An overview of laser surface modification of die steels

In recent years, surface modification using advanced heat source like laser has been replacing the conventional methods to produce amorphous microstructure via rapid solidification. Due to the benefits of laser to enhance the tribological and mechanical properties of materials’ surface, several laser surface processing were developed including laser surface modification, namely laser alloying, transformation hardening, surface amorphization, shock hardening and glazing. In high temperature applications, the laser surface modification technique is beneficial to prolong the die life cycle, and also to improve the surface roughness of thermal barrier coatings (TBC). To produce the amorphous layer at a particular depth, laser parameter such as irradiance, frequency, and exposure time are controlled. Variations of parameter may result in modified microhardness properties of heat affected zone and transition zone. Nevertheless, works on laser glazing of bearings, railroad rails and TBC had proven the surface properties were enhanced through laser glazing to cope with excessive load, wear, fatigue, bending and friction demand

Thermal stability of laser treated die material for semi-solid metal forming

This paper presents laser surface modification work performed to improve the lifetime of die materials. Die material AISI H13, with typical hardness in the range of 42 to 48 HRC, offers high wear and corrosion resistance. However the cyclic high temperature conditions along with exposure to high viscosity molten metal in semi-solid forming cause the die to wear and crack with resultant shortened die lifetime. In this study, the thermal stability of die material at elevated temperature was investigated through micro-hardness testing and a metallographic study. AISI H13 samples were laser glazed using CO2 continuous wave mode laser with 10.6 μm wavelength. Samples were attached to a specially designed rotating chuck to enable it to be rotated at speeds up to 1500 rpm and allow flat surface glazing to take place. The micro-hardness was measured for as-glazed samples and annealed samples which were held at temperatures ranging from 550oC to 800oC with 50oC intervals. The metallographic study conducted examined the formation of three zones at different depths which were the glazed zone, the heat affected zone and the substrate. As a result of rapid heating and cooling from the laser glazing process, a metallic glass layer was developed which exhibited an average micro-hardness of 900 HV when exposed to 3.34E+10 W/m2 laser irradiance within a range of 0.0011 to 0.0018 s exposure time. Crystallization in glazed zone increased as the annealing temperature increased. As the annealing temperature reached above approximately 600oC, the micro-hardness decreased to approximately 600 HV (equivalent to approx. 54 HRC) due to local crystallization. These findings show potential direct application of glazed dies for non-ferrous semi-solid forming and the requirement for thermal barrier protection for application at higher temperatures

Evolutionary Behavior Tree Approaches for Navigating Platform Games

Computer games are highly dynamic environments, where players are faced with a multitude of potentially unseen scenarios. In this article, AI controllers are applied to the Mario AI Benchmark platform, by using the Grammatical Evolution system to evolve Behavior Tree structures. These controllers are either evolved to both deal with navigation and reactiveness to elements of the game, or used in conjunction with a dynamic A* approach. The results obtained highlight the applicability of Behavior Trees as representations for evolutionary computation, and their flexibility for incorporation of diverse algorithms to deal with specific aspects of bot control in game environments

Effect of vibration on the shear strength of impacted bone graft in revision hip surgery

Aims: Studies on soil mechanics have established that when vibration is applied to an aggregate, it results in more efficient alignment of particles and reduces the energy required to impact the aggregate. Our aim was to develop a method of applying vibration to the bone impaction process and assess its impact on the mechanical properties of the impacted graft. Methods: Phase 1. Eighty bovine femoral heads were milled using the Noviomagus bone mill. The graft was then washed using a pulsed lavage normal saline system over a sieve tower. A vibration impaction device was developed which housed two 15V DC motors with eccentric weights attached inside a metal cylinder. A weight was dropped onto this from a set height 72 times so as to replicate the bone impaction process. A range of frequencies of vibration were tested, as measured using an accelerometer housed in the vibration chamber. Each shear test was then repeated at four different normal loads so as to generate a family of stress-strain curves. The Mohr-Coulomb failure envelope from which the shear strength and interlocking values are derived was plotted for each test. Phase 2. Experiments were repeated with the addition of blood so as to replicate a saturated environment as is encountered during operative conditions. Results Phase 1. Graft impacted with the addition of vibration at all frequencies of vibration showed improved shear strength when compared to impaction without vibration. Vibration at sixty Hertz was displayed the largest effect and was found to be significant. 3 Phase 2. Graft impacted with the addition of vibration in a saturated aggregate displayed lower shear strengths for all normal compressive loads than that of impaction without vibration. Conclusions Civil engineering principles hold true for the impaction bone grafting procedure. In a dry aggregate the addition of vibration may be beneficial to the mechanical properties of the impacted graft. In our system the optimal frequency of vibration was 60 Hz. Under saturated conditions the addition of vibration is detrimental the shear strength of the aggregate. This may be explained by the process of liquefaction

