scholarly journals Post-Processing of Cold Sprayed Ti-6Al-4V Coatings by Mechanical Peening

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1038
Author(s):  
Niroj Maharjan ◽  
Ayan Bhowmik ◽  
Chunwai Kum ◽  
Jiakun Hu ◽  
Yongjing Yang ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Volume Fraction ◽  
Aerospace Industry ◽  
Metal Alloys ◽  
High Porosity ◽  
Post Processing ◽  
Premature Failure ◽  
Additive Manufacturing Technology ◽  
Hammer Peening ◽  
Compressive Residual Stresses

Cold spray is an emerging additive manufacturing technology used in the aerospace industry to repair damaged components made of expensive metal alloys. The cold sprayed layer is prone to surface integrity issues such as high porosity and inadequate bonding at the substrate-coating interface, which may cause premature failure of the repaired component. This study explored the use of mechanical peening as a post-processing method to improve the surface integrity of the cold sprayed component by modifying mechanical properties near the surface. Two mechanical peening processes, deep cold rolling (DCR) and controlled hammer peening (CHP), were utilized to improve cold sprayed Ti-6Al-4V coating on the Ti-6Al-4V substrate. Experimental results indicate that DCR and CHP increase the strength of the bond between the coating and substrate due to introduction of compressive residual stresses. In addition, porosity is also reduced by as much as 71%. The improvement is attributed to both the compacting effect of peening processes and the increment in the volume fraction of deformed regions.

scholarly journals Surface Integrity of AISI 52100 Bearing Steel after Robot-Based Machine Hammer Peening

2020 ◽  
Vol 4 (2) ◽  
pp. 61
Author(s):  
Robby Mannens ◽  
Lars Uhlmann ◽  
Felix Lambers ◽  
Andreas Feuerhack ◽  
Thomas Bergs
Keyword(s):  
Surface Layer ◽  
Surface Integrity ◽  
Bearing Steel ◽  
Forming Process ◽  
Premature Failure ◽  
Machine Hammer Peening ◽  
Aisi 52100 ◽  
Aisi 52100 Steel ◽  
Hardness Increase ◽  
Hammer Peening

AISI 52100 steel is often used as material for highly loaded rolling bearings in machine tools. An improved surface integrity, which can be achieved by means of mechanical surface layer finishing, can avoid premature failure. One of these finishing processes is machine hammer peening (MHP) which is a high-frequency incremental forming process and mostly used on machining centers. However, the influence of robot-guided MHP processing on the surface integrity of AISI 52100 steel is still unknown. Therefore, the objective of this work is to investigate experimentally the robot-based influences during MHP processing and the resulting surface integrity of unhardened AISI 52100 steel. The results show that the axial and lateral deviations of the robot due to process vibrations are in the lower µm range, thus enabling stable and reproducible MHP processing. By selecting suitable MHP process parameters and thus defined contact energies, even ground surfaces can be further smoothed and a hardness increase of 75% in the energy range considered can be achieved. In addition, compressive residual stress maxima of 950 MPa below the surface and a grain size reduction to a surface layer depth of 150 µm can be realized.

scholarly journals Additive Manufactured 316L Stainless-Steel Samples: Microstructure, Residual Stress and Corrosion Characteristics after Post-Processing

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 182
Author(s):  
Suvi Santa-aho ◽  
Mika Kiviluoma ◽  
Tuomas Jokiaho ◽  
Tejas Gundgire ◽  
Mari Honkanen ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Sample Surface ◽  
Post Processing ◽  
Magnesium Chloride Solution ◽  
Manufacturing Method ◽  
Four Point Bending ◽  
Traditional Manufacturing ◽  
Processing Steps ◽  
Compressive Residual Stresses

Additive manufacturing (AM) is a relatively new manufacturing method that can produce complex geometries and optimized shapes with less process steps. In addition to distinct microstructural features, residual stresses and their formation are also inherent to AM components. AM components require several post-processing steps before they are ready for use. To change the traditional manufacturing method to AM, comprehensive characterization is needed to verify the suitability of AM components. On very demanding corrosion atmospheres, the question is does AM lower or eliminate the risk of stress corrosion cracking (SCC) compared to welded 316L components? This work concentrates on post-processing and its influence on the microstructure and surface and subsurface residual stresses. The shot peening (SP) post-processing levelled out the residual stress differences, producing compressive residual stresses of more than −400 MPa in the AM samples and the effect exceeded an over 100 µm layer below the surface. Post-processing caused grain refinement and low-angle boundary formation on the sample surface layer and silicon carbide (SiC) residue adhesion, which should be taken into account when using the components. Immersion tests with four-point-bending in the heated 80 °C magnesium chloride solution for SCC showed no difference between AM and reference samples even after a 674 h immersion.

scholarly journals Effect of machine hammer peening on the surface integrity of a ZnAl-based corrosion protective coating

