Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Eingeladener Vortrag
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Automotive engine lubricants
(2019)
In 2003, ASTM Manual 37, Fuels and Lubricants Handbook: Technology, Properties, Performance and Testing, featured a chapter discussing automotive lubricants, including engine oils, automatic transmission fluids, manual transmission fluids, gear lubricants, and greases. This chapter, by Schwartz, Tung, and McMillan, surveyed all of these classes of lubricants, up to its publication in 2003.
More recently, the period between 2003 and 2010 has been addressed as part of a book copublished by ASTM and SAE International (coeditors Simon Tung and George Totten), where Fox surveyed the development of engine oil specifications that emerged during those years.
This chapter surveys the evolution of engine oil design and testing since 2002 and concludes with insights into future directions offered by recent tribological research. Our objective is to provide a reader new to the field with an understanding of the following:
- Engine oil composition and formulation
- North American engine oil specification development, and an outline of emergent European specifications
- How emergent specifications and legislative requirements are linked to the introduction of new engine hardware
- How tribological innovation can contribute to future enhancements in engine efficiency
In parallel, we will provide several tables comparing groups of contemporaneous specifications.
Additive Manufacturing (AM) in terms of laser powder-bed fusion (L-PBF) offers new prospects regarding the design of parts and enables therefore the production of lattice structures. These lattice structures shall be implemented in various industrial applications (e.g. gas turbines) for reasons of material savings or cooling
channels. However, internal defects, residual stress, and structural deviations from the nominal geometry are unavoidable.
In this work, the structural integrity of lattice structures manufactured by means of L-PBF was non-destructively investigated on a multiscale approach.
A workflow for quantitative 3D powder analysis in terms of particle size, particle shape, particle porosity, inter-particle distance and packing density was established.
Synchrotron computed tomography (CT) was used to correlate the packing
density with the particle size and particle shape. It was also observed that at least about 50% of the powder porosity was released during production of the struts.
Struts are the component of lattice structures and were investigated by means of laboratory CT. The focus was on the influence of the build angle on part porosity and surface quality. The surface topography analysis was advanced by the quantitative characterisation of re-entrant surface features. This characterisation was compared with conventional surface parameters showing their complementary
information, but also the need for AM specific surface parameters.
The mechanical behaviour of the lattice structure was investigated with in-situ CT under compression and successive digital volume correlation (DVC). The Deformation was found to be knot-dominated, and therefore the lattice folds unit cell layer wise.
The residual stress was determined experimentally for the first time in such lattice structures. Neutron diffraction was used for the non-destructive 3D stress investigation. The principal stress directions and values were determined in dependence of the number of measured directions. While a significant uni-axial stress state was found in the strut, a more hydrostatic stress state was found in the knot. In both cases, strut and knot, seven directions were at least needed to
find reliable principal stress directions.
To increase the competitiveness of jacket substructures compared to monopiles a changeover from an individual towards a serial jacket production based on automated manufactured tubular joints combined with standardized pipes has to be achieved. Therefore, this paper addresses fatigue tests of automatically welded tubular X-joints focusing on the location of the technical fatigue crack. The detected location of the technical crack is compared to numerical investigations predicting the most fatigue prone notch considering the structural stress approach as well as the notch stress approach. Besides, the welding process of the automated manufactured tubular X-joints is presented.
The determination of mechanical properties of welded Steel structures such as strength or ductility is a subject of high interest for the majority of Companies in the area of metal Processing. The material Parameters can be obtained by performing the tensile test on the samples made from a part of a component. In some cases, it is highly expensive to produce the tensile specimens especially from the weld metal, which contains different type of microstructure such as weld seam or heat affected zone in an extremely small area. Therefore, a method is described in this paper to determine the material Parameters of high strength Steel structures and welded joints locally and without any additional effort to perform the tensile test. In this method, instrumented indentation technique (IIT), an indenter is pushed on the flat surface of a specimen in a certain period of time and simultaneously the applied force and the corresponding indentation path are measured. The data related to the force-indentation diagram is given as input to an artificial neural network (ANN) to obtain the material Parameters. The ANN can be trained by generating the large qualitative data sets with numerical Simulation of the IIT procedure. The Simulation must be run several times with the different material model parameter sets to generate the numerous
force-indentation diagrams as the inputs of ANN. Then, the trained ANN is validated by performing the IIT on the welded joints and comparing the obtained material Parameters from ANN with the tensile test.
Consequently, the mechanical properties of welded joints can be determined by performing the IIT and evaluating the resulting data by the ANN.
Predictive Methods for Determining the Thermal Decomposition Properties of Hazardous Substances
(2019)
Due to the fast development and availability of computers, predictive approaches are increasingly used in the evaluation process of hazardous substances complementary to experiments. Their use was recommended as alternative to experimental testing by the REACH regulation to complete the lack of knowledge on properties for existing substances that must be registered before 2018 (upon quantities). Among the proposed predictive approaches, Quantitative Structure Property Relationships (QSPR) are powerful methods to predict macroscopic properties from the only molecular structure of substances. In that context, the HAZPRED project (2015-2018, founded by the SAF€RA consortium) aims to develop theoretical models (e.g. QSPR) and small-scale tests to predict complex physico-chemical properties (e.g. thermal stability, explosivity) of hazardous substances to complete the lack of knowledge on these hazardous substances quickly or to understand their decomposition behaviour better. In particular, this contribution will present the work done in this project on the physical hazards of organic peroxides and self-reactive substances: gathering of existing experimental data, new experimental campaigns, review of existing models and proposition of new estimation methods.
Most knowledge about the structure, function, and evolution of early compound eyes is based on investigations in trilobites. However, these studies dealt mainly with the cuticular lenses and little was known about internal anatomy. Only recently some data on crystalline cones and retinula cells were reported for a Cambrian trilobite species. Here, we describe internal eye structures of two other trilobite genera. The Ordovician Asaphus sp. reveals preserved crystalline cones situated underneath the cuticular lenses. The same is true for the Devonian species Archegonus (Waribole) warsteinensis, which in addition shows the fine structure of the rhabdom in the retinula cells. These results suggest that an apposition eye with a crystalline cone is ancestral for Trilobita. The overall similarity of trilobite eyes to those of myriapods, crustaceans, and hexapods corroborates views of a phylogenetic position of trilobites in the stem lineage of Mandibulata.
In this paper we report on the characterization by X-ray computed tomography of calcium phosphate (CaP) and polycaprolactone (PCL) coatings on Ti-6Al-4V alloy scaffolds used as a material for medical implants. The cylindrical scaffold has greater porosity of the inner part than the external part, thus, mimicking trabecular and cortical bone, respectively. The prismatic scaffolds have uniform porosity. Surface of the scaffolds was modified with calcium phosphate (CaP) and polycaprolactone (PCL) by dip-coating to improve biocompatibility and mechanical properties. Computed tomography performed with X-ray and synchrotron radiation revealed the defects of structure and morphology of CaP and PCL coatings showing small platelet-like and spider-web-like structures, respectively.
