5 Werkstofftechnik
Filtern
Dokumenttyp
- Vortrag (331)
Sprache
- Englisch (331) (entfernen)
Referierte Publikation
- nein (331) (entfernen)
Schlagworte
- Additive Manufacturing (37)
- Additive manufacturing (23)
- Corrosion (20)
- Microstructure (19)
- Ontology (17)
- Glass (16)
- Ceramics (12)
- Fatigue (11)
- Crack growth (9)
- Creep (9)
Organisationseinheit der BAM
- 5 Werkstofftechnik (331)
- 5.1 Mikrostruktur Design und Degradation (91)
- 5.2 Metallische Hochtemperaturwerkstoffe (91)
- 5.4 Multimateriale Fertigungsprozesse (73)
- 5.6 Glas (41)
- 5.5 Materialmodellierung (38)
- 5.3 Polymere Verbundwerkstoffe (34)
- 8 Zerstörungsfreie Prüfung (32)
- 9 Komponentensicherheit (32)
- 7 Bauwerkssicherheit (27)
Eingeladener Vortrag
- nein (331) (entfernen)
Knowledge representation in the materials science and engineering (MSE) domain is a vast and multi-faceted challenge: Overlap, ambiguity, and inconsistency in terminology are common. Invariant and variant knowledge are difficult to align cross-domain. Generic top-level semantic terminology often is too abstract, while MSE domain terminology often is too specific.
In this presentation, an approach how to maintain a comprehensive and intuitive MSE-centric terminology composing a mid-level ontology–the PMD core ontology (PMDco)–via MSE community-based curation procedures is shown.
The PMDco is designed in direct support of the FAIR principles to address immediate needs of the global experts community and their requirements. The illustrated findings show how the PMDco bridges semantic gaps between high-level, MSE-specific, and other science domain semantics, how the PMDco lowers development and integration thresholds, and how to fuel it from real-world data sources ranging from manually conducted experiments and simulations as well as continuously automated industrial applications.
The surface corrosion behaviour is a key issue which determines whether the material is applicable at a given atmosphere. Medium-entropy alloy FeCrNi alloy was exposed to synthetic air at 1000°C, 1050°C, and 1100 °C for up to 1000 h using a thermobalance. The oxidation rate was parabolic at 1000 and 1050°C, but breakaway occurred at 1100°C after 5 h of aging time. The whole oxide scales formed under the isothermal oxidation tests spalled off and additional oxidation tests were carried out at 1000 °C and 1050°C for 24 h and up to 100 h at 1000°C in a tubular furnace. The corrosion behaviour of the MEA was analysed by scanning electron microscope, energy-dispersive X-ray spectroscopy, and X-ray diffraction and compared to the behaviour of 316 L. The experimental results showed that under all conditions chromium is the main diffusion element resulting in the formation of a Cr2O3 layer at the MEA surface. Spallation of the layer induces the formation of additional oxidation products under the surface of the (spalled off) chromia layer.
This research deals with the development of the Vickers hardness knowledge graph, mapping the example dataset in them, and exporting the data-mapped knowledge graph as a machine-readable Resource Description Framework (RDF). Modeling the knowledge graph according to the standardized test procedure and using the appropriate upper-level ontologies were taken into consideration to develop the highly standardized, incorporable, and industrial applicable models. Furthermore, the Ontopanel approach was utilized for mapping the real experimental data in the developed knowledge graphs and the resulting RDF files were successfully evaluated through the SPARQL queries.
Low-temperature co-fired ceramics (LTCC) are used to fabricate multilayer circuits which are robust in harsh environments. Thick-film technology is well established for the metallization of circuit boards and microsystems. For specific sensor applications, the combination of LTCC and thin-film technology is advantageous to reach higher structure resolutions. Due to the high roughness of as-fired LTCC surfaces compared with silicon-wafers, the deposition of low-defect- films with narrowly specified properties is challenging. The deposited thin-films are structured either by lift-off or by etching. The latter is less error-prone and thus preferred in industry provided the selected materials allow it. There is spare literature about thin films on commercial LTCC comparing different material systems or sintering techniques. For developing thin-film sensors on multilayer circuits it is crucial to identify thin-film-compatible commercial LTCC material as well as the crucial surface properties. In this work we evaluate the thin-film capability of different LTCC compositions and surface qualities.
To evaluate the influence of the material composition on the thin film capability, 200 nm Ni-thin films were deposited on three different constrained-sintered LTCC (CT708, CT800 and DP951) by electron beam physical vapour deposition. The effect of surface quality was assessed by thin-film deposition on free-sintered, pressure-assisted sintered, and polished DP951. The thin-films were structured by covering corresponding sections with a UV-curable photo resin and subsequent etching of the uncovered surface, leaving behind the desired structure.
The etched Ni-thin films showed high difference in failure rate and sheet resistance regarding the used LTCC-material. DP951 had the lowest sheet resistance and no failure, whereas CT800 had a high sheet resistance and a failure rate of 40 %. These results are correlated with surface roughness of the LTCC, scanning electron micrographs of the deposited thin-films, and the chemical resistance of the LTCC against commonly used etching media. Contrary to the expectations, no correlation between roughness and thin-film capability was found. The LTCC with high failure rate showed a strong chemical attack by the used etching medium. Additionally, the adhesion of thin-films on DP951 is better than on CT708 and CT800.
Grain boundary (GB) chemical and structural variations can significantly influence materials performance. The former is generally ascribed to the structural gradient between the grain and GB. While GB segregation may be accompanied by chemical and structural variations, clear insights about the GB’s thermodynamic phase behaviour upon coupling between its chemistry and structure is lacking. Using the CALPHAD integrated density-based phase field model, we study the co-evolution of GB’s structure and segregation in Fe-Mn alloys. We found that the GB segregation transition is amplified if its structure can respond to chemical variation. Additionally, the coupling between GB structural and segregation evolution was found to enable co-existence of the spinodally formed low- and high-Mn phases within the GB. In the light of atomistic simulations, we expand on investigating the correlation between the parameters that characterise the GB density map with GB properties.
Several recent studies have revealed that the phase decomposition in medium- and high-entropy alloys is triggered by solute segregation at grain boundaries. The chemically complex nature of these alloys already clues that such segregation in materials should be something more than the interaction between solutes and grain boundary, but also affected by the solute-solute interactions during the segregation. In fact, experiments indicate the significance of such solute-solute interaction. Yet, the mechanisms of co-segregation in multi-component alloys are rather challenging to explore and rarely studied quantitatively. Recently, a CALPHAD-integrated density-based phase-field model has been proposed for studying grain boundary phenomena. Several applications of this model have shown its expansive capacity for investigating grain boundary segregation and phase behavior. In this talk, the applications of this model to studying co-segregation phenomena and grain boundary phase diagrams in multi-component alloys are presented ––the term ‘co-segregation’ here refers to co-evolution and any mutual interplay among the solutes and grain boundary during the segregation. In particular, the iron-based ternary and quaternary alloys are discussed. I show how a grain boundary may have its own miscibility gap and how this immiscibility can influence the co-segregation behavior. As an alternative to grain boundary phase diagrams, rather suited for binary and ternary alloys, a new concept of co-segregation maps for screening and segregation design in multi-component alloys is presented. Applying the co-segregation maps, the nonlinear Mn and Cr co-segregation in Fe-Co-Mn-Cr is discussed.
