667 research outputs found
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Manufacturing technology
The specific goals of the Manufacturing Technology thrust area are to develop an understanding of fundamental fabrication processes, to construct general purpose process models that will have wide applicability, to document our findings and models in journals, to transfer technology to LLNL programs, industry, and colleagues, and to develop continuing relationships with industrial and academic communities to advance our collective understanding of fabrication processes. Advances in four projects are described here, namely Design of a Precision Saw for Manufacturing, Deposition of Boron Nitride Films via PVD, Manufacturing and Coating by Kinetic Energy Metallization, and Magnet Design and Application
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Implementation of an acoustic emission proximity detector for use in generating glass optics
We are using the approach acoustic emission (AE) signal during a grinding operation to detect the proximity of the grinding wheel relative to a brittle material workpiece and are using this detection as a feed- back control signal in our CNC. The repeatability of the AE signal during the wheel approach is the key that allows AE to be used as a proximity detector and is demonstrated at LLNL to be about mm. We noted significant changes of the AE signal as process parameters are modified, but conclude that with a quick CNC calibration routine and holding the parameters constant during a given operation, the AE system can be successfully used to sense pre- contact wheel- to- workpiece separation. Additionally, the AE sensing system allows real- time monitoring during grinding to provide in- process information. The first prototype of an AE system on a commercially available generator is currently be tested at the Center for Optics Manufacturing
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Performance evaluation of bound diamond ring tools
LLNL is collaborating with the Center for Optics Manufacturing (COM) and the American Precision Optics Manufacturers Association (APOMA) to optimize bound diamond ring tools for the spherical generation of high quality optical surfaces. An important element of this work is establishing an experimentally-verified link between tooling properties and workpiece quality indicators such as roughness, subsurface damage and removal rate. In this paper, we report on a standardized methodology for assessing ring tool performance and its preliminary application to a set of commercially-available wheels. Our goals are to (1) assist optics manufacturers (users of the ring tools) in evaluating tools and in assessing their applicability for a given operation, and (2) provide performance feedback to wheel manufacturers to help optimize tooling for the optics industry. Our paper includes measurements of wheel performance for three 2-4 micron diamond bronze-bond wheels that were supplied by different manufacturers to nominally- identical specifications. Preliminary data suggests that the difference in performance levels among the wheels were small
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Progress toward a performance based specification for diamond grinding wheels
This work sought to improve the communication between users and makers of fine diamond grinding wheels. A promising avenue for this is to formulate a voluntary product standard that comprises performance indicators that bridge the gap between specific user requirements and the details of wheel formulations. We propose a set of performance specifiers of figures-of-merit, that might be assessed by straightforward and traceable testing methods, but do not compromise proprietary information of the wheel user of wheel maker. One such performance indicator might be wheel hardness. In addition we consider technologies that might be required to realize the benefits of optimized grinding wheels. A non-contact wheel-to- workpiece proximity sensor may provide a means of monitoring wheel wear and thus wheel position, for wheels that exhibit high wear rates in exchange for improved surface finish
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In-process EDM truing to generate complex contours on metal-bond, superabrasive grinding wheels for precision grinding structural ceramics
The demand and use of precision grinding of structural ceramics continue to increase as the worldwide advanced ceramic industry surpasses $20 billion is sales. Included in this industry are engineering structural ceramics, electronic ceramics, bioceramics and others. These materials are used in applications such as engine components, casting and extrusion dies, bearings, medical implants, nozzles, thermal insulators, and more. Along with the variety of ceramic applications comes a broad range of precision requirements, which in turn leads to various required processes to accommodate a spectrum of specifications. A process for grinding ceramic components to micrometer tolerances was employed and further developed at Lawrence Livermore National Laboratory for two separate grinding projects
NuSTAR ground calibration: The Rainwater Memorial Calibration Facility (RaMCaF)
The Nuclear Spectroscopic Telescope Array (NuSTAR) is a NASA Small Explorer mission that will carry the first focusing hard X-ray (5-80 keV ) telescope to orbit. The ground calibration of the three flight optics was carried out at the Rainwater Memorial Calibration Facility (RaMCaF) built for this purpose. In this article we present the facility and its use for the ground calibration of the three optics
Electrochemical oxidation of dihydronicotinamide adenine dinucleotide (NADH) : Comparison of highly oriented pyrolytic graphite (HOPG) and polycrystalline boron-doped diamond (pBDD) electrodes
The electro-oxidation of nicotinamide adenine dinucleotide (NADH) is studied at bare surfaces of highly oriented pyrolytic graphite (HOPG) and semi-metallic polycrystalline boron-doped diamond (pBDD). A comparison of these two carbon electrode materials is interesting because they possess broadly similar densities of electronic states that are much lower than most metal electrodes, but graphite has carbon sp2-hybridization, while in diamond the carbon is sp3-hybridised, with resulting major differences in bulk structure and surface termination. Using cyclic voltammetry (CV), it is shown that NADH oxidation is facile at HOPG surfaces but the reaction products tend to strongly adsorb, which causes rapid deactivation of the electrode activity. This is an important factor that needs to be taken into account when assessing HOPG and its intrinsic activity. It is also shown that NADH itself adsorbs at HOPG, a fact that has not been recognized previously, but has implications for understanding the mechanism of the electro-oxidation process. Although pBDD was found to be less susceptible to surface fouling, pBDD is not immune to deterioration of the electrode response, and the reaction showed more sluggish kinetics on this electrode. Scanning electrochemical cell microscopy (SECCM) highlights a significant voltammetric variation in electroactivity between different crystal surface facets that are presented to solution with a pBDD electrode. The electroactivity of different grains correlates with the local dopant level, as visualized by field emission-scanning electron microscopy. SECCM measurements further prove that the basal plane of HOPG has high activity towards NADH electro-oxidation. These new insights on NADH voltammetry are useful for the design of optimal carbon-based electrodes for NADH electroanalysis
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