155 research outputs found
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Advanced manufacturing by spray forming: Aluminum strip and microelectromechanical systems
Spray forming is an advanced materials processing technology that converts a bulk liquid metal to a near-net-shape solid by depositing atomized droplets onto a suitably shaped substrate. By combining rapid solidification processing with product shape control, spray forming can reduce manufacturing costs while improving product quality. INEL is developing a unique spray-forming method based on de Laval (converging/diverging) nozzle designs to produce near-net-shape solids and coatings of metals, polymers, and composite materials. Properties of the spray-formed material are tailored by controlling the characteristics of the spray plume and substrate. Two examples are described: high-volume production of aluminum alloy strip, and the replication of micron-scale features in micropatterned polymers during the production of microelectromechanical systems
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Performance aspects of de Laval spray-forming nozzles
Spray forming is a multiphase fabrication technology in which a spray of finely atomized liquid droplets is directed onto a suitably shaped substrate or pattern to produce a coherent, near-net-shape deposit The technology can simplify materials processing where simultaneously improving product quality. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials using de Laval nozzles. Here we briefly describe the flow field characterization and atomization behavior of liquid metals in linear de Laval nozzles, and illustrate their versatility by summarizing results from three spray-forming programs. In one program, low-carbon steel strip >0.75 mm was produced. In another program, polymer membranes [approximately] 5 [mu]m thick were spray formed. Finally, recent results in spray forming molds, dies, and related tooling for rapid prototyping are described
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Spray Rolling Aluminum Strip
Spray forming is a competitive low-cost alternative to ingot metallurgy for manufacturing ferrous and non-ferrous alloy shapes. It produces materials with a reduced number of processing steps, while maintaining materials properties, with the possibility of near-net-shape manufacturing. However, there are several hurdles to large-scale commercial adoption of spray forming: 1) ensuring strip is consistently flat, 2) eliminating porosity, particularly at the deposit/substrate interface, and 3) improving material yield. Through this program, a new strip/sheet casting process, termed spray rolling, has been developed, which is an innovative manufacturing technique to produce aluminum net-shape products. Spray rolling combines the benefits of twin-roll casting and conventional spray forming, showing a promising potential to overcome the above hurdles associated with spray forming. Spray rolling requires less energy and generates less scrap than conventional processes and, consequently, enables the development of materials with lower environmental impacts in both processing and final products. Spray Rolling was developed as a collaborative project between the University of California-Davis, the Colorado School of Mines, the Idaho National Engineering and Environmental Laboratory, and an industry team. The following objectives of this project were achieved: (1) Demonstration of the feasibility of the spray rolling process at the bench-scale level and evaluation of the materials properties of spray rolled aluminum strip alloys; and (2) Demonstration of 2X scalability of the process and documentation of technical hurdles to further scale up and initiate technology transfer to industry for eventual commercialization of the process
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Microstructure Evolution During Spray Rolling and Heat Treatment of 2124 Al
Spray rolling is a strip casting technology that combines elements of spray forming and twin-roll casting. It consists of atomizing molten metal with a high velocity inert gas, quenching the resultant droplets in flight, and directing the spray between mill rolls. In-flight convection heat transfer from atomized droplets and conduction heat transfer at the rolls rapidly move an alloy’s latent heat. Hot deformation of the semi-solid material in the rolls results in fully consolidated, rapidly-solidified product. While similar in many ways to twin-roll casting, spray rolling is able to process a broader range of alloys and operates at a higher production rate. A laboratory-scale strip caster has been constructed at INL and used to evaluate the interplay of processing parameters and strip quality while producing strips up to 200 mm wide and 1.6 – 6.4 mm thick. Plans are underway to scale to 600 mm width and demonstrate steady-state operation. As-spray-rolled strip is characterized by a flat, uniformly thick profile with minimal porosity or segregation. This paper examines how processing parameters influence the microstructure transformations that take place during spray rolling and post-deposition heat treatment of 2124 Al
Helium identification with LHCb
The identification of helium nuclei at LHCb is achieved using a method based on measurements of ionisation losses in the silicon sensors and timing measurements in the Outer Tracker drift tubes. The background from photon conversions is reduced using the RICH detectors and an isolation requirement. The method is developed using pp collision data at √(s) = 13 TeV recorded by the LHCb experiment in the years 2016 to 2018, corresponding to an integrated luminosity of 5.5 fb-1. A total of around 105 helium and antihelium candidates are identified with negligible background contamination. The helium identification efficiency is estimated to be approximately 50% with a corresponding background rejection rate of up to O(10^12). These results demonstrate the feasibility of a rich programme of measurements of QCD and astrophysics interest involving light nuclei