Wind turbine rotor blades are produced as aerodynamic, three-dimensionally formed sandwich shell structures using mainly glass fiber reinforced plastics (GFRP). The GFRP used today have the potential to withstand the harsh operating conditions of rotor blades over the projected service life of 20 years. Premature damages that occur can be traced primarily back to design and/or manufacturing imperfections, as well as unusually high load scenarios (for instance lightning strikes, or strong winds combined with system control errors). Therefore, rotor blades have to be repaired several times (on average 2-3 times) during their projected service life. Approximately 70% of these are repairs of small- to medium-sized sandwich shells, carried out by technicians directly accessing the blade by suspended roping at the wind turbine location. The goal is to execute repairs that will last over the remaining service life, i.e. be sustainable.
Within the framework of a research project carried out at BAM, Division 5.3 Polymer Matrix Composites, Department 5 for Materials Engineering, not only was the geometric shape (round vs. square in relation to the top view) varied, but also the layup of the scarf repair structure, variables that have not been studied systematically to-date. Sub-component scale sandwich shell specimens with representative repairs were used in this work in addition to coupon-scale specimens that are more commonly seen in literature. These sub-component shell specimens were tested using a unique shell test bench under loading conditions representative of wind turbine blade shell operating conditions with respect to fatigue strength. Using non-destructive testing methods (field strain measurement and thermography), damage development and distribution was monitored and analyzed in-situ. As a result, a concept was developed in which the repaired areas showed at least equivalent if not higher fatigue strength than the reference shells that were not repaired.
In our current view, reference datasets in the MSE domain represent specific material properties, e.g., structural, mechanical, … characteristics. A reference dataset must fulfill high-quality standards, not only in precision of measurement but also in a comprehensive documentation of material, processing, and testing history (metadata). This Infrastructure Use Case (IUC) aims to develop a framework for generating reference material datasets using creep data of a single crystal Ni-based superalloy as a best practice example. In a community-driven process, we aim to encourage the discussion and establish a framework for the creation and distribution of reference material datasets. In this poster presentation, we highlight our current vision and activities and intend to stimulate the discussion about the topic reference datasets and future collaborations and work.
The essence of dynamic failure is closely linked to the formation of adiabatic shear bands (ASB), which result from the localization of shear strain under high deformation speeds accompanied by a rapid temperature increase. Understanding this phenomenon is crucial in view of safety issues when impacts of fast rotating machine components (i.e. aircraft turbine blades) may occur. Our contribution addresses both the experimental evidence and characterization of ASBs due to high-speed impact tests at the Split HOPKINSON pressure bar (SHPB) setup and the finite element analysis to determine the parameters of the underlying constitutive model, which is closely related to JOHNSON-COOK (JC) material model.
Experimental investigations were performed on notched shear specimens made of the fine -grained structural steel S690QL and the displacements in the regions affected by shear localization were measured with subset-based local Digital Image Correlation (DIC). The displacement fields, obtained in the SHPB tests, were considered as an objective to validate and to identify the constitutive parameters with. The JC model could reasonably reproduce the displacement distribution. In order to overcome the issues with mesh dependency we provide a nonlocal extension based on the implicit gradient model approach.
This is an interactive workshop of the Plattform MaterialDigital (PMD) on Semantic Web technologies (SWT) where we delve into the world of ontology development and data structuring in the field of materials science and engineering (MSE). This workshop is designed to equip participants with essential skills in categorizing classes within ontologies, with a special emphasis on the PMD Core Ontology (PMDco). Discover the immense value of ontologies for MSE data reproducibility and reuse and harness the power of PMDco to foster your data management practices.
In this workshop, you will explore the intricacies of class categorization when developing ontologies in the MSE domain. Through interactive discussions and hands-on exercises, you will learn effective techniques for structuring and organizing ontologies to enhance data retrieval and analysis. You will gain valuable insights into best practices and considerations for class categorization, aiming at optimal data organization and management within your MSE projects.
One of the highlights of this workshop is the introduction to PMDco, a mid-level ontology in the field of MSE developed community-driven in the frame of the project PMD. Learn about PMDco, its underlying concepts, and its application in detail. Discover how PMDco provides a comprehensive framework for MSE data representation, enabling seamless integration and interoperability across different systems and platforms. In addition to exploring PMDco, this workshop will illustrate the benefits of data interoperability and SWT with respect to leveraging the full potential of MSE data.
The high-temperature corrosion behaviors of the equimolar CrCoNi medium- and CrMnFeCoNi high-entropy alloy were studied in a gas atmosphere consisting of a volumetric mixture of 10% H2O, 2% O2, 0.5% SO2, and 87.5% Ar at 800 °C for up to 96 h. Both alloys were initially single-phase fcc structured and showed a mean grain size of ~50 µm and a homogeneous chemical composition. The oxide layer thickness of the Cantor alloy CrMnFeCoNi increased linearly with exposure time while it remained constant at ~1 µm for CrCoNi. A Cr2O3 layer and minor amounts of (Co,Ni)Cr2O4 developed on CrCoNi while three layers were detected on the Cantor alloy. These layers were a thin and continuous chromium rich oxide layer at the oxide/alloy interface, a dense (Mn,Cr)3O4 layer in the center and a thick and porous layer of Mn3O4 and MnSO4 at the gas/oxide interface. Additionally, a few metal sulfides were observed in the CrMnFeCoNi matrix. These results were found to be in reasonable agreement with thermodynamic calculations.
High entropy alloys (HEA) are a new class of materials that have been investigated since the early 2000s and offer great potential to replace conventional alloys. However, since they sometimes have significant contents of expensive alloying elements such as Co or Ni, their use is only conceivable in highly stressed areas of components. For this purpose, the weldability with conventional alloys such as high-alloy austenitic steels must be investigated. In addition to the resulting microstructure, the mechanical properties are also fundamental for the usability of HEAs in DMWs. For this purpose, TIG welds of CoCrFeMnNi HEA (cold rolled and recrystallized state) with AISI 304 austenitic steel are investigated. These mechanical properties are analyzed in this work by means of tensile tests and local hardness measurement. The local strain behavior of the welded joints is also characterized by means of Digital Image Correlation (DIC). The results of the local hardness measurement show a clear influence of the initial condition of the HEA on the HAZ. Thus, the HEA in the cold-rolled condition shows a clear softening because of recrystallization processes in the HAZ. On the other hand, there is no influence on the hardness of the weld metal, which is approx. 200 HV0.1 in both cases. The tensile tests show a consistent failure of the weld in the weld metal. However, regardless of the HEA condition, strengths in the range of the recrystallized HEA (RM ~ 550–600 MPa) are achieved, although with significantly reduced fracture elongations.
