Microstructural Evolution of an Interface Region in a Nickel-Based Superalloy Joint Produced by Direct Energy Deposition

Microstructure analysis of additively manufactured (AM) materials is an important step in understanding the interrelationship between mechanical properties and materials performance. Literature on the effect of a laser-based AM process parameters on the microstructure in the substrate-deposit interface is limited. The interface region, the adjoining area of substrate and deposit, is characterized by the presence of the fusion zone (FZ) and heat affected zone (HAZ) experiencing rapid thermal gyrations resulting in thermal induced transformations. Inconel 718 was utilized as a work material for both the substrate and deposit. Three blocks of Inconel 718 material were deposited by Direct Energy Deposition (DED) using three different laser powers, 550W, 750W and 950W, respectively. A coupled thermo-mechanical transient approach was utilized to correlate temperature history to the evolution of microstructure. Thermal history of the deposition process was monitored with the thermocouples installed inside the substrate material. Interface region of the blocks were analysed with Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) including electron back-scattered diffraction (EBSD) technique. Laser power was found to influence the dissolution of intermetallic precipitated phases in the substrate and grain growth in the interface region. Microstructure and thermal history data were utilized to draw conclusive comparisons between the investigated process parameters.

Piezoelectric Bimorph Harvester Based on Different Lead Zirconate Titanate Materials to Enhance Energy Collection

Nowadays, the increasing applicability of internet of things (IoT) systems has changed the way that the world around is perceived. The massive interconnection of systems by means of sensing, processing and communication, allows multitude of data to be at our fingertips. In this way, countless advances have been made in different fields such as personal care, predictive maintenance in industry, quality control in production processes, security, and in everything imaginable. However, all these electronic systems have in common the need to be electrically powered. In this context, batteries and wires are the most commonly used solutions, but they are not a definitive solution in some applications, because of the attainability, the serviceability, or the performance requirements. Therefore, the need arises to look for other types of solutions based on energy harvesting and long-life electronics. Energy Harvesting can be defined as the action of capturing energy from the environment and store it for an instantaneous use or later use. Among the materials capable of harvesting energy from the environment, such as thermoelectrics, electromagnetics, photovoltaics or triboelectrics, the most suitable is the piezoelectric material. The phenomenon of piezoelectricity is one of the most powerful sources for energy harvesting, ranging from a few micro wats to hundreds of wats, depending on certain factors such as material type, geometry, excitation frequency, mechanical and electrical configurations, among others. In this research work, an exhaustive study is carried out on how different types of piezoelectric materials and electrical configurations influence the maximum power that a bimorph harvester is able to extract from mechanical vibrations. A series of experiments has been carried out in which the manufactured bimorph specimens are excited under fixed inertial vibrational conditions. In addition, in order to evaluate the dependence of the maximum transferred power, different load resistors are tested. In this way, the pure active power that achieves the maximum power transfer can be approximated. In this paper, we present the design of low-cost energy harvesting solutions based on piezoelectric smart materials with tunable frequency. The results obtained show the differences in energy extraction between the PZT materials studied and their electrical configurations. The aim of this work is to gain a better understanding of the behavior of piezoelectric materials, and the design process of bimorph PZT harvesters to optimize environmental energy extraction.

Accelerated Ageing of Unidirectional Flax Fibers Reinforced Recycled Polypropylene Composites

Over the last decades, worldwide environmental awareness has grown due to the depletion of raw material resources and global warming. This awareness has prompted the development of new products more environmentally friendly. Among these products are biocomposite materials reinforced with natural fibers. The main challenge in developing the use of biocomposites in exterior applications is the lack of knowledge about their durability and the evolution of their mechanical and physicochemical properties in the long term. The aim of this work is to study the photooxidation of unidirectional (UD) composites based on recycled matrix. For this purpose, UD flax fiber composites based on recycled polypropylene were prepared by thermocompression. An accelerated aging test was carried out using a xenon arc WeatherOmeter. The consequences of UV exposure on the chemical composition and morphology of the surface of composites as well as on their tensile mechanical properties have been reported. The results showed that accelerated aging had a significant effect on the surface of these composites while it had little impact on their mechanical properties.

