The effectiveness of combining rolling deformation with wire-arc additive manufacture on β-Grain refinement and texture modification in Ti-6Al-4V

In Additive Manufacture (AM), with the widely used titanium alloy Ti–6Al–4V, the solidification conditions typically result in undesirable, coarse-columnar, primary β grain structures. This can result in a strong texture and mechanical anisotropy in AM components. Here, we have investigated the efficacy of a new approach to promote β grain refinement in Wire–Arc Additive Manufacture (WAAM) of large scale parts, which combines a rolling step sequentially with layer deposition. It has been found that when applied in-process, to each added layer, only a surprisingly low level of deformation is required to greatly reduce the β grain size. From EBSD analysis of the rolling strain distribution in each layer and reconstruction of the prior β grain structure, it has been demonstrated that the normally coarse centimetre scale columnar β grain structure could be refined down to < 100 μm. Moreover, in the process both the β and α phase textures were substantially weakened to close to random. It is postulated that the deformation step causes new β orientations to develop, through local heterogeneities in the deformation structure, which act as nuclei during the α → β transformation that occurs as each layer is re-heated by the subsequent deposition pass

Alternative friction stir welding technology for titanium–6Al–4V propellant tanks within the space industry

Friction stir welding (FSW) offers an appealing solid state joining alternative to traditional fusion welding techniques for titanium alloys because it reduces problems associated with high temperature processing. Propellant tanks are a critical component of every spacecraft and contain several weld seams and a prime candidate for this innovative technology. This paper reviews the current technological maturity of FSW relative to titanium alloys and considers the application with respect to a pressure vessel. FSW is currently in a period of significant investment by large engineering companies and international research institutions. The technology is advancing and evolving to cater for high temperature alloys. Stationary shoulder FSW and hybrid techniques show promising potential with respect to Ti–6Al–4V. The tool material and limited process window for this material are restrictive factors at present but can be overcome with future development

Residual stress of as-deposited and rolled Wire + Arc Additive Manufacturing Ti–6Al–4V components

Wire + arc additive manufacturing components contain significant residual stresses, which manifest in distortion. High-pressure rolling was applied to each layer of a linear Ti–6Al–4V wire + arc additive manufacturing component in between deposition passes. In rolled specimens, out-of-plane distortion was more than halved; a change in the deposits' geometry due to plastic deformation was observed and process repeatability was increased. The Contour method of residual stresses measurements showed that although the specimens still exhibited tensile stresses (up to 500 MPa), their magnitude was reduced by 60%, particularly at the interface between deposit and substrate. The results were validated with neutron diffraction measurements, which were in good agreement away from the baseplate

Energy and force analysis of Ti-6Al-4V linear friction welds for computational modeling input and validation data

The linear friction welding (LFW) process is finding increasing use as a manufacturing technology for the production of titanium alloy Ti-6Al-4V aerospace components. Computational models give an insight into the process, however, there is limited experimental data that can be used for either modeling inputs or validation. To address this problem, a design of experiments approach was used to investigate the influence of the LFW process inputs on various outputs for experimental Ti-6Al-4V welds. The finite element analysis software DEFORM was also used in conjunction with the experimental findings to investigate the heating of the workpieces. Key findings showed that the average interface force and coefficient of friction during each phase of the process were insensitive to the rubbing velocity; the coefficient of friction was not coulombic and varied between 0.3 and 1.3 depending on the process conditions; and the interface of the workpieces reached a temperature of approximately approximately 1273 K (1000 °C) at the end of phase 1. This work has enabled a greater insight into the underlying process physics and will aid future modeling investigations.EPSRC, Boeing Company, Welding Institut

A system approach for modelling additive manufacturing in defence acquisition programs

Defence Contractors and NATOMinistry of Defences (MoDs) are currently exploiting Additive Manufacturing (AM) Technology to improve availability of defence platforms and support soldiers deployed in remote Area of Operations (AO). Additive Manufacturing is considered a disruptive technology when employed in a military context to reduce the reliance on supply chains and improve the responsiveness to Operation Tempo (OT). This papers aims at presenting a novel system approach to model the end-to-end process of delivering a product printed with AM and estimate accurately the time and costs of AM. Understanding better the time and costs of AM will allow the MoDs and Defence Contractors to perform comparison with current practices and support their decision making in AM technology acquisition

