Preparation and Anodizing of SiCp/Al Composites with Relatively High Fraction of SiCp

By properly proportioned SiC particles with different sizes and using squeeze infiltration process, SiCp/Al composites with high volume fraction of SiC content (Vp = 60.0%, 61.2%, 63.5%, 67.4%, and 68.0%) were achieved for optical application. The flexural strength of the prepared SiCp/Al composites was higher than 483 MPa and the elastic modulus was increased from 174.2 to 206.2 GPa. With an increase in SiC volume fraction, the flexural strength and Poisson’s ratio decreased with the increase in elastic modulus. After the anodic oxidation treatment, an oxidation film with porous structure was prepared on the surface of the composite and the oxidation film was uniformly distributed. The anodic oxide growth rate of composite decreased with SiC content increased and linearly increased with anodizing time

Bulk TiB2-based ceramic composites with improved mechanical property using Fe-Ni-Ti-Al as a sintering aid

The densification behavior, microstructure and mechanical properties of bulk TiB2-based ceramic composites, fabricated using the spark plasma sintering (SPS) technique with elements of (Fe–Ni–Ti–Al) sinter-aid were investigated. Comparing the change of shrinkage displacement of pure TiB2 and TiB2–5 wt% (Fe–Ni–Ti–Al), the addition of elements Fe–Ni–Ti–Al into TiB2 can facilitate sintering of the TiB2 ceramics. As the sintering temperature exceeds 1300 °C, the relative density does not significantly change. Alumina particles and austenite (Fe–Ni–Ti) metallic binder distributed homogeneously in the grain boundary of TiB2 can inhibit the growth of the TiB2 grains when the sintering temperature is below 1300 °C. The density and particle size of TiB2 greatly influence the mechanical behavior of TiB2–5 wt% (Fe–Ni–Ti–Al) composites. The specimen sintered at 1300 has the highest microhardness of 21.1 ± 0.1 GPa with an elastic modulus of 461.4 GPa. The content of secondary borides (M2B, being M = Fe, Ni), which are more brittle than TiB2 particles, can also influence the fracture toughness. The specimen sintered at 1500 °C has the highest fracture toughness of 6.16 ± 0.30 MPa•m1/2 with the smallest M2B phase. The results obtained provide insight into fabrication of ceremic composites with improved mechanical property

A new insight into high-strength Ti62Nb12.2Fe13.6Co6.4Al5.8 alloys with bimodal microstructure fabricated by semi-solid sintering

It is well known that semi-solid forming could only obtain coarse-grained microstructure in a few alloy systems with a low melting point, such as aluminum and magnesium alloys. This work presents that semi-solid forming could also produce novel bimodal microstructure composed of nanostructured matrix and micro-sized (CoFe)Ti2 twins in a titanium alloy, Ti62Nb12.2Fe13.6Co6.4Al5.8. The semi-solid sintering induced by eutectic transformation to form a bimodal microstructure in Ti62Nb12.2Fe13.6Co6.4Al5.8 alloy is a fundamentally different approach from other known methods. The fabricated alloy exhibits high yield strength of 1790 MPa and plastic strain of 15.5%. The novel idea provides a new insight into obtaining nano-grain or bimodal microstructure in alloy systems with high melting point by semi-solid forming and into fabricating high-performance metallic alloys in structural applications

A comparison of wear behaviour of heat resistant steel engine valves and TiAl engine valves

The increasingly demand for higher performance internal combustion engines (ICEs) has led to higher temperatures in the combustion chamber. As a result, TiAl valves have been investigated with a view to their use in a natural gas fuelled diesel ICE, taking advantage of their low density and good high temperature resistance. In this work, comparison bench tests for traditional steel valves and TiAl valves were carried out through the use of specially designed wear testing apparatus. Compared to the traditional valves made from heat resistant steel (X60, X85), the TiAl valves have 50 % lower mass, leading to a decrease in the impact seating forces during the engine operation. With the reduction of the inertia of engine valve movement, the dynamic characteristics of the engine valve train system can be optimized. Each contact pair of valve and seat insert was tested for 3 million impact cycles. Compared to the austenitic exhaust valves (X60) tested at 700 °C, the TiAl valve had better wear resistance and the wear loss decreased by 24.8 %. The predominant wear mechanism is considered to be a combination of oxidative wear and adhesive wear. However, for the intake valves tested at 400 °C, the wear loss of the TiAl valve was three times higher than the martensitic intake valves (X85). The predominant wear mechanism can be identified as abrasive wear and adhesive wear. It is therefore concluded that the TiAl exhaust valve is a potential solution for a natural gas fuelled diesel

Optimization of friction welding process parameters for 42Cr9Si2 hollow head and sodium filled engine valve and valve performance evaluation

Due to their design, hollow cavity and filled sodium, hollow head and sodium filled engine valves (HHSVs) have superior performance to traditional solid valves in terms of mass and temperature reduction. This paper presents a new manufacturing method for 42Cr9Si2 steel hollow head and sodium filled valves. An inertia friction welding process parameter optimization was conducted to obtain a suitable process parameter range. The fatigue strength of 42Cr9Si2 steel at elevated temperatures was evaluated by rotating bending fatigue test with material specimens. Performance evaluation tests for real valve components were then carried out using a bespoke bench-top apparatus, as well as a stress evaluation utilizing a finite element method. It was proved that the optimized friction welding parameters of HHSV can achieve good welding quality and performance, and the HHSV specimen successfully survived defined durability tests proving the viability of this new method. The wear resistance of the HHSV specimens was evaluated and the corresponding wear mechanisms were found to be those classically defined in automotive valve wear

Effect of the Different High Volume Fraction of SiC Particles on the Junction of Bismuthate Glass-SiCp/Al Composite