The full-notch creep test (FNCT) is a common method to evaluate the environmental stress cracking (ESC) behavior of high-density polyethylene (PE-HD) container materials . The test procedure as specified in ISO 16770 provides a comparative measure of the resistance against ESC using the time to failure of specimens mechanically loaded in a well-defined liquid environment. Since the craze-crack damage mechanism underlying the ESC process is associated with brittle failure, the occurrence of globally brittle fracture surfaces is a prerequisite to consider an FNCT measurement as representative for ESC . Therefore, an optical evaluation of FNCT fracture surfaces concerning their brittleness is essential. Due to the experimental setup, an inevitable increase of the true mechanical stress and the associated appearance of small ductile parts on fracture surfaces is induced in any case. Hence, an FNCT experiment is considered as 'valid', if the corresponding fracture surface is predominantly brittle . Based on laser scanning microscopy (LSM) height data of FNCT fracture surfaces , a universal and easy-to-use phenomenological criterion was developed to assess the validity of distinct FNCT experiments. This criterion is supposed to facilitate a quick evaluation of FNCT results in practical routine testing.
During their lifetime, polymer components subjected to mechanical loads and environmental influences show a loss of their mechanical properties required for their specific applications. In this respect, the craze-crack damage mechanism slow crack growth (SCG) is relevant for PE-HD components used in high-performance applications such as pipes and containers for the storage and transport of dangerous goods. SCG is considered to be the major failure mechanism in polyolefins and it typically occurs suddenly and unexpectedly. Due to the fields of application, SCG is a safety relevant issue. To test for the resistance of PE-HD pipe and container materials against SCG, the full-notch creep test (FNCT) is widely applied in Europe. In this study, SCG phenomena in PE-HD are investigated in detail based on an improved FNCT, especially including the consideration of the influence of environmental liquids effecting the damage mechanism. Using an enhanced fracture surface and a crack propagation analysis with imaging techniques such as light microscopy (LM), laser scanning microscopy (LSM), X-ray computed tomography (CT-scan) and scanning electron microscopy (SEM), detailed data concerning SCG are obtained.
The combined application of FNCT and such imaging techniques is explicitly advantageous and recommended to gain important information on damage occurring to PE-HD induced by mechanical stress and the influence of environmental liquids, which is essential within the Fourth Industry Revolution.
Alkali and alkaline earth chlorides are discussed as heat storage media and are characterized by their low price and high availability. Disadvantages are a high corrosion rate and formation of Cr6+ ions in the melt, as observed in various binary chlorine salt melts. In our work the system NaCl-KCl-MgCl2 is considered. The storage capacity in this salt system is between 2 and 3 MWh per 10 t salt, depending on composition, melting temperature and working temperature. At the same time the system offers a eutectic line, which allows a high variance of the composition and possibly different corrosion rates can be observed. Corrosion tests in melts were carried out and the corrosion layers investigated. The tests with chloride melts on 12% Cr steel show an inner corrosion zone of up to 40 µm depth after 96 hours. The corrosion mechanisms and potential solutions are discussed.
Carbidic Austempered Ductile Iron (CADI) microstructures containing eutectic carbides can be produced by the addition of carbide stabilizing elements, such as chromium. Carbides formed from the addition of Cr are eutectic of M3C type. The presence of such hard phases can enhance the abrasion wear resistance of ductile iron. A new CADI can be produced by the addition of Nb. Niobium carbide particles are formed in the beginning of solidification and remain stable once they are insoluble in solid iron matrix. The dry sand abrasive wear resistance of ductile irons alloyed with 1.0, 1.8, and 2.4 wt% Nb were tested in both “as-cast” and “heat treated” conditions using standard ASTM G65. Results were compared to abrasive wear data obtained on ductile iron alloyed with 1 wt% Cr, CADI (1 wt% Cr), and the basic composition of iron without carbide stabilizing elements. In the “ascast” condition, the addition of Nb did not lead to a reduction in wear, while CADI with Nb is a promising substitute for CADI with Cr addition, because both materials showed very similar values of abrasion resistance.
Micro-ploughing and micro-cutting mechanisms were observed on the worn surfaces of ductile irons. Abrasive wear resistance of these alloys was correlated with the volume fraction of carbides.
Thermodynamic study of a refractory complex concentrated alloy (rCCA) using the CALPHAD method
(2019)
Multi-principal-element alloys (MPEAs), have recently come to the attention of the scientific community due to their potential for improving properties such as, e.g. mechanical strength and oxidation resistance in high temperature structural applications. The AlMo0.5NbTa0.5TiZr refractory (r)CCA is one such candidate, showing a two-phase microstructure after a two-stage heat treatment under argon atmosphere at a controlled cooling rate. Since the application conditions intended for this alloy require a long-term high temperature (> 700 °C) mechanical and oxidation resistance, it becomes necessary to assess the possible phase development in this regime. The diagrams reveal that two BCC-based phases could form during alloy solidification, where one phase would be enriched with Mo, Nb and Ta while the other phase, with Al, Ti and Zr. Activity oxides diagrams show that a stable form of aluminum oxide (α-Al2O3, Pearson symbol: hR10, corundum) can be formed.
Formation of interphases between inorganic nanofillers and thermoplastic matrices are usually correlated to short-range interactions which does not exceed more than tens of nanometers away from the surface of the filler. Nevertheless, in nanocomposites with thermosetting matrices, the effect of nanofillers on the properties of the matrix is not limited to the immediate vicinities, but a long-range property alteration of the bulk polymer may be observed. The interaction between nanofillers and the polymer can disturb the curing reaction and alters the chemical, physical and mechanical properties of the polymer network in the matrix phase. In our studies, we aim to investigate short and long-range interphases of a nanocomposite system consisting of a thermosetting matrix (DGEBA) filled with an inorganic nanoparticle (boehmite). For this purpose, a combination of atomic force microscopy (AFM)-based approaches is implemented. Scanning kelvin probe microscopy (SKPM) was used to map the compositional contrast and the interphase with different electrical properties than the bulk. The mechanical properties of the interphase were probed by high resolution intermodulation AFM. (ImAFM). Furthermore, infrared spectroscopy AFM (AFM-IR) is used to investigate the chemical structure of the matrix at different distances from the nanoparticle. SKPM and (AFM-IR) measurements both show a long-range (to 10 µm) effect of boehmite on the chemical structure and surface potential of the bulk epoxy, respectively, whereas ImAFM force measurements reveals a short-range mechanical interphase between the filler and the matrix. The AFM-IR demonstrated the existence of unreacted anhydride hardener at the interphase. This indicates the preferential absorption of anhydride on the surface of boehmite. The consequence of such a selective interaction between the inorganic filler and the epoxy components is disturbance of the epoxy-hardener stoichiometric ratio, the curing mechanism. and the alteration of bulk properties of the matrix.