Measurement of forward charged hadron flow harmonics in peripheral PbPb collisions at √sNN = 5.02 TeV with the LHCb detector
Flow harmonic coefficients,
v
n
, which are the key to studying the hydrodynamics of the quark-gluon plasma (QGP) created in heavy-ion collisions, have been measured in various collision systems and kinematic regions and using various particle species. The study of flow harmonics in a wide pseudorapidity range is particularly valuable to understand the temperature dependence of the shear viscosity to entropy density ratio of the QGP. This paper presents the first LHCb results of the second- and the third-order flow harmonic coefficients of charged hadrons as a function of transverse momentum in the forward region, corresponding to pseudorapidities between 2.0 and 4.9, using the data collected from PbPb collisions in 2018 at a center-of-mass energy of 5.02
TeV
. The coefficients measured using the two-particle angular correlation analysis method are smaller than the central-pseudorapidity measurements at ALICE and ATLAS from the same collision system but share similar features
Curvature-bias corrections using a pseudomass method
Momentum measurements for very high momentum charged particles, such as muons from electroweak vector boson decays, are particularly susceptible to charge-dependent curvature biases that arise from misalignments of tracking detectors. Low momentum charged particles used in alignment procedures have limited sensitivity to coherent displacements of such detectors, and therefore are unable to fully constrain these misalignments to the precision necessary for studies of electroweak physics. Additional approaches are therefore required to understand and correct for these effects. In this paper the curvature biases present at the LHCb detector are studied using the pseudomass method in proton-proton collision data recorded at centre of mass energy √(s)=13 TeV during 2016, 2017 and 2018. The biases are determined using Z→μ + μ - decays in intervals defined by the data-taking period, magnet polarity and muon direction. Correcting for these biases, which are typically at the 10-4 GeV-1 level, improves the Z→μ + μ - mass resolution by roughly 18% and eliminates several pathological trends in the kinematic-dependence of the mean dimuon invariant mass
Study of the doubly charmed tetraquark T+cc
Quantum chromodynamics, the theory of the strong force, describes interactions of coloured quarks and gluons and the formation of hadronic matter. Conventional hadronic matter consists of baryons and mesons made of three quarks and quark-antiquark pairs, respectively. Particles with an alternative quark content are known as exotic states. Here a study is reported of an exotic narrow state in the D0D0π+ mass spectrum just below the D*+D0 mass threshold produced in proton-proton collisions collected with the LHCb detector at the Large Hadron Collider. The state is consistent with the ground isoscalar T+cc tetraquark with a quark content of ccu⎯⎯⎯d⎯⎯⎯ and spin-parity quantum numbers JP = 1+. Study of the DD mass spectra disfavours interpretation of the resonance as the isovector state. The decay structure via intermediate off-shell D*+ mesons is consistent with the observed D0π+ mass distribution. To analyse the mass of the resonance and its coupling to the D*D system, a dedicated model is developed under the assumption of an isoscalar axial-vector T+cc state decaying to the D*D channel. Using this model, resonance parameters including the pole position, scattering length, effective range and compositeness are determined to reveal important information about the nature of the T+cc state. In addition, an unexpected dependence of the production rate on track multiplicity is observed
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Spray-formed tooling and aluminum strip
Spray forming is an advanced materials processing technology that converts a bulk liquid metal to a near-net-shape solid by depositing atomized droplets onto a suitably shaped substrate. By combining rapid solidification processing with product shape control, spray forming can reduce manufacturing costs while improving product quality. De Laval nozzles offer an alternative method to the more conventional spray nozzle designs. Two applications are described: high-volume production of aluminum alloy strip, and the production of specialized tooling, such as injection molds and dies, for rapid prototyping
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Spray-forming monolithic aluminum alloy and metal matrix composite strip
Spray forming with de Laval nozzles is an advanced materials processing technology that converts a bulk liquid metal to a near-net-shape solid by depositing atomized droplets onto a suitably shaped substrate. Using this approach, aluminum alloys have been spray formed as strip, with technoeconomic advantages over conventional hot mill processing and continuous casting. The spray-formed strip had a flat profile, minimal porosity, high yield, and refined microstructure. In an adaptation to the technique, 6061 Al/SiC particulate-reinforced metal matrix composite strip was produced by codeposition of the phases
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