Links Between Machining Parameters and Surface Integrity in Drilling Ni-Superalloy

In aerospace industry, the manufacturing of critical parts (high energy components) requires an important validation process to guarantee the quality of the produced parts, and thus their fatigue lifecycle. Globally, this validation consists in freezing the cutting conditions using metallurgical analysis or fatigue trials, and a test on the first article. This process is extremely complex and expensive. In this way establishing the correlation between the cutting conditions and the surface integrity will help us to optimize the manufacture of those parts. In this article, by the means of an experimental method, we define a domain of validation by combining the cutting conditions according to the classic criteria established by AFNOR E66-520 norm (Couple-Tool-Material) and the criteria of surface integrity for the drilling of a Nickel-base superalloy. The experimental device consists in drilling a Ø15.5 mm hole on a 3-axis milling centre instrumented by a 4 components Kistler dynamometer (Fx, Fy, Fz and Mz), a spindle power sensor “Watt-pilote” and three accelerometers placed following the directions X, Y and Z. Scanning Electron Microscopy (SEM) observations, micro-hardness tests and topographic measurements with an optical profilometer, are carried out to characterize the metallurgical state of the holes manufactured. Finally, correlations were respectively made between the cutting conditions, the recorded signals and the metallurgical state of the holes

Apodized pupil Lyot coronagraphs for arbitrary apertures. V. Hybrid Shaped Pupil designs for imaging Earth-like planets with future space observatories

We introduce a new class of solutions for Apodized Pupil Lyot Coronagraphs (APLC) with segmented aperture telescopes to remove broadband diffracted light from a star with a contrast level of $10^{10}$. These new coronagraphs provide a key advance to enabling direct imaging and spectroscopy of Earth twins with future large space missions. Building on shaped pupil (SP) apodization optimizations, our approach enables two-dimensional optimizations of the system to address any aperture features such as central obstruction, support structures or segment gaps. We illustrate the technique with a design that could reach $10^{10}$ contrast level at 34\,mas for a 12\,m segmented telescope over a 10\% bandpass centered at a wavelength $\lambda_0=$500\,nm. These designs can be optimized specifically for the presence of a resolved star, and in our example, for stellar angular size up to 1.1\,mas. This would allow probing the vicinity of Sun-like stars located beyond 4.4\,pc, therefore fully retiring this concern. If the fraction of stars with Earth-like planets is \eta_{\Earth}=0.1, with 18\% throughput, assuming a perfect, stable wavefront and considering photon noise only, 12.5 exo-Earth candidates could be detected around nearby stars with this design and a 12\,m space telescope during a five-year mission with two years dedicated to exo-Earth detection (one total year of exposure time and another year of overheads). Our new hybrid APLC/SP solutions represent the first numerical solution of a coronagraph based on existing mask technologies and compatible with segmented apertures, and that can provide contrast compatible with detecting and studying Earth-like planets around nearby stars. They represent an important step forward towards enabling these science goals with future large space missions.Comment: 9 pages, 6 figures, ApJ accepted on 01/04/201

Explosion risks from nanomaterials

International audienceEmerging nanomanufactured products are being incorporated in a variety of consumer products ranging from closer body contact products (i.e. cosmetics, sunscreens, toothpastes, pharmaceuticals, clothing) to more remote body-contact products (electronics, plastics, tires, automotive and aeronautical), hence posing potential health and environmental risks. The new field of nanosafety has emerged and needs to be explored now rather than after problems becomes so ubiquitous and difficult to treat that their trend become irreversible. Such endeavour necessitates a transdisciplinary approach. A commonly forgotten and/or misunderstood risk is that of explosion/detonation of nanopowders, due to their high specific active surface areas. Such risk is emphasized and illustrated with the present development of an appropriate risk analysis. For this particular risk, a review of characterization methods and their limitations with regard to nanopowders is presented and illustrated for a few organic and metallic nanopowders