Local Mechanical Analysis of Arch Foot of Space Y-Beam Arch Bridge

To study the local force characteristics of a spatial Y-arch bridge, a medium-bearing spatial Y-arch bridge is used as the object of study, and the finite element software FEA is used to establish a spatial finite element model and analyze the force conditions of the arch legs under different most unfavorable loading conditions. It is found that the forces on the arch foot under different conditions are mainly in the longitudinal direction and transverse direction, which should be considered for strengthening. The research results can provide reference for the design and construction of the same type of bridge.

Mechanical Behavior of Recycled Mortars Manufactured from Moisture Correction Using the Halogen Light Thermogravimetric Balance as an Alternative to the Traditional ASTM C 128 Method

To obtain high mechanical performance, the fresh conditions of a mortar are decisive. Measuring the absorption of aggregates used in mortar mixes is a fundamental requirement for proper design of the mixes prior to their placement in construction sites. In this sense, absorption is a determining factor in the design of a mix because it conditions the amount of water, which in turn affects the water/cement ratio and the final porosity of the mortar. Thus, this work focuses on the mechanical behavior of recycled mortars manufactured from moisture correction using the Thermogravimetric Balancing Halogen Light (TBHL) technique in comparison with the traditional ASTM C 128 International Standard method. The advantages of using the TBHL technique are favorable in terms of reduced consumption of resources such as materials, energy and time. The results show that in contrast to the ASTM C 128 method, the TBHL alternative technique allows obtaining a higher precision in the absorption values of recycled aggregates, which is reflected not only in a more efficient process in terms of sustainability in the characterization of construction materials, but also in an effect on the mechanical performance of recycled mortars.

Finite Element Analysis of Different Architectures for Bone Scaffold

Bone Scaffolds are fundamental architecture or a support structure that allows the regeneration of lost or damaged tissues and they are developed as a crucial tool in biomedical engineering. The structure of bone scaffolds plays an important role in treating bone defects. The shape of the bone scaffold performs a vital role, specifically pore size and shape, which help understand the behavior and strength of the scaffold. In this article, first, fundamental aspects of bone scaffold design are established. Second, the behavior of each architecture of the bone scaffold with biomaterials is discussed. Finally, for each structure, the stress analysis was carried out. This study aimed to design a porous and mechanically strong bone regeneration scaffold that can be successfully manufactured. Four porous architectures of the bone scaffold were designed using Rhinoceros solid modelling software. The structure model consisted of repeatable unit cells arranged in layers to fill the chosen scaffold volume. The mechanical behavior of used biocompatible material is studied with the help of ANSYS 19.2 software. It is also playing significant role to predict the strength of defined structures or 3 dimensional models.

Literature Review on Metallurgical Properties of Ti/Al Weld Joint Using Laser Beam Welding

Several situations arise in industrial practice which calls for joining of dissimilar metals. With increasing demand in the application requirements, dissimilar metal joining becomes inevitable in modern engineering industries. The metals employed are the structure for effective and utilization of the special properties of each metal. The purpose of this paper is to present the research and development status of titanium (Ti) and aluminium (Al) dissimilar alloys weldment by the researchers worldwide. The detailed analysis of problems faced during welding of dissimilar metal joint for Ti/Al metal combinations are discussed. Microstructural variations in heat affected zone (HAZ), fusion zone (FZ), Intermetallic compound (IMC) layer and surface fracture of weldments are analysed. Additionally, mechanical property variations and microstructural feature have been studied by the researchers. The paper provides a detailed literature review of Ti/Al dissimilar metal joint microchemistry and property variation across the weldment.

Simulation on Influence of Environmental Conditions on Part Distortion in Fused Deposition Modelling

Fused Deposition Modelling (FDM) is one of the additive manufacturing techniques that has become highly attractive in the industrial and academic sectors. However, parts fabricated through FDM are highly susceptible to geometrical defects such as warpage, shrinkage, and delamination that can severely affect their function. Among the thermoplastic polymer feedstock for FDM, semi-crystalline polymers are highly prone to part distortion due to polymer crystallization. In this study, the influence of FDM processing conditions such as chamber temperature and print bed temperature on the induced thermal residual stress and resulting warpage are investigated using 3D transient thermal model for a semi-crystalline polymer. The thermo-mechanical properties and the viscoelasticity of the polymer, as well as the crystallization physics which considers the crystallinity of the polymer, are coupled with the evolving temperature gradient of the print model. From the results it was observed that increasing the chamber temperature from 25 °C to 75 °C leads to a decrease of 3.3% residual stress and increase of 0.4% warpage, while decreasing bed temperature from 100 °C to 60 °C resulted in 27% increase in residual stress and a significant rise of 137% in warpage. The simulated warpage data are validated by comparing it with the measured warpage values of the samples using 3D scanning.

