Micro-Drilling of ZTA and ATZ Ceramic Composit: Effect of Cutting Parameters on Surface Roughness

Ceramics are a class of materials widely used during last fifteen years for orthopaedic applications. It is well known that they are characterized by low wear rate, and friction coefficient. However, these materials are very difficult to machine into complex shapes because of their brittleness and high hardness. The most effective method to increase the crack resistance is the formation of a composite structure. This class of materials, composed by two or more different ceramics, can present higher characteristic respect to the single component, like fracture toughness and flexural strength. This paper presents a study of the influence of cutting parameters (cutting speed, feed rate and step number) onto the hole surface roughness and deformation due to the drill operation. The ceramic composite materials AZT (alumina toughened zirconia) and ZTA (zirconia toughened alumina) were first characterized in terms of hardness and roughness. After the drilling test, the holes were analyzed using scanning electron microscope (SEM) and an advanced 3-dimensional non-contact optical profilomete

Quando l'idea acquista spessore: tecnologie additive a confronto

"Le “nuove” tecnologie additive [1] stanno cambiando il mondo del manufacturing sia in termini di progettazione sia di modalità di produzione; tale rinnovamento si traduce, di fatto, nella realizzazione secondo una nuova modalità di oggetti dalle caratteristiche più svariate. Il miglioramento più evidente si è avuto grazie al superamento dei tradizionali vincoli che, per esempio, la produzione con stampi comporta; il principale vantaggio ottenuto è l’enorme fl essibilità che le nuove tecnologie additive garantiscono, fl essibilità da intendersi sia in termini di forme e materiali, sia in relazione alla grande varietà di pezzi differenti che è possibile realizzare contemporaneamente

Grazing function g and collimation angular acceptance

The grazing function g is introduced—a synchrobetatron optical quantity that is analogous (and closely connected) to the Twiss and dispersion functions β, α, η, and η′. It parametrizes the rate of change of total angle with respect to synchrotron amplitude for grazing particles, which just touch the surface of an aperture when their synchrotron and betatron oscillations are simultaneously (in time) at their extreme displacements. The grazing function can be important at collimators with limited acceptance angles. For example, it is important in both modes of crystal collimation operation—in channeling and in volume reflection. The grazing function is independent of the collimator type—crystal or amorphous—but can depend strongly on its azimuthal location. The rigorous synchrobetatron condition g=0 is solved, by invoking the close connection between the grazing function and the slope of the normalized dispersion. Propagation of the grazing function is described, through drifts, dipoles, and quadrupoles. Analytic expressions are developed for g in perfectly matched periodic FODO cells, and in the presence of β or η error waves. These analytic approximations are shown to be, in general, in good agreement with realistic numerical examples. The grazing function is shown to scale linearly with FODO cell bend angle, but to be independent of FODO cell length. The ideal value is g=0 at the collimator, but finite nonzero values are acceptable. Practically achievable grazing functions are described and evaluated, for both amorphous and crystal primary collimators, at RHIC, the SPS (UA9), the Tevatron (T-980), and the LHC

Effect of in-source beam shaping and laser beam oscillation on the electromechanical properties of Ni-plated steel joints for e-vehicle battery manufacturing

Laser welding is a key enabling technology that transitions toward electric mobility, producing joints with elevated electrical and mechanical properties. In the production of battery packs, cells to busbar connections are challenging due to strict tolerances and zero-fault policy. Hence, it is of great interest to investigate how beam shaping techniques may be exploited to enhance the electromechanical properties as well as to improve material processability. Industrial laser systems often provide the possibility to oscillate dynamically the beam or redistribute the power in multicore fibers. Although contemporary equipment enables elevated flexibility in terms of power redistribution, further studies are required to indicate the most adequate solution for the production of high performance batteries. Within the present investigation, both in-source beam shaping and beam oscillation techniques have been exploited to perform 0.2-0.2 mm Ni-plated steel welds in lap joint configuration, representative of typical cell to busbar connections. An experimental campaign allowed us to define process feasibility conditions where partial penetration welds could be achieved by means of in-source beam shaping. Hence, beam oscillation was explored to perform the connections. In the subset of feasible conditions, the mechanical strength was determined via tensile tests alongside electrical resistance measurements. Linear welds with a Gaussian beam profile enabled joints with the highest productivity at constant electromechanical properties. Spatter formation due to keyhole instabilities could be avoided by redistributing the emission power via multicore fibers, while dynamic oscillation did not provide significant benefits