Slow crack growth (SCG) under the influence of external fluid media, usually termed environmental stress cracking (ESC), is still one of the most frequent origins of severe damage and failure of polymeric materials. For polyethylene (PE) this is relevant for mass products, like bottles for consumer products, but also for high-performance materials for pipes or industrial packaging, including containers for chemicals and other dangerous goods. Especially for high-density polyethylene (PE-HD) the susceptibility to SGC and ESC is depending on the complex interplay between molecular weight and architecture and the resulting semicrystalline morphology, especially the formation of tie-molecules.
A reliable assessment of the resistance against this damage phenomenon is essential for demanding as well as safety-critical applications and has to take into account suitable testing methodologies and conditions in combination with environmental media reflecting the properties representative for typical fillings and relevant components causing ESC. In this context a better understanding of different influencing factors, such as sorption, swelling or surface activity is necessary together with a detailed characterization of different stages of crack propagation and underlying mechanisms. Therefor well-established testing methods, such as the Full Notch Creep Test (FNCT), were complemented by detailed fracture surface analysis using e.g. LSM and SEM in combination with a time-dependent optical monitoring of the progressing crack growth.
For the crack growth also the ratio of fibrillated craze zone to crack opening is important for the deeper understanding of crack propagation and related material parameters which can be additionally addressed by X-ray computed tomography.
The efforts taken within the project ‘platform MaterialDigital’ (PMD, materialdigital.de) to store FAIR data in accordance with a standard-compliant ontological representation (‘application ontology’) of a tensile test of metals at room temperature (ISO 6892-1:2019-11) will be presented. This includes the path from developing an ontology in accordance with the respective standard, converting ordinary data obtained from standard tests into the interoperable RDF format, up to connecting the ontology and data. The semantic connection of the ontology and data leads to interoperability and an enhanced ability of querying. For further reusability of data and knowledge semantically stored, the PMD core ontology (PMDco) was developed, which is a mid-level ontology in the field of MSE. The semantic connection of the tensile test application ontology to the PMDco is also presented. Moreover, Ontopanel, a tool for domain experts facilitating visual ontology development and mapping for FAIR data sharing in MSE, is introduced briefly.
Towards interoperability: Digital representation of a material specific characterization method
(2023)
Certain metallic materials gain better mechanical properties through controlled heat treatments. In age-hardenable aluminum alloys, the strengthening mechanism is based on the controlled formation of nanometer sized precipitates, which hinder dislocation movement. Analysis of the microstructure and especially the precipitates by transmission electron microscopy allows identification of precipitate types and orientations. Dark-field imaging is often used to image the precipitates and quantify their relevant dimensions.
The present work aims at the digital representation of this material-specific characterization method. Instead of a time-consuming, manual image analysis, a digital approach is demonstrated. The integration of an exemplary digital workflow for quantitative precipitation analysis into a data pipeline concept is presented. Here ontologies enable linking of contextual information to the resulting output data in a triplestore. Publishing digital workflow and ontologies ensures the reproducibility of the data. The semantic structure enables data sharing and reuse for other applications and purposes, demonstrating interoperability.
Oxide thermoelectric semiconducting materials like p-type calcium cobaltite Ca3Co4O9 are investigated as oxidation- and temperature-resistant thermoelectric materials for thermoelectric generators (TEGs). To realize TEGs in planar film technology, the powder aerosol deposition (PAD) method is emerging recently. PAD is a method to obtain dense ceramic films directly from the synthesized starting powders without a subsequent high temperature step.
In the present work, Ca3Co4O9 (CCO) powders are processed by PAD to ceramic films at room temperature. The thermoelectric properties of the films (film thickness 10 – 20 µm) are characterized from room temperature to 900°C. Additionally, the layer morphology and texture of the films will be investigated.
As result, the Seebeck coefficient of the CCO-PAD film is comparable to pressed and sintered CCO-bulk materials during the 1st heating cycle to 900°C. The morphology of the films after the thermal treatment shows strong aligned crystallites resulting in a strong texture of the films. The electrical conductivity increases strongly during the 1st heating cycle to 900°C and stays almost constant afterwards. Compared to CCO-bulks, the films provide higher electrical conductivity which could be explained by the oriented crystal growth in-plane direction of the film.
The relationship between thermoelectric properties and layer morphology as a function of thermal annealing parameters will be further investigated.
Low-temperature co-fired ceramics (LTCC) are used to fabricate robust multilayer circuits. Typically, thick-film technology is applied for metallization. For specific sensor applications, thin films are deposited directly on the as-fired LTCC-surface. These deposited thin films are structured either by lift-off or by etching. The latter is less error-prone and thus preferred in industry provided the selected materials allow it.
200 nm Ni-thin films were deposited on three different commercial constrained-sintered LTCC (CT708, CT800 and DP951) by electron beam physical vapour deposition. The thin-films were structured by covering corresponding sections with a UV-curable photo resisn and subsequent etching of the uncovered surface, leaving behind the desired structure. The etched Ni-thin film showed high difference in failure rate and sheet resistance regarding the used LTCC-material. DP951 had the lowest sheet resistance and no failure, whereas the CT800 had a failure rate of 40 %. The LTCC with high failure rate showed a strong chemical attack by the used etching medium. To address this phenomenon, the chemical resistance of the three different commercial LTCC (CT708, CT800 and DP951) against four different commonly used etching media (sulphuric acid, phosphoric acid, aqua regia, and hydrofluoric acid) is investigated. The dissolved ions are analyzed by ICP-OES to correlate the LTCC-composition and its chemical resistance.
Destructive and non-destructive 3D-characterization of inner metal structures in ceramic packages
(2023)
Ceramic multilayer packages provide successful solutions for manifold
applications in telecommunication, microsystem, and sensor technology. In such packages, three-dimensional circuitry is generated by combination of structured and metallized ceramic layers by means of tape casting and multilayer technology. During development and for quality assurance in manufacturing, characterization of integrity, deformation, and positioning of the inner metal features is necessary.
Visualization with high resolution and material contrast is needed.
Robot-assisted 3D-materialography is a useful technique to characterize such multimaterial structures. In that, many sections of the specimen are polished and imaged automatically. A three-dimensional representation of the structure is created by digital combination of the image stack. A quasi non-destructive approach is to perform X-ray computer tomography (CT) with different beam energies. The energies are chosen to achieve a good imaging of either the metal features, or the ceramic matrix of the structure. The combination of the respective tomograms results in a high contrast representation of the entire structure. Both methods were tested to characterize Ag and Ag/Pd conductors in a ceramic multilayer package. The results were compared in terms of information content, effort, and applicability of the methods.
3D printing or additive manufacturing in space is of great value for long-term human spaceflight missions and space stations, conveniently offering access to a ‘virtual warehouse’ of tools and spare parts on the push of a button. The process only needs one type of feedstock such as powder or filament and only as much material as the final part requires, giving it a huge weight benefit over traditional subtractive methods.
While 3D printers are already operational on the ISS since 2014, the utilized processes are only capable of manufacturing relatively low strength parts from polymers not suitable for many tools or critical components. To gain access to high quality metal prints, a modified Laser Powder Bed Fusion (LPBF) process was developed to stabilize the critical powder bed in microgravity through a gas flow [2]. This setup was able to generate a (miniature) steel wrench during parabolic flights, but a reliable layer deposition has raised challenges due to the combination of gas flow parameters with microgravity conditions. Furthermore, the quality and density of the powder bed, which is critical for the process, cannot be examined afterward on the ground. This is due to hyper gravity phases during the flight that are influencing the properties of the powder bed.
