Fracture Resistance of Repaired 5Y-PSZ Zirconia Crowns after Endodontic Access

This study analyzed the fracture load before and after a chewing simulation of zirconia crowns that were trepanned and repaired using composite resin. Overall, 3 groups with 15 5Y-PSZ crowns in each group were tested. For group A, the fracture load of the unmodified crowns was evaluated. For group B, the crowns were trepanned and repaired using composite resin, also followed by a fracture test. For group C, crowns were prepared like in group B but received thermomechanical cycling before the final fracture tests. Furthermore, scanning electron microscopy (SEM) and X-ray microscopy (XRM) analysis were performed for group C. The mean fracture loads and standard deviation were 2260 N ± 410 N (group A), 1720 N ± 380 N (group B), and 1540 N ± 280 N (group C). Tukey-Kramer multiple comparisons showed a significant difference between groups A and B (p < 0.01) and groups A and C (p < 0.01). After ageing, surface fissures were detected via SEM, but no cracks that reached from the occlusal to the inner side of the crown were detected via XRM. Within the limitations of this study, it can be stated that trepanned and composite-repaired 5Y-PSZ crowns show lower fracture loads than 5Y-PSZ crowns without trepanation

Ion Beam Processing for Sample Preparation of Hybrid Materials with Strongly Differing Mechanical Properties

For studies of the interface zone of metallic composites with significantly differing mechanical properties across the interface, high-quality sample preparation is paramount. In particular, the analysis of the composition or geometric characteristics of intermetallic phases close to the interface requires a preparation specifically adapted to the actual sample. In the present study, the combination of ion beam processing and a conventional metallographic preparation routine is investigated. It is shown that by utilizing a suitable combination of metallographic and ion beam processing routines, the interface zone of metallic composites can be prepared specifically targeted to a given analytical task. Especially for material combinations with largely differing mechanical properties of the base materials, ion beam processing can greatly improve the sample preparation quality. © 2020, The Author(s)

An X-ray Microscopy Study of the Microstructural Effects on Thermal Conductivity in Cast Aluminum-Copper Compounds

A metallurgical joint between aluminum and copper established by compound casting provides for high thermal conductivity, which is required for lightweight cooling solutions in applications such as high-power light-emitting diodes or computer processors. If casting is employed in a silane-doped inert gas atmosphere whose oxygen partial pressure is adequate to extreme high vacuum, reoxidation of the active surfaces of aluminum and copper is prevented, and thus a metallurgical bond can be created directly between aluminum and copper. With this approach, thermal conductivities as high as 88.3 W/m·K were realized. In addition, X-ray microscopy was used to shed light on the microstructure–thermal property relationship. It is demonstrated that both porosity and non-bonded areas have a substantial impact on the thermophysical properties of the compound zone. Based on the data obtained, casting parameters can be developed that provide for defect-free bonding zones and optimal heat transfer between the joining partners

Tailored Forming of Hybrid Bevel Gears with Integrated Heat Treatment

“In recent years, multi-material designs of technical components have been gaining in importance. When combining different materials in a single component, it is possible to achieve high performance and extended functionality while simultaneously saving cost-intensive or rare materials. One promising approach to manufacture hybrid parts such as bi-metal gears is the utilization of the technology of tailored forming. This technology includes three main process steps: producing of bi-metal workpieces, forming and finishing. At the example of bevel gears, bi-metal preforms were produced by laser cladding of the martensitic steel X45CrSi9-3 on a cylindrical substrate made of the carbon steel C22.8 and formed to the final gear geometry by means of hot die forging. Subsequently, the hot bevel gears were directly quenched from hot-forming temperature by an air-water spray and self-tempered using the residual heat. To analyse the effect of each process step on the microstructure, specimens were extracted from cladded, forged and heat treated components and investigated by means of metallographic analysis and hardness measurements. The results demonstrate that cladded workpieces were successfully formed to complex toothed parts without any defects. The hot forming process has a positive impact on the welded layer and the interface zone by grain refinement and the associated improved mechanical properties. The required hardness values at the tooth flanks were achieved by the integrated heat treatment"

Contact geometry modification of friction-welded semi-finished products to improve the bonding of hybrid components

To improve the bond strength of hybrid components when joined by friction welding, specimens with various front end surface geometries were evaluated. Rods made of aluminum AA6082 (AlSi1MgMn/EN AW-6082) and the case-hardening steel 20MnCr5 (AISI 5120) with adapted joining surface geometries were investigated to create both a form-locked and material-bonded joint. Eight different geometries were selected and tested. Subsequently, the joined components were metallographically examined to analyze the bonding and the resulting microstructures. The mechanical properties were tested by means of tensile tests and hardness measurements. Three geometrical variants with different locking types were identified as the most promising for further processing in a forming process chain due to the observed material bond and tensile strengths above 220 MPa. The hardness tests revealed an increase in the steel’s hardness and a softening of the aluminum near the transition area. Apparent intermetallic phases in the joining zone were analyzed by scanning electron microscopy (SEM) and an accumulation of silicon in the joining zone was detected by energy-dispersive X-ray spectroscopy (EDS). © 2021 by the authors. Licensee MDPI, Basel, Switzerland

Microstructural evolution and mechanical properties of hybrid bevel gears manufactured by tailored forming