Thermal fatigue properties of laser treated steels

This paper presents the thermal fatigue resistance of laser treated steels. The C40 and AISI H13 steels were machined into a geometry which allowed thermal gradients on the inner and outer surface during testing. A CO2 laser system was used with a focused spot size of 0.09 mm on the sample surface. The laser peak power and pulse repetition frequency (PRF) range were set to 760 and 1515 W, and 2900 to 3500 Hz respectively. The thermal fatigue machine used consists of Nabertherm model cylindrical high temperature furnace with digital control panel, controlled temperature quenching system, and pneumatics control sample movement mechanism. The thermal fatigue test involved immersion of samples into molten aluminium, and quenched in ionised water emulsion at 17°C temperature. The quenching system equipped with thermocouple to control the water temperature. Testing was done at a total of 1,750 number of cycles. Internal surface cooling was controlled by water inlet and outlet tubes. Samples were cleaned using NaOH solution after thermal fatigue testing to remove oxides on the surface. The solution temperature and magnetic stirrer speed were set to 100°C and 4.5 rpm respectively. Samples were characterised using scanning electron microscope (SEM), energy discharge x-ray spectroscopy (EDXS) and 2D stylus profilometer. Presence of different phases on the sample surface were analysed from back-scattered detector micrographs. Heat checks were observed on laser glazed surface at several regions. Carbides and oxides elements were detected on the sample surface after the thermal fatigue test. The relationship between surface roughness of laser treated surface and thermal fatigue behaviour was investigated

Parametric study for graphene reinforced aluminum matrix composites production using Box Behnken design

The production of graphene reinforced aluminum matrix composite through powder metallurgical route requires optimization of process parameters to obtain better performance characteristics. One of the advanced method available for statistical analysis of parameters is Response Surface Methodology (RSM). The statistical analysis was carried out with three parameters, weight percentage of graphene reinforcement Wg (0.05%, 0.1% and 0.2%), stirring time ST(1h, 2h and 3h) and compaction pressure Pc(16T, 17T and 19T) while sintering temperature T kept constant. The performance of the Box Behnken design was analyzed and optimized using Design Expert software for the effective production of composites. From the results obtained from the analysis, the best set of parameters were considered for the future production of composites

A novel method for incorporation of micron-sized SiC particles into molten pure aluminum utilizing a Co coating

Ceramic particles typically do not have sufficiently high wettability by molten metal for effective bonding during metal matrix composite fabrication. In this study, a novel method has been used to overcome this drawback. Micron-sized SiC particles were coated by a cobalt metallic layer using an electroless deposition method. A layer of cobalt on the SiC particles was produced prior to incorporation in molten pure aluminum in order to improve the injected particle bonding with the matrix. For comparison, magnesium was added to the melt in separate experiments as a wetting agent to assess which method was more effective for particle incorporation. It was found that both of these methods were more effective as regard ceramic particulate incorporation compared with samples produced with as-received SiC particles injected into the pure aluminum matrix. SEM images indicated that cobalt coating of the particles was more effective than magnesium for incorporation of fine SiC particles (below 30 lm), while totally the incorporation percentage of the particles was higher for a sample in which Mg was added as a wetting agent. In addition, microhardness tests revealed that the cobalt coating leads to the fabrication of a harder composite due to increased amount of ceramic incorporation, ceramic-matrix bonding, and possibly also to formation of Al-Co intermetallic phases

Effect of interfacial-active elements addition on the incorporation of micron-sized SiC particles in molten pure aluminum

Ceramic particles generally have poor wettability by liquid metal, leading to a major drawback in fabrication of cast metal matrix composites (MMCs). In this work, the effect of 1 wt. % of Ca, Mg, Si, Ti, Zn and Zr interfacial-active alloying elements was studied on the incorporation of micron-sized SiC particles into the molten pure aluminum using the vortex casting method at 680 1C. The results indicated that Ti, Zr, Zn and Si were not positively effective in improving particulate incorporation, while Ca and especially Mg were very efficient at increasing the incorporation of ceramic particles into the molten Al. Also, it was revealed that Al3Ti, and Al3Zr intermetallic phases were formed for samples containing Ti and Zr, making hybrid MMCs with a higher amount of hardness. Finally, it was found that a reaction layer between Al and SiC particles was formed at the Al/SiC interface for all of the samples, expect for the ones containing Si and Ti, indicating that for most of the samples at 680 1C an exothermic reaction took place between the Al and SiC particles

Graphene and derivatives – Synthesis techniques, properties and their energy applications

2D nanomaterials with exceptional electrical, mechanical and thermal properties are promising reinforcing materials for fabricating high-performance composite materials. Rapid developments in nanotechnology in recent years have facilitated the development of advanced materials for functional devices. In particular, this review is focussed on the application of graphene nanoparticle-based composites (GNP's) and graphene derivatives in the fields of energy storage and conversion devices. This review focuses on these recent developments including the synthesis of graphene-based materials and its derivative, as well as the related achieved electrical, mechanical and thermal properties

Prediction of properties for the production and application of graphene reinforced metal matrix composites

This paper presents the development of finite element analysis (FEA) modelling for the prediction of the properties of the metal matrix composites (MMCs) reinforced with graphene. Process parameters taken into consideration were matrix metal (such as Al, Mg Ti, Ni, Cu and Fe) and volume fractions (1%, 5%, 10%, 15%, and 20%) of graphene. The FEA model was developed using ANSYS 14 based on the assumptions that it is free of voids and irregularities, and that the graphene sheets are perfectly aligned. Modelling results were discussed in relation to experimental data from the literature and also verified with theoretical methods; Rule of Mixtures (ROM) and Bettie’s reciprocal theorem. The comparative study of results obtained from the analysis of composite has shown that the properties such as Young's moduli and Poisson's ratio and electrical conductivity of the material are significantly enhanced by the reinforcing graphene in the metal matrix. In particular, it was found that there is a significant increase of longitudinal Young's modulus with increasing volume fraction of graphene reinforcement. Graphene reinforced MMCs has the capability as an advanced composite material of being applied in many highly demanding advanced engineering applications in aero, auto and energy industries. In this paper, the case for application of aluminium-graphene metal matrix composite as the material of choice for power transmission lines is elaborated