Microstructural Design of the Cast Iron via Laser Hardening with Defocused Beam of the Continuous Wave CO2 Laser

The cast iron is widely used in mechanical parts due to its good properties, as damping, good fluidity, resistance to deformation, excellent machinability and low cost. However, the number of its applications are reduced because its low corrosion, wear and friction resistance. The microstructure of the metallic materials has high influence on these properties. Laser hardening can improve these properties via designing of the microstructure. The evaluation of the laser parameter influence on the microstructural features is vital for a correct design of the microstructure and therefore, good improvement of the metallic material properties. Although the various laser parameter influence has been analysed on sundry papers, the influence of the distance from focal point and scan speed in the laser hardening microstructures has been rarely evaluated in the literature. Thus, the influence of this parameter on the microstructures generated through laser hardening is the subject matter of this work. The experiments were carried out with continuous wave carbon dioxide laser on samples of ground cast iron. The atmosphere was air flow at 0.7MPa, the laser operated at 100W and the scan rates were 1mm/s and 5mm/s. The distances to focal point of the laser beams ranged from 0.0mm to 5.6mm. The microstructures of the samples were revealed via nital and evaluated with optical microscopy. This work shown that the microstructure of gray iron cast can be designed by mean of laser hardening. In addition, laser hardened zones had various microstructures (e.g. austenitic, martensitic, pearlite and dendritic). The type of the microstructures in laser treated zones was determined by distance from focal point and scan speed. Moreover, the width and the depth of the laser hardened zones were generally enlarged with the increasing of the distance from focal point. Furthermore, the laser irradiation at slow rates, i.e. 1mm/s, produced laser hardened zones larger than laser scan at 5mm/s. In future works, the hardness, wear and friction resistance of the laser hardened samples will be evaluated because the literature review indicates that austenitic and martensitic microstructures show high values of these properties

Surface texturing of aluminium alloy AA2024-T3 by picosecond laser: Effect on wettability and corrosion properties

The effects of laser texturing on the corrosion and wettability of AA2024-T3 using an IR Nd:Vanadate picosecond (ps) laser was studied. Three types of texture patterns were generated: dimples with 5% and 50% area density (percentage of surface area textured); cross groove patterns with an area density of 64%; and concentric ring patterns with an area density of 70%. For the higher area densities, the surface character changed from hydrophilic to hydrophobic. The evolution of the open circuit potential over time, potentiodynamic polarization curves and electrochemical impedance spectroscopy were then investigated and analysed. The results revealed that ultrashort ps laser surface texturing did not modify the corrosion behaviour of AA 2024-T3 in the test solution.This work was supported by the Spanish Ministry of Science and Innovation [SMOTI MAT2009-13751] and the Spanish Ministry of Economy and Competitiveness [MAT2013-48224-C2-1-R-MUNSUTI].Peer Reviewe

Understanding the corrosion behaviour of Al-Mg alloy fabricated using a Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) process

Metal additive manufacturing (AM) is an emerging disruptive technology capable of manufacturing complex shaped components that are difficult to manufacture through conventional methods. However, the corrosion behaviour of AM fabricated parts must be considered for safety critical applications. For this reason, we have studied the relationship between AM fabricated Scalmalloy (Al-Mg-Sc-Zr) microstructures and their corresponding corrosion behaviours. This comparison has been drawn against a comparable commercial Al-Mg alloy (5182). The corrosion resistance of the samples in salt water was assessed via various electrochemical analytics techniques. It was observed that Scalmalloy produced better corrosion resistance than 5182 Al-alloy. This can be attributed to the spontaneous formation of a passive film on refined AM microstructure and the presence of Sc and Zr, specifically when samples were fabricated with higher density (less porosity). The alloys’ corrosion mechanisms were dependent on immersion time and the microstructural features of the samples

Improving Commercial Motor Bike Rim Disc Hardness Using a Continuous-Wave Infrared Fibre Laser