Hand-Held Laser Welding of AISI301LN for components with aesthetic requirements: Toward the integration of machine and human intelligence

The use of Hand-Held Laser Welding (HHLW) systems in the industry has been rapidly growing in recent years as an alternative solution to conventional manual arc-based welding systems. The decreasing cost of fiber laser sources and optics has been a driving factor in enabling a wider use of HHLW systems, beyond the established advantages of laser technology with respect to arc-based systems. While the industrial use of HHLW increases, the subject matter has been studied sparingly in the scientific literature. Due to the intrinsic flexibility of the technology, HHLW systems are highly appealing for joining relatively low thickness metals (≤2 mm) in autogenous configuration in sectors where production lots present low batch and high variability. However, a critical aspect of HHLW is correlated to the operator skill, where welding velocities can vary within and between the welds affecting both their aesthetic and mechanical properties. Hence, the development of combined digital and physical approaches to support manual operations may be highly beneficial. The current study presents an open laboratory HHLW system designed for process development purposes. Beyond conventional manual welding operations, the welding torch could be arranged in different configurations. The system could be combined with a linear axis (enabling welding with stable velocity and inclination) or manually with the aid of a newly developed roller device designed to provide constant speed and inclination. First, the process was benchmarked by joining in butt weld configuration 2 mm thick AISI301LN stainless steel sheets with the linear axis. Successively, four operators with different levels of training (rookie and professional) realized welds with the system in hand-held configuration and with the mechanical roller. The weld width variability was assessed as a direct indicator for aesthetic compliance while tensile tests were allowed to determine the mechanical properties of the joint obtained with different configurations

Digital Twin and Cloud BIM-XR Platform Development: From Scan-to-BIM-to-DT Process to a 4D Multi-User Live App to Improve Building Comfort, Efficiency and Costs

Digital twins (DTs) and building information modelling (BIM) are proving to be valuable tools for managing the entire life cycle of a building (LCB), from the early design stages to management and maintenance over time. On the other hand, BIM platforms cannot manage the geometric complexities of existing buildings and the large amount of information that sensors can collect. For this reason, this research proposes a scan-to-BIM process capable of managing high levels of detail (LODs) and information (LOIs) during the design, construction site management, and construction phases. Specific grades of generation (GOGs) were applied to create as-found, as-designed, and as-built models that interact with and support the rehabilitation project of a multi-level residential building. Furthermore, thanks to the sharing of specific APIs (Revit and Autodesk Forge APIs), it was possible to switch from static representations to novel levels of interoperability and interactivity for the user and more advanced forms of building management such as a DT, a BIM cloud, and an extended reality (XR) web platform. Finally, the development of a live app shows how different types of users (professionals and non-expert) can interact with the DT, in order to know the characteristics with which the environments have been designed, as well as the environmental parameters, increasing their degree of control, from the point of view of improving comfort, use, costs, behaviour, and good practices. Finally, the overall approach was verified through a real case study where the BIM-XR platform was built for energy improvements to existing buildings and facade renovations

Impact of 40 years poplar cultivation on soil carbon stocks and greenhouse gas fluxes

