced structures is compatible with potential orthopaedic applications.
Abstract: Physical vapor deposition under conditions of an obliquely incident flux results in a film formation with an inclined columnar structure. These columns will be oriented toward the vapor source because of the self-shadowing effect, and they are homogenously distributed on the substrate surface because of the limited surface diffusion ability of ad-atoms when there is no additional substrate heating.
In this work, the oblique angle electron beam evaporation technique is used to fabricate thin films containing inclined nanorods. The results demonstrate that depending on the thin film composition, the morphology of the nanorods is changed as well. The galvanostatic analysis of these thin film anodes reveals that a composite CuSn nanorods having approximately 900mAhg-1 of initial discharge capacity, performs higher electrochemical performance compared to pure Sn nanorods containing anode material. The long cycle life and the advanced electrochemical properties of the nanostructured composite electrode might be attributed to its improved mechanical tolerance and enhanced electrical conductivity depending on the Cu presence in the nanorods.
Abstract: In the present paper, a gyrotron cavity is analyzed in the absence of electron beam for dispersion, attenuation and RF efficiency. For all these characteristics, azimuthally symmetric TE0n modes have been considered. The attenuation characteristics for TE0n modes indicated decrease in attenuation constant as the frequency is increased. Interestingly, the lowest order TE01 mode resulted in lowest attenuation. Further, three different cavity wall materials have been selected for attenuation characteristics. The cavity made of material with higher conductivity resulted in lower attenuation. The effect of material electrical conductivity on the RF efficiency has also been observed and has been found that the RF efficiency rapidly decreases as the electrical conductivity of the cavity material decreases. The RF efficiency rapidly decreases with increasing diffractive quality factor. The ohmic loss variation as a function of frequency of operation for three different cavities made of copper, aluminum and nickel has been observed. The ohmic losses are lowest for the copper cavity and hence the highest RF efficiency.
Abstract: A nonlinear model of two-beam free-electron laser
(FEL) in the absence of slippage is presented. The two beams are
assumed to be cold with different energies and the fundamental
resonance of the higher energy beam is at the third harmonic of lower
energy beam. By using Maxwell-s equations and full Lorentz force
equations of motion for the electron beams, coupled differential
equations are derived and solved numerically by the fourth order
Runge–Kutta method. In this method a considerable growth of third
harmonic electromagnetic field in the XUV and X-ray regions is
predicted.
Abstract: Charging and discharging phenomenon on the surface
of materials can be found in plasma display panel, spacecraft
charging, high voltage insulator, etc. This report gives a simple
explanation on this phenomenon. A scanning electron microscope
was used not only as a tool to produce energetic electron beam to
charge an insulator without metallic coating and to produce a surface
discharging (surface breakdown/flashover) but also to observe the
visible charging and discharging on the sample surface. A model of
electric field distribution on the surface was developed in order to
explain charging and discharging phenomena. Since charging and
discharging process involves incubation time, therefore this process
can be used to evaluate the insulation property of materials under
electron bombardment.
Abstract: The ionizing radiation of livestock wastewater for the
removal of nitrogen and phosphorus was studied in the presence of a
natural zeolite. The feasibility of a combined process of zeolite ion
exchange and electron beam irradiation of livestock wastewater was
also investigated. The removal efficiencies of NH4
+-N, T-N and T-P
were significantly enhanced by electron beam irradiation after zeolite
ion exchange as a pre-treatment. The presence of silica zeolite
accelerated the decomposition rate of livestock wastewater in the
electron beam irradiation process. These results indicate that the
combined process of zeolite ion exchange and electron beam
irradiation has the potential for the treatment of livestock wastewater
Abstract: This paper reports the fatigue crack growth behaviour
of gas tungsten arc, electron beam and laser beam welded Ti-6Al-4V
titanium alloy. Centre cracked tensile specimens were prepared to
evaluate the fatigue crack growth behaviour. A 100kN servo
hydraulic controlled fatigue testing machine was used under constant
amplitude uniaxial tensile load (stress ratio of 0.1 and frequency of
10 Hz). Crack growth curves were plotted and crack growth
parameters (exponent and intercept) were evaluated. Critical and
threshold stress intensity factor ranges were also evaluated. Fatigue
crack growth behaviour of welds was correlated with mechanical
properties and microstructural characteristics of welds. Of the three
joints, the joint fabricated by laser beam welding exhibited higher
fatigue crack growth resistance due to the presence of fine lamellar
microstructure in the weld metal.
Abstract: Three-dimensional simulation of harmonic up
generation in free electron laser amplifier operating simultaneously
with a cold and relativistic electron beam is presented in steady-state
regime where the slippage of the electromagnetic wave with respect
to the electron beam is ignored. By using slowly varying envelope
approximation and applying the source-dependent expansion to wave
equations, electromagnetic fields are represented in terms of the
Hermit Gaussian modes which are well suited for the planar wiggler
configuration. The electron dynamics is described by the fully threedimensional
Lorentz force equation in presence of the realistic planar
magnetostatic wiggler and electromagnetic fields. A set of coupled
nonlinear first-order differential equations is derived and solved
numerically. The fundamental and third harmonic radiation of the
beam is considered. In addition to uniform beam, prebunched
electron beam has also been studied. For this effect of sinusoidal
distribution of entry times for the electron beam on the evolution of
radiation is compared with uniform distribution. It is shown that
prebunching reduces the saturation length substantially. For
efficiency enhancement the wiggler is set to decrease linearly when
the radiation of the third harmonic saturates. The optimum starting
point of tapering and the slope of radiation in the amplitude of
wiggler are found by successive run of the code.
Abstract: The peculiarities of the nanoscale structure-phase
states formed after electroexplosive carburizing and subsequent
electron-beam treatment of technically pure titanium surface in different regimes are established by methods of transmission electron
diffraction microscopy and physical mechanisms are discussed. Electroexplosive carburizing leads to surface layer formation
(40 m thickness) with increased (in 3.5 times) microhardness. It consists of β-titanium, graphite (monocrystals 100-150 nm,
polycrystals 5-10 nm, amorphous particles 3-5nm), TiC (5-10 nm), β-Ti02 (2-20nm). After electron-beam treatment additionally increasing the microhardness the surface layer consists of TiC.