Modification of 316L steel powders with bronze using high energy ball milling for use as a binder component in PBF-LB/M printing of diamond-metal matrix composites

For the processing of diamond-metal matrix composites, the powder bed fusion using a laser for metals (PBF-LB/M), represents a new promising method for the additive manufacturing of diamond tools for concrete and rock machining, even with more complicated geometries. Previous research activities show a strong tendency for cracking and delamination during the construction process of the samples. This behavior is caused by thermal residual stresses associated with the embedded diamonds. To control these negative effects on the process side, the volume energy density is reduced accordingly, which, however, led to increased pore formation. This publication deals with an approach on the material side to modify a 316L stainless steel base powder with an addition of 20 wt% bronze via a high energy ball milling (HEBM) process in such a way that a homogeneous solid solution phase is created. A significantly increasing of the melting interval and a decreasing of both solidus and liquidus temperature was observed, which can reduce pore formation in the PBF-LB/M-process. In addition, XRD-diffractometry and SEM/EDS-analysis showed that the homogeneous solid solution phase of this alloyed powder segregates again into Fe- and Cu-rich phases when heated up to the melting point

Secondary structure classification of amino-acid sequences using state-space modeling

The secondary structure classification of amino acid sequences can be carried out by a statistical analysis of sequence and structure data using state-space models. Aiming at this classification, a modified filter algorithm programmed in S is applied to data of three proteins. The application leads to correct classifications of two proteins even when using relatively simple estimation methods for the parameters of the state-space models. Furthermore, it has been shown that the assumed initial distribution strongly influences the classification results referring to two proteins

Spectral estimation for psycho-physiological data Estimating lower-dimensional representations in frequency space

Two different estimation techniques for the spectrum of a nonstationary time series are compared empirically. Both of them are assuming a time-dependent autoregressive (AR-) model for the data. The fifirst estimation technique used is the Frequency State Dependent Model (FSDM-) technique (Schmitz and Urfer, 1997), a modification of the well known Kalman-filter approach. The FSD-Model is based on Priestleys SD-Models for the analysis of nonstationary time series (e.g.,Priestley, 1988). An alternative approach for estimating AR-parameters of nonstationary time series was proposed by Tsatsannis and Giannkis (1993). The basic idea is to directly decompose the time-dependent autoregressive parameters into their wavelet representation and to select suitable wavelet coefficients for reconstruction. In either case, Kitagawa's (1983) "instantaneous spectrum" is calculated to obtain the actual spectral estimates. Applied to empirical data, both approaches lead to similar spectral estimates. However, simulations show how crucial the selection of wavelet coefficients is when applying the latter technique

Microstructural and tribo-mechanical properties of arc-sprayed CoCr-based coatings

Due to their superior wear and oxidation resistance, Stellite™ coatings are widely used in industrial applications, where the coatings are exposed to high temperature. Common processes for applying Stellite™ coatings include the high-velocity oxy-fuel spraying, laser cladding, and plasma transferred arc welding. Although Stellite™ welding consumables or similar welding consumables in the form of cored wires (CoCr base without industrial property rights) are commercially available, there are hardly any studies on arc-sprayed Stellite™ coatings available in the literature. In this study, the microstructural characteristics of arc-sprayed deposits were investigated, which were produced using a CoCr-based cored wire with addition of 4.5 wt.% tungsten. The produced deposits were examined in its as-sprayed state as well as after exposed to elevated temperatures. The microstructure was scrutinized by means of electron microscopy, energy-dispersive x-ray spectroscopy, as well as x-ray diffraction analyses using synchrotron radiation. Tribo-mechanical tests were conducted in order to assess the performance of the arc-sprayed coating. The findings were discussed and compared to those obtained from conventional CoCr-based coatings. It was found that the arc-sprayed CoCr-based coating is predominantly composed of Co-rich, Cr-rich lamellae or lamellae comprising a Co(Cr)-rich solid solution interspersed with various oxides between the individual lamellae. Solid solution hardening serves as dominant strengthening mechanism, while precipitation hardening effects are hardly evident. With regard to the oxidation behaviour, the as-sprayed coating mainly contains CoCr2O4 as well as traces of Co3O4. For heating above 550 °C, coating surface additionally consists of Fe2O3 and Co3O4. In dry sliding experiments, the arc-sprayed CoCr-based coating shows a decreased wear resistance compared to CoCr-based coatings processed by HVOF and PTA, whereas the coefficient of friction (COF) sliding against alumina was similar to the COF observed for the HVOF-sprayed CoCr-based coating, but lower than the COF obtained for the CoCr-based hardfacing alloy deposited by PTA

Influence of direct splat-affecting parameters on the splat-type distribution, porosity, and density of segmentation Cracks in Plasma-Sprayed YSZ Coatings

The integrity and properties of ceramic coatings produced by atmospheric plasma spraying are highly controlled by the splat morphology and splat interconnection. In this study, the influence of selected parameters (spray angle, surface velocity of the spray gun, and substrate temperature) on splat morphology and coating microstructure was investigated. A favorite set of spray gun parameters, of which their effects on splat morphology and coating microstructure have been verified by previous experiments, were used to conduct the experiments for the present work. It was found that depositing fully molten particles on a hot substrate increases the fraction of disk-like splats by about 60% at the expense of the fraction of irregular splats. Preheating the substrate also increases the pore count and level of coating porosity, while it does not influence the density of segmentation cracks. In contrast, the surface velocity of the spray gun does not affect the splat morphology while a slow speed decreases the coating porosity and plays a significant role in generating segmentation cracks. Shifting the spray angle by 15° distorts up to 20% of disk-like splats and slightly decreases the porosity level. However, changing the spray angle does not affect the generation of segmentation cracks