Biomechanical Findings in Patients with Bipartite Medial Cuneiforms

Bipartite medial cuneiforms are relatively rare but may play a significant role in biomechanical and gait abnormalities. It is believed that a bipartite medial cuneiform may alter the available range of motion due to its larger morphological variant, thus limiting the metatarsal plantarflexion needed to achieve adequate hallux dorsiflexion for normal gait. Radiographic and clinical assessment were performed on two patients who reported with foot pain along the first ray. Both patients had visible bipartite medial cuneiforms on MRI. Using gait plate and Metascan ™ analysis, both were noted to have four measurements far beyond the expected range. Medial and lateral heel peak pressure, hallux peak pressure, and 1st metatarsal peak pressure were all noted to be increased. These measurements are believed to be increased due to the hindrance placed on the available ROM of the first ray by the increased size of the medial cuneiform. A larger patient population would be needed to fully understand this developmental anomaly.

Failure Analysis of a Fractured Control Pressure Tube from an Aircraft Engine

This paper studies a failure case of a fuel pressure supply tube from an aircraft engine. Multiple fracture cases of the fuel pressure control tube from aircraft engines have been reported. The studied set was composed by the mentioned tube, a welded connecting pipe, where the fracture has been produced, and a union nut. The fracture has been produced in one of the most critical zones of the tube, in a region next to the supporting body of the union nut to the connector. The tube material was X6CrNiTi18-10, an austenitic stainless steel. Chemical composition was determined using an X-Ray fluorescence spectrometer (XRF) and combustion equipment. Furthermore, the material was characterized mechanically, by a hardness test, and microstructurally using a stereo microscope and an optical microscope. The results confirmed that the material was within specifications. To determine the macrofractographic features, a visual examination and an observation using a stereo microscope of the tube fracture surface were carried out. The results revealed a tube plastic macrodeformation, surface damaged and signs of a possible corrosion process. Fracture surface was also inspected by scanning electron microscopy (FE-SEM), equipped with an energy-dispersive X-ray microanalysis system (EDX), to determine the microfractographic features in order to find out the failure mechanism involved in the fracture. Fatigue striations, which are typical from a progressive fracture by a fatigue mechanism, were observed. The origin of the fracture was placed in defects located on the outer wall of the tube, leading to a final overload fracture.

Early Age Behavior of Wind Turbine Gravity Foundations

Wind turbine gravity foundations are designed to resist overturning failure through gravitational forces resulting from their masses. Owing to the relatively high volume of the cementitious material present, the foundations tend to suffer thermal strains and internal cracking due to high temperatures and temperature gradients depending on factors such as geometry, mix design and level of restraint. This is a result of a fully coupled mechanism commonly known as THMC (Thermo- Hygro - Mechanical - Chemical) coupling whose kinetics peak during the early age of concrete. The focus of this paper is therefore to present and offer a discussion on the temperature and humidity evolutions occurring in mass pours such as wind turbine gravity foundations based on sensor results obtained from the monitoring of an actual wind turbine foundation. To offer prediction of the evolutions, the formulation of a 3D Thermal-Hydro-Chemical (THC) model that is mainly derived from classical fundamental physical laws is also presented and discussed. The THC model can be mathematically fully coupled in Finite Element analyses. In the current study, COMSOL Multi-physics software was used to simulate the 3D THC coupling that occurred in the monitored wind turbine foundation to predict the temperature evolution at five different points within the foundation from time of casting.