International audienceWithin the JRC Kyoto Experiment in the Regional Park and UN-Biosphere Reserve "Parco Ticino" (North-Italy, near Pavia), the soil carbon stocks and fluxes of CO2, N2O, and CH4 were measured in a poplar plantation in comparison with a natural mesohygrophilous deciduous forest nearby, which represents the pristine land cover of the area. Soil fluxes were measured using the static and dynamic closed chamber techniques for CH4 N2O, and CO2, respectively. We made further a pedological study to relate the spatial variability found with soil parameters. Annual emission fluxes of N2O and CO2 and deposition fluxes of CH4 were calculated for the year 2003 for the poplar plantation and compared to those measured at the natural forest site. N2O emissions at the poplar plantation were 0.15$plusmn;0.1 g N2O m-2 y-1 and the difference to the emissions at the natural forest of 0.07±0.06 g N2O m-2 y-1 are partly due to a period of high emissions after the flooding of the site at the end of 2002. CH4 consumption at the natural forest was twice as large as at the poplar plantation. In comparison to the relict forest, carbon stocks in the soil under the poplar plantation were depleted by 61% of surface (10 cm) carbon and by 25% down the profile under tillage (45 cm). Soil respiration rates were not significant different at both sites with 1608±1053 and 2200±791 g CO2 m-2 y-1 at the poplar plantation and natural forest, respectively, indicating that soil organic carbon is much more stable in the natural forest. In terms of the greenhouse gas budget, the non-CO2 gases contributed minor to the overall soil balance with only 0.9% (N2O) and -0.3% (CH4 of CO2-eq emissions in the natural forest, and 2.7% (N2O) and -0.2% of CO2-eq. emissions in the poplar plantation. The very high spatial variability of soil fluxes within the two sites was related to the morphology of the floodplain area, which was formed by the historic course of the Ticino river and led to a small-scale (tenth of meters) variability in soil texture and to small-scale differences in elevation. Differences of site conditions are reflected by differences of inundation patterns, ecosystem productivity, CO2 and N2O emission rates, and soil contents of carbon and nitrogen. Additional variability was observed during a flooding event and after fertilisation at the poplar site. Despite of this variability, the two sites are comparable as both originate from alluvial deposits. The study shows that changes in soil carbon stocks and related fertility are the most visible phenomena after 40 years of land use change from a pristine forest to a fast growing poplar plantation. Therefore, the conservation and careful management of existing carbon stocks deserves highest priority in the context of the Kyoto Protocol

Measurements of the effect of collisions on transverse beam halo diffusion in the Tevatron and in the LHC

Beam-beam forces and collision optics can strongly affect beam lifetime, dynamic aperture, and halo formation in particle colliders. Extensive analytical and numerical simulations are carried out in the design and operational stage of a machine to quantify these effects, but experimental data is scarce. The technique of small-step collimator scans was applied to the Fermilab Tevatron collider and to the CERN Large Hadron Collider to study the effect of collisions on transverse beam halo dynamics. We describe the technique and present a summary of the first results on the dependence of the halo diffusion coefficient on betatron amplitude in the Tevatron and in the LHC.Comment: 4 pages, 2 figures. Submitted to the Proceedings of the ICFA Mini-Workshop on Beam-beam Effects in Hadron Colliders (BB2013), Geneva, Switzerland, 18-22 March 201

Analytical modeling and characterization of ring beam profiles for high-power lasers used in industrial manufacturing

Active fibre lasers are widely used in the industry for different manufacturing applications ranging from cutting, to welding and additive manufacturing. The recent introduction of the multiple-core fibre lasers allows these sources to flexibly change the Power Density Distribution (PDD) from conventional Gaussian profiles towards ring shapes. While the advantages of the novel beam shapes over the conventional ones are still being explored, the need for modeling tools to define the PDD shapes becomes more evident. This work studies the analytical modeling of Gaussian to ring profiles with the aim to move towards standardized parameters referable to the manufacturing processes. The proposed models combine Gaussian and annular components to define the novel beam shapes. Among the different models assessed, the Torus and Multi-Gaussian approaches exhibited the best fitting quality thus enabling the definition of descriptive metrics of the PDD. The modeling framework developed was validated on an industrial Laser Powder Bed Fusion (LPBF) system with a double-core light source. The beam shape variation along the propagation axis was assessed to analyze the effect of defocusing using the developed beam parameters. Eventually, the best performing model was furtherly validated with a bead on plate experiment to explain how the model coefficients can be jointly exploited to predict the material response using a Gaussian or a ring beam profile

Tailoring the microstructure of Fe-2.9wt.%Si alloy in laser powder bed fusion using in-source beam shaping

Tuning the irradiance profile of the laser beam opens up new possibilities in terms of controlling the thermal field the material is subjected to during laser powder bed fusion (PBF-LB/M). This control can be exploited to manipulate the material's microstructure. In this work, a contemporary high power fibre laser with in-source beam shaping capability was used to test different irradiance profiles ranging from Gaussian to ring during the PBF-LB/M of Fe-2.9wt.%Si alloy. This soft magnetic alloy is used in electrical machines, and its magnetic properties are known to be correlated to the microstructure. Initially, the experimental work assessed the influence of peak and ring irradiance levels on densification and grain morphology. In a second experimental run, the influence of the beam profile on the conventionally employed energy density was verified. The results demonstrated that the use of combined Gaussian-ring profiles offers a method for manipulating grain size and shape from a columnar towards an equiaxed shape, without requiring a change in the scan strategy