2020 ◽  
Vol 318 ◽  
pp. 01008
Author(s):  
Alina Timmermann ◽  
Mohamed Abdulgader ◽  
Leif Hagen ◽  
Alexander Koch ◽  
Philipp Wittke ◽  
...  
Keyword(s):  
Corrosion Fatigue ◽  
Surface Integrity ◽  
Protective Coatings ◽  
Fatigue Behavior ◽  
Turbine Blades ◽  
Fatigue Properties ◽  
Machine Hammer Peening ◽  
Coated Surfaces ◽  
Thermally Sprayed ◽  
Hammer Peening

Thermally sprayed protective coatings are applied onto many mechanically stressed components such as support structures, shafts, turbine blades or heat exchangers. In addition to the static or cyclic load, a superimposition with corrosion processes occurs in many cases. Thermal sprayed ZnAl coatings are known for their performant corrosion protection properties. Within this context, the potential of ZnAl-based layer systems was analyzed regarding corrosion fatigue behavior. Therefore, a timeand cost-efficient testing strategy based on a corrosion-superimposed load increase procedure was used to estimate the effects of a corrosive attack during cyclic loading. The investigated coating systems were thermally sprayed and partially post-processed with a Machine Hammer Peening (MHP) operation. This treatment was identified as an appropriate technique for compressing and smoothing coated surfaces. The inter-relationships between the parametrization of the MHP process, the resulting surface integrity, and the estimated corrosion fatigue properties were analyzed. The investigations indicate a positive effect of MHP post-processing operations on the surface properties of the ZnAl-based coating system.

scholarly journals Thermally Assisted Machine Hammer Peening of Arc-Sprayed ZnAl-Based Corrosion Protective Coatings

2021 ◽  
Vol 5 (4) ◽  
pp. 109
Author(s):  
Andreas Wirtz ◽  
Mohamed Abdulgader ◽  
Michael P. Milz ◽  
Wolfgang Tillmann ◽  
Frank Walther ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Protective Coatings ◽  
Fatigue Behavior ◽  
Wind Waves ◽  
Offshore Wind ◽  
Coating Materials ◽  
Corrosive Media ◽  
Machine Hammer Peening ◽  
Hammer Peening ◽  
Compressive Residual Stresses

Structural elements of offshore facilities, e.g., offshore wind turbines, are subject to static and dynamic mechanical and environmental loads, for example, from wind, waves, and corrosive media. Protective coatings such as thermal sprayed ZnAl coatings are often used for protection, mainly against corrosive stresses. The Machine Hammer Peening (MHP) process is an innovative and promising technique for the post-treatment of ZnAl coating systems that helps reducing roughness and porosity and inducing compressive residual stresses. This should lead to an enhancement of the corrosion fatigue behavior. In this paper, the effect of a thermally assisted MHP process was investigated. The softening of the coating materials will have a direct effect on the densification, residual porosity and the distribution of cracks. The investigation results showed the influence of thermally assisted MHP on the surface properties, porosity, residual stresses, and hardness of the post-treated coatings. The best densification of the coating, i.e., the lowest porosity and roughness and the highest compressive residual stresses, were achieved at a process temperature of 300 °C. A further increase in temperature on the other hand caused a higher porosity and, in some cases, locally restricted melting of the coating and consequently poorer coating properties.

Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0

2021 ◽  
pp. 1-24
Author(s):  
Ganzi Suresh
Keyword(s):  
Additive Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Three Dimensional ◽  
Metal Alloys ◽  
Layer By Layer ◽  
Post Processing ◽  
Clear Insight ◽  
Am Processes ◽  
Insight Into

Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.

Improving UV Resistance of Fibers: Idealized Computational Model Predicting the Distribution of UV Blocking Cylindrical Nanoparticles in Protective Polymeric Layer

2015 ◽  
Vol 10 (1) ◽  
pp. 155892501501000
Author(s):  
Abdelfattah Mohamed Seyam ◽  
Rahul Vallabh ◽  
Ahmed H. Hassanin
Keyword(s):  
Aspect Ratio ◽  
Computational Model ◽  
High Performance ◽  
Volume Fraction ◽  
Three Dimensional ◽  
High Strength ◽  
Uv Protection ◽  
Uv Resistance ◽  
Premature Failure ◽  
Areal Coverage

High strength fibers such as PBO and Kevlar are used to produce composites, bulletproof vests, tendons of giant scientific balloons, and other high performance products. These fibers, however, are known to degrade upon exposure to Ultraviolet (UV) radiation which causes premature failure of the end-products. Improving UV resistance of high strength fibers like PBO through methods such as adding UV inhibiting particles during filament spinning or dyeing/coating process is not only extremely difficult, but often fails to provide the adequate UV protection. As an alternative to conventional approaches, UV protection of high performance yarns/braids can be effectively achieved by covering them with a polymeric sheath containing dispersed UV inhibiting nanoparticles. In this work, a computational model was developed to optimize critical factors such as thickness (weight) of the protective sheath and the amount of UV blockers for a given particle size, which influence the UV protective efficiency of the sheath. In order to simulate three-dimensional dispersion of nanoparticles in a polymer matrix, the model considers a random distribution of cylindrical nanoparticles of different size, aspect ratio, and volume fraction in a three-dimensional volume of protective sheath of a given length, width, and thickness. 2D visualization and image analysis techniques were utilized to determine the area projected by the particles on the x-y plane (areal coverage provided by nanoparticles). The areal coverage values obtained from the model were found to be higher than the experimental results due to the agglomeration of nanoparticles in the sheath caused during the polymer compounding process. However, the purpose of the model is to serve as a benchmarking tool to aid in the design and development of UV protective sheaths and films, and not to estimate absolute UV protection values. Analysis of the relationship between areal coverage and various input parameters in the model show that areal coverage increases with an increase in particle volume fraction and film thickness, and a decrease in particle diameter and length. It was also found that areal coverage was more significantly influenced by particle aspect ratio than by particle length.

