Microwave Heating of Cordierite Ceramic Substrate for After Treatment Systems

Selective catalyst reduction is one of the most affordable and successful technologies aimed at reducing NOx emissions from diesel engines. However, the reduction process can be achieved if a certain temperature is reached for the ceramic substrate of the catalytic core. The required temperatures for catalytic reaction vary from 2500 C to 4500 C depending on the technology applied in the catalytic processes. This paper aims at presenting preliminary research in microwave cordierite heating, which is a type of magnesium aluminium silicate used as ceramic honeycomb substrate (catalyst monolith) in the after treatment system in the automotive industry. The research focused on testing the Mg2Al4Si5O18 composite material (cordierite) for different microwave heating regimes in order to establish the level of microwave power required for fast heating. This application will be subject for the further development of new MW-SCR after treatment systems in order to reduce the NOx emissions at cold start engine or low operating regimes of non-road mobile machinery engines. The ceramic composite material was heated for 5 levels of microwave power, from 600 W to 1400 W, using a 6 kW microwave generator coupled with a matching load impedance tuner, and the temperatures were recorded using an IR pyrometer.

Effect of Material on the Mechanical Properties of Additive Manufactured Thermoplastic Parts

Additive manufacturing (AM) also called 3D printing, is an emerging process in the manufacturing sector with increasing new applications in aerospace, prototyping, medical devices and product development, among others. The resistance of the AM part is determined by the chosen material and the printing parameters. As novel materials and AM methods are continuously being developed, there is a need for the development and mechanical characterization of suitable materials for 3D printing. In this study, the influence of the material and the 3D-printing parameters on the mechanical properties of additive manufactured thermoplastic parts was investigated. Three different filaments that are commercially available: Polylactic acid (PLA), acrylonitrile butadiene styrene (ABS) and Tritan were used. Tensile and flexural tests were carried out, in accordance to ASTM standards, to investigate and compare the mechanical properties of the AM parts as a function of material used. The results showed that the type of filaments had the greatest influence on the mechanical properties of the AM parts. The maximum strength and stiffness were obtained for the PLA specimens. Tritan displayed the highest deformation, while the PLA manifested the lowest deformation capacity. The mechanical properties of the printed parts also depend on the printing parameters. The parameters used in this work are a good compromise between the printing time and the mechanical properties.

Metal Alloys for Filaments in 3D Fusion Filament Modelling Printing Process

The paper presents experimental research regarding the application of specific low melting metals in the FDM process. Previous trends in the transfer of the filament from the spool to the hot-end showed that the filament undergoes specific mechanical stress during the transfer. To achieve an appropriate transfer the filament should prove stiffness and resistance to the mechanical actions of the transfer wheels. At the same time, the entrance to the hot-end creates specific resistance to the movement of the filament, and the filament undergoes important deformations. The experimental research used three materials characterized by melting temperature below 260oC: Sn-58Bi, Sn-9Zn, and Sn-3.5Ag. Sn-58Bi showed a yield stress above 50 MPa, but very low extension during the tensile test. Sn-9Zn exhibited a yield stress above 30 MPa, and about double the extension during the tensile test. Sn-3.5Ag displayed a yield stress above 25 MPa, and extension in excess of 8%. The analysis of the surface was performed, revealing that the increase of the yield stress influenced the appearance of specific prints given by the transfer wheels. The deepest prints were measured for Sn-3.5Ag and they were maximum 100 μm. The other two materials were stiffer and the prints have depths below 50 μm. According to the obtained results, each of the tested materials can be an appropriate solution to filament use for the FDM 3D printing process.

AM-FFF of Objects Using Commercial PLA Based Shape Memory Polymer Printed by an Open-Source 3D Printer

The 4D additive manufacturing processes are considered today as the "next big thing" in R&D. The aim of this research is to provide two examples of commercial PLA based shape memory polymer (SMP) objects printed on an open-source 3D printer in order to proof the feasibility of such novel 4D printing process. To that purpose, a PLA based filament of eSUN (4D filament e4D-1white, SMP) was chosen, and two applications, a spring and a vase, were designed by 3D-printing with additive manufacturing (AM) fused filament fabrication (FFF) technique. The 4D-printed objects were successfully produced, the shape memory effect and their functionality were demonstrated by achieving the shape-memory cycle of programming, storage and recovery.

Elaboration and Characterization of the Nanometric Titanium Diboride Powders by Mechanical Milling Method

The research activities are oriented towards elaborating and characterizing nano-sized powders by powder metallurgy technologies based on wet milling in a planetary mill. For the elaboration of the TiB2 powders, a wet milling regime of initial powders was used up to nano size with the following parameters: milling technology by collision, milling times, rotational speed. The characterization of the TiB2 material will include particle size distribution analysis. EDXS and SEM analysis were used to study the structural evolution of the powder after ball milling. The mechanical milling technology, by its milling regimes, proved to be very efficient, obtaining a reduction of the titanium diboride powders particle size up to 50% compared to the initial unmilled powders.