Ignition and explosion of nanopowders: something new under the dust

International audienceThis work deals with the study of ignition and explosion characteristics of nanoparticles. It has been carried out on various powders: zinc, aluminum, carbon blacks... Specific behaviours have been highlighted during the first phase of this project (Nanosafe 2). For instance, it has been demonstrated that there mainly exists two combustion regimes that are either kinetically controlled, for small size particles, or diffusion controlled, for large size particles (generally with diameters greater than 1 or 2 µm). It has been found that as the particle size decreases, minimum ignition temperature and minimum ignition energy decrease (even lower than 1 mJ), indicating higher potential inflammation and explosion risks for metallic nanopowders. Moreover, the presence of agglomerates in the nanopowders could modify their reactivity. Thus, the explosion severity of Al powders tends to increase as the specific surface area decreases, before reaching a peak for 1 µm particle size. These results are essential for industries producing or handling nanopowders in order to propose/design new and proper prevention and protection means. Nevertheless, the validity of the classical characterization tools with regard to nanopowders should be discussed. For example, the experimental laminar flame velocity of Al dusts has been compared to a theoretical one, determined by Huang's model, which assumes that the propagation of the flame is run mainly by conduction. It has shown a good agreement. However, under certain conditions, the Al flame propagation is expected to be mainly conducted by radiation. Two hypotheses can then be made. On the one hand, it can be assumed that the 20 L sphere probably disturbs the flame propagation and thermal mechanisms by absorbing radiation (wall quenching effect). On the other hand, it has been observed, thanks to the use of a high speed camera that the preheating zone is smaller for some nanopowders than for micro-particles (figure below). It could notably be explained by the fact that the flame radiation is absorbed by the cloud of unburnt Al nanopowders. Several other factors may have an impact on the explosion severity. If these points are correctly addressed, it will be possible to get more reliable ignition and explosion characteristics

Impact of disturbed drilling conditions on the surface integrity of a Nickel-base superalloy

Manufacturing critical parts for aerospace industry requires an important validation process to guarantee the quality of the produced components, and thus their fatigue life. Even with the best cutting conditions, disturbances can occur during the process and may have a direct impact on metallurgical quality. Through an experimental approach, this work presents the impact, during machining, of a lubricant interruption on the surface integrity and on the Process Monitoring signals. Finally a correlation between the thickness of the thermo-mechanically affected layer and the cutting power is made

The effect of agglomeration on the emission of particles from nanopowders flow

International audienceThis paper suggests an original method to evaluate the possible emission of particles from a nanopowder submitted to a shear stress in dense phase and the resulting degree of agglomeration of the particles released. The method is based upon the monitoring of the rheological signature of the nanopowders, thanks to a powder rheometer. As a function of the increasing shear rate, the powder flow will evolve from the newtonian state (dense powder) to the coulombian state (dense rheofluidified phase). If the shear rate is high enough, the powder will be set in suspension and the kinetic state (a leaner dense phase submitted to particles collisions) will be reached. The shear stress in this state is dependent on the particle or the agglomerate diameter for cohesive powders, which can be then calculated from rheograms. Carbon black and silica nanopowders have been tested and compared to other experiments carried out on non cohesive glass beads microparticles, chosen as reference. For the different glass beads powders, the average value of their 'agglomerate' diameter is 12% different of the primary diameter, indicating agglomeration of less than two particles. Nanometric agglomerates were found to be of hundred micrometers diameter. That is in line with the high tendency of the nanoparticles to agglomerate. This work can be used to evaluate the current safety tests, such as Hartmann's tube or 20 L sphere apparatuses, to verify whether the standard equipment for microparticles is suitable for the use of nanoparticles. This is linked to research projects like NanoSafe 2

Evolution du niveau d'agglomération de nanopoudres d'aluminium : une approche rhéologique