The production of multi-metal bulk components requires suitable manufacturing technologies. On the example of hybrid bevel gears featuring two different steels at the outer surface and on the inside, the applicability of the novel manufacturing technology of Tailored Forming was investigated. In a first processing step, a semi-finished compound was manufactured by cladding a substrate using a plasma transferred arc welding or a laser hotwire process. The resulting semi-finished workpieces with a metallurgical bond were subsequently near-net shape forged to bevel gears. Using the residual heat after the forging process, a process-integrated heat treatment was carried out directly after forming. For the investigations, the material combinations of 41Cr4 with C22.8 (AISI 5140/AISI 1022M) and X45CrSi9-3 with C22.8 (AISI HNV3/AISI 1022M) were applied. To reveal the influence of the single processing steps on the resulting interface, metallographic examinations, hardness measurements and micro tensile tests were carried out after cladding, forging and process-integrated heat treatment. Due to forging and heat-treatment, recrystallization and grain refinement at the interface and an increase in both, hardness and tensile strength, were observed. © 2020 by the authors. Licensee MDPI, Basel, Switzerland

Hot forming of shape memory alloys in steel shells: formability, interface, bonding quality

Metal forming of shape memory alloys (SMA) can be challenging since these are very often brittle due to their intermetallic character. However, formability is often needed not only for realising the desired geometry but also for tailoring the microstructure and the functional properties. To investigate whether the encapsulation in a steel shell can improve the formability of shape memory alloys, Co49Ni21Ga30 and Ni49.5Fe14.5Mn4.0Ga26.0Co6.0 samples were subjected to tensile tests, upsetting, rolling and extrusion. A ferritic steel (1.0503) was used as the shell material. The shell was employed to curtail the formation of tensile stresses in the core, to maintain high temperatures during processing and to prevent oxidation. With this approach, not only forming of the SMA in the steel shell was possible but also an intensive metallurgical bond between the SMA and the steel shell can be achieved during hot rolling or extrusion

Non-destructive Evaluation of Workpiece Properties along the Hybrid Bearing Bushing Process Chain

To combine the advantages of two materials, hybrid bulk metal workpieces are attractive for subsequent processes such as metal forming. However, hybrid materials rely on the initial bond strength for the effective transfer of applied loads. Thus, a non-destructive evaluation of the bonding along the production process chain is of high interest. To evaluate to what extent non-destructive testing can be employed to monitor the bonding quality between the joining partners steel and aluminum and to characterize the age hardening condition of the aluminum component, ultrasonic testing and electrical conductivity measurements were applied. It was found that a lateral angular co-extrusion process can create homogeneous bonding although the electrical conductivity of the aluminum is altered during processing. A previous bonding before the subsequent die forging process leads to a sufficient bonding in areas with little deformation and is therefore, advantageous compared to unjoined semi-finished products, which do not form a bonding if the deformation ratio is too small. An influence of the subsequent heat treatment on the bonding is not visible in the ultrasonic testing signals though a homogenized electrical conductivity can be detected, which indicates uniform artificial aging conditions of the aluminum allo

Investigations on Additively Manufactured Stainless Bearings

Additive manufacturing with multi-material design offers great possibilities for lightweight and function-integrated components. A process chain was developed in which hybrid steel–steel-components with high fatigue strength were produced. For this, a material combination of stainless powder material Rockit® (0.52 wt.% C, 0.9% Si, 14% Cr, 0.4% Mo, 1.8% Ni, 1.2% V, bal. Fe) cladded onto ASTM A572 mild steel by plasma arc powder deposition welding was investigated. Extensive material characterization has shown that defect-free claddings can be produced by carefully adjusting the welding process. With a tailored heat treatment strategy and machining of the semi-finished products, bearing washers for a thrust cylindrical roller bearing were produced. These washers showed a longer fatigue life than previously produced bearing washers with AISI 52100 bearing steel as cladding. It was also remarkable that the service life with the Rockit® cladding material was longer than that of conventional monolithic AISI 52100 washers. This was reached through a favourable microstructure with finely distributed vanadium and chromium carbides in a martensitic matrix as well as the presence of compressive residual stresses, which are largely retained even after testing. The potential for further enhancement of the cladding performance through Tailored Forming was investigated in compression and forging tests and was found to be limited due to low forming capacity of the material

Investigations on tailored forming of aisi 52100 as rolling bearing raceway

Hybrid cylindrical roller thrust bearing washers of type 81212 were manufactured by tailored forming. An AISI 1022M base material, featuring a sufficient strength for structural loads, was cladded with the bearing steel AISI 52100 by plasma transferred arc welding (PTA). Though AISI 52100 is generally regarded as non-weldable, it could be applied as a cladding material by adjusting PTA parameters. The cladded parts were investigated after each individual process step and subsequently tested under rolling contact load. Welding defects that could not be completely eliminated by the subsequent hot forming were characterized by means of scanning acoustic microscopy and micrographs. Below the surface, pores with a typical size of ten µm were found to a depth of about 0.45 mm. In the material transition zone and between individual weld seams, larger voids were observed. Grinding of the surface after heat treatment caused compressive residual stresses near the surface with a relatively small depth. Fatigue tests were carried out on an FE8 test rig. Eighty-two percent of the calculated rating life for conventional bearings was achieved. A high failure slope of the Weibull regression was determined. A relationship between the weld defects and the fatigue behavior is likely. © 2020 by the authors. Licensee MDPI, Basel, Switzerland