Dynamics of Ultrasonic Consolidation

Ultrasonic consolidation (UC) is a solid state rapid manufacturing process derived from ultrasonic welding of thin metal foils coupled with contour milling to achieve functional accurate components. The bonding of metal is accomplished by the local application of high frequency vibration energy under pressure producing a metallurgical bond without melting the base material. Its unique nature allows the design and fabrication of structural panels for satellites, production of injection molding tools, functionally graded structures, metal-matrix composites, embedded sensors, armor, and fiber embedded adaptive structures. It is commonly theorized that interfacial motion and friction at the bonding interface play a prominent role in the bonding process by removing surface contaminants, allowing direct metal to metal contact, and producing sufficient stress to induce plastic flow. The substrate\u27s geometry is also crucial in the bonding process. Researchers have experimentally observed that as the height of build specimen approaches its width, the bonding process degrades, and no further foils may be welded. This work explores the process as the dimensions of the build specimen modeled as a standard parallelepiped, approaches the critical geometry through a combination of numerical, analytical and experimental analysis. We examine the resonances of a build feature due to a change in geometry and material properties using a three dimensional Rayleigh-Ritz model. A simple nonlinear dynamic model of the Ultrasonic Consolidation Process examines how the geometry change may influence the overall process dynamics. This simple model is use to provide estimates of how changes is substrate geometry affect the differential motion at the bonding interface and the amount of changing friction force due to build height. The trends of changes in natural frequency, and differential motion, are compared to experimental limits on build height. These analyses lead to several predictions on build height that are verified experimentally. Finally, the work examines the effectiveness of using support material to extend the build height limit of the process. The results show that a proximity to a resonance excitation is clearly responsible for bonding degradation at features built with the nominal tape width of 0.9375 inches. However, for small widths other factors such as surface topography, and contact area may play an important role in bonding degradation

Performance of Stainless Steel AlSi 304 Wire Reinforced Metal Matrix Composites Made Using Ultrasonic Additive Manufacturing in Bending

Ultrasonic additive manufacturing (UAM) is a solid-state additive and subtractive manufacturing process that utilizes ultrasonic energy to produce layered metallic parts. The process is easily extended to create advanced multi-material structures, e.g., metal matrix composites, functionally graded metallic components, and shape memory alloys. This research utilizes a three point bending test to compare the elastic modulus in metal matrix composites (MMC’s) specimens consisting of stainless steel wire reinforcements with an aluminum matrix to unreinforced test specimens; both specimens are produced by UAM. In the MMC the volume fraction of wire is relatively low, 0.77%, yet yields an average increase in modulus of 8.9%.Mechanical Engineerin

Examination of Build Height in Ultrasonic Consolidation for Foil Width Specimens Using Supports

Ultrasonic consolidation (UC) is a novel, solid-state, additive manufacturing fabrication process. It consists of ultrasonic joining of thin metal foils and contour milling to directly produce functional components in a variety of geometries. The bond between layers forms when an ultrasonic horn creates a local oscillating stress field at the mating surfaces. It is commonly theorized that the high frequency vibration under pressure produces a metallurgical bond without melting the base material. The mechanism behind the bond is believed to be due to interfacial motion and friction that disrupts surface contaminants, arguably allowing direct metal to metal contact, and producing sufficient stress to induce plastic flow and promote the growth of grains across the mating surfaces. Ignored in this explanation is the role of substrate dimensions on the quality and strength of the joining process. Researchers have previously examined the effective height limitations of the build process, i.e., the limiting height to width ratio of one of the component features being fabricated. This paper extends the experimental work on using support materials to extend build height on specimens using two different candidate materials, tin bismuth, and a mixture of sugar, corn syrup, and water, referred to as “candy”. Tin bismuth and candy the represent the extremes of a tradeoff between convenience and stiffness that a support material must possess.Mechanical Engineerin

