Improving Tribological Properties of Cast Al-Si Alloys Through Application of Wear-Resistant Thermal Spray Coatings

Flame Spray Thermal Spray coatings are low-cost, high-wear surface-treatment technologies. However, little has been reported on their potential effects on cast automotive aluminum alloys. The aim of this research was to investigate the tribological properties of as-sprayed NiCrBSi and WC/12Co Flame Spray coatings applied to two cast aluminum alloys: high-copper LM24 (AlSi8Cu3Fe), and low-copper LM25 (AlSi7Mg). Potential interactions between the mechanical properties of the substrate and the deposited coatings were deemed to be significant. Microstructural, microhardness, friction, and wear (pin-on-disk, microabrasion, Taber abrasion, etc.) results are reported, and the performance differences between coatings on the different substrates were noted. The coefficient of friction was reduced from 0.69-0.72 to 0.12-0.35. Wear (pin-on-disk) was reduced by a factor of 103-104, which was related to the high surface roughness of the coatings. Microabrasion wear was dependent on coating hardness and applied load. Taber abrasion results showed a strong dependency on the substrate, coating morphology, and homogeneity

University Public-Access Mandates Are Good for Science

A new and better order to make scholarship available for free to all is emerging through deposit mandates like those adopted by Harvard, MIT, and Kansas

The Electrochemical Deposition of Zn-Mn Coating from Choline Choloride-urea Deep Eutectic Solvent

Electrochemical and microscopic techniques were used for characterization of Zn˗Mn coatings electrodeposited from choline chloride˗urea deep eutectic solvent. Cyclic voltammograms show that there was no discernible Mn reduction peak when only Mn2+ was present in DES solution. The distinct Mn peak developed only upon addition of Zn2+ to the solution, probably due to previous Zn nucleation on the steel substrate. It was found that 22-27 wt.% Mn, was deposited at current densities of 3-8 mA cm-2, amounts significantly higher than in aqueous electrolytes. Since higher deposition current densities resulted in the formation of a porous surface consisting of clusters of nodular crystallites, the optimal deposition c.d was determined to be 3 mA cm˗2

Development and Calibration of a Field-Deployable Microphone Phased Array for Propulsion and Airframe Noise Flyover Measurements

A new aeroacoustic measurement capability has been developed consisting of a large channelcount, field-deployable microphone phased array suitable for airframe noise flyover measurements for a range of aircraft types and scales. The array incorporates up to 185 hardened, weather-resistant sensors suitable for outdoor use. A custom 4-mA current loop receiver circuit with temperature compensation was developed to power the sensors over extended cable lengths with minimal degradation of the signal to noise ratio and frequency response. Extensive laboratory calibrations and environmental testing of the sensors were conducted to verify the design's performance specifications. A compact data system combining sensor power, signal conditioning, and digitization was assembled for use with the array. Complementing the data system is a robust analysis system capable of near real-time presentation of beamformed and deconvolved contour plots and integrated spectra obtained from array data acquired during flyover passes. Additional instrumentation systems needed to process the array data were also assembled. These include a commercial weather station and a video monitoring / recording system. A detailed mock-up of the instrumentation suite (phased array, weather station, and data processor) was performed in the NASA Langley Acoustic Development Laboratory to vet the system performance. The first deployment of the system occurred at Finnegan Airfield at Fort A.P. Hill where the array was utilized to measure the vehicle noise from a number of sUAS (small Unmanned Aerial System) aircraft. A unique in-situ calibration method for the array microphones using a hovering aerial sound source was attempted for the first time during the deployment

Improving tribological properties of cast Al-Si alloys through application of wear-resistant thermal spray coatings

Flame Spray Thermal Spray coatings are low-cost, high-wear surface-treatment technologies. However, little has been reported on their potential effects on cast automotive aluminum alloys. The aim of this research was to investigate the tribological properties of as-sprayed NiCrBSi and WC/12Co Flame Spray coatings applied to two cast aluminum alloys: high-copper LM24 (AlSi8Cu3Fe), and low-copper LM25 (AlSi7Mg). Potential interactions between the mechanical properties of the substrate and the deposited coatings were deemed to be significant. Microstructural, microhardness, friction, and wear (pin-on-disk, microabrasion, Taber abrasion, etc.) results are reported, and the performance differences between coatings on the different substrates were noted. The coefficient of friction was reduced from 0.69-0.72 to 0.12-0.35. Wear (pin-on-disk) was reduced by a factor of 103-104, which was related to the high surface roughness of the coatings. Microabrasion wear was dependent on coating hardness and applied load. Taber abrasion results showed a strong dependency on the substrate, coating morphology, and homogeneity