Investigation of joints from laser powder fusion processed and conventional material grades of 18MAR300 nickel maraging steel

Even though the buildup rate of laser powder bed fusion processes (LPBF) has steadily increased in recent years by using more and more powerful laser systems, the production of large-volume parts is still extremely cost-intensive. Joining of an additively manufactured complex part to a high-volume part made of conventional material is a promising technology to enhance economics. Today, constructors have to select the most economical joining process with respect to the individual field of application. The aim of this research was to investigate the hybrid joint properties of LBPF and conventionally casted 18MAR300 nickel maraging steel depending on the manufacturing process and the heat treatment condition. Therefore, the microstructure and the strength of the hybrid joints manufactured by LPBF or vacuum brazing were examined and compared to solid material and joints of similar material. It was found that the vacuum-brazed hybrid joints using a 50.8-μm-thick AuNi18 foil provide a high tensile strength of 904 MPa which is sufficient for a broad field of application. Furthermore, the additively manufactured hybrid samples offered with 1998 MPa a tensile strength more than twice as high but showed a considerable impact of buildup failures to the strength in general

Impact of tungsten incorporation on the tribomechanical behavior of AlCrWxSiN films at room and elevated temperature

AlCrWxSiN thin films (0 ≤ x ≤ 17.1 at.%) were synthesized by means of a hybrid magnetron sputtering process, merging direct current (DC) as well as tungsten high power impulse magnetron sputtering (HiPIMS) supplies. The influences of increasing the tungsten contents on the structural as well as the friction and wear behavior at room and high temperatures (500 °C) were elaborated. As a reference, a W61.4N38.6 system served to analyze synergetic effects on the oxidation behavior. Increased tungsten contents in AlCrWxSiN resulted in more distinctive (200)-, (202)-, and (311)- crystal orientations. A W/Cr ratio of ~1 could be correlated with a denser film growth, the highest hardness (24.3 ± 0.7 GPa), and a significantly decreased wear coefficient (<0.3 × 10−5 mm3/Nm). Tribological tests performed at room temperature revealed that the coefficient of friction decreased with higher tungsten contents to µ~0.35. In contrast, at elevated temperatures, the coefficient of friction increased with higher W concentrations due to spotty oxidations in the wear track, which resulted in a locally increased surface roughness. Finally, a phase transformation of the WN film to m-WO3 did not contribute to a friction reduction at 500 °C

WC decomposition phenomena in ID-HVOF-sprayed WC-CoCr coatings using fine powder feedstock

Over the last few decades, the high velocity oxygen fuel (HVOF) spraying of WC-CoCr for internal diameter (ID) coating has attracted much interest for hard chrome replacement. Current demands for the ID coating of small cylindrical parts necessitates the use of specialized spray gun equipment and powder feedstocks with small particle size fractions. Due to the limited spray distance inside cylindrical parts with small IDs, the process control, spraying fine WC-CoCr powders, meets new challenges to avoid significant WC decomposition, which increases the risk of mechanical degradation. Within the scope of this study, ID-HVOF spraying using a fine-structured WC-CoCr (−15 + 5 μm) feedstock with a mean WC particle size of 400 nm is examined with respect to the WC decomposition phenomena using X-ray diffraction (XRD). Hence, a statistical design of experiments (DoE) is utilized to systematically analyze various spray parameter settings along with their interaction as part of the WC to W2C conversion

The effect of machined surface conditioning on the coating interface of high velocity oxygen fuel (HVOF) sprayed coating

Roughening the substrate surface is essential for thermal sprayed coatings. In this regard, sandblasting has established itself as an easy to use surface conditioning procedure. The quality of the obtained roughness depends on the conditions of the sandblasting material, adjusted parameters, and the kind of the process execution (manual or mechanical). These preconditions limit the reproducibility of the roughness obtained. Sandblasting causes residual compressive stress and may also lead to the inclusion of sand particles and notches in the roughened surface, which affects the interfacial properties of the coating, as well as the flexural strength of the coated parts. The hardness of the roughened surface plays, thereby, an important role. However, in order to reliably avoid these effects, microfinishing can be used as an alternative to generate a homogenous roughened substrate surface, control the induced residual stresses, and increase the reproducibility. In addition, the roughened surface pattern can be produced during the chip forming process of the to-be-coated parts. The utilization of the appropriate combination of machining processes and parameters should lead to the required surface pattern and thus to an enhanced coating adhesion and flexural strength of the coated part. The induced residual stresses and the quality of the obtained surface roughness have a significant influence on the coating adhesion and the lifespan of the coated parts. This paper aims to analyze, as a first step, the effect of the turning and microfinishing on the surface conditioning of the bearing steel 100Cr6 (AISI 52100). The investigation concludes by comparing the microfinished with the sandblasted surfaces with regard to the interface to and the adhesion of the WC–Co high velocity oxygen fuel (HVOF) sprayed coatings on them. Surface conditioning plays a decisive role by the induced residual stresses and the elimination of adhesion defects