Data series subtraction with unknown and unmodeled background noise

LISA Pathfinder (LPF), ESA's precursor mission to a gravitational wave observatory, will measure the degree to which two test-masses can be put into free-fall, aiming to demonstrate a residual relative acceleration with a power spectral density (PSD) below 30 fm/s$^2$/Hz$^{1/2}$ around 1 mHz. In LPF data analysis, the measured relative acceleration data series must be fit to other various measured time series data. This fitting is required in different experiments, from system identification of the test mass and satellite dynamics to the subtraction of noise contributions from measured known disturbances. In all cases, the background noise, described by the PSD of the fit residuals, is expected to be coloured, requiring that we perform such fits in the frequency domain. This PSD is unknown {\it a priori}, and a high accuracy estimate of this residual acceleration noise is an essential output of our analysis. In this paper we present a fitting method based on Bayesian parameter estimation with an unknown frequency-dependent background noise. The method uses noise marginalisation in connection with averaged Welch's periodograms to achieve unbiased parameter estimation, together with a consistent, non-parametric estimate of the residual PSD. Additionally, we find that the method is equivalent to some implementations of iteratively re-weighted least-squares fitting. We have tested the method both on simulated data of known PSD, and to analyze differential acceleration from several experiments with the LISA Pathfinder end-to-end mission simulator.Comment: To appear Phys. Rev. D90 August 201

Optimal Design of Calibration Signals in Space Borne Gravitational Wave Detectors

Future space borne gravitational wave detectors will require a precise definition of calibration signals to ensure the achievement of their design sensitivity. The careful design of the test signals plays a key role in the correct understanding and characterization of these instruments. In that sense, methods achieving optimal experiment designs must be considered as complementary to the parameter estimation methods being used to determine the parameters describing the system. The relevance of experiment design is particularly significant for the LISA Pathfinder mission, which will spend most of its operation time performing experiments to characterize key technologies for future space borne gravitational wave observatories. Here we propose a framework to derive the optimal signals in terms of minimum parameter uncertainty to be injected to these instruments during its calibration phase. We compare our results with an alternative numerical algorithm which achieves an optimal input signal by iteratively improving an initial guess. We show agreement of both approaches when applied to the LISA Pathfinder case

Low flow controls on benthic and hyporheic macroinvertebrate assemblages during supra-seasonal drought

Despite the widely accepted importance of the hyporheic zone as a habitat for stream macroinvertebrates during floods, few data exist regarding community composition and distribution during periods of low flow or drought in perennial streamsi Integrating research on hyporheic invertebrates with results from a long-term study of a U K river provided the opportunity to examine how surface and hyporheic macroinvertebrate communities respond to inter-annual variability in river flow and periods of groundwater drought. Changes in the riverine macroinvertebrate community associated with low flow included a reduction in species richness and the number of individuals per sample, particularly aquatic insects. The hyporheic community was characterized by a relatively homogeneous composition during a period of severe low flow, punctuated by short-term changes associated with variation in water temperature rather than changes in discharge. We present a conceptual model of the processes influencing benthic and hyporheic invertebrates under low-flow conditions. Previous studies have seldom integrated these two assemblages and their interactions. The model presented highlights the potential importance of surface water and hyporheic zone linkages for riverine invertebrate communities under a range of flow conditions

Patterns of nucleotide diversity at the regions encompassing the Drosophila insulin-like peptide (dilp) genes: demography vs positive selection in Drosophila melanogaster.

In Drosophila, the insulin-signaling pathway controls some life history traits, such as fertility and lifespan, and it is considered to be the main metabolic pathway involved in establishing adult body size. Several observations concerning variation in body size in the Drosophila genus are suggestive of its adaptive character. Genes encoding proteins in this pathway are, therefore, good candidates to have experienced adaptive changes and to reveal the footprint of positive selection. The Drosophila insulin-like peptides (DILPs) are the ligands that trigger the insulin-signaling cascade. In Drosophila melanogaster, there are several peptides that are structurally similar to the single mammalian insulin peptide. The footprint of recent adaptive changes on nucleotide variation can be unveiled through the analysis of polymorphism and divergence. With this aim, we have surveyed nucleotide sequence variation at the dilp1-7 genes in a natural population of D. melanogaster. The comparison of polymorphism in D. melanogaster and divergence from D. simulans at different functional classes of the dilp genes provided no evidence of adaptive protein evolution after the split of the D. melanogaster and D. simulans lineages. However, our survey of polymorphism at the dilp gene regions of D. melanogaster has provided some evidence for the action of positive selection at or near these genes. The regions encompassing the dilp1-4 genes and the dilp6 gene stand out as likely affected by recent adaptive events