LSST Science Book, Version 2.0

A survey that can cover the sky in optical bands over wide fields to faint magnitudes with a fast cadence will enable many of the exciting science opportunities of the next decade. The Large Synoptic Survey Telescope (LSST) will have an effective aperture of 6.7 meters and an imaging camera with field of view of 9.6 deg^2, and will be devoted to a ten-year imaging survey over 20,000 deg^2 south of +15 deg. Each pointing will be imaged 2000 times with fifteen second exposures in six broad bands from 0.35 to 1.1 microns, to a total point-source depth of r~27.5. The LSST Science Book describes the basic parameters of the LSST hardware, software, and observing plans. The book discusses educational and outreach opportunities, then goes on to describe a broad range of science that LSST will revolutionize: mapping the inner and outer Solar System, stellar populations in the Milky Way and nearby galaxies, the structure of the Milky Way disk and halo and other objects in the Local Volume, transient and variable objects both at low and high redshift, and the properties of normal and active galaxies at low and high redshift. It then turns to far-field cosmological topics, exploring properties of supernovae to z~1, strong and weak lensing, the large-scale distribution of galaxies and baryon oscillations, and how these different probes may be combined to constrain cosmological models and the physics of dark energy.Comment: 596 pages. Also available at full resolution at http://www.lsst.org/lsst/sciboo

Heterozygous Variants in KMT2E Cause a Spectrum of Neurodevelopmental Disorders and Epilepsy.

We delineate a KMT2E-related neurodevelopmental disorder on the basis of 38 individuals in 36 families. This study includes 31 distinct heterozygous variants in KMT2E (28 ascertained from Matchmaker Exchange and three previously reported), and four individuals with chromosome 7q22.2-22.23 microdeletions encompassing KMT2E (one previously reported). Almost all variants occurred de novo, and most were truncating. Most affected individuals with protein-truncating variants presented with mild intellectual disability. One-quarter of individuals met criteria for autism. Additional common features include macrocephaly, hypotonia, functional gastrointestinal abnormalities, and a subtle facial gestalt. Epilepsy was present in about one-fifth of individuals with truncating variants and was responsive to treatment with anti-epileptic medications in almost all. More than 70% of the individuals were male, and expressivity was variable by sex; epilepsy was more common in females and autism more common in males. The four individuals with microdeletions encompassing KMT2E generally presented similarly to those with truncating variants, but the degree of developmental delay was greater. The group of four individuals with missense variants in KMT2E presented with the most severe developmental delays. Epilepsy was present in all individuals with missense variants, often manifesting as treatment-resistant infantile epileptic encephalopathy. Microcephaly was also common in this group. Haploinsufficiency versus gain-of-function or dominant-negative effects specific to these missense variants in KMT2E might explain this divergence in phenotype, but requires independent validation. Disruptive variants in KMT2E are an under-recognized cause of neurodevelopmental abnormalities

Process Refinement Through Design of Experiments (Taguchi) to Reduce Porosity Levels of Thin Flame Spray NiCrBSi Coatings on Cast Aluminium Alloys

Thin(16matrix of key deposition parameters was constructed to develop the optimum spray parameters. The effects of parameter variations on the porosity levels of these coatings were assessed. Key parameter interactions were reported. Quantifiable interactions between the selected parameters were noted for the LM24 substrate. However, on the LM25 substrate these interactions were much less defined. Corrosion performance of the optimised coatings, based on electrochemical impedance spectroscopy, was reported. The presence of through-pores in the coatings were shown to reduce the corrosion resistance of the coated systems by a factor of 10, in dilute NaCl solutions, compared to bulk 316L stainless steel

Impact of Intermetallic Precipitates on the Tribological and/or Corrosion Performance of Cast Aluminium Alloys: a Short Review

The role of various intermetallic precipitates (IMP), or secondary phase particles, in governing the wear and corrosion performance characteristics of cast aluminium alloys is outlined in this brief review. Such alloys are especially important in transport applications where their low weight, low cost and recyclability make them very attractive. However alloy wear and/or corrosion behaviour often limit their industrial application and more work needs to done to extend their use into other areas. Careful control of IMP nucleation and growth rates may be beneficial, especially in alloys exposed to corrosive environments. Silicon, copper and magnesium are all important elements for enhanced mechanical strength and tribological performance but often to the detriment of alloy corrosion resistance. Other elements such as iron may also play a significant role in deleterious IMP formation. Use of dispersoids based on novel (quasicrystals) seed alloys with similar lattice characteristics to the α-Al matrix may result in further exploitation of these alloys

Localised Galvanic Corrosion Processes in Thermal Spray Coated/Cast Aluminium Alloy systems

Cast Aluminium Alloys, because of the propensity of aluminium to react with impurities and alloying elements, are prone to developing IM impurities during the solidification process. These IM phases can act, in some fluids, as initiation sites for localised corrosion processes, resulting in degradation phenomena, such as pitting. Whilst Thermal Spray coatings can improve the wear resistance of Cast Aluminium Alloys, their corrosion performance may be hampered by the presence of through porosity within the coating. The present work details some preliminary studies of the localised corrosion processes occurring at the interface area between a Thermal Spray coating and a cast aluminium alloy. Using the SVP100 SVET system, cross sections of the coated samples, immersed in a NaCl or NaCl/HCl solution, were scanned, over extended periods, in order to map the progressive development of cathodic and anodic areas. EIS sampling, over periods of up to 72 hours, and the results of the Acidified Salt Spray cabinet testing are also presented. Although only preliminary work has been performed thus far, the premise that the presence of more noble metals along the path of open pores in Thermal Spray coatings on cast Aluminium Alloy, LM25, in the presence of an aggressive aqueous solution, results in the expedited corrosion of the substrate is demonstrated. This occurs, preferentially, around the intermetallic phases, predominantly Fe-based, and results in further destruction of the coating, through spalling, exposing additional substrate to corrosive attack