In this paper, the challenges of the layer deposition are revised, and the subsequent evolution of the recoating system explained. Later, the challenges of an in-situ quality control, evaluation, and quantification of the properties of the powder bed are examined. As a solution, a high-resolution line-scanner is proposed and its implementation int the compact LPBF system demonstrated. Its ability to measure common defects such as ridges in the deposited layer is shown in experiments at normal gravity. As an illustration, Figure 1 shows an extreme case of the formation of ridges.
The increasing importance of resource availability and closed-loop material cycles are driving materials research to reduce alloying content in conventional materials or even substitute them with more sustainable alternatives. Intermetallic iron aluminide alloys (FeAl) present a potential alternative. Many alloy concepts for improved high-temperature properties or ductility have already been successfully implemented in casting technologies on a laboratory scale. However, successful testing of FeAl alloys on an industrial scale was still pending at the beginning of the project.
Therefore, the aim of the project was to develop simulation-based casting concepts for industrial casting processes using the base alloy Fe-26Al-4Mo-0.5Ti-1B and to narrow down process limits by means of hot cracking tests. Findings were transferred into practice-oriented guidelines for casting of iron aluminides, which is accessible to future applicants in SMEs. The focus was placed on centrifugal casting combined with investment casting or die casting. In addition to numerous design and casting process parameters, heat treatments and alloying additions (Al, Mo, B) were varied to determine the influence of alloying elements on castability, microstructure and mechanical properties. Data from microstructure analyses (microscopic imaging, determination of grain sizes as well as phase compositions and volume fractions, fractography), mechanical tests (hardness measurements, compression tests, ambient and high-temperature tensile tests, creep tests) as well as measurements of thermophysical properties could be generated on the base alloy. Correlations of materials data with process variables allowed conclusions to be drawn on strengthening mechanisms and ductility of the alloy and how they can be controlled in terms of processing and component design. Successful casting of highly complex components with thin wall thicknesses and optimised alloy compositions points out prospects for new fields of application.
Due to their unique physico-chemical properties, nanoparticles are well established in research and industrial applications. A reliable characterization of their size, shape, and size distribution is not only mandatory to fully understand and exploit their potential and develop reproducible syntheses, but also to manage environmental and health risks related to their exposure and for regulatory requirements. To validate and standardize methods for the accurate and reliable particle size determination nanoscale reference materials (nanoRMs) are necessary. However, there is only a very small number of nanoRMs for particle size offered by key distributors such as the National Institute of Standards and Technology (NIST) and the Joint Research Centre (JRC) and, moreover, few provide certified values. In addition, these materials are currently restricted to polymers, silica, titanium dioxide, gold and silver, which have a spherical shape except for titania nanorods. To expand this list with other relevant nanomaterials of different shapes and elemental composition, that can be used for more than one sizing technique, we are currently building up a platform of novel nanoRMs relying on iron oxide nanoparticles of different shape, size and surface chemistry. Iron oxide was chosen as a core material because of its relevance for the material and life sciences.
Due to combined cyclic mechanical and thermal loading during operation, the material of exhaust gas conducting components of combustion engines is exposed to thermomechanical fatigue (TMF). This leads to formation and growth of cracks, especially at the most highly stressed points of these components. In order to better predict the service life of cracked components before failure, it is necessary to identify a crack propagation law for the material used. Isothermal crack propagation tests have been carried out at several temperatures with a typical cast iron to identify such a law. The crack length is measured by the potential drop method. The compliance method, fractography and thermographic camera measurements have been used to validate and calibrate the potential drop measurements. Each of the isothermal tests has been simulated using a specially developed FEM-algorithm based on remeshing and remapping. This algorithm has been implemented in python and ABAQUS. Thereby, the crack tip region is modeled by collapsed Quad8 elements. From the individual simulations, the cyclic crack tip opening displacement (ΔCTOD) is extracted and regarded as a potential fracture mechanics parameter which controls the crack growth rate. By combining the data from the experiments and the simulations, the crack propagation law has been identified. Finally, anisothermal crack propagation tests have been performed for validation of the crack growth law.
Laser powder bed fusion (PBF-LB/M) of metallic alloys is a layer wise additive manufacturing process which provides significant scope for more efficient designs of components, benefiting performance and weight, leading to efficiency improvements for various sectors of industry. However, to benefit from these design freedoms, knowledge of the high produced induced residual stress and mechanical property anisotropy associated with the unique microstructures is critical. X-ray and neutron diffraction are considered the benchmark for non-destructive characterization of surface and bulk internal residual stress. The latter, characterized by the high penetration power in most engineering alloys, allows for the use of diffraction angle close to 90° enabling a near cubic sampling volume to be specified. However, the complex microstructures of columnar growth with inherent crystallographic texture typically produced during PBF-LB/M of metallics present significant challenges to the assumptions typically required for time efficient determination of residual stress. These challenges include the selection of an appropriate set of diffraction elastic constants and a representative strain-free reference for the material of interest. In this presentation advancements in the field of diffraction-based residual stress analysis of L-PBF Inconel 718 will be presented. The choice of an appropriate set of diffraction-elastic constants depending on the underlying microstructure will be described.
Investigation of degradation of the aluminum current collector in lithium-ion batteries by GD-OES
(2022)
Lithium-ion batteries (LIBs) are one technology to overcome the challenges of climate and energy crisis. They are widely used in electric vehicles, consumer electronics, or as storage for renewable energy sources. However, despite innovations in batteries' components like cathode and anode materials, separators, and electrolytes, the aging mechanism related to metallic aluminum current collector degradation causes a significant drop in their performance and prevents the durable use of LIBs. Glow-discharge optical emission spectroscopy (GD-OES) is a powerful method for depth-profiling of batteries' electrode materials. This work investigates aging-induced aluminum deposition on commercial lithium cobalt oxide (LCO) batteries' cathodes. The results illustrate the depth-resolved elemental distribution from the cathode surface to the current collector. An accumulation of aluminum is found on the cathode surface by GD-OES, consistent with results from energy-dispersive X-ray spectroscopy (EDX) combined with focused ion beam (FIB) cutting. In comparison to FIB-EDX, GD-OES allows a fast and manageable depth-profiling. Results from different positions on an aged cathode indicate an inhomogeneous aluminum film growth on the surface. The conclusions from these experiments can lead to a better understanding of the degradation of the aluminum current collector, thus leading to higher lifetimes of LIBs.
The Global Exploration Strategy of the International Space Exploration Coordination Group (ISECG) describes a timeframe of 2020 and beyond with the ultimate aim to establish a human presence on Mars towards the 2040ies. The next steps lie on the Moon with a focus on the coming 10 years. Early lunar surface missions will establish a capability in support of lunar science and prepare and test mission operations for subsequent human exploration of Mars and long-duration human activities on the Moon.