A Comparative Study of the Short Term Cold Resistance Response in Distantly Related Drosophila Species: The Role of regucalcin and Frost

The molecular basis of short term cold resistance (indexed as chill-coma recovery time) has been mostly addressed in D. melanogaster, where candidate genes (Dca (also known as smp-30) and Frost (Fst)) have been identified. Nevertheless, in Drosophila, the ability to tolerate short term exposure to low temperatures evolved several times independently. Therefore, it is unclear whether variation in the same candidate genes is also responsible for short term cold resistance in distantly related Drosophila species. It should be noted that Dca is a candidate gene for cold resistance in the Sophophora subgenus only, since there is no orthologous gene copy in the Drosophila subgenus. Here we show that, in D. americana (Drosophila subgenus), there is a north-south gradient for a variant at the 5′ non-coding region of regucalcin (a Dca-like gene; in D. melanogaster the proteins encoded by the two genes share 71.9% amino acid identities) but in our D. americana F2 association experiment there is no association between this polymorphism and chill-coma recovery times. Moreover, we found no convincing evidence that this gene is up-regulated after cold shock in both D. americana and D. melanogaster. Size variation in the Fst PEST domain (putatively involved in rapid protein degradation) is observed when comparing distantly related Drosophila species, and is associated with short term cold resistance differences in D. americana. Nevertheless, this effect is likely through body size variation. Moreover, we show that, even at two hours after cold shock, when up-regulation of this gene is maximal in D. melanogaster (about 48 fold expression change), in D. americana this gene is only moderately up-regulated (about 3 fold expression change). Our work thus shows that there are important differences regarding the molecular basis of cold resistance in distantly related Drosophila species

Characterization of the clinical and immunologic phenotype and management of 157 individuals with 56 distinct heterozygous NFKB1 mutations

Background: An increasing number of NFKB1 variants are being identified in patients with heterogeneous immunologic phenotypes. Objective: To characterize the clinical and cellular phenotype as well as the management of patients with heterozygous NFKB1 mutations. Methods: In a worldwide collaborative effort, we evaluated 231 individuals harboring 105 distinct heterozygous NFKB1 variants. To provide evidence for pathogenicity, each variant was assessed in silico; in addition, 32 variants were assessed by functional in vitro testing of nuclear factor of kappa light polypeptide gene enhancer in B cells (NF-kappa B) signaling. Results: We classified 56 of the 105 distinct NFKB1 variants in 157 individuals from 68 unrelated families as pathogenic. Incomplete clinical penetrance (70%) and age-dependent severity of NFKB1-related phenotypes were observed. The phenotype included hypogammaglobulinemia (88.9%), reduced switched memory B cells (60.3%), and respiratory (83%) and gastrointestinal (28.6%) infections, thus characterizing the disorder as primary immunodeficiency. However, the high frequency of autoimmunity (57.4%), lymphoproliferation (52.4%), noninfectious enteropathy (23.1%), opportunistic infections (15.7%), autoinflammation (29.6%), and malignancy (16.8%) identified NF-kappa B1-related disease as an inborn error of immunity with immune dysregulation, rather than a mere primary immunodeficiency. Current treatment includes immunoglobulin replacement and immunosuppressive agents. Conclusions: We present a comprehensive clinical overview of the NF-kappa B1-related phenotype, which includes immunodeficiency, autoimmunity, autoinflammation, and cancer. Because of its multisystem involvement, clinicians from each and every medical discipline need to be made aware of this autosomal-dominant disease. Hematopoietic stem cell transplantation and NF-kappa B1 pathway-targeted therapeutic strategies should be considered in the future.Peer reviewe