Adhesive bonding of copper prepared by laser-interference near the interference structuring limits

Adhesive bonding requires adequate surface preparation for ensuring an appropriate joint quality. The interest in adhesive joining has recently expanded to thermal systems having a large number of joints employed for manufacturing and assembly. This study presents surface topology of copper 110 produced by a laser-interference setup that would theoretically yield a periodicity of 1.7 mm, which is near the 1.6-2 mm structuring limit that was estimated based on thermal diffusion length scale for an 8 ns laser pulse. The results show that although the expected periodic interference structuring was not attained, the melt-induced texturing was affected by the laser-interference profile. Single-lap shear tests are performed with specimen surfaces prepared by traditional abrasion and laser interference structuring methods. Several laser processing parameters, such as the laser spot size, density, number of pulses, and raster speed were studied. Scanning electron microscope and profilometry measurements were used to characterize the processed surface microstructures. Web-like structures, which indicate widespread melting, were shown to be formed at different processing conditions. Based on the surface topologies investigated, two laser raster speeds were selected to make single-lap-joint specimens. Baseline joints were prepared by abrading joining specimens. The shear-lap strength and displacement at maximum load were shown to be higher by 16.8% and 43.8% for the laser-structured specimens than those of the baseline specimens, respectively. Moreover, the load-displacement curves indicate that the laser-structured joints are more ductile than those without laser-structuring. The increase ductility for the laser-structured joints was found to yield an increase in the energy absorbed during shear-lap testing of approximately of 80-90% over those measured for baseline joints. It is another indicator that laser-interference structuring enhanced the bonding performance of single-lap shear joints

Plastic Straining of Iridium Alloy DOP-26 during Cup Sizing Operations

DOP-26 iridium alloy cups are used for fuel cladding for radioisotope power systems. The cups are deep drawn and recrystallized prior to final fabrication operations. This study characterizes the plastic deformation of cups during a sizing operation following the recrystallization heat treatment. The purpose of the sizing operation is to achieve the specified roundness, diameter, and radius dimensions of the cup. The operation introduces various levels of plastic strain in the cup. Plastic strain can be a cause of inhomogeneous or abnormal grain growth during subsequent exposure to elevated temperature during the service life of the fueled clad. This is particularly true in the case of cups which have irregularities in the cup walls from the deep drawing operations. Diameter and roundness measurements were made on two cups both before and after sizing. Plastic strain levels were calculated using the ABAQUSTM finite element software. The calculated plastic strain levels in both cups were below 0.025, a value shown to be below the critical strain for abnormal grain growth during a simulated service exposure. The calculated maximum plastic strain was found to increase with increased applied sizing load and was not sensitive to the input value for the clearance between the cup and the sizing die. The calculated geometry of the sized cups was in good agreement with the measurements on the finished cups

CRADA Final Report for NFE-08-01826: Development and application of processing and processcontrol for nano-composite materials for lithium ion batteries

Oak Ridge National Laboratory and A123 Systems, Inc. collaborated on this project to develop a better understanding, quality control procedures, and safety testing for A123 System’s nanocomposite separator (NCS) technology which is a cell based patented technology and separator. NCS demonstrated excellent performance. x3450 prismatic cells were shown to survive >8000 cycles (1C/2C rate) at room temperature with greater than 80% capacity retention with only NCS present as an alternative to conventional polyolefin. However, for a successful commercialization, the coating conditions required to provide consistent and reliable product had not been optimized and QC techniques for being able to remove defective material before incorporation into a cell had not been developed. The work outlined in this report addresses these latter two points. First, experiments were conducted to understand temperature profiles during the different drying stages of the NCS coating when applied to both anode and cathode. One of the more interesting discoveries of this study was the observation of the large temperature decrease experienced by the wet coating between the end of the infrared (IR) drying stage and the beginning of the exposure to the convection drying oven. This is not a desirable situation as the temperature gradient could have a deleterious effect on coating quality. Based on this and other experimental data a radiative transfer model was developed for IR heating that also included a mass transfer module for drying. This will prove invaluable for battery coating optimization especially where IR drying is being employed. A stress model was also developed that predicts that under certain drying conditions tensile stresses are formed in the coating which could lead to cracking that is sometimes observed after drying is complete. Prediction of under what conditions these stresses form is vital to improving coating quality. In addition to understanding the drying process other parameters such as slurry quality and equipment optimization were examined. Removal of particles and gels by filtering, control of viscosity by %solids and mixing adjustments, removal of trapped gas in the slurry and modification of coater speed and slot die gap were all found to be important for producing uniform and flaw-free coatings. Second, an in-line Hi-Pot testing method has been developed specifically for NCS that will enable detection of coating flaws that could lead to soft or hard electrical shorts within the cell. In this way flawed material can be rejected before incorporation into the cell thus greatly reducing the amount of scrap that is generated. Improved battery safety is an extremely important benefit of NCS. Evaluation of battery safety is usually accomplished by conducting a variety of tests including nail penetration, hot box, over charge, etc. For these tests entire batteries must be built but the resultant temperature and voltage responses reveal little about the breakdown mechanism. In this report is described a pinch test which is used to evaluate NCS quality at various stages including coated anode and cathode as well as assembled cell. Coupled with post-microscopic examination of the damaged ‘pinch point’ test data can assist in the coating optimization from an improved end-use standpoint. As a result of this work two invention disclosures, one for optimizing drying methodology and the other for an in-line system for flaw detection, have been filed. In addition, 2 papers are being written for submission to peer-reviewed journals

