Processing of hybrid laminates integrating ZrB2/SiC and SiC layers

Tape casting technique was used to develop hybrid laminates constituting by SiC and ZrB2-SiC layers; the main aim is obtaining a structure which integrate the unique properties of these materials and potentially extent their application temperature range. Multilayer with ZrB2-SiC layers stacked in between SiC ones were successfully processed. Thin cracks propagated in the composite layers without affecting SiC ones; their formation was due to residual stresses developed in the two materials because of the differences in their shrinkage and coefficients of thermal expansion. However, these cracks did not significantly affect the material properties: relative density, elastic modulus and flexural strength of hybrid laminates was indeed only slightly lower than those of laminates made up of layers with the same composition

Influence of focus offset on the microstructure of an intermetallic gamma-TiAl based alloy produced by electron beam powder bed fusion

It is well established in literature that, when processing intermetallic gamma-TiAl components by electron beam powder bed fusion, a banded microstructure is frequently formed because of an inhomogeneous Al distribution since more pronounced evaporation of Al occurs at the top of the melt pool. This feature is particularly promoted when highly energetic process parameters (high beam currents, slow beam speeds, narrow line offsets) are used. Therefore, an approach already suggested in the literature to reduce the Al loss is to minimize the energy level of the process parameter during production. However, there is a limit to such kind of approach: minimizing the beam current or increasing the beam speed, or increasing the line offset will, at a certain point, results in not being able to achieve a completely dense material and thus some process -induced porosity, the so-called lack-of-fusion defects, starts to occur in the produced parts.In this study, the effect of an additional parameter of the electron beam powder bed fusion process is taken under consideration: the focus offset (FO), i.e. the distance between the focusing plane of the electron beam with respect to the powder bed. The effect of the FO on the residual porosity, microstructure, phase composition, hardness as well as chemical composition is investigated, thus having the possibility to demonstrate that also the FO can affect the Al loss and play a fundamental role in the generation of a homogenous microstructure, contributing to mitigate the appearance of a banded microstructure

Information-rich quality controls prediction model based on non-destructive analysis for porosity determination of AISI H13 produced by electron beam melting

The number of materials processed via additive manufacturing (AM) technologies has rapidly increased over the past decade. As of these emerging technologies, electron beam powder bed fusion (EB-PBF) process is becoming an enabling technology to manufacture complex-shaped components made of thermal-cracking sensitive materials, such as AISI H13 hot-work tool steel. In this process, a proper combination of process parameters should be employed to produce dense parts. Therefore, one of the first steps in the EB-PBF part production is to perform the process parameter optimization procedure. However, the conventional procedure that includes the image analysis of the cross-section of several as-built samples is time-consuming and costly. Hence, a new model is introduced in this work to find the best combination of EB-PBF process parameters concisely and cost-effectively. A correlation between the surface topography, the internal porosity, and the process parameters is established. The correlation between the internal porosity and the melting process parameters has been described by a high robust model (R-adj(2) = 0.91) as well as the correlation of topography parameters and melting process parameters (R-adj(2) = 0.77-0.96). Finally, a robust and information-rich prediction model for evaluating the internal porosity is proposed (R-adj(2) = 0.95) based on in situ surface topography characterization and process parameters. The information-rich prediction model allows obtaining more robust and representative model, yielding an improvement of about 4% with respect to the process parameter-based model. The model is experimentally validated showing adequate performances, with a RMSE of 2% on the predicted porosity. This result can support process and quality control designers in optimizing resource usage towards zero-defect manufacturing by reducing scraps and waste from destructive quality controls and reworks

Residual stress investigation on Ti-48Al-2Cr-2Nb samples produced by Electron Beam Melting process

Ti-48Al-2Cr-2Nb (Ti-48-2-2) is an intermetallic alloy belonging to a family of gamma-TiAl intermetallic alloys that are attracting significant attention. Electron Beam Melting (EBM) process is today the only manufacturing process that allows effective production of parts made by these kinds of alloys. Proper process control avoids high temperatures in the surrounding areas that may generate significant residual stresses that could cause micro-cracks. In this paper, an investigation on the residual stress state on Ti-48-2-2 parts is carried out using the hole drilling method. In particular, the influence of EBM process parameters is evaluated in order to understand the effects of the residual stresses on part integrity