The in-house developed bismuthate glass and the SiCp/Al composites with different volume fractions of SiC particles (namely, 60 vol.%, 65 vol.%, 70 vol.%, and 75 vol.%) were jointed by vacuum hot-pressing process. The novel material can be used for the space mirror. The SiCp is an abbreviation for SiC particle. Firstly, the SiCp/Al composites with different vol.% of SiC particle were manufactured by using infiltration process. In order to obtain a stable bonding interface, the preoxide layers were fabricated on the surfaces of these composites for reacting with the bismuthate glass. The coefficient of thermal expansion (CTE) was carried out for characterizing the difference between the composites and bismuthate glass. The sealing quality of the composites and the bismuthate glass was quantified by using shear strength testing. The optical microstructures showed the particles were uniformly distributed in the Al matrix. The SEM image shows that a smooth oxidation layer was generated on the SiCp/Al composite. The CTE testing result indicated that the higher the vol.% of the particles in the composite, the lower the CTE value. The shear strength testing result disclosed that SiCp/Al composite with relatively low CTE value was favorable to obtain a bonding interface with high strength

Study of Quenching and Partitioning (Q&P) and Ultrasonic Surface Rolling (USR) Process on Microstructure and Mechanical Property of a High-Strength Martensitic Steel

Steel with a combination of strength and plasticity is prevalently demanded for lightweight design and emission reductions in manufacturing. In this study, a high-strength Cr-Ni-Mo martensitic steel treated by quenching and partitioning (Q&P) and ultrasonic surface rolling (USR) processes was studied for both strength and plasticity enhancement. Specimens were austenitized at 850 °C and then quenched to 240 °C via cooling by water, oil, and normalization in quenching. This was followed by partitioning, in which two groups of specimens were heated to 370 °C and 350 °C for 45 min, respectively. At last, all the specimens were quenched to room temperature with the same methods of quenching. The highest tensile strength increased from 681.73 MPa to 1389.76 MPa when compared to as-received (AR) steel after the Q&P process. The USR process with a static force of 800 N further improved the tensile strength of specimens with high tensile strength after the Q&P process, which improved from 1389.76 MPa to 1586.62 MPa and the product’s strength and elongation (PSE) increased from 15.76 GPa% to 15.9 GPa%, while the total elongation showed a mitigatory decrease from 11.34% to 10.02%. Tensile fractures were also studied and verified using a combination of strength and plasticity after a combined process of Q&P and USR

Effect of Pulsed Magnetic Field on Spark Plasma Sintering of Iron-Based Powders

Iron-based powders were sintered by spark plasma sintering coupled with different pulsed magnetic field strength ranging from 0 to 3.93MAm1. The effects of pulsed magnetic field on the sintering behavior of the powders as well as the microstructure and mechanical properties of sintered alloys were investigated. The results showed that the sintering temperature field on the cross section of sample was more uniform via coupling a pulsed magnetic field. The density, hardness and bending strength of the alloy sintered by coupling an appropriate pulsed magnetic field, arose to 7.75 gcm3, 55 HRC and 1235MPa, respectively. There was no remarkable change of sintered density with a further increase of pulsed magnetic field strength, while the hardness and bending strength of sintered alloys adversely decreased. The roles of pulsed magnetic field coupled with electric field are explained to accelerate the diffusion and reaction of alloying elements by raising sintering temperature, facilitate powders rearrangement, intensify sparking among powders, improve the growth of sintering neck and the formation of new sintering neck, and reduce the sintering temperature gradient on cross section. [doi:10.2320/matertrans.M2010057

Effects of an industrial passive assistive exoskeleton on muscle activity, oxygen consumption and subjective responses during lifting tasks.

The purpose of this study was to evaluate the effects of an industrial passive assisted exoskeleton (IPAE) with simulated lifting tasks on muscle activity, oxygen consumption, perceived level of exertion, local perceived pressure, and systemic usability. Eight workers were required to complete two lifting tasks with and without the IPAE, that were single lifting tasks (repeated 5 times) and 15 min repeated lifting tasks respectively. Both of the tasks required subjects to remove a toolbox from the ground to the waist height. The test results showed that IPAE significantly reduced the muscle activity of the lumbar erector spinae, thoracic erector spinae, middle deltoid and labrum-biceps muscles; the reduction effect during the 15 min lifting task was reached 21%, 12%, 32% and 38% respectively. The exoskeleton did not cause significant differences in oxygen consumption and the perceived level of exertion, but local perceived pressure on the shoulders, thighs, wrists, and waist of the subjects could be produced. 50% of the subjects rated the usability of the equipment as acceptable. The results illustrate the good potential of the exoskeleton to reduce the muscle activity of the low back and upper arms. However, there is still a concern for the obvious contact pressure

Machining Performance of TiAlN-Coated Cemented Carbide Tools with Chip Groove in Machining Titanium Alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B

In this paper, TiAlN-coated cemented carbide tools with chip groove were used to machine titanium alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B under dry conditions in order to investigate the machining performance of this cutting tool. Wear mechanisms of TiAlN-coated cemented carbide tools with chip groove were studied and compared to the uncoated cemented carbide tools (K20) with a scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). The effects of the cutting parameters (cutting speed, feed rate and depth of cut) on tool life and workpiece surface roughness of TiAlN-coated cemented carbide tools with chip groove were studied with a 3D super-depth-of-field instrument and a surface profile instrument, respectively. The results showed that the TiAlN-coated cemented carbide tools with chip groove were more suitable for machining TC7. The adhesive wear, diffusion wear, crater wear, and stripping occurred during machining, and the large built-up edge formed on the rake face. The optimal cutting parameters of TiAlN-coated cemented carbide tools were acquired. The surface roughness Ra decreased with the increase of the cutting speed, while it increased with the increase of the feed rate