Metal Compression Forming of aluminum alloys and metal matrix composites

Metal Compression Forming (MCF) is a variant of the squeeze casting process, in which molten metal is allowed to solidify under pressure in order to close porosity and form a sound part. However, the MCF process applies pressure on the entire mold face, thereby directing pressure on all regions of the casting and producing a uniformly sound part. The process is capable of producing parts with properties close to those of forgings, while retaining the near net shape, complexity in geometry, and relatively low cost of the casting process

The second flight of the SUNRISE balloon-borne solar observatory: overview of instrument updates, the flight, the data and first results

The SUNRISE balloon-borne solar observatory, consisting of a 1~m aperture telescope that provided a stabilized image to a UV filter imager and an imaging vector polarimeter, carried out its second science flight in June 2013. It provided observations of parts of active regions at high spatial resolution, including the first high-resolution images in the Mg~{\sc ii}~k line. The obtained data are of very high quality, with the best UV images reaching the diffraction limit of the telescope at 3000~\AA\ after Multi-Frame Blind Deconvolution reconstruction accounting for phase-diversity information. Here a brief update is given of the instruments and the data reduction techniques, which includes an inversion of the polarimetric data. Mainly those aspects that evolved compared with the first flight are described. A tabular overview of the observations is given. In addition, an example time series of a part of the emerging active region NOAA AR~11768 observed relatively close to disk centre is described and discussed in some detail. The observations cover the pores in the trailing polarity of the active region, as well as the polarity inversion line where flux emergence was ongoing and a small flare-like brightening occurred in the course of the time series. The pores are found to contain magnetic field strengths ranging up to 2500~G and, while large pores are clearly darker and cooler than the quiet Sun in all layers of the photosphere, the temperature and brightness of small pores approach or even exceed those of the quiet Sun in the upper photosphere.Comment: Accepted for publication in The Astrophysical Journa

Shape modeling technique KOALA validated by ESA Rosetta at (21) Lutetia

We present a comparison of our results from ground-based observations of asteroid (21) Lutetia with imaging data acquired during the flyby of the asteroid by the ESA Rosetta mission. This flyby provided a unique opportunity to evaluate and calibrate our method of determination of size, 3-D shape, and spin of an asteroid from ground-based observations. We present our 3-D shape-modeling technique KOALA which is based on multi-dataset inversion. We compare the results we obtained with KOALA, prior to the flyby, on asteroid (21) Lutetia with the high-spatial resolution images of the asteroid taken with the OSIRIS camera on-board the ESA Rosetta spacecraft, during its encounter with Lutetia. The spin axis determined with KOALA was found to be accurate to within two degrees, while the KOALA diameter determinations were within 2% of the Rosetta-derived values. The 3-D shape of the KOALA model is also confirmed by the spectacular visual agreement between both 3-D shape models (KOALA pre- and OSIRIS post-flyby). We found a typical deviation of only 2 km at local scales between the profiles from KOALA predictions and OSIRIS images, resulting in a volume uncertainty provided by KOALA better than 10%. Radiometric techniques for the interpretation of thermal infrared data also benefit greatly from the KOALA shape model: the absolute size and geometric albedo can be derived with high accuracy, and thermal properties, for example the thermal inertia, can be determined unambiguously. We consider this to be a validation of the KOALA method. Because space exploration will remain limited to only a few objects, KOALA stands as a powerful technique to study a much larger set of small bodies using Earth-based observations.Comment: 15 pages, 8 figures, 2 tables, accepted for publication in P&S

The Sunrise Mission

The first science flight of the balloon-borne \Sunrise telescope took place in June 2009 from ESRANGE (near Kiruna/Sweden) to Somerset Island in northern Canada. We describe the scientific aims and mission concept of the project and give an overview and a description of the various hardware components: the 1-m main telescope with its postfocus science instruments (the UV filter imager SuFI and the imaging vector magnetograph IMaX) and support instruments (image stabilizing and light distribution system ISLiD and correlating wavefront sensor CWS), the optomechanical support structure and the instrument mounting concept, the gondola structure and the power, pointing, and telemetry systems, and the general electronics architecture. We also explain the optimization of the structural and thermal design of the complete payload. The preparations for the science flight are described, including AIV and ground calibration of the instruments. The course of events during the science flight is outlined, up to the recovery activities. Finally, the in-flight performance of the instrumentation is briefly summarized.Comment: 35 pages, 17 figure

Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking

Approximately 68% of the aluminum produced in the United States is first cast into ingots prior to further processing into sheet, plate, extrusions, or foil. The direct chill (DC) semi-continuous casting process has been the mainstay of the aluminum industry for the production of ingots due largely to its robust nature and relative simplicity. Though the basic process of DC casting is in principle straightforward, the interaction of process parameters with heat extraction, microstructural evolution, and development of solidification stresses is too complex to analyze by intuition or practical experience. One issue in DC casting is the formation of stress cracks [1-15]. In particular, the move toward larger ingot cross-sections, the use of higher casting speeds, and an ever-increasing array of mold technologies have increased industry efficiencies but have made it more difficult to predict the occurrence of stress crack defects. The Aluminum Industry Technology Roadmap [16] has recognized the challenges inherent in the DC casting process and the control of stress cracks and selected the development of 'fundamental information on solidification of alloys to predict microstructure, surface properties, and stresses and strains' as a high-priority research need, and the 'lack of understanding of mechanisms of cracking as a function of alloy' and 'insufficient understanding of the aluminum solidification process', which is 'difficult to model', as technology barriers in aluminum casting processes. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress cracks from the current level of 5% to 2%. Decreasing stress crack incidence is important for improving product quality and consistency as well as for saving resources and energy, since considerable amounts of cast metal could be saved by eliminating ingot cracking, by reducing the scalping thickness of the ingot before rolling, and by eliminating butt sawing. Full-scale industrial implementation of the results of the proposed research would lead to energy savings in excess of 6 trillion Btu by the year 2020. The research undertaken in this project aimed to achieve this objective by a collaboration of industry, university, and national laboratory personnel through Secat, Inc., a consortium of aluminum companies. During the four-year project, the industrial partners and the research team met in 16 quarterly meetings to discuss research results and research direction. The industrial partners provided guidance, facilities, and experience to the research team. The research team went to two industrial plants to measure temperature distributions in commercial 60,000-lb DC casting ingot production. The project focused on the development of a fundamental understanding of ingot cracking and detailed models of thermal conditions, solidification, microstructural evolution, and stress development during the initial transient in DC castings of the aluminum alloys 3004 and 5182. The microstructure of the DC casting ingots was systematically characterized. Carefully designed experiments were carried out at the national laboratory and university facilities as well as at the industrial locations using the industrial production facilities. The advanced computational capabilities of the national laboratories were used for thermodynamic and kinetic simulations of phase transformation, heat transfer and fluid flow, solidification, and stress-strain evolution during DC casting. The achievements of the project are the following: (1) Identified the nature of crack formation during DC casting; (2) Developed a novel method for determining the mechanical properties of an alloy at the nonequilibrium mushy zone of the alloy; (3) Measured heat transfer coefficients (HTCs) between the solidifying ingot and the cooling water jet; (4) Determined the material constitutive model at high temperatures; and (5) Developed computational capabilities for the simulation of cracking formation in DC casting ingot. The models and the database developed in this project have been used to predict crack formation and to determine the optimal conditions for DC casting. The results demonstrated that cracking formation is strongly affected by casting conditions and the composition of the alloy. Scrap rate due to crack formation can be significantly reduced by controlling the cast speed and the concentrations of the alloy

Optical and infrared flares from a transient Galactic soft gamma-ray repeater

Soft gamma-ray repeaters (SGRs) are a rare type of gamma-ray transient sources that are ocasionally detected as bursts in the high-energy sky. They are thought to be produced by magnetars, young neutron stars with very strong magnetic fields of the order of 10^(14-15) G. Only three such objects are known in our Galaxy, and a fourth one is associated with the supernova remnant N49 in the Large Magellanic Cloud. In none of these cases has an optical counterpart to either the gamma-ray flares or the quiescent source been identified. Here we present multi-wavelength observations of a puzzling source, SWIFT J195509+261406, for which we detected more than 40 flaring episodes in the optical band over a time span of 3 days, plus a faint infrared flare 11 days later, after which it returned to quiescence. We propose that SWIFT J195509+261406 is a member of a subgroup of SGRs for which the long-term X-ray emission is transient in nature. Furthermore, it is the first SGR for which bursts have been detected in the optical and near-infrared bands and maybe the link between the "persistent" SGRs and the dim isolated neutron stars.Comment: Version submitted to Nature on 31 Jan 2008. A substantially revised version of this work has been published in Nature, vol. 455 issue 7212 pp 506-509 under the title "Flares from a Galactic magnetar suggest a missing link to dim isolated neutron stars