Stress corrosion cracking of additively manufactured alloy 625

Laser bed powder fusion (LPBF) is an additive manufacturing technology for the fabrication of semi-finished components directly from computer-aided design modelling, through melting and consolidation, layer upon layer, of a metallic powder, with a laser source. This manufacturing technique is particularly indicated for poor machinable alloys, such as Alloy 625. However, the unique microstructure generated could modify the resistance of the alloy to environment assisted cracking. The aim of this work was to analyze the stress corrosion cracking (SCC) and hydrogen embrittlement resistance behavior of Alloy 625 obtained by LPBF, both in as-built condition and after a standard heat treatment (grade 1). U-bend testing performed in boiling magnesium chloride at 155 and 170◦C confirmed the immunity of the alloy to SCC. However, slow strain rate tests in simulated ocean water on cathodically polarized specimens highlighted the possibility of the occurrence of hydrogen embrittlement in a specific range of strain rate and cathodic polarization. The very fine grain size and dislocation density of the thermally untreated specimens appeared to increase the hydrogen diffusion and embrittlement effect on pre-charged specimens that were deformed at the high strain rate. Conversely, heat treatment appeared to mitigate hydrogen embrittlement at high strain rates, however at the slow strain rate all the specimens showed a similar behavior

production and characterization of ni and cu composite coatings by electrodeposition reinforced with carbon nanotubes or graphite nanoplatelets

Electrodeposition is well-known as a versatile and economical processing technique to produce metal coatings on conductive substrates. Recently, it has been gaining increasing interest also for the production of tailored composite coatings, containing for instance floropolymers or silicon carbide. A more novel approach concerns the use of carbon nanotubes or even graphene, in the form of graphite nano-platelets. The production of Ni- and Cu-based nanocomposites containing carbon nanoreinforcements was carried out by using standard electrodeposition conditions, but with a particular attention to the dispersion of the nanotubes. The obtained coatings were strong and well adherent to the steel substrate, and presented rather well dispersed carbon nanotubes or graphite nanoplatelets, even if some agglomerates could be present in samples obtained from highly concentrated suspensions. In the case of nickel-based composite coatings, the size of nickel grains was reduced, and pin-on-disc tests demonstrated a significant increase in the life of the coating. In the case of copper-based composite coatings, thermal diffusivity measurements demonstrated that the carbon nanomaterial does not reduce the conductivity of the pure copper coating

Novel diagnostic DNA methylation episignatures expand and refine the epigenetic landscapes of Mendelian disorders

Overlapping clinical phenotypes and an expanding breadth and complexity of genomic associations are a growing challenge in the diagnosis and clinical management of Mendelian disorders. The functional consequences and clinical impacts of genomic variation may involve unique, disorder-specific, genomic DNA methylation episignatures. In this study, we describe 19 novel episignature disorders and compare the findings alongside 38 previously established episignatures for a total of 57 episignatures associated with 65 genetic syndromes. We demonstrate increasing resolution and specificity ranging from protein complex, gene, sub-gene, protein domain, and even single nucleotide-level Mendelian episignatures. We show the power of multiclass modeling to develop highly accurate and disease-specific diagnostic classifiers. This study significantly expands the number and spectrum of disorders with detectable DNA methylation episignatures, improves the clinical diagnostic capabilities through the resolution of unsolved cases and the reclassification of variants of unknown clinical significance, and provides further insight into the molecular etiology of Mendelian conditions

Novel diagnostic DNA methylation episignatures expand and refine the epigenetic landscapes of Mendelian disorders.

Overlapping clinical phenotypes and an expanding breadth and complexity of genomic associations are a growing challenge in the diagnosis and clinical management of Mendelian disorders. The functional consequences and clinical impacts of genomic variation may involve unique, disorder-specific, genomic DNA methylation episignatures. In this study, we describe 19 novel episignature disorders and compare the findings alongside 38 previously established episignatures for a total of 57 episignatures associated with 65 genetic syndromes. We demonstrate increasing resolution and specificity ranging from protein complex, gene, sub-gene, protein domain, and even single nucleotide-level Mendelian episignatures. We show the power of multiclass modeling to develop highly accurate and disease-specific diagnostic classifiers. This study significantly expands the number and spectrum of disorders with detectable DNA methylation episignatures, improves the clinical diagnostic capabilities through the resolution of unsolved cases and the reclassification of variants of unknown clinical significance, and provides further insight into the molecular etiology of Mendelian conditions