Given the extreme costs involved in the shipping of material from Earth, a prerequisite for future human exploration is the manufacturing of elements directly on the Moon’s surface. Unlike the equipment, which at the beginning will have to be brought from Earth, raw materials and energy could be available following the concept of In-Situ Resource Utilization. The ESA OSIP PAVING THE ROAD (PAVER) study investigates the use of a laser to sinter regolith into paving elements for use as roadways and launch pads thus mitigating dust issues for transport and exploration vehicles.
The ESA-funded study examines the potential of using a laser (12 kW CO2 laser with spot beam up to 100 mm) for layer sintering of lunar and martian regolith powders to manufacture larger 3D elements and provide know-how for the automatic manufacture of paving elements in the lunar environment. The project contributes to the first step toward the establishment of a lunar base and will lead to the construction of equipment capable of paving areas and manufacturing 3D structures.
PAVER project sets the starting point for an examination of the larger context of lunar exploration. Mission scenarios will look at different phases of lunar exploration: Robotic Lunar Exploration, Survivability, Sustainability, and Operational Phase. A proposed Technology Roadmap investigates the mission scenario and analyses how, and to which extent, laser melting/sintering will play a role in the various phases of exploration. The paper contextualizes laser sintering within selected mission scenarios and discusses the different kinds of infrastructure that can be produced at each phase of the mission. The outcome of the study includes the detailing of the TRL steps in the project and an outline of a timeline for the different elements. Covered aspects include terrain modelling such as operation pads, roadways, or towers, non-pressurized building structures to protect machinery, and habitat envelopes, to protect and shield humans against dust, micrometeoroids, and radiation.
Powder bed technologies are amongst the most successful Additive Manufacturing (AM) techniques. Powder bed fusion and binder jetting especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability. The application of these techniques to most ceramics has been difficult so far, because of the challenges related to the deposition of homogeneous powder layers when using fine powders. In this context, the “layerwise slurry deposition” (LSD) has been developed as a layer deposition method which enables the use of powder bed AM technologies also for advanced ceramic materials. The layerwise slurry deposition consists of the layer-by-layer deposition of a ceramic slurry by means of a doctor blade, in which the slurry is deposited and dried to achieve a highly packed powder layer. This offers high flexibility in the ceramic feedstock used, especially concerning material and particle size. The LSD technology can be combined with binder jetting to develop the so-called “LSDprint” process for the additive manufacturing of ceramics. The LSDprint technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing. In this presentation, the LSD process will be introduced and several examples of application ranging from silicate to high-performance ceramics will be shown. Recent developments towards the scale-up and industrialization of this process will be discussed, alongside future perspectives for the multi-material additive manufacturing.
At the Workshop "Neutron and Synchrotron Monitoring in Aerospace Advanced Manufacturing" at the Institute of Materials Physics in Space, German Aerospace Center (DLR) in Cologne, we presented on the opportunities and our experiences of using a powder based additive manufacturing process for in-space manufacturing applications in microgravity.
Although the slow crack growth in glass is dominated by stress-corrosion phenomena, it also should reflect the underlaying intrinsic fracture behavior controlled by glass chemistry and structure. To investigate such underlaying phenomena, crack growth velocity in alkali silicate glasses was measured in vacuum across 10 orders of magnitude with double cantilever beam technique. Measured and literature crack growth data were compared with calculated intrinsic fracture toughness data obtained from Young’s moduli and theoretical fracture surface energy. Data analysis reveals slight correlation with the packing density and significant deviations from the intrinsic brittle fracture behavior. These deviations do not follow simple compositional trends. Two opposing processes may explain this finding: a decrease in the apparent fracture surface energy due to stress-induced chemical changes at the crack tip and its increase due to energy dissipation during fracture.
Efforts towards digitalization in the material science and technology community have enhanced in the last years. In 2019 the German digitalization initiative platform „MaterialDigital“1 (MD) has been started. Numerous projects concerning digitalization, including the copper related project „KupferDigital“ (copper digital) have been initiated under the umbrella of MD. The initiative strives to
address numerous issues concerning data access, exchange, security, provenance and sovereignty. Heterogeneous data origin, storage and evaluation often result in problems concerning comparability and reproducibility of scientific and technological results. In many cases material data are recorded, but the methods of testing are insufficiently described, or such information is not communicated along with the raw data. The material data can also have numerous different formats such as paper printouts, pdfs, excel sheets or csv-files. Hence, gathering and integrating material data from different sources is challenging for potential users like materials scientists and engineers, especially if there are contradictory data where the reasons for contradictions is not clear due their vague description. In order to address these problems, data should comply to the so called „FAIR“ principle which calls for data to be findable, accessible, interoperable, and reusable (FAIR)2 and hence be accessible via so-called decentralized but interconnected data spaces. By using knowledge representation withontologies, data can be enriched with meaning and the methods of the testing procedures can be accurately provided. In this presentation we want to introduce our approach to such knowledge representation based on a high-throughput alloy development process for Cu-based alloys³ along with characterization techniques such as hardness testing and microstructural characterization (e.g. EBSD – Electron Backscattered Diffraction).
3D-printed landing pads on the moon: Paving the road for large area sintering of lunar regolith.
A prerequisite for lunar exploration and beyond is the manufacturing of objects directly on the moon, given the extreme costs involved in the shipping of material from Earth. Looking at processes, raw materials, and energy sources, equipment will certainly have to be brought from Earth at the beginning. Available on the moon are lunar regolith as raw material and the sun as an energy source. One of the first steps towards the establishment of a lunar base is the creation of infrastructure elements, such as roads and landing pads.
We’ll introduce you to the ESA-project PAVER that demonstrates the sintering and melting of lunar regolith simulant material to produce large scale 3D printed elements that could be used during human and robotic lunar explorations.
Additive manufacturing methods such as laser powder bed fusion (LPBF) allow geometrically complex parts to be manufactured within a single step. However, as an aftereffect of the localized heat input, the rapid cooling rates are the origin of the large residual stress (RS) retained in as-manufactured parts. With a view on the microstructure, the rapid directional cooling leads to a cellular solidification mode which is accompanied by columnar grown grains possessing crystallographic texture. The solidification conditions can be controlled by the processing parameters and the scanning strategy. Thus, the process allows one to tailor the microstructure and the texture to the specific needs. Yet, such microstructures are not only the origin of the mechanical anisotropy but also pose metrological challenges for the diffraction-based RS determination. In that context the micromechanical elastic anisotropy plays an important role: it translates the measured microscopic strain to macroscopic stress. Therefore, it is of uttermost importance to understand the influence of the hierarchical microstructures and the texture on the elastic anisotropy of LPBF manufactured materials.
This study reveals the influence of the build orientation and the texture on the micro-mechanical anisotropy of as-built Inconel 718. Through variations of the build orientation and the scanning strategy, we manufactured specimens possessing [001]/[011]-, [001]-, and [011]/[111]-type textures. The resulting microstructures lead to differences in the macroscopic mechanical properties. Even further, tensile in-situ loading experiments during neutron diffraction measurements along the different texture components revealed differences in the microstrain response of multiple crystal lattice planes. In particular, the load partitioning and the residual strain accumulation among the [011]/[111] textured specimen displayed distinct differences measured up to a macroscopic strain of 10 %. However, the behavior of the specimens possessing [001]/[011]-and [001]-type texture was only minorly affected. The consequences on the metrology of RS analysis by diffraction-based methods are discussed.