Mechanical Properties, Structure and Fracture Behavior of Additive Manufactured FFF-ABS Specimens

The Fused Filament Fabrication (FFF) method is one of the most important additive manufacturing (AM) technologies. This technology is used today with various kinds of thermoplastic materials, including ABS. The present study deals with the flexural strength and axial deflection of ABS specimens versus relative density, to observe the influence of build-orientations, build model and microscopic level defects of these properties. In this study, the mechanical and structural characterization of AM-FFF ABS material was studied by CAD modelling of different orientations, three point bending mechanical testing, visual testing, and multifocal light microscopy observation, including fractography analysis. To that end, three different standard building orientations (Flat, On Edge and Upright) were printed, and each was built in two different angle orientations (-45o/+45o and 0°/90o). Based on the three point bending testing results, it was found that the specimen with the highest flexural strength was not necessarily the one with the highest deflection. It was also observed that On Edge 0/+90o orientations showed a relatively larger flexural strength difference in comparison to other building orientations (Flat and Upright). When the mechanical properties achieved from a bending test next to the building platform were compared to the properties far from the building platform, only a slight difference was found, which means that the flexural strength difference results from the building strategy and it is not related to the specific bending surface. Based on fractography observation, there is a major difference in the mechanical properties and fracture surface appearance, when the samples are bent between the layers (Upright orientation) or when the samples are bent through the layers (Flat and On Edge orientation).

Effect of Pre-Post TIG Welding Heat Treatment on Cast NI Superalloy

The effect of a pre (before) and post (after) heating welding treatment on the microstructure and mechanical properties of the scrap blades made of cast INC738LC superalloy is the main goal of the present investigation. The filler used in TIG welding was a INC 625 solution hardened superalloy as the proposed solution for hot cracking of the INC738LC cast superalloy in literature. The TIG welding was processed with respect to the constantly optimized parameters (current, voltage, speed, gas flux rate and number of passes) to make a mechanical properties comparison between the as received superalloy and the welded superalloy with heat treated specimens. The characterization techniques employed in this study are hardness measurements, tensile tests, optical microscopy and scanning electron microscopy. We found that the proposed preheating improves the TIG welding of the INC 738 LC superalloy specimens and the post welding heat treatment enhances its mechanical properties.

Selected Applications of Stimuli-Responsive Polymers: 4D Printing by the Fused Filament Fabrication Technology

In the past few years four-dimensional (4D) printing technologies have attained worldwide interest and they are now considered the "next big thing". The aim of this research is to provide three selected examples of stimuli-responsive polymer (SRP) applications additively manufactured (AM) by the fused filament fabrication (FFF) technique. To that end, a CCT BLUE filament of thermo-responsive polymer was chosen to produce a water temperature indicator, which changes colour from blue to white when temperature increases; a CCU RED filament of photo-responsive polymer was used to produce a sunlight / UV indicator bracelet; a transparent PLA CLEAR polymer, a CCU RED photo-responsive polymer, and an electrical conductive PLA polymer were selected to produce a smart business card stand. The temperature indicator capability was analysed based on examining colour changes as a function of temperature changes. The sunlight/UV indicator capability was analysed based on the inspection of colour change as a function of absorbed sun/ultraviolet light. The electrical conductivity of the conductive PLA polymer was examined by performing resistance measurements. All three objects were successfully produced and their functionality was demonstrated. We hope that these examples will catalyse the expansion of FFF 4D printed SRP applications, as much work remains to be done in designing the parts and developing FFF printing parameters that take advantage of the stimuli-responsive materials currently being developed for FFF technology.

Metallurgical and Corrosion Property of Additive Manufactured Titanium Alloy-Ti6Al4V

Additive manufacturing (AM) is an important manufacturing technology that has changed the way products are designed and manufactured. Laser Metal Deposition (LMD), an AM technology, has the capability of producing components using a 3-Dimensional CAD model, through a layer by layer formation process just like any other AM technology. In this study, the influence of the scanning speed on the corrosion property of Titanium alloy-Ti6Al4V using LMD process was investigated. The scanning speed varied between 0.02 m/s and 0.14 m/s while other processing parameters were kept constant. The electrochemical corrosion test was conducted in sodium chloride (NaCl) solution. The result revealed that the corrosion resistance property was found to increase with the scanning speed.

Process Parameter Influence on Tensile Property of Friction Stir Processed Al/Ni-Fe Composite

Friction stir processing (FSP) is a solid-state processing technique that has proven to be an efficient surface modification process for producing aluminium matrix composites (AMCs). However, practical challenges still occur during the processing of AMCs even though extensive progress has been made in recent years. In the present study, the influence of FSP process parameters on the tensile property of Al-Ni-Fe composite has been investigated. The process parameters studied were rotational speed and advancing speed. The rotational speed varied between 600 and 1000 rpm while the advancing speed varied between 70 and 210 mm/min. The rotational speed was kept constant at each setting and the advancing speed varied. Other processing parameters were kept constant throughout the experiments. The results were compared with those of the base metal (Al). The results showed that the tensile strength decreased as the advancing speed increased. The highest tensile strength was obtained at a rotational speed of 1000 rpm and an advancing speed of 70 mm/min.