Engineering Topology of Photonic Systems for Sustainable Molecular Structure: Autopoiesis Systems

This paper introduces topological order in descried social systems starting with the original concept of autopoiesis by biologists and scientists, including the modification of general systems based on socialized medicine. Topological order is important in describing the physical systems for exploiting optical systems and improving photonic devices. The stats of topologically order have some interesting properties of topological degeneracy and fractional statistics that reveal the entanglement origin of topological order, etc. Topological ideas in photonics form exciting developments in solid-state materials, that being; insulating in the bulk, conducting electricity on their surface without dissipation or back-scattering, even in the presence of large impurities. A specific type of autopoiesis system is interrelated to the main categories amongst existing groups of the ecological phenomena interaction social and medical sciences. The hypothesis, nevertheless, has a nonlinear interaction with its natural environment ‘interactional cycle’ for exchange photon energy with molecules without changes in topology (i.e., chemical transformation into products do not propagate any changes or variation in the network topology of physical configuration). The engineering topology of a biosensor is based on the excitation boundary of surface electromagnetic waves in photonic band gap multilayer films. The device operation is similar to surface Plasmonic biosensors in which a photonic band gap film replaces metal film as the medium when surface electromagnetic waves are excited. The use of photonic band gap film offers sharper surface wave resonance leading to the potential of greatly enhanced sensitivity. So, the properties of the photonic band gap material are engineered to operate a sensor at any wavelength and conduct a surface wave resonance that ranges up to 470 nm. The wavelength is not generally accessible with surface Plasmon sensing. Lastly, the photonic band gap films have robust mechanical functions that offer new substrates for surface chemistry to understand the molecular design structure, and create sensing chips surface with different concentrations of DNA sequences in the solution to observe and track the surface mode resonance under the influences of processes that take place in the spectroscopic environment. These processes led to the development of several advanced analytical technologies, which are automated, real-time, reliable, reproducible and cost-effective. This results in faster and more accurate monitoring and detection of biomolecules on refractive index sensing, antibody–antigen reactions with a DNA or protein binding. Ultimately, the controversial aspect of molecular frictional properties is adjusted to each other in order to form unique spatial structure and dynamics of biological molecules for providing the environment mutual contribution in investigation of changes due the pathogenic archival architecture of cell clusters.

A Practical Construction Technique to Enhance the Performance of Rock Bolts in Tunnels

In Swedish tunnel construction, a critical issue that has been repeatedly acknowledged is corrosion and, consequently, failure of the rock bolts in rock support systems. The defective installation of rock bolts results in the formation of cavities in the cement mortar that is regularly used to fill the area under the dome plates. These voids allow for water-ingress to the rock bolt assembly, which results in corrosion of rock bolt components and eventually failure. In addition, the current installation technique consists of several manual steps with intense labor works that are usually done in uncomfortable and exhausting conditions, e.g., under the roof of the tunnels. Such intense tasks also lead to a considerable waste of materials and execution errors. Moreover, adequate quality control of the execution is hardly possible with the current technique. To overcome these issues, a non-shrinking/expansive cement-based mortar filled in the paper packaging has been developed in this study which properly fills the area under the dome plates without or with the least remaining cavities, ultimately that diminishes the potential of corrosion. This article summarizes the development process and the experimental evaluation of this technique for the installation of rock bolts. In the development process, the cementitious mortar was first developed using specific cement and shrinkage reducing/expansive additives. The mechanical and flow properties of the mortar were then evaluated using compressive strength, density, and slump flow measurement methods. In addition, isothermal calorimetry and shrinkage/expansion measurements were used to elucidate the hydration and durability attributes of the mortar. After obtaining the desired properties in both fresh and hardened conditions, the developed dry mortar was filled in specific permeable paper packaging and then submerged in water bath for specific intervals before the installation. The tests were enhanced progressively by optimizing different parameters such as shape and size of the packaging, characteristics of the paper used, immersion time in water and even some minor characteristics of the mortar. Finally, the developed prototype was tested in a lab-scale rock bolt assembly with various angles to analyze the efficiency of the method in real life scenario. The results showed that the new technique improves the performance of the rock bolts by reducing the material wastage, improving environmental performance, facilitating and accelerating the labor works, and finally enhancing the durability of the whole system. Accordingly, this approach provides an efficient alternative for the traditional way of tunnel bolt installation with considerable advantages for the Swedish tunneling industry.