Inorganic nanoparticles are used to improve the performance of epoxy as the matrix phase in fiber-reinforced composites used for aerospace applications. The effectiveness of nanofillers on property enhancement of thermosetting polymers depends on many factors including the interaction between the functional groups of nanofillers and the polymer reactants. In the current work, we study the effect of boehmite nanoparticles (BNPs) on properties of anhydride-cured bisphenol-A-diglycidyl ether (DGEBA). Dynamic mechanical thermal analysis (DMTA) and a high-resolution force measurement approach called intermodulation atomic force microscopy (ImAFM) were carried out to investigate the thermomechanical and nanomechanical properties of this material, respectively. It was found that BNPs lead to decrease of glass transition temperature (Tg) and crosslink density of the polymer network meanwhile significantly enhancing the Young’s modulus. Besides formation of a soft interphase near the particles, significant changes in local stiffness of polymer matrix far from the interphase was observed with ImAFM. Thus, boehmite induces long-range chemical alteration on the matrix. This effect has a higher impact on overall composite properties compared to the formation of interphase which is only a short-range effect. The local chemical evaluations on the soft interphase using an infrared-AFM method (NanoIR) revealed the accumulation of anhydride hardener near the boehmite interface. Based on these observations the effect of boehmite on the curing of epoxy is hypothesized to be governed by the strong interaction between boehmite and the anhydride. This interaction causes changes the ratio of reactants in the epoxy mixture and hence alteration of curing pathway and the network architecture. In future studies we examine this hypothesis by measuring the thermomechanical properties of cured epoxies in which the epoxy-hardener ratio is systematically altered and further comparing to those properties of nanocomposites shown in the current study.
Eu2+ is used to replace toxic Pb2+ in metal halide perovskite nanocrystals (NCs). The synthesis implies injection of cesium oleate into a solution of europium (II) bromide at an experimentally determined optimum temperature of 130 ○C and a reaction time of 60 s. Structural analysis indicates the formation of spherical CsEuBr3 nanoparticles with a mean size of 43 ± 7 nm. Using EuI2 instead of EuBr2 leads to the formation of 18-nm CsI nanoparticles, while EuCl2 does not show any reaction with cesium oleate forming 80-nm EuCl2 nanoparticles.
The obtained CsEuBr3 NCs exhibit bright blue emission at 413 nm (FWHM 30 nm) with a room temperature photoluminescence quantum yield of 39%. The emission originates from the Laporte-allowed 4f7–4f65d1 transition of Eu2+ and shows a PL decay time of 263 ns.
The long-term stability of the optical properties is observed, making inorganic lead-free CsEuBr3 NCs promising deep blue emitters for optoelectronics.
A new dual purpose cask design was developed for the safe transport and interim storage of spent fuel elements of German research reactors. In the framework of the safety assessment within the licensing procedure the Bundesanstalt für Materialforschung und –prüfung (BAM) as competent authority performed a series of drop tests according to the IAEA-Regulations. The package consists of a cylindrical thick-walled ductile cast iron cask body closed by a double lid system with metallic seals. A lid and bottom sided impact limiter consisting of a wood/steel construction limit the mechanical impact loading. The full-scale test specimen was equipped with a basket and assembled with dummy-fuel elements. The package and test specimen, respectively have a total mass of approximately 24 metric tons.
The mechanical test program included three 9m free drop tests, in horizontal, vertical and oblique cask orientation onto the lid system. Additionally, a 1m-puncture drop test followed the horizontal drop test to consider an IAEA-test sequence. The horizontal and vertical drop tests were performed at a temperature of minus 40°C. During the oblique drop test the upper impact limiter was heated to +80°C. The tests were conducted onto an unyielding target, fulfilling the requirements of the IAEA regulations.
The test specimen was considerably instrumented with strain gauges and accelerometers. Transient strains at selected locations of the inner and outer container walls, of the primary and secondary lid, as well as of the corresponding lid bolts were measured during the drop tests. Furthermore, decelerations in different locations at the cask body and the lids were measured. The complex geometrical deformation of the impact limiters due to the impact were determined by optical 3d- measurements using the projected fringe method in combination with multi-image photogrammetry. Before and after the drop tests the leakage rate of the lid system was determined by helium leakage testing.
The experimental results contribute to the evaluation of the package response to mechanical tests, demonstrating safety under normal and accident conditions of transport. Especially to the verification of the dynamic finiteelement model of the package used in the package design safety report. The paper describes the performance of the drop tests, selected test results focusing on the lid screws and the cask body and the deformation of the impact limiters as well as impact kinematics, respectively.
Singlet oxygen can severely damage biological tissue, which is exploited in photodynamic therapy (PDT). In PDT, the effective range is limited by the distribution of the photosensitizer (PS) and the illuminated area. However, no distinction is made between healthy and pathological tissue, which can cause undesired damage. This encouraged us to exploit the more acidic pH of cancerous tissue and design pH-controllable singlet oxygen-generating boron-dipyrromethene (BODIPY) dyes. A pH sensitivity of the dyes is achieved by the introduction of an electronically decoupled, photoinduced electron transfer (PET)-capable subunit in meso-position of the BODIPY core. To favor triplet-state formation as required for singlet Oxygen generation, iodine substituents were introduced at the chromophore core. The resulting pH-controlled singlet oxygen-generating dyes with pKa values in the physiological range were subsequently assessed regarding their potential as pH-controlled PS for PDT.
Using HeLa cells, we could successfully demonstrate markedly different pH-dependent cytotoxicities upon illumination.
The hydration process of Portland cement in a cementitious system is crucial for development of the high-quality cementbased construction material. Complementary experiments of Xray diffraction analysis (XRD), scanning electron microscopy (SEM) and time-resolved laser fluorescence spectroscopy (TRLFS) using europium (Eu(III)) as an optical probe are used to analyse the hydration process of two cement systems in the absence and presence of different organic admixtures.
We Show that different analysed admixtures and the used sulphate carriers in each cement system have a significant influence on the hydration process, namely on the time-dependence in the formation of different hydrate phases of cement. Moreover, the effect of a particular admixture is related to the type of sulphate carrier used.
The quantitative information on the amounts of the crystalline cement paste components is accessible via XRD analysis. Distinctly different morphologies of ettringite and calcium-silicate-hydrates (C-S-H) determined by SEM allow visual conclusions about formation of these phases at particular ageing times. The TRLFS data provides information about the admixture influence on the course of the silicate reaction. The dip in the dependence of the luminescence decay times on the hydration time indicates the change in the structure of C-S-H in the early hydration period. Complementary information from XRD, SEM and TRLFS provides detailed information on distinct periods of the cement hydration process.
Glass
(2019)
Overview about the key activities of division 5.6 glass and the diversity of the material glass. For the vacuum hot extraction method (VHE-MS) some examples are presented e. g. for the measurement of water content or the determination of diffusion coefficient of hydrogen in glasses. Finally, an outlook is shown on the robot controlled glass screening device which will be available next year.
Morphologies of Fresnoite surface crystals of BT0.75S glass under different atmospheric conditions
(2019)
Fresnoite glass-ceramics are characterized by piezoelectric, pyroelectric and non-linear optical properties. These properties can be adjusted by orienting the fresnoite crystals during crystallization. Crystallization begins at the surface. The first surface crystals are not oriented perpendicular and, therfore, produce a surface layer that has not the intended properties. To overcome this issue, the formation of fresnoite surface crystals at different atmospheric conditions was studied.