Pore Scale Investigation of Heat Conduction of High Porosity Open-Cell Metal Foam/Paraffin Composite

2017 ◽  
Vol 139 (9) ◽  
Author(s):  
Yuanpeng Yao ◽  
Huiying Wu ◽  
Zhenyu Liu
Keyword(s):  
Heat Conduction ◽  
Pore Size ◽  
Metal Foam ◽  
Volume Fraction ◽  
Experimental Studies ◽  
Scale Model ◽  
Small Scale ◽  
High Porosity ◽  
Pore Scale ◽  
Open Cell

In this paper, a numerical model employing an approximately realistic three-dimensional (3D) foam structure represented by Weaire–Phelan foam cell is developed to study the steady-state heat conduction of high porosity open-cell metal foam/paraffin composite at the pore-scale level. The conduction problem is considered in a cubic representative computation unit of the composite material with a constant temperature difference between one opposite sides of the cubic unit (the other outer surfaces of the cubic unit are thermally insulated). The effective thermal conductivities (ETCs) of metal foam/paraffin composites are calculated with the developed pore-scale model considering small-scale details of heat conduction, which avoids using adjustable free parameters that are usually adopted in the previous analytical models. Then, the reason why the foam pore size has no evident effect on ETC as reported in the previous macroscopic experimental studies is explored at pore scale. Finally, the effect of air cavities existing within solid paraffin in foam pore region on conduction capacity of metal foam/paraffin composite is investigated. It is found that our ETC data agree well with the reported experimental results, and thus by direct numerical simulation (DNS), the ETC data of different metal foam/paraffin composites are provided for engineering applications. The essential reason why pore size has no evident effect on ETC is due to the negligible interstitial heat transfer between metal foam and paraffin under the present thermal boundary conditions usually used to determine the ETC. It also shows that overlarge volume fraction of air cavity significantly weakens the conduction capacity of paraffin, which however can be overcome by the adoption of high conductive metal foam due to enhancement of conduction.

scholarly journals Investigation of Thermal, Mechanical and Transport Properties of Ultra-Lightweight Foamed Concrete (ULFC) Strengthened with Alkali Treated Banana Fibre

2021 ◽  
Vol 86 (1) ◽  
pp. 123-139
Author(s):  
Mohammed Hassan Nensok ◽  
Md Azree Othuman Mydin ◽  
Hanizam Awang
Keyword(s):  
Compressive Strength ◽  
Thermal Properties ◽  
Water Absorption ◽  
Volume Fraction ◽  
Fibre Volume Fraction ◽  
Fibre Volume ◽  
High Porosity ◽  
Control Specimen ◽  
Sem Images ◽  
Banana Fibre

Traditionally, Ultralightweight Foam Concrete (ULFC) is primarily used to replace filling excavations, ditch restoration and underground channels, because of their high porosity, water absorption and low strength. Yet, ULFC is characterized by excellent thermal properties and could be an alternative for sustainable energy-efficient building material. This study investigates the properties of an ULFC strengthened with alkali-treated banana fibre. The low density ULFC of 600kg/m3 was fabricated and strengthened with alkali-treated banana fibre. Fibre volume fraction of 0.25%, 0.35%, 0.45% and 0.55% were compared to the unreinforced specimens, serving as the control specimen (no fibre addition). Mix proportioning of 1:1.5:0.45 of cement, sand, and water was respectively adopted throughout the mix. The alkali treated banana fibre strengthened ULFC was tested for compressive strength, sorptivity and thermal properties. Morphology of the treated fibre and ULFC composites was studied using SEM micrograph. The result depicts that ULFC exhibited the optimum compressive strength of 1.1604N/mm2 with the fibre volume fraction of 0.35%. Sorptivity or rate of water absorption was testified to upsurge, after 24 hours duration at fibre volume fraction of 0.55%, recording a 56.12% increment compared to the control specimen. The finding displays that at the highest-fibre volume fraction of 0.55%, thermal conductivity and diffusivity decrease by 13.17% and 28.16%, correspondingly, whiles the specific heat capacity increases to 37.17% all compared with unreinforced specimens. SEM images reveal that the presence of lumen and the nature of porous and fibrous alkali-treated banana fibre. Hence, it is endorsed that ULFC produced with alkali-treated banana fibre should be utilized as an infill material for composite system.

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