Soil-Structure Interaction Models for the Reinforced Foundation System: A State-of-the-Art Review

Challenges of weak soil subgrade are often resolved either by stabilization or reinforcing it. However, it is also practiced to reinforce the granular fill to improve the load-settlement behavior of it over weak soil strata. The inclusion of reinforcement in the engineered granular fill provided a new impetus for the development of enhanced Soil-Structure Interaction (SSI) models, also known as mechanical foundation models or lumped parameter models. Several researchers have been working in this direction to understand the mechanism of granular fill-reinforcement interaction and the response of weak soil under the application of load. These models have been developed by extending available SSI models such as the Winkler Model, Pasternak Model, Hetenyi Model, Kerr Model etc., and are helpful to visualize the load-settlement behavior of a physical system through 1-D and 2-D analysis considering beam and plate resting on the foundation, respectively. Based on the literature survey, these models are categorized as ‘Reinforced Pasternak Model,’ ‘Double Beam Model,’ ‘Reinforced Timoshenko Beam Model,’ and ‘Reinforced Kerr Model’. The present work reviews the past 30+ years of research in the field of SSI models for reinforced foundation systems, presenting the conceptual development of these models systematically and discussing their limitations. A flow-chart showing procedure for compution of deformation and mobilized tension is also incorporated in the paper. Special efforts are taken to tabulate the parameters and their significance in the load-settlement analysis, which may be helpful in future studies for the comparison and enhancement of results and findings of physical models. 

Three-Dimensional State with Doublet Mechanics

In this study, it is aimed to obtain general stress expressions for the examination of mechanical behaviors of planar straight axis nano rods by using doublet mechanics. The superiority of this method over other scale dependent methods is that it is directly related to the structure of nanomaterial and it models solid structure with points at finite distances between them. In other words, value of small scale effect is known exactly. To the best of authors’ knowledge, after micro modulus matrix is obtained by using Generalized Hooke’s Law and the essential transformation matrix expressing relationships between macro and micro stress and strain matrix, the stress equations that include the effect of axial extension are acquired for the three-dimensional state for the first time in the literature. In plane and out of plane static and dynamic behaviors can be studied using analytical and/or numerical approaches without any restrictions. Since the value of the small scale size parameter is precisely known in the theory used, it is thought that the results to be obtained will be more accurate than other scale size theories.

Combination of Tensile Strength and Elongation of Reverse Rolled TaNbHfZrTi Refractory High Entropy Alloy

The refractory high entropy alloys are potential materials for high-temperature applications because of their ability to retain high strength up to 1600°C. However, their practical applications were limited due to poor elongation at room temperature. Therefore, decreasing the average valence electron concentrations (VEC) is an effective design strategy to improve the intrinsic ductility of refractory high entropy alloys. In this work, the high-entropy alloy TaNbHfZrTi was processed at room temperature by each step reverse rolling up to a 90% reduction in thickness. Subsequently, the reverse rolled 90% samples were utilized for annealing treatment at 800°C and 1000°C for 1 h to understand phase stability, microstructure, texture, and mechanical properties. The reverse rolled 90% condition contains body-centered cubic (BCC) single-phase; upon annealing at 800 °C, the formation of secondary phase BCC-2 prevailed. The partial recrystallization and complete recrystallization microstructures were developed for annealed at 800°C and 1000°C, respectively. The reverse rolled condition and 1000°C annealed temperature exhibit extraordinary room temperature tensile properties with high ultimate tensile strength (UTS) without compromising loss of ductility called “strength-ductility” trade-off. The reverse-rolled 90% and annealing treatment carried out at temperature about 1000°C for 1 h consist of UTS 1430 MPa and 1556 MPa with an appreciable amount of 21% and 20% elongation, respectively. The development of hierarchical microstructure prevailed for the annealed 1000°C which led to the simultaneous increase in tensile strength and elongation.