This study is focused on examining the feasibility of applying laser hardening to a commercial metallic bike rim, employing a CW IR fibre laser. The research comprises two main phases. The first phase involves an assessment of the impact of laser parameters on the metallic microstructure, while the second phase involves the actual laser hardening of the bike rim. A comprehensive evaluation encompassing hardness measurements, optical microscopy, and scanning electron microscopy was conducted on the samples. The microstructure type can be manipulated by skilfully adjusting the laser parameters, allowing for the creation of various microstructure variants within the laser-hardened zone for specific laser conditions. In this regard, multiple microstructure types were observed. The hardness of the laser-processed zones exhibited variations corresponding to the specific microstructure. Notably, the molten zone (MZ) and the second heat-affected zone (HAZ II) exhibited the highest levels of hardness. Furthermore, it was observed that a scan overlap of ≥ 75% led to an augmentation in hardness. This study sheds light on the intricate interplay between laser parameters, microstructure, and resultant hardness in the context of laser hardening of metallic materials

iWindCr field trial and electrochemical analysis for corrosion detection and monitoring offshore wind turbine's MP-TP steel components

A Proof-of-Concept (POC) low power-low current wireless sensor network (WSN) for corrosion detection and monitoring of offshore wind turbine (OWT)’s component, entitled iWindCr, has been developed and field trialled in one of the OWTs in the UK south region. This paper reports on the setting up and outcomes of this field trial. The trial has successfully demonstrated the working functionality of the WSN by measuring changes of the Open Circuit Potential (OCP) and Zero Resistance Ammeter (ZRA) electrochemical parameters over a period of time. The state of corrosion and estimated life of an M72 galvanised steel stud, part of the Monopile (MP)-transition piece (TP) flanged connection were evaluated using the real-time data from the WSN with reference to the material’s corrosion thresholds from the iWindCr database. The paper details the electrochemical analysis processes in relation to the Electrochemical Impedance Spectroscopy (EIS), Potentiodynamic Polarisation Curve (PPC) in addition to the OCP and ZRA techniques. The electrochemical parameters and corrosion threshold values from seawater immersion tests of the steel alloys SS316L and S355, the typical MP-TP materials are presented

An investigation into the use of incoherent UV light to augment IR nanosecond pulsed laser texturing of CFRP composites for improved adhesion

The preparation of Carbon Fibre Reinforced Polymers (CFRP) surfaces for adhesive bonding has been widely reported. Such reports include laser texturing using both near-infrared (IR) lasers and ultraviolet (UV) lasers. In this report, we present, for the first time, findings showing that surface treatment of CFRP using incoherent UV light, at 254 nm wavelength, can increase the adhesive bonding strength of CFRP by 75 % compared to non-treated samples. It is also around 10 % stronger than NIR laser-textured samples. However, combination treatments, where the UV irradiation is conducted either before or after laser texturing did not give a significant benefit over the laser-textured samples. A germicidal 46 W 254 nm UV lamp was used for the UV light treatment, while an IR nanosecond pulsed fibre laser operating at 1064 nm was used for the laser texturing treatment. The material tested was an autoclave-cured T700 CFRP composite. The wettability of the treated CFRP surfaces and the adhesive bonding were quantitatively assessed. This study concludes that low-cost incoherent UV treatment effectively reduces the water contact angle of the CFRP surface and activates CFRP surfaces. All treatments led to bonding strengths at least 50% greater than for the untreated surfaces. The predominant failure mode for UV-treated samples was Cohesive Substrate Failure (CSF), indicating that the adhesion strength exceeded the interlaminar shear strength of the CFRP material. All samples treated with the laser (including combined treatment with UV) exhibited Light Fibre Tear Failure

Acceleration mechanism of abrasive particle in ultrasonic polishing under synergistic physical vibration and cavitation: Numerical study