Resonant nonlinear magneto-optical effects in atoms

In this article, we review the history, current status, physical mechanisms, experimental methods, and applications of nonlinear magneto-optical effects in atomic vapors. We begin by describing the pioneering work of Macaluso and Corbino over a century ago on linear magneto-optical effects (in which the properties of the medium do not depend on the light power) in the vicinity of atomic resonances, and contrast these effects with various nonlinear magneto-optical phenomena that have been studied both theoretically and experimentally since the late 1960s. In recent years, the field of nonlinear magneto-optics has experienced a revival of interest that has led to a number of developments, including the observation of ultra-narrow (1-Hz) magneto-optical resonances, applications in sensitive magnetometry, nonlinear magneto-optical tomography, and the possibility of a search for parity- and time-reversal-invariance violation in atoms.Comment: 51 pages, 23 figures, to appear in Rev. Mod. Phys. in Oct. 2002, Figure added, typos corrected, text edited for clarit

An opportunistic Search for Extraterrestrial Intelligence (SETI) with the Murchison Widefield Array

© 2016. The American Astronomical Society. All rights reserved. A spectral line image cube generated from 115 minutes of MWA data that covers a field of view of 400 sq, deg. around the Galactic Center is used to perform the first Search for ExtraTerrestrial Intelligence (SETI) with the Murchison Widefield Array (MWA). Our work constitutes the first modern SETI experiment at low radio frequencies, here between 103 and 133 MHz, paving the way for large-scale searches with the MWA and, in the future, the low-frequency Square Kilometre Array. Limits of a few hundred mJy beam-1 for narrowband emission (10 kHz) are derived from our data, across our 400 sq. deg. field of view. Within this field, 45 exoplanets in 38 planetary systems are known. We extract spectra at the locations of these systems from our image cube to place limits on the presence of narrow line emission from these systems. We then derive minimum isotropic transmitter powers for these exoplanets; a small handful of the closest objects (10 s of pc) yield our best limits of order 1014 W (Equivalent Isotropic Radiated Power). These limits lie above the highest power directional transmitters near these frequencies currently operational on Earth. A SETI experiment with the MWA covering the full accessible sky and its full frequency range would require approximately one month of observing time. The MWA frequency range, its southern hemisphere location on an extraordinarily radio quiet site, its very large field of view, and its high sensitivity make it a unique facility for SETI

Measurement of the Neutron Spin Structure Function g1ng_1^n with a Polarized ^3He Target

Results are reported from the HERMES experiment at HERA on a measurement of the neutron spin structure function $g_1^n(x,Q^2)$ in deep inelastic scattering using 27.5 GeV longitudinally polarized positrons incident on a polarized $^3$He internal gas target. The data cover the kinematic range $0.023<x<0.6$ and $1 (GeV/c)^2 < Q^2 <15 (GeV/c)^2$. The integral $\int_{0.023}^{0.6} g_1^n(x) dx$ evaluated at a fixed $Q^2$ of $2.5 (GeV/c)^2$ is $-0.034\pm 0.013(stat.)\pm 0.005(syst.)$. Assuming Regge behavior at low $x$, the first moment $\Gamma_1^n=\int_0^1 g_1^n(x) dx$ is $-0.037\pm 0.013(stat.)\pm 0.005(syst.)\pm 0.006(extrapol.)$.Comment: 4 pages TEX, text available at http://www.krl.caltech.edu/preprints/OAP.htm

Modelling of friction stir welding of DH36 steel

A 3-D computational fluid dynamics (CFD) model was developed to simulate the friction stir welding of 6-mm plates of DH36 steel in an Eulerian steady-state framework. The viscosity of steel plate was represented as a non- Newtonian fluid using a flow stress function. The PCBN-WRe hybrid tool was modelled in a fully sticking condition with the cooling system effectively represented as a negative heat flux. The model predicted the temperature distribution in the stirred zone (SZ) for six welding speeds including low, intermediate and high welding speeds. The results showed higher asymmetry in temperature for high welding speeds. Thermocouple data for the high welding speed sample showed good agreement with the CFD model result. The CFD model results were also validated and compared against previous work carried out on the same steel grade. The CFD model also predicted defects such as wormholes and voids which occurred mainly on the advancing side and are originated due to the local pressure distribution between the advancing and retreating sides. These defects were found to be mainly coming from the lack in material flow which resulted from a stagnant zone formation especially at high tra- verse speeds. Shear stress on the tool surface was found to in- crease with increasing tool traverse speed. To produce a “sound” weld, the model showed that the welding speed should remain between 100 and 350 mm/min. Moreover, to prevent local melt- ing, the maximum tool’s rotational speed should not exceed 550 RPM