Glass powders are promising candidates for manufacturing a broad diversity of sintered materials like sintered ¬glass-ceramics, glass matrix composites or glass bonded ceramics with tailored mechanical, thermal, electrical and optical properties and complex shape. Its wide and precise adjustability makes this class of materials a key component for advanced technologies. Processing of glass or composite powders often allow even more flexibility in materials design. At the same time, however, processing can have substantial effects on the glass powder surface and sinterability. Thus, mechanical damage and surface contamination can strongly enhance surface crystallization, which may retard or even fully prevent densification. Whereas sintering and concurrent crystallization have been widely studied, partially as cooperative effort of the TC7 of the ICG, and although glass powder sintering is predominantly applied for glasses of low crystallization tendency, sintering is also limited by gas bubble formation or foaming. The latter phenomenon is much less understood and can occur even for slow crystallizing glass powders. The lecture illustrates possible consequences of glass powder processing on glass sintering, crystallization and foaming.
Synchrotron based absorption edge tomography for the analysis of 3D printed polymer embedded MOF
(2019)
Absorption edge tomography, also known as differential tomography at absorption edges, is a method which exploits the sudden change of the attenuation coefficient, when the photon energy crosses the absorption edge of an element. Synchrotron radiation is the best source for absorption edge tomography, because of its small bandwidth, high intensity and easily adjustable photon energy. The synchrotron beamline BAMline at the synchrotron radiation facility BESSY II in Berlin, which is operated by the Bundesanstalt für Materialforschung und -prüfung (BAM), provides a monochromatized beam in a photon energy range from 5 keV up to 80 keV with a bandwidth of 2%, when the double multilayer monochromator is used. Together with the microtomography setup, this enables differential tomography with submicron resolution at the K edge of the elements from chromium up to the lanthanides, and up to uranium, when the L edges are used as well.
In this work, metal organic frameworks (MOFs) embedded in polymer are characterized using differential tomography. MOFs are microporous structures of metal ions, coordinated by organic linker molecules, that can be used in a broad field of applications, especially in gas storage and catalysis. In this work, polymer embedded MOFs were extruded into filaments, which were subsequently used for 3d-printing to profit from the specific properties of the MOFs in polymeric materials combined with the arbitrary shapes provided by 3d-printing. For the extrusion, different polymer classes like ABS, polyester- and polyetherurethanes, as well as different MOFs (ZIF-8, ZIF-67, HKUST-1) were used to create MOF containing filaments with a nominal diameter of 3.0 mm. Differential tomography at the edges of the Zn, Co, and Cu was then used to find the distribution of the corresponding MOF in the filament and to analyze the shape of the inclusions.
Extracellular vesicles (EV) are cell-derived particles in body fluids, which have excellent potential as next-generation biomarkers. The exploitation of EV requires reliable measurements, which is currently very difficult, as most EV are smaller than 200 nm. At present, flow cytometry (FCM) is the most appropriate technique for EV analysis in biological samples, as FCM is readily available in many clinical laboratories and allows to identify cell-specific EV at high throughput. However, due to technical variations between different FCM instruments, EV concentration measurements are currently not well comparable between most laboratories. Therefore, EV reference materials and standardized reference methods are urgently needed to calibrate flow rate, light scattering intensity, and fluorescence intensity of FCM in the sub-micrometer size range. This requires a better matching of the optical properties of calibration beads and EV as can be realized with current polystyrene calibration beads.
The EMPIR project 18HLT01 “MetVes II” aims to develop synthetic reference materials and traceable measurement methods to standardize EV measurements. The reference materials should resemble EV properties, so that calibrations are reliable and do not require a change of acquisition settings. Hence, the reference materials should contain particles with a traceable number concentration in the range of 109–1012 particles/mL to calibrate flow rate, a traceable size with discrete diameters between 50–1000 nm and a refractive index (RI) in the range of 1.37–1.42 to calibrate scattering intensity, and a traceable fluorescence intensity between 100–100,000 molecules of equivalent soluble fluorochromes (MESF). At BAM, various approaches to prepare such low-RI nanometer-sized reference materials will be studied, preliminary results of the primary characterization of these candidate reference particles will be presented, and possible applications besides FCM-based EV detection will be outlined.
Due to the stochastic nature of crack nucleation by Vickers indentation, a statistical analysis of propagation rates of 185 radial cracks was performed. Crack growth was observed directly using a video camera with high Image acquisition rate. It is found that propagation rates are controlled by the environmental reactions at the crack-tip shortly after their initiation (< 1 s). Calibration of the stress intensity KI showed that the residual stress factor χ and the exponent n of the equation KI==χPc−n (with P==load and c==crack length) are broadly distributed among the 185 analyzed cracks, ranging from 10−16 to 104 and from 0.1 to 5, respectively. For the most frequent crack, the equation KI==0.052Pc−1.47 holds. The results show that correlations of indentation-induced crack length to stress intensity necessitate the use of statistical significant data that are calibrated by the environmental reactions at the crack-tip.
Hydrogen gas diffusivity of fourteen glasses of the Na2O-Al2O3-SiO2 system are studied along the joins quartzalbite-jadeite-nepheline (Qz-Ab-Jd-Np, fully polymerized) and albite-sodium disilicate (Ab-Ds, depolymerized).
Density measurements show that ionic porosity decreases from 54.4% (Qz) to 51.5% (Np) and from 52.4% (Ab) to 50.2% (Ds). Hydrogen diffusivity D follows similar trends but at another scale. D at 523 K decreases from 4×10−12 to 3×10−14m2 s−1 (Qz-Np) and from 4×10−13 to 3×10−15m2 s−1 (Ab-Ds). Charge compensating Na+ acting as a filling agent in fully polymerized network structures leads to up to one order of Magnitude higher diffusivities as depolymerized glass structures of the same SiO2 content where Na+ takes the role of a
modifier ion. Temperature dependence of the diffusivity indicates that both the activation energy involved with the moving H2 molecule as well as the accessible volume in the structure contribute to this compositional trend.
During carbon sequestration the CO2-induced corrosion of injection pipe steels is a relevant safety issue when emission gasses are compressed into deep geological layers. The reliability of the high alloyed steel X35CrMo17 suitable as injection pipe for the geological onshore CCS-site (Carbon Capture and Storage) in the Northern German Basin, is demonstrated in laboratory experiments in equivalent corrosive environment (T = 60 °CC, p = 1–100 bar, aquifer water, CO2-flow rate of 9 L/h, 700–8000 h exposure time). Corrosion kinetics and microstructure were characterized and compared to other potential injection pipe steels (42CrMo4, X46Cr13, X20Cr13 and X5CrNiCuNb16-4).
