Processing and Microstructure of WC-CO Cermets by Laser Engineering Net Shaping

Submicron-sized tungsten carbide-cobalt (WC-Co) powder and nanostructured WC-Co powder were applied to make thick wall samples by the Laser Engineered Net Shaping (LENS®) process. It was found that decomposition and decarburization of WC was limited during laser deposition because of the features of the LENS® process: high cooling rate, short heating time, and low oxygen concentration. The effects of working distance, as well as laser power, powder feed rate, and traverse speed on microstructure were studied in this paper. Thermal behavior leading to the observed microstructures that result from the variations in the processing parameters was investigated in detailMechanical Engineerin

Design of ultraprecision machine tools with application to manufacturing of miniature and micro components

Currently the underlying necessities for predictability, producibility and productivity remain big issues in ultraprecision machining of miniature/microproducts. The demand on rapid and economic fabrication of miniature/microproducts with complex shapes has also made new challenges for ultraprecision machine tool design. In this paper the design for an ultraprecision machine tool is introduced by describing its key machine elements and machine tool design procedures. The focus is on the review and assessment of the state-of-the-art ultraprecision machining tools. It also illustrates the application promise of miniature/microproducts. The trends on machine tool development, tooling, workpiece material and machining processes are pointed out

Fabrication of micro-structures for optically driven micromachines using two-photon photopolymerization of UV curing resins

Two-photon photopolymerization of UV curing resins is an attractive method for the fabrication of microscopic transparent objects with size in the tens of micrometers range. We have been using this method to produce three-dimensional structures for optical micromanipulation, in an optical system based on a femtosecond laser. By carefully adjusting the laser power and the exposure time we were able to create micro-objects with well-defined 3D features and with resolution below the diffraction limit of light. We discuss the performance and capabilities of a microfabrication system, with some examples of its products.Comment: 12 pages, 10 figure

Freeform Fabrication of Biological Scaffolds by Projection Photopolymerization

This article presents a micro-manufacturing method for direct, projection printing of 3- dimensional (3D) scaffolds for applications in the field of tissue engineering by using a digital micro-mirror-array device (DMD) in a layer-by-layer process. Multi-layered scaffolds are microfabricated using curable materials through an ultraviolet (UV) photopolymerization process. The pre-patterned UV light is projected onto the photocurable polymer solution by creating the “photomask” design with graphic software. Poly (ethylene glycol) diacrylate (PEGDA), is mixed with a small amount of dye (0.3 wt %) to enhance the fabrication resolution of the scaffold. The DMD fabrication system is equipped with a purging mechanism to prevent the accumulation of oligomer, which could interfere with the feature resolution of previously polymerized layers. The surfaces of the pre-designed, multi-layered scaffold are covalently conjugated with fibronectin for efficient cellular attachment. Our results show that murine marrow-derived progenitor cells successfully attached to fibronectin-modified scaffolds.Mechanical Engineerin

Surface imaging of metallic material fractures using optical coherence tomography

We demonstrate the capability of optical coherence tomography (OCT) to perform topography of metallic surfaces after being subjected to ductile or brittle fracturing. Two steel samples, OL 37 and OL 52, and an antifriction Sn-Sb-Cu alloy were analyzed. Using an in-house-built swept source OCT system, height profiles were generated for the surfaces of the two samples. Based on such profiles, it can be concluded that the first two samples were subjected to ductile fracture, while the third one was subjected to brittle fracture. The OCT potential for assessing the surface state of materials after fracture was evaluated by comparing OCT images with images generated using an established method for such investigations, scanning electron microscopy (SEM). Analysis of cause of fracture is essential in response to damage of machinery parts during various accidents. Currently the analysis is performed using SEM, on samples removed from the metallic parts, while OCT would allow in situ imaging using mobile units. To the best of our knowledge, this is the first time that the OCT capability to replace SEM has been demonstrated. SEM is a more costly and time-consuming method to use in the investigation of surfaces of microstructures of metallic materials. © 2014 Optical Society of America

A comparative study of X-ray tomographic microscopy on shales at different synchrotron facilities: ALS, APS and SLS.

Synchrotron radiation X-ray tomographic microscopy (SRXTM) was used to characterize the three-dimensional microstructure, geometry and distribution of different phases in two shale samples obtained from the North Sea (sample N1) and the Upper Barnett Formation in Texas (sample B1). Shale is a challenging material because of its multiphase composition, small grain size, low but significant amount of porosity, as well as strong shape- and lattice-preferred orientation. The goals of this round-robin project were to (i) characterize microstructures and porosity on the micrometer scale, (ii) compare results measured at three synchrotron facilities, and (iii) identify optimal experimental conditions of high-resolution SRXTM for fine-grained materials. SRXTM data of these shales were acquired under similar conditions at the Advanced Light Source (ALS) of Lawrence Berkeley National Laboratory, USA, the Advanced Photon Source (APS) of Argonne National Laboratory, USA, and the Swiss Light Source (SLS) of the Paul Scherrer Institut, Switzerland. The data reconstruction of all datasets was handled under the same procedures in order to compare the data quality and determine phase proportions and microstructures. With a 10× objective lens the spatial resolution is approximately 2 µm. The sharpness of phase boundaries in the reconstructed data collected from the APS and SLS was comparable and slightly more refined than in the data obtained from the ALS. Important internal features, such as pyrite (high-absorbing), and low-density features, including pores, fractures and organic matter or kerogen (low-absorbing), were adequately segmented on the same basis. The average volume fractions of low-density features for sample N1 and B1 were estimated at 6.3 (6)% and 4.5 (4)%, while those of pyrite were calculated to be 5.6 (6)% and 2.0 (3)%, respectively. The discrepancy of data quality and volume fractions were mainly due to different types of optical instruments and varying technical set-ups at the ALS, APS and SLS

All-optical atom surface traps implemented with one-dimensional planar diffractive microstructures

We characterize the loading, containment and optical properties of all-optical atom traps implemented by diffractive focusing with one-dimensional (1D) microstructures milled on gold films. These on-chip Fresnel lenses with focal lengths of the order of a few hundred microns produce optical-gradient-dipole traps. Cold atoms are loaded from a mirror magneto-optical trap (MMOT) centered a few hundred microns above the gold mirror surface. Details of loading optimization are reported and perspectives for future development of these structures are discussed.Comment: 7 pages, 15 figure