National audienceFrom micrometric size to nanometric size, the increase of the surface energies allows the agglomeration to be preponderant and then, the risks linked to powders are changed. When the toxicity, the inflammation and explosion risks of nanoparticles are mentioned, the agglomerates must be taken into account. The effect of agglomeration in the behavior of nanopowders has been studied from experimental observation of agglomerated nanopowders of aluminum subjected to shear in a powder rheometer. In order to understand the effect of deagglomeration on the powders, the agglomerate strength has been estimated thanks to the porosity of the powder bed contained in the rheometer cell. This one is ranged between 10 kPa and 1 MPa. The rheological tests show that, compared with the micrometric aluminum, the aluminum nanopowders have a peculiar behavior in the Geldart's classification, being in both class A and C. This fact is due to the facility of nanoparticles to agglomerate and to stay agglomerated.Lorsque l'on passe de la dimension micrométrique à la dimension nanométrique, l'augmentation importante des énergies de surface rend prépondérants les phénomènes d'agglomération. Ceci modifie l'appréhension des risques liés aux poudres. Pour parler de toxicité, de risques d'inflammation et d'explosion des nanoparticules, nous devons prendre en compte la présence d'agglomérats. L'effet de l'agglomération sur la dispersibilité des nanopoudres a été étudié à partir d'observations expérimentales de nanopoudres agglomérées d'aluminium soumises au cisaillement fourni par un rhéomètre à poudres. Pour comprendre l'effet de la désagglomération sur les poudres, nous avons déjà estimé la contrainte d'agglomération mise en jeu à partir de la porosité du lit de poudres contenues dans la cellule du rhéomètre. Cette contrainte est globalement ici comprise entre 10 kPa et 1MPa. Les tests en rhéologie ont montré qu'en comparaison avec une poudre d'aluminium micrométrique, les nanopoudres d'aluminium ont un comportement particulier vis-à-vis de la classification de Geldart, appartenant à la fois aux classes A et C, ceci étant du à la facilité des nanoparticules à s'agglomérer et à le rester

The Skull Vibration-Induced Nystagmus Test of Vestibular Function—A Review

A 100-Hz bone-conducted vibration applied to either mastoid induces instantaneously a predominantly horizontal nystagmus, with quick phases beating away from the affected side in patients with a unilateral vestibular loss (UVL). The same stimulus in healthy asymptomatic subjects has little or no effect. This is skull vibration-induced nystagmus (SVIN), and it is a useful, simple, non-invasive, robust indicator of asymmetry of vestibular function and the side of the vestibular loss. The nystagmus is precisely stimulus-locked: it starts with stimulation onset and stops at stimulation offset, with no post-stimulation reversal. It is sustained during long stimulus durations; it is reproducible; it beats in the same direction irrespective of which mastoid is stimulated; it shows little or no habituation; and it is permanent—even well-compensated UVL patients show SVIN. A SVIN is observed under Frenzel goggles or videonystagmoscopy and recorded under videonystagmography in absence of visual-fixation and strong sedative drugs. Stimulus frequency, location, and intensity modify the results, and a large variability in skull morphology between people can modify the stimulus. SVIN to 100 Hz mastoid stimulation is a robust response. We describe the optimum method of stimulation on the basis of the literature data and testing more than 18,500 patients. Recent neural evidence clarifies which vestibular receptors are stimulated, how they cause the nystagmus, and why the same vibration in patients with semicircular canal dehiscence (SCD) causes a nystagmus beating toward the affected ear. This review focuses not only on the optimal parameters of the stimulus and response of UVL and SCD patients but also shows how other vestibular dysfunctions affect SVIN. We conclude that the presence of SVIN is a useful indicator of the asymmetry of vestibular function between the two ears, but in order to identify which is the affected ear, other information and careful clinical judgment are needed

High-contrast imager for Complex Aperture Telescopes (HiCAT): 1. Testbed design

Searching for nearby habitable worlds with direct imaging and spectroscopy will require a telescope large enough to provide angular resolution and sensitivity to planets around a significant sample of stars. Segmented telescopes are a compelling option to obtain such large apertures. However, these telescope designs have a complex geometry (central obstruction, support structures, segmentation) that makes high-contrast imaging more challenging. We are developing a new high-contrast imaging testbed at STScI to provide an integrated solution for wavefront control and starlight suppression on complex aperture geometries. We present our approach for the testbed optical design, which defines the surface requirements for each mirror to minimize the amplitude-induced errors from the propagation of out-of-pupil surfaces. Our approach guarantees that the testbed will not be limited by these Fresnel propagation effects, but only by the aperture geometry. This approach involves iterations between classical ray-tracing optical design optimization, and end-to-end Fresnel propagation with wavefront control (e.g. Electric Field Conjugation / Stroke Minimization). The construction of the testbed is planned to start in late Fall 2013.Comment: Proc. of the SPIE 8864, 10 pages, 3 figures, Techniques and Instrumentation for Detection of Exoplanets V