A main source of current challenges in materials science and engineering is the ever-increasing complexity in materials chemistry and processing resulting in complex microstructures, making the assessment of process-microstructure-property-performance relations difficult, even unmanageable. Here the computational materials science is facing the same situation. In this talk, I share a viewpoint that the complexities in chemistry, processing and microstructures can be circumscribed by integrating existing knowledges of bulk thermodynamics and kinetics to the unknown thermodynamics and kinetics of microstructure elements. To this end, I discuss several successful examples on grain boundary segregation engineering how this scientific advance can be conducted. A roadmap is proposed, beginning to form on generalizing the concept of phase diagrams.
Die technischen Möglichkeiten der robotischen Glasschmelzanlage der BAM werden vorgestellt.
The homogeneous introduction of organic additives is a prerequisite for good processability of ceramic powders during dry pressing. The addition of organic additives by wet route via ceramic slurries offers advantages over dry processing. The organic content can be reduced and a more homogeneous distribution of the additives on the particle surface is achieved. In addition to the measurements of zeta potential and viscosity, sedimentation analysis by optical centrifugation was also tested and successfully used to characterize the ceramic slurries and accurately evaluate of the suitability of different types, amounts, and compositions of organic additives.
Spray drying of well-stabilized slurries usually results in mostly hollow granules with a hard shell leading to sintered bodies with defects and reduced strength and density. By purposefully degrading the slurry stability after dispersion of the ceramic powder, the drying behavior of the granules in the spray drying process and thus the granule properties can be influenced. Destabilization of the slurry and thus partial flocculation was quantified by optical centrifugation. Spray drying of the destabilized alumina slurries resulted in "non-hollow" granules without the detrimental hard shell and thus improved granule properties.
Further improvement of the granules was achieved by installing ultrasonic atomization in the spray dryer. A narrower granule size distribution was achieved, which had a positive effect on, among other things, the flowability of the granules.
Specimens produced from this granules had fewer defects of smaller size, leading to better results for the density and strength of the sintered bodies. The observations made for alumina could be transferred to zirconia and as well to ZTA with 20 wt% zirconia.
A large amount of publicly available data is reproduced every day in the field of materials science, while these kind of material data can have different formats and types like paper-type publications, standards, datasheets or isolated datasets in repositories. However, gathering a specific library from such extensive and diverse material data is always challenging for the materials scientists and engineers, since the time-related limitations are not allowed to fully access the large publicly available databases; search across these disparate databases, manage the large volumes of heterogeneous datasets, and integrate data from multiple sources. To address these challenges and make data findable, accessible, interoperable, and reusable (FAIR), an efficient data management system is necessary to build comprehensive, documented, and connected data spaces in the future. A formal standardized knowledge representation through an ontology can address such problems and make data more available and interoperable between related domains. Ontology can also rich machine processable semantic descriptions that increases the performance of scientific searches. In this regard, the Platform MaterialDigital (PMD) is currently working on developing a high-level ontology for the materials and material related processes. For example, in one of the PMD projects of “KupferDigital”, we will try to develop a data ecosystem for digital materials research based on ontology-based digital representations of copper and copper alloys. As a case study, this paper describes the methodology for ontology development of Brinell hardness, based on PMD core ontology. The methodology we describe includes the following steps; gathering the required domain terminology from different resources like standards (DIN EN ISO 6506-1) and test reports, representing the performance of a standard-conformant hardness test and the treatment of the recorded values up to a “reportable” hardness value for a material, designing the process chain according to the semantic technologies, and developing a domain-level ontology of Brinell hardness based on PMD ontology semantic formalization. Apart the mentioned methodology, some interesting tools and methods were introduced and ontology design challenges and possible solutions for modelling materials and processes were discussed. Furthermore, a dataset from the Brinell hardness measurement of cast copper samples is prepared for testing the query process.
Up to now, oriented surface crystallization phenomena are discussed controversially, and related studies are restricted to few glasses. For silicate glasses we found a good correlation between the calculated surface energy of crystal faces and oriented surface nucleation. Surface energies were estimated assuming that crystal surfaces resemble minimum energy crack paths along the given crystal plane. This concept was successfully applied by Rouxel in calculating fracture surface energies of glasses. Several oriented nucleation phenomena can be herby explained assuming that high energy crystal surfaces tend to be wetted by the melt. This would minimize the total interfacial energy of the nucleus. Furthermore, we will discuss the evolution of the microstructure and its effect on the preferred crystal orientation.
Engineering grain boundaries demands a quantitative description of both their segregation and specific phase behavior. Recently I have proposed a density-based model for grain boundary thermodynamics that enables CALPHAD integrated derivation of grain boundary phase diagrams, broadly applied now in studying various alloys. Combining this model with experimental investigations, in this talk, new aspects of interfacial segregation and phase transformation revealed in polycrystalline alloys are discussed. The effect of elastic interaction on grain boundary phase behavior is incorporated. We consider Al alloys and novel high-entropy alloys and discuss a general strategy for grain boundary engineering.
Due to the increasing scarcity of critical raw materials current high-temperature materials are sought to be replaced by alloys based on more abundant metals. One possibility within the class of intermetallics are iron aluminides, which combine sustainability and cost-efficiency with the prospect of mass savings. Iron aluminides show competitive specific strength up to 700 °C and excellent creep and wet corrosion resistance by small additions of Mo, Ti and B. Nevertheless, a Mo content of above 2 at.% which is needed for optimum corrosion resistance results in enhanced brittleness, especially at room temperature. This is why alloys with these Mo fractions were only mechanically tested under compressive loading so far. Still, testing of static and creep properties under tensile loading is required for reliable component design. Besides high standards for crack-free processing, data acquisition for tensile loads is especially complicated by environmental embrittling effects for iron aluminides. To cope with these challenges, the AiF research project “WAFEAL – Materials applications for iron aluminides” was initiated. The main goal is to collect standardised data on ambient and high-temperature tensile properties and creep properties. Samples with a nominal composition of Fe-26Al-4Mo-0.5Ti-1B [at.%] were manufactured via centrifugal casting in ceramic shell moulds followed by machining. Heat treatment for homogenisation and final polishing were carried out where appropriate. A summary of the achieved tensile and creep properties such as yield and tensile strength, maximum elongation, secondary creep rate and stress exponents will be given. Results will be also discussed regarding the influence of temperature, stress level and microstructure on the damage mechanisms. Furthermore, the effect of different alloy concentrations on the mechanical response at different temperatures will be outlined within a small experimental series.