Strongly Coupled Finite Element Formulation of Electromechanical Systems with Integrated Mesh Morphing using Radial Basis Functions

The paper introduces a method to efficiently simulate nonlinear changing electrostatic fields occurring in micro-electromechanical systems (MEMS). Large deflections of the capacitor electrodes usually introduce nonlinear electromechanical forces on the mechanical system. Traditional finite element methods require a time-consuming remeshing process to capture exact results for this physical domain interaction. In order to accelerate the simulation process and eliminate the remeshing process, a formulation of a strongly coupled electromechanical transducer element will be introduced which uses a combination of finite-element with an advanced mesh morphing technique using radial basis functions (RBF). The RBF allows large geometrical changes of the electric field domain while retain high element quality of the deformed mesh. Coupling effects between mechanical and electrical domains are directly included within the element formulation. Fringing field effects are described accurate by using traditional arbitrary shape functions.

Empirical Analysis of Velocity Behavior for Collaborative Robots in Transient Contact Cases

In this paper, a suitable measurement setup is presented to conduct force and pressure measurements for transient contact cases at the example of lathe machine tending. Empirical measurements were executed on a selected collaborative robot’s behavior regarding allowable operating speeds under consideration of sensor- and workpiece-specific factors. Comparisons between the theoretic calculations proposed in ISO/TS 15066 and the practical measurement results reveal a basis for future research. With the created database, preliminary risk assessment and economic assessment procedures of collaborative machine tending cells can be facilitated.

Separation of Composites for Recycling: Measurement of Electrostatic Charge of Carbon and Glass Fiber Particles

Composite waste from manufacturing can consist of different fiber materials, including blends of different fiber. Commercially, the recycling of composite waste is currently limited to carbon fiber waste and recycling glass fiber waste is currently not economically viable due to the low cost of virgin glass fiber and the reduced mechanical properties of the recovered fibers. For this reason, the recycling of hybrid fiber materials, where carbon fiber is blended with glass fibers, cannot be processed economically. Therefore, a separation method is required to remove the glass fiber materials during the recycling process. An electrostatic separation method is chosen for this work because of the significant difference between carbon and glass fiber electrical properties. In this study, an experimental rig has been developed to measure the electrostatic charge achievable as the materials are passed through a tube. A range of particle lengths (80-100 µm, 6 mm and 12 mm), surface state conditions (0%SA, 2%SA and 6%SA), and several tube wall materials have been studied. A polytetrafluoroethylene (PTFE) tube and recycled fiber without sizing agent were identified as the most suitable parameters for the electrical separation method. It was also found that shorter fiber lengths helped to encourage particle flow and attain higher charge values. These findings can be used to develop a separation process to enable the cost-effective recycling of hybrid fiber composite waste. 

Effect of Non-Metallic Inclusion from the Continuous Casting Process on the Multi-Stage Forging Process and the Tensile Strength of the Bolt: A Case Study

The paper presents the influence of non-metallic inclusions on the multi-stage forging process and the mechanical properties of the dodecagon socket bolt used in the automotive industry. The detected metallurgical defect was so large that it directly influenced the mechanical properties of the bolt and resulted in failure to meet the requirements of the mechanical property class. In order to assess the defect, an X-ray examination and metallographic examination of the defective bolt were performed, showing exogenous non-metallic inclusion. The size of the defect on the cross section was 0.531 mm in width and 1.523 mm in length; the defect was continuous along the entire axis of the bolt. In analysis, a finite element method (FEM) simulation of the multi-stage forging process was designed, taking into account a non-metallic inclusion parallel to the sample axis, reflecting the studied case. The process of defect propagation due to material upset in the head area was analyzed. The final forging stage in shaping the dodecagonal socket and filling the flange area was particularly studied. The effect of the defect was observed to significantly reduce the effective cross-section as a result of the expansion of the defect perpendicular to the axis of the bolt. The mechanical properties of products with and without the defect were analyzed. In the first step, the hardness test confirmed that the required value for the mechanical class 8.8 of both bolt types was obtained. In the second step, the bolts were subjected to a static tensile test. The bolts without the defect gave a positive result, while all 10 bolts with the defect gave a negative result, achieving a tensile strength below the requirements. Tensile strength tests were confirmed by metallographic tests and FEM simulation with perpendicular inclusion spread in the area of the head. The bolts were damaged directly under the bolt head, which is inconsistent with the requirements of ISO 898-1. It has been shown that non-metallic inclusions with orientation in accordance with the axis of the bolt can directly cause loss of functionality and these defects should be detected even before assembling in the machine element.