Ultrasonic technology is widely applied in the engineering ceramic polishing processes without the limitation of material properties and ideally integrated into computer numerical control system. Ultrasonic-induced cavitation and mechanical vibration effect could accelerate the motion of solid abrasives. The individual behaviors of microjet/shockwave of ultrasonic cavitation in gases and liquids, and micro-abrasives with simple harmonic vibrations in solids and liquids has been extensively studied. To conduct a systematic and integrated study of abrasives behavior in the polishing contact region involving abrasive, surround-workpiece wall, ultrasonic physical vibration, and ultrasonic cavitation impact, a novel model integrating the free abrasive motion velocity and fixed abrasive indentation depth under multi-scale contact was proposed according to Hertzian contact theory, Greenwood-Williamson model, indentation deformation theory, the basic equations of cavitation bubble dynamics, cavitation impact control equations, and Newton's law of motion equation. The effects of ultrasonic amplitude, ultrasonic frequency, preloading force and particle size on the proposed model were investigated by theoretical analysis and numerical simulations. Ultrasonic physical vibration mainly influences the dynamic gap and further influence the number of different abrasives. Furthermore, the indentation depth of fixed abrasive depends mainly on the abrasive geometry. As the contact gap and abrasive size decrease, the indentation depth gradually decreases. Under the synergistic effect of cavitation-induced shock wave and microjet, the velocity of free abrasive in this paper is generally 0–150 m/s, and the kinetic energy of free abrasive increases roughly linearly with increasing frequency and approximately as a quadratic function with increasing particle size. Increasing the preloading force leads to a reduction in the abrasive kinetic energy. Besides, the kinetic energy induced by the shock wave has a cliff-like increment at an amplitude of 0.7–0.8 μm. It is revealed that the abrasive kinetic energy is suppressed by the cavitation bubble expansion and collapse at smaller ultrasonic pressure amplitude and surround-wall distance. This research provides a theoretical reference for the modeling of potential defects and material removal on the workpiece surface caused by abrasive motion during polishing, and reduces the trial cost for parameter optimization in actual polishing processing

A Study of the Corrosion Resistance of 316L Stainless Steel Manufactured by Powder Bed Laser Additive Manufacturing

Commercially available 316L (1.4404) stainless steel is commonly used for industrial filtration due to its combination of good material properties, particularly its corrosion resistance, which is a critical factor for filters in corrosive (e.g., saltwater) environments. Recently, laser powder bed fusion (LPBF) has enabled new more complex and efficient filtration pieces to be manufactured from this material. However, it is critical to know how the corrosion resistance is affected by this manufacturing strategy. Here, the corrosion resistance of LPBF manufactured 316L stainless steel is compared with wrought 316L sheet. The corrosion of the samples in saltwater was assessed with asymmetric electrochemical noise, potentiodynamic polarisation curve, and electrochemical impedance spectroscopy. The samples before and after corrosion were examined with scanning electron microscopy and energy-dispersive spectroscopy. The LPBF samples had higher corrosion resistance than the sheet samples and were more noble. The corrosion resistance of the LPBF sample increased with time, while the wrought sample corrosion resistance reduced over time. The corrosion mechanism of both samples was stable with time, formed of a passive film process and a bared material process. This paper presents the first study about the temporal evolution of the LPBF 316L stainless steel corrosion mechanism

Corrosion threshold data of metallic materials in various operating environment of offshore wind turbine parts (tower, foundation, and nacelle/gearbox)

This paper outlines corrosion thresholds for different environmental conditions of metallic materials commonly used in the tower, foundation, and nacelle/gearbox of an offshore wind turbine. These threshold values were derived from laboratory corrosion testing employing electrochemical analysis techniques, using the media/solvents that are representative to the operating environment of those wind turbine parts, such as seawater, grease, oils/lubricants, or their combination, at room temperature and at 328K. These values can provide an indication when general/local corrosion or protective film/surface damages have occurred. They can thus be utilised for detecting and monitoring corrosion at certain locations in the wind turbine structure. The presented data have been verified and validated to ensure their repeatability and reliability by means of numerous laboratory tests in accordance to the relevant engineering test standards and an extensive literature/published data review

Bridging the Divide Between Iterative Optical Polishing and Automation

Several recent business reports have described the global growth in demand for optical and photonic components, paralleled by technical reports on the growing shortage of skilled manufacturing staf to meet this demand. It is remarkable that producing ultraprecision surfaces remains so dependent on people, in contrast to other sectors of the economy, e.g., car manufacturing. Clearly, training can play some role, but ultimately, only process automation can provide the solution. This paper explores why automation is a challenge and summarizes multidisciplinary work aiming to assemble the building blocks required to realize automation