The aim of a fractographic investigation is the evaluation of macroscopic and microscopic fracture surface characteristics and, as a result, the determination of the fracture mechanism of a component from a failure case. The basis for such evaluations of fracture characteristics comes from actual comparative mechanical testing and from the literature. A fractographic analysis can be very complex and, in any case, requires considerable experience. In the IGF project "iFrakto", software is being developed that quantitatively determines fracture characteristics and fracture mechanisms utilizing digitized expert knowledge, machine learning, and standard 2D and topographical data from SEM imaging. Topographical data are obtained from 4QBSE detector using shape-from-shading technology. In the medium term, a software tool should provide knowledge-based suggestions for the evaluation of fracture surfaces in real time during SEM work or at subsequent evaluation. As a basis for this, round robins were carried out among fractographers in order to create a knowledge base, to query the practice-relevant requirements for such tools and to carry out first practical tests. Actual results are presented and the relevance of the evaluation strategy is evaluated.
The aim of a fractographic investigation is the evaluation of macroscopic and microscopic fracture surface characteristics and, as a result, the determination of the fracture mechanism of a component from a failure case. The basis for such evaluations of fracture characteristics comes from actual comparative mechanical testing and from the literature. A fractographic analysis can be very complex and, in any case, requires considerable experience.
Machine learning methods enables the quantitative determination of fracture characteristics and fracture mechanisms utilizing digitized expert knowledge [1]. Although the application of SE images provides promising results, additional information is required to obtain reliable solutions. As expected, BSE and 3D information helps to improve the classification (Fig. 1). But only a fast, widely integrated, and automated topography measurement can provide the required amount of referenced surface data for the application of machine learning methods.
To fulfil these requirements, topographical data are obtained from a BSE detector with four symmetric segments (4Q-BSE) using shape-from-shading technology [2]. Surface height calculation is performed live during image acquisition and provides immediate feedback in three dimensions. All available signals (SE, BSE and more if applicable) are recorded simultaneously together with the surface topography and stored in a multichannel data file. This guaranties the same geometrical reference for all data, which is required for further analysis (Fig. 2).
When applying machine learning methods to topographic data together with SEM images, topographic information must be provided as depth image. Consequently, a unique height scale is required for all applied data with different magnifications. This requires a calibrated height measurement, which is ensured with the integrated 3D calibration of the topographic acquisition and a dedicated calibration sample. Thus, a large number of data sets from different fracture samples was generated and used as training data for machine learning.
Substitution of lead oxide in low-melting glasses, e.g., for application in silver metallization pastes, is a current research goal. This work is focused on the investigation of silver diffusion in alkali zinc borate glasses (X2O-ZnO-B2O3, X = Li, Na, K, Rb). In addition, the redox state of silver (Ag) and thus the type of diffusing silver species were studied. For this purpose, a metallic silver coating was applied on glass cubes by means of sputtering. Heat treatment of the samples was performed close to the glass transition temperatures at 470 °C for 2 h under air and nitrogen atmosphere. Coating thickness was 1.8 µm after heat treatment, measured by a white light interferometer.
Silver diffusion profiles were measured by means of secondary neutral mass spectrometry. The silver diffusion coefficients are in the range of ~10-14 cm2/s and indicate no significant differences depending on the type of alkali ions in the glass. Dissolved Ag+-ions and [Agm]n+-clusters in the glasses were differentiated using fluorescence spectroscopy.
Precipitated metallic silver particles in the sodium containing glass were observed by means of transmission electron microcopy. Their mean particle diameter was ~6 nm.
Towards Interoperability: Digital Representation of a Material Specific Characterization Method
(2022)
Certain metallic materials gain better mechanical properties through controlled heat treatments. For example, in age-hardenable aluminum alloys, the strengthening mechanism is based on the controlled formation of nanometer sized precipitates, which represent obstacles to dislocation movement. Precise tuning of the material structure is critical for optimal mechanical behavior in the application. Therefore, analysis of the microstructure and especially the precipitates is essential to determine the ideal parameters for the interplay of material and heat treatment. Transmission electron microscopy (TEM) is utilized to identify precipitate types and orientations in a first step. Dark-field imaging (DF-TEM) is often used to image the precipitates and to quantify their relevant dimensions.
The present work aims at the digital representation of this material-specific characterization method. Instead of a time-consuming, manual image analysis, an automatable, digital approach is demonstrated. Based on DF-TEM images of different precipitation states of a wrought aluminum alloy, a modularizable digital workflow for quantitative precipitation analysis is presented. The integration of this workflow into a data pipeline concept will also be discussed. Thus, by using ontologies, the raw image data, their respective contextual information, and the resulting output data from the quantitative precipitation analysis can be linked in a triplestore. Publishing the digital workflow and the ontologies will ensure the reproducibility of the data. In addition, the semantic structure enables data sharing and reuse for other applications and purposes, demonstrating interoperability.
The presented work is part of two digitization initiatives, the Platform MaterialDigital (PMD, materialdigital.de) and Materials-open-Laboratory (Mat-o-Lab).
Ontologies that represent a map of the concepts and relationships between them, are becoming an effective solution for data standardization and integration of different resources in the field of materials science, as efficient data storage and management is the building block of material digitization. However, building a domain ontology is not a simple task. It requires not only a collaborative effort between ontologists and domain experts, but also the modeling approaches and tools play a key role in the process. Among all approaches, graphical representation of domain ontologies based on standard conceptual modeling languages is widely used because of its intuitiveness and simplicity. Various tools have been developed to realize this approach in an intuitive way, such as Protégé plugins and web visualization tools.
The Materials-open-Lab (MatOLab) project, which aims to develop ontologies and workflows in accordance with testing standards for the materials science and engineering domains, adopted a UML (Unified Modeling Language) approach based on the diagrams.net. It is a powerful, popular, open-source graphical editor. In practical case studies, however, many users’ needs could not be met, such as reusing ontology, conversion, and data mapping. Users must switch between different tools to achieve a certain step, and thereby invariably increase learning cost. The lack of validation also leads to incorrect diagrams and results for users who are not familiar with the ontology rules. To address these issues, we designed Ontopanel, a diagrams.net-based plugin that includes a set of pipeline tools for semantic modeling: importing and displaying protégé-like ontologies, converting diagrams to OWL, validating diagrams by OWL rules, and mapping data. It uses diagrams.net as the front-end for method modeling and Django as the back-end for data processing. As a web-based tool, it is very easy to expand its functionality to meet changing practical needs.
Following the new paradigm of materials development, design and optimization, the digitalization of materials and processes is the main goal which imposes a huge challenge. In this respect, the quality assurance of processes and output data as well as the interoperability between applications following FAIR (findability, accessibility, interoperability, reusability) principles are to be ensured. This includes storage, processing and querying of data in a preferably standardized form, also addressing the incorporation of standardization bodies. To meet the challenge to contextualize material data in a way that is consistent with all stakeholders, all necessary information on the condition of the material including production and application-related changes have to be made available via a uniform, machine-readable description. For this purpose, ontologies are to be used since they allow for machine-understandable knowledge representations and semantic conceptualizations that are needed for data management and the digitalization in the field of materials science.
With respect to this currently ever-growing topic of integration and reuse of data and knowledge from synthesis, production and characterization of materials, this presentation shows the efforts taken within the project Platform MaterialDigital (PMD, materialdigital.de) to store tensile test data in accordance with a standard-compliant ontological representation. The includes the path from developing an ontology in accordance with the respective standard, converting ordinary and arbitrarily selected data gained from standard tests into the interoperable RDF format, up to connecting the ontology and data, respectively. Finally, such data can be queried from a triple store.