Coupons of X5CrNiCuNb16-4 that may be used as injection pipe with 16% Chromium and 0.05% Carbon (1.4542, AISI 630) were exposed for 3000 h to CO2-saturated saline aquifer water similar to the conditions in the Northern German Basin at ambient pressure and 60 °C. Surface corrosion layers and pits reveal carbonate corrosion products on the surface such as FeCO3 and FeOOH as the main precipitation phases with no dependence on the original surface roughness. Corrosion rates for polished and technical surfaces were below 0.005 mm/year compared to corrosion rates of 0.035 mm/year after shot peening.
Coupons of X5CrNiCuNb16-4 with different surface roughness that may be utilized as injection pipe with 16% Chromium and 0.05% Carbon (1.4542, AISI 630) were exposed for 3000 h to CO2-saturated saline aquifer water simulating the conditions in the Northern German Basin at ambient pressure and 60 °C. Additionally, corrosion fatigue experiments (ambient pressure, technically clean CO2, saline aquifer water of Stuttgart Aquifer) were performed using specimen of X46Cr13 (1.4043, AISI 420C) with regard to the influence of the roughness of technical surfaces on the number of cycles to failure at different stress amplitudes. Specimen of Duplex stainless steel X2CrNiMoN22-3-2 (1.4462) for corrosion fatigue experiments were provided with technical surfaces after machining as well as polished surfaces. Results were obtained at load amplitudes ranging from 175 MPa to 325 MPa in the geothermal brine of the Northern German Basin at 98 °C. The main precipitation phases on the surface as well as within pits reveal carbonates or hydroxides such as siderite (FeCO3) and ferrous hydroxide goethite (FeOOH) independent of the original surface roughness. Corrosion rates for polished and technical surfaces were below 0.005 mm/year compared to corrosion rates of 0.035 mm/year after shot peening. Specimen with technical surfaces tested at high stress amplitudes (>275 MPa) lasted longer (cycles to failure: P50% at Sa 300 MPa=5x105) than specimen with polished surfaces (cycles to failure: P50% at Sa 300 MPa=1.5x105). This behavior is emphasized by the slope coefficient (technical surfaces k = 19.006, polished surfaces k=8.78) meaning earlier failure for polished at high stress amplitude Sa. Although rather low scatter ranges (technical surface: TN=1:1.35, polished surface: TN=1.1.95) indicate no change in failure mechanism it may be assumed that at low stress pitting is the initiating crack growth process whereas at high stress amplitudes the formation of micro cracks is reason for crack propagation and failure.
During capture and storage technology (CCS) as well as in geothermal energy production Steels need to withstand the corrosive environment such as: heat, pressure, salinity of the aquifer and CO2-partial pressure. 1.4542 shows unusual corrosion phenomena, but is still sufficiently resistant in corrosive environments. To better understand its behaviour differently heat treated coupons of 1.4542 and for comparison X20Cr13 and X46Cr13 were kept in the artificial brine of the Northern German Basin at T=60 °C. Ambient pressure as well as p=100 bar for 700 h - 8000 h in water saturated supercritical CO2 and CO2-saturated synthetic aquifer Environment was applied. Fatigue tests were performed via push-pull tests with a series of 30 specimens from 150 MPa to 500 MPa (sinusoidal dynamic test loads, R=-1; resonant frequency ~ 30 Hz). FeCO3 and FeOOH are corrosion products also after dynamic corrosion tests. Martensitic microstructure offers good corrosion resistance in geothermal environment. The S-N-curve showing no typical fatigue strength and very steep slopes of possible fatigue strength for finite life. Possible influencing artefacts, such as Al-inclusions could not be correlated to early rupture despite specimens containing inclusions at the fracture surface and cross section reached lower number of cycles. Applied potential proofed to enhance fatigue life tremendously.
Corrosion fatigue specimen with different surfaces (technical surfaces after machining and polished surfaces) of high alloyed martensitic stainless steel X46Cr13 (1.4043) and duplex stai nless steel X2CrNiMoN22 3 2 (1.4462) were compared at load amplitudes from 175 MPa to 325 MPa in the geothermal brine of the N orthern German Basin at 98 °C. Surface corrosion layers and pits reveal carbonate corrosion products on the surface such as FeCO 3 and FeOOH as the main precipitation phases with no dependence on the original surface roughness . At high stress amplitudes above 275 MPa technical surfaces (P50% at σa 300 MPa=5 × 10 5 ) resulted in more cycles to failure than polished (P50% at σa 300 MPa=1.5 × 10 5 ). The greater slope coefficient for technical surfaces k = 19.006 compared to polished surfaces k =8.78 demonstrate s earlier failure at given stress amplitude σa .
In this poster we will present some results of a research projects dealing with Arabic recipes of black inks. To improve conservation practices of Arabic manuscripts we have assessed the feasibility of the recipes collected from many Arabic sources on bookmaking and reproduced the most common inks. Ink samples were then artificially aged and analysed using an array of analytical techniques, mostly non-invasive, in order to build a database of Arabic inks and their ingredients and also to verify the detection limits of the portable equipment employed.
We will show procedures and problems concerning the identification of ink types and ingredients using reflectography (in Vis, IR and UV), X-Ray Fluorescence, Infrared and Raman spectroscopy. The focus will be in particular on squid ink and mixed inks – both in the form of carbon inks with the addition of tannins and of a mixture of carbon and iron gall inks – which are particularly difficult to detect. We will also examine the results of iron gall inks made with iron filings or nails instead of vitriol, the various precursor used to extract gallic acid that are mentioned in the sources as surrogates of gall nuts.
Without precaution, insects may cause serious damage to museum collections. Quarantine of potentially infested objects can be logistically challenging. Anoxia under controlled Nitrogen atmosphere is a most gentle but also time-consuming method to eradicate insect pests in all kinds of different materials. Treatment results are usually affected by duration, temperature, humidity and residual oxygen content. During a two-year research project, 34 relevant pest insect species of all developmental stages were tested in different materials (wood, paper, wool) to monitor treatment success and to determine optimum treatment parameters. Duration of treatment ranged from one to three weeks at temperatures of 20–27 °C. As expected, results showed significant differences in mortality among tested species. Highest tolerance of hypoxic conditions was found in elder larvae of Hylotrupes bajulus. Although this species is an unlikely museum pest, it may serve as an overall most tolerant reference. Anobiids and other wood boring beetles are more often an issue related to cultural heritage. A combination of three weeks exposure time at maximum 0.5% residual oxygen and 24 °C, alternatively 1%
residual oxygen and 27 °C are recommended for infested artefacts. Imbedding materials in general had no influence on mortality. This study was funded by Deutsche Bundesstiftung Umwelt (DBU).
Biofouling constitutes a major challenge in the application of biosensors and biomedical implants, as well as for (food) packaging and marine equipment. In this work, an antifouling surface coating based on the combination of mussel-inspired dendritic polyglycerol (MI-dPG) and an amine-functionalized block copolymer of linear polyglycerol (lPG−b−OA11, OA = oligo-amine) was developed. The coating was compared to a MI-dPG surface which was postfunctionalized with commercially available amine-terminated Polyethylene glycol (HO−PEG−NH2) of similar molecular weight. In the current work, These coatings were compared in their chemical stability, protein fouling characteristics, and cell fouling characteristics. The lPG−b−OA11-functionalized coating showed high chemical stability in both phosphate buffered saline (PBS) and sodium dodecyl sulfate (SDS) solutions and reduced the adhesion of fibrinogen from human plasma with 99% and the adhesion of human serum albumin with 96%, in comparison to the bare titanium dioxide substrate. Furthermore, the Proliferation of human umbilical vein endothelial cells (HUVECs) was reduced with 85% when the lPG−b−OA11 system was compared to bare titanium dioxide. Additionally, a reduction of 94% was observed when the lPG−b−OA11 system was compared to tissue culture polystyrene.
In service, most materials are operated under simultaneous corrosive and mechanical load and there are very few methods capable for testing material degradation under these conditions, especially when it comes to high resolution analysis. For this purpose, in this work, a tensile module capable of uniaxial stretching and compression with up to 5 kN force was integrated into an AFM stage. The elimination of the need for sample unmounting and remounting and the resulting possibility of keeping the sample under constant mechanical load during AFM measurements not only enables a precise positioning of the area of interest but also allows for the analysis of processes in the elastic deformation regime.
This methodology was demonstrated for two case studies. Scanning Kelvin Probe Force Microscopy (SKPFM) was used as the main tool to characterize the deformation behavior. Moreover, a flexible electrochemical measurement cell was used to enable electrochemical analysis by means of electrochemical impedance spectroscopy (EIS) and Linear Sweep Voltammetry (LSV) during AFM measurements at different levels of strain. The in situ AFM results are complemented by microstructure analysis by means of electron backscatter diffraction (EBSD).
In the first case study, the deformation induced delamination of a thin organic coating on AA2024 T3 aluminium alloy was investigated as a function of alloy surface treatment. The formation of cracks in the insulating passive film enabled an early detection of deformation processes by means of SKPFM. The second case study focused on the comparison of corrosion and deformation behavior of conventional and additively manufactured 316 stainless steels. In comparison to the conventional 316 stainless steel, the effect of processing was clearly detectable on the additively manufactured material as zones of inhomogeneous potential, which also affected the initiation of local corrosion processes. The contribution will provide detailed information on the new AFM setup and summarize our results from both case studies.
The performance of functional coatings and adhesively joined hybrid components relies strongly on the stability of the polymer-metal interface. With the increasing utilization of multi-material structures in the automotive and aerospace industry, it is of great scientific and technical interest to understand the processes leading to interface degradation and to develop novel strategies to increase corrosion and delamination resistance.
The aim of this project is to develop thin epoxy-based films and their carbon nanofiller loaded composites on aluminium alloy AA2024-T3 as a model system and to investigate their interfacial stability under corrosive and coupled corrosive-mechanical load. Spin coating was used for the layer-by-layer deposition of poly[(o-cresyl glycidyl ether)-co-formaldehyde] and poly-(ethylenimine) bi-layers. Atomic force microscopy (AFM) results indicate a very homogeneous and dense film with low surface roughness. Carbon nanofillers were introduced either by mixing into the coating components or in between individual layers to control the separation between the carbon nanofillers and alloy surface. The film chemistry and barrier properties were characterized by means of spectroscopic and electrochemical methods, respectively. The degradation and delamination behavior of the epoxy-based films was characterized by means of in situ AFM corrosion experiments. The quantitative imaging (QI) mode allowed the observation of hydrogen-generation induced blister formation during exposure to corrosive electrolyte and how the local corrosion processes evolved with exposure time. Complementary energy dispersive X-ray spectroscopy (EDX) analysis was performed to correlate the corrosion behavior with the different intermetallic particle chemistries and distributions. The presentation will summarize our results on the effect of interface chemistry and carbon nanofiller – alloy separation on the initiation of local corrosion processes on thin film covered AA2024-T3 aluminium alloys.
The presentation summarizes our recent results on the coupled electrochemical methods for high resolution corrosion studies. The combination of Scanning Electrochemical Microscopy (SECM) and multielectrode (MMA) based real-time corrosion monitoring was presented as a new method for achieving high time resolution in local electrochemical analysis. Correlative imaging by means of Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM) was demonstrated as a tool for the investigation of local corrosion processes initiated by the intermetallic particles (IMPs) on AA2024-T3 aluminium alloy.
The study presented here focusses on a systematic analysis of oxidation mechanisms of the well-known Cr20Mn20Fe20Co20Ni20 alloy and one of its ternary sub-system Cr33.3Co33.3Ni33.3 which were reported in the literature to exhibit attractive mechanical properties. Both alloys are single phase fcc prior to oxidation and were simultaneously exposed to different oxygen containing atmospheres at 700° C and 800° C for durations up to 288 h. Cr20Mn20Fe20Co20Ni20 showed poor oxidation resistance at high temperatures due to its high amount of manganese leading to the formation of non-protective Mn-oxide scales. In contrast, a relatively homogeneous and protective chromia layer was found to form on CrCoNi at 700° C and 800° C after each exposure time. Mass change-, SEM- and XRD analysis of the oxide layers were performed in the present study and provide a better understanding of the oxidation mechanisms as well as the impact of the alloy composition on oxidation behavior.
Roaldite – Fe4N – has been identified in the São Julião de Moreira iron meteorite using electron backscatter diffraction (EBSD) and simultaneously acquired energy-dispersive x-ray spectroscopy (EDS). Mean-periodic-number images derived from raw EBSD patterns confirm this phase by an even higher spatial resolution compared to EDS.
Roaldite appears in the form of systematically and repetitively aligned plates. Despite the locally heavy plastic deformation, it is shown that the origin of the oriented precipitation of roaldite is linked to the orientation of the kamacite matrix. Roaldite can be considered to be precipitated from kamacite using an inverse Kurdjumov-Sachs (K-S) or Nishiyama-Wassermann (N-W) orientation relationship. A more accurate discrimination is impossible due to the accumulated shock deformation, which blurs the local reference orientation of kamacite. The habit plane of roaldite is found to be {112}R, which is most likely parallel to {120}K of kamacite. Some of the roaldite plates contain two orientation variants which repeatedly alternate. Their misorientation angle is about 12°.
The common fatigue life certification of aircrafts according to the certification Standards 23 and 25 follows a building block approach. Static tests at room temperature as well in humid and high temperature conditions are done on the coupon level. Additionally, a full-scale static and fatigue test must be performed on the complete airframe (minimum on the fuselage together with the wing). For each type-certificate the complete building block approach test program must be performed.
Traditionally in Germany, the certification of sailplanes (Certification Standard 22) follows rather a family concept. A shared data base was created over the last 50 years based upon a large number of material testing. In addition to static tests at room temperature and hot-humid conditions, fatigue tests are also done on the coupon level. Additional static and fatigue tests were done on complex structures such as spar-beams, fuselages and full-scale wing structures. However, for each type-certificate, only static tests should be performed in full-scale. This concept is determined by the certification memorandum CM-S-006 “Composite Lightweight Aircraft” 2017.
The presentation was given as an introduction to the discussion about the future expectations and developments of the EASA concerning the type-certification of lightweight aircrafts according to CS22 at the OSTIVE Sailplane Development Panel Meeting at the EASA in Cologne on the 11th of October 2019.
Over the past years economic and environmental considerations have led to a markedly increased demand for efficiency and flexibility in petrochemical plants. The operational temperatures and pressures required today can only be achieved by using new creep-resistant grades of steel. The modified 13CrMoV9-10 vanadium steel shows a good resistance against creep and compressed hydrogen and has been in use for the construction of petrochemical reactors since the mid-1990s. Nevertheless, processing of this type of steel requires extreme care during the welding procedure. This is due to its low toughness and high strength in the welded state when not post weld heat treated combined with increased susceptibility to cracking during stress relaxation. Previous research into crack formation in creep-resistant steels has largely focused on thermal and metallurgical factors; however, little knowledge has been gathered regarding the influence of the welding procedure on crack formation during post weld heat treatment considering real-life manufacturing conditions. The influence of heat control on the mechanical properties has been investigated by simulating the welding and subsequent post weld heat treatment operations during the construction of petrochemical reactors using a special 3-D testing facility on the laboratory scale.
This work is subdivided in two parts. In part I of this study the stresses resulting from preheating, welding, dehydrogenation heat treatment and the final post weld heat treatment were analyzed during experiments under varied heat control. In all experiments stress relief cracks formed during post weld heat treatment could be observed. The total crack lengths correlated with the welding induced stresses.
Part II of this work is dedicated to the characterization of the cracks and the microstructure. The application of a special acoustic emission analysis indicated that the cracks formed in a temperature range between 300 °C and 500 °C during the post weld heat treatment. In comparison to small scale specimens welded without additional shrinkage restraint, the toughness of the restrained welds was significantly decreased. SEM and TEM analyses of all samples revealed accelerated aging due to early precipitation of special carbides during post weld heat treatment under component relevant restraint.
A concept for the growth of silica shells with a thickness of 5–250 nm onto oleate-coated NaYF4:Yb3+/Er3+ upconversion nanoparticles (UCNP) is presented. The concept enables the precise adjustment of shell thicknesses for the preparation of thick-shelled nanoparticles for applications in plasmonics and sensing. First, an initial 5–11 nm thick shell is grown onto the UCNPs in a reverse microemulsion. This is followed by a stepwise growth of these particles without a purification step, where in each step equal volumes of tetraethyl orthosilicate and ammonia water are added, while the volumes of cyclohexane and the surfactant Igepal® CO-520 are increased so that the ammonia water and surfactant concentrations remain constant. Hence, the number of micelles stays constant, and their size is increased to accommodate the growing core–shell particles. Consequently, the formation of core-free silica particles is suppressed. When the negative zeta potential of the particles, which continuously decreased during the stepwise growth, falls below −40 mV, the particles can be dispersed in an ammoniacal ethanol solution and grown further by the continuous addition of tetraethyl orthosilicate to a diameter larger than 500 nm. Due to the high colloidal stability, a coalescence of the particles can be suppressed, and single-core particles are obtained. This strategy can be easily transferred to other nanomaterials for the design of plasmonic nanoconstructs and sensor systems.
The present work deals with the development of a strategy for the prevention of end crater defects in high-power laser welding of thick-walled circumferential welds. A series of experiments were performed to understand the influence of the welding Parameters on the formation of end crater defects such as pores, cracks, root excess weld metal and shrinkage cavities in the overlap area. An abrupt switch-off of the laser power while closing the circumferential weld leads to a formation of a hole which passes through the whole welded material thickness. A laser power ramp-down causes solidification cracks which are initiated on the transition from full-penetration mode to partial penetration. Defocusing the laser beam led to promising results in terms of avoiding end crater defects. Cracks and pores in the overlap area could be effectively avoided by using defocusing techniques.
A strategy for avoiding of end crater imperfections was tested on flat specimens of steel grade S355J2 with a wall thickness of between 8 mm and 10 mm and then transferred on the 10 mm thick pipe sections made of high-strength pipeline steel API5L-X100Q.
Using magnetic materials for energy conversion as an example, this lecture shows how X-ray tomography investigations can contribute to structure elucidation in composites and solid samples. The components are tested non-destructively in order to characterize cracks, pores and other defects and their influence on the functional properties three-dimensionally and in good time in the life cycle of the material. If you combine microtomography with other methods of magnetic material characterization, you can make unique statements about the structure and the functional properties.
To date, there are only very few technologies available for the conversion of low temperature waste heat to electricity. In this talk, we first describe the principle of thermomagnetic generators. Then we focus on the impact of topology of the magnetic circuit within thermomagnetic generators. We demonstrate that the key operational parameters strongly depend on the genus, i.e. the number of holes within the magnetic circuit.
To date, there are only very few technologies available for the conversion of low temperature waste heat to electricity. In this talk, we first describe the principle of thermomagnetic generators. Then we focus on the impact of topology of the magnetic circuit within thermomagnetic generators. We demonstrate that the key operational parameters strongly depend on the genus, i.e. the number of holes within the magnetic circuit.
To date, there are only very few technologies available for the conversion of low temperature waste heat to electricity. In this talk, we first describe the principle of thermomagnetic generators. Then we focus on the impact of topology of the magnetic circuit within thermomagnetic generators. We demonstrate that the key operational parameters strongly depend on the genus, i.e. the number of holes within the magnetic circuit.
To date, there are only very few technologies available for the conversion of low temperature waste heat to electricity. In this talk, we first describe the principle of thermomagnetic generators. Then we focus on the impact of topology of the magnetic circuit within thermomagnetic generators. We demonstrate that the key operational parameters strongly depend on the genus, i.e. the number of holes within the magnetic circuit.
To date, there are very few technologies available for the conversion of low-temperature waste heat into electricity. Thermomagnetic generators are one approach proposed more than a century ago. Such devices are based on a cyclic change of magnetization with temperature. For thermomagnetic materials, we used a commercial magnetocaloric alloy with a transition temperature of 300 K.
To date, there are very few technologies available for the conversion of low-temperature waste heat into electricity. Thermomagnetic generators are one approach proposed more than a century ago. Such devices are based on a cyclic change of magnetization with temperature. For thermomagnetic materials, we used a commercial magnetocaloric alloy with a transition temperature of 300 K.
Using magnetic materials for energy conversion as an example, this lecture shows how X-ray tomography investigations can contribute to structure elucidation in composites and solid samples. The components are tested non-destructively in order to characterize cracks, pores and other defects and their influence on the functional properties three-dimensionally and in good time in the life cycle of the material. If you combine microtomography with other methods of magnetic material characterization, you can make unique statements about the structure and the functional properties.
For the vast majority of ellipsometric measurements, the application of planar substrates is mandatory and requires a proper sample alignment prior to the measurement. Here, the authors present a generalized approach of how to extract the isotropic ellipsometric sample parameters from an imaging Mueller-matrix measurement even if the sample is significantly misaligned. They validate the method by layer-thickness calculations based on imaging Mueller-matrix measurements of flat crystalline silicon samples that were misaligned on purpose. Furthermore, they also exploit this method’s capabilities to perform spatially resolved layer-thickness measurements of a single-layer indium-tin-oxide coating on a fused-silica microlens without the need of realignment or repositioning of the sample during the measurement.
Among the various welding technologies, resistance spot welding (RSW) and laser beam welding (LBW) play a significant role as joining methods for the automobile industry. The application of RSW and LBW for the automotive body alters the microstructure in the welded areas. It is necessary to identify the mechanical properties of the welded material to be able to make a reliable statement about the material behavior and the strength of welded components. This study develops a method by which to determine the mechanical properties for the weldment of RSW and LBW for two dual phase (DP) steels, DP600 and DP1000, which are commonly used for the automotive bodies. The mechanical properties of the resistance spot weldment were obtained by performing tensile tests on the notched tensile specimen to cause an elongation of the notched and welded area in order to investigate its properties. In order to determine the mechanical properties of the laser beam weldment, indentation tests were performed on the welded material to calculate its force-penetration depth-curve. Inverse numerical simulation was used to simulate the indentation tests to determine and verify the parameters of a nonlinear isotropic material model for the weldment of LBW. Furthermore, using this method, the parameters for the material model of RSW were verified. The material parameters and microstructure of the weldment of RSW and LBW are compared and discussed. The results show that the novel method introduced in this work is a valid approach to determine the mechanical properties of welded high-strength steel structures. In addition, it can be seen that LBW and RSW lead to a reduction in ductility and an increase in the amount of yield and tensile strength of both DP600 and DP1000.
The present work is intended to make a contribution to the monitoring of civil engineering structures. The detection of damage to structures is based on the evaluation of spatially and temporally distributed hybrid measurements. The acquired data can be evaluated purely geometrically or physically. It is preferable to do the latter, since the cause of damage can be determined by means of geometrical-physical laws in order to be able to intervene in time and ensure the further use of the structures. For this reason, the continuum mechanical field equations in conjunction with the finite element method and hybrid measurements are combined into a single evaluation method by the adjustment calculation. This results in two challenges.
The first task deals with the relationship between the finite element method and the method of least squares. The finite element method solves certain problem classes, which are described by a system of elliptical partial differential equations. Whereas the method of least squares solves another class of problems, which is formulated as an overdetermined system of equations. The striking similarity between both methods is known since many decades. However, it remains unresolved why this resemblance exists. The contribution is to clarify this by examining the variational calculus, especially with regard to its methodological procedure. Although the well-known Gauss-Markov model within the method of least squares and the finite element method solve inherently different problem classes, it is shown that both methods can be derived by following the same methodological steps of the variational calculus. From a methodical viewpoint, this implies that both methods are not only similar, but actually the same. In addition, it is pointed out where a possible cross-connection to other methods exists.
The second task introduces a Measurement- and Model-based Structural Analysis (MeMoS) by integrating the finite element method into the adjustment calculation. It is shown in numerical examinations how this integrated analysis can be used for parameter identification of simple as well as arbitrarily shaped structural components. Based on this, it is examined with which observation types, with which precision and at which location of the structure these measurements must be carried out in order to determine the material parameters as precisely as possible. This serves to determine an optimal and economic measurement set-up. With this integrated analysis, a substitute model of a geometrically complex structure can also be determined. The issue of the detection and localisation of damage within a structure is studied by means of this structural analysis. The Measurement and Model-based Structural Analysis is validated using two different test setups, an aluminum model bridge and a bending beam.
In additive manufacturing (AM) Laser Metal Deposition (LMD), parts are built by welding layers of powder feedstock onto a substrate. Applications for steel powders include forging tools and structural components for various industries. For large parts, the choice of tool-paths influences the build-rate, the part performance and the distortions in a highly geometry-dependent manner. With weld-path lengths in the range of hundreds of meters, a reliable, automated tool path generation is essential for the usability of LMD processes.
In this contribution, automated tool-path generation approaches are shown and their results are discussed for arbitrary geometries. The investigated path strategies are the classical approaches: “Zig-zag-” and “contour-parallel-strategies”. After generation, the tool-paths are automatically formatted into g-code for experimental build-up and ASCII for a numerical simulation model. Finally, the tool paths are discussed in regards to volume-fill, microstructure and porosity for the experimental samples.
This work presents a part of the IGF project 18737N “Welding distortion simulation” (FOSTA P1140)
Spherical mesoporous bioactive glasses in the silicon dioxide (SiO2)-phosphorus pentoxide (P2O5)–calcium oxide (CaO) system with a high specific surface area of up to 300m2/g and a medium pore radius of 4 nm were synthesized by using a simple one-pot surfactant-assisted sol–gel synthesis method followed by calcination at 500–700°C. The authors were able to control the particle properties by varying synthesis parameters to achieve microscale powders with spherical morphology and a particle size of around 5–10 mm by employing one structure-directing agent. Due to a high Calcium oxide content of 33·6mol% and a phosphorus pentoxide content of 4·0mol%, the powder showed very good bioactivity up to 7 d of immersion in simulated Body fluid. The resulting microspheres are promising materials for a variety of life science applications, as further processing – for example, granulation – is unnecessary. Microspheres can be applied as materials for powder-based additive manufacturing or in stable suspensions for drug release, in bone cements or fillers.
Metal phosphonates are promising materials for applications in fuel cells, due to their high proton conductivity and higher chemical and thermal stability compared to the industry standard (e.g. Nafion®). Additionally, metal phosphonates are precursors to porous carbon materials with evenly distributed centers for ORR catalysis. As a fast and sustainable synthesis, mechanochemistry is the synthesis method of choice. Thorough characterization is carried out by XRD, MAS-NMR, XAS, BET, and DVS.
The efficient and sensitive detection of pathogenic microorganisms in aqueous environments, such as water used in medical applications, drinking water, and cooling water of industrial plants, requires simple and fast methods suitable for multiplexed detection such as flow cytometry (FCM) with optically encoded carrier beads. For this purpose, we combine fluorescent Cd-free Ag−In−S ternary quantum dots (t-QDs) with fluorescence Lifetimes (LTs) of several hundred nanoseconds and superparamagnetic Fe3O4 nanoparticles (SPIONs) with mesoporous CaCO3 microbeads to a magneto-fluorescent bead platform that can be surface-functionalized with bioligands, such as antibodies. This inorganic bead platform enables immuno-magnetic separation, target enrichment, and target quantification with optical readout. The beads can be detected with steady-state and time-resolved fluorescence microscopy and flow cytometry (FCM). Moreover, they are suited for readout by time gated emission. In the following, the preparation of these magneto-fluorescent CaCO3 beads, their spectroscopic and analytic characterization, and their conjugation with bacteria-specific antibodies are presented as well as proof-of-concept measurements with Legionella pneumophila including cell cultivation and plating experiments for bacteria quantification. Additionally, the possibility to discriminate between the long-lived emission of the LT-encoded capture and carrier CaCO3 beads and the short-lived Emission of the dye-stained bacteria with time-resolved fluorescence techniques and single wavelength excitation is demonstrated.
Nanoparticles (NPs