In the field of material science and engineering (MSE), most mechanical test methods are standardized which serves as a valid basis for ontology development. Therefore, the well-known tensile test of metals at room temperature (DIN EN ISO standard 6892-1:2019-11) was selected to be considered as one of the first use cases in PMD. This consideration within the PMD features both, the ontological representation of such a tensile test in accordance with the standard as well as exemplary data generation. The semantic connection of the ontology and data leads to interoperability and an enhanced ability of querying.
The mechanical strength of wrought high-strength aluminum alloys is essentially based on precipitation hardening, possibly in combination with prior forming, e. g. by stretching. Important parameters for achieving an optimum combination of hardness, strength, ductility, toughness, and further properties such as corrosion resistance are age-hardening temperature and time.
During thermal (mechanical) treatment, nucleation and growth of precipitates takes place, leading to the desired degree of hardening. In aluminum alloys, precipitation sequences are usually passed through, i. e. a sequence of metastable precipitates is formed before the stable phase can precipitate. The optimum combination of properties is therefore based on a certain (optimum) microstructure, which can, however, change during the use of a component, since the microstructure is not stable. This happens in particular when the operating temperatures are close to the aging temperature and/or the operating times are sufficiently long. An external mechanical load may accelerate the processes. The presentation gives some examples for this.
The presentation shows the results of high cycle fatigue (HCF) tests from the aluminium alloy EN AW-2618A. This study investigates the mean stress influence in the T61 condition and the effect of overaging. For this purpose, axial HCF tests were carried out at room temperature and different stress ratios (R=-1, R=0.1) as well as with overaged conditions (T61+10h@230°C, T61+1000h@230°C). After completion of the tests, the fracture surfaces were examined to study crack initiation.
Liquid phase sintering of glass bearing silver pastes used in photovoltaics and microelectronics is poorly understood. In particular, the role of different network modifiers acting in the glass component and the question of the most suitable atmospheric oxygen level during sintering are still under considerable debate. To tackle these issues, low-melting and lead-free X2O-ZnO-B2O3 glasses with X = Li, Na, K and Rb (LZB, NZB, KZB and RZB) were prepared. Infrared spectroscopy showed that the glass structure was similar to each other, while an increase of tetrahedrally coordinated boron with increasing field strength of the alkali was evident. In turn, the glass transition temperature (from differential thermal analysis) increased in the order: RZB (449 °C) < KZB (460 °C) < NZB (465 °C) < LZB (472 °C). Powders of each glass were mixed with organics to receive silver-glass-pastes containing 30 vol% glass and these were subjected to heating microscopy in air. Although similar onset temperatures of sintering were recorded for Ag-NZB and Ag-LZB glass pastes, and for Ag-RZB paste and KZB-Ag-paste, respectively, differences in the crystallization behavior and final densification were observed between the former and the latter group. These were translated in terms of differences in silver dissolution and reprecipitation among the two groups. Further, running the experiments in nitrogen gas showed that sintering of all pastes was considerably hampered. The slow-down of the sinter kinetics was found to be in line with the assumed lower oxidation and dissolution of silver ions into the glass-forming liquid.
Fully-reversed fatigue behavior of scarf joint repairs for wind turbine blade shell applications
(2022)
Due to manufacturing imperfections which can propagate to damage under in-service loads, wind turbine rotor blades, made primarily of glass fiber reinforced polymers (GFRP), often fail significantly before their design life. To enable a quick and cost-effective return to service, localized repairs can be executed by technicians in the field, directly accessing the blades by suspended roping. Scarf joint repairs, shown to be highly efficient with a smooth load transition across angled joint walls and a restored aerodynamic profile, are the focus of this study. The damage mechanisms of these structures were examined under fully-reversed mechanical cyclic loading with a load ratio R = -1, which was made possible on the coupon scale by a custom designed anti-buckling support. The number of cycles to failure were compared across load levels. While the scarf joint ratio was held constant at 1:50, known from industry and literature to be a good compromise between restored mechanical properties and repair size, the layup sequence was varied between small-to-large and large-to-small. Hereby the effect of the presence of resin pockets and fiber orientation mismatch between the parent and repair structure on the failure mechanism as well as fatigue strength of ±45° GFRP scarf joint repair structures was studied. Strain development across the joint length was measured to assess stiffness degradation in addition to the fatigue strength recovery of scarf joint structures with respect to pristine reference specimens. Grayscale analysis was used to monitor the damage state leading to fracture across the specimens. Post-mortem fractography analysis with light microscopy described the global failure mechanisms as well as local damage distribution within the structure, all of which provided insight to critical variables in scarf joint GFRP structures under fully-reversed mechanical cyclic loading, allowing for the tailoring of such repairs on wind turbine blade shells for maximum restoration of service life.
To reveal the corrosion resistance of casing steel/mortar interface in CO2 injection condition, sandwich samples were prepared and exposed up to 20 weeks in aquifer fluid under 10 MPa and 60 °C.
Cross section analysis revealed the crevice corrosion as main mechanism instead of pitting corrosion despite very high concentration of Cl in NGB.
EDS element line scan analysis of the 20-week-exposed metal/mortar coupon showed Chloride distribution, which still not reached the metal/mortar interface, explaining no pitting was observed.
It was confirmed that FeCO3 cannot protect the steel surface in CO2 saturated NGB.
To verify the protective possibility of passivation happened on casing steel/mortar interface, simulated pore solution was synthesized and used to passivate the steel for 42 days. OCP and EIS confirmed the formation of passive layer.
The 42 day passivated layer was broken during the first minute of exposure in CO2 saturated NGB.
However, due to high concentration of Ca2+, a new carbonate CaCO3 dense layer was formed, increased the corrosion resistance of steel surface.
Powder bed technologies are amongst the most successful Additive Manufacturing (AM) techniques. Powder bed fusion and binder jetting especially are leading AM technologies for metals and polymers, thanks to their high productivity and scalability.
The application of these techniques to most ceramics has been difficult so far, because of the challenges related to the deposition of homogeneous powder layers when using fine powders.
In this context, the "layerwise slurry deposition" (LSD) has been developed as a layer deposition method which enables the use of powder bed AM technologies also for advanced ceramic materials. The layerwise slurry deposition consists of the layer-by-layer deposition of a ceramic slurry by means of a doctor blade, in which the slurry is deposited and dried to achieve a highly packed powder layer. This offers high flexibility in the ceramic feedstock used, especially concerning material and particle size.
The LSD technology can be combined with binder jetting to develop the so-called “LSDprint” process for the additive manufacturing of ceramics.
The LSDprint technology combines the high-speed printing of binder jetting with the possibility of producing a variety of high-quality ceramics with properties comparable to those achieved by traditional processing.
In this presentation, the LSD process will be introduced and several examples of application ranging from silicate to high-performance ceramics will be shown.
Recent developments towards the scale-up and industrialization of this process will be discussed, alongside future perspectives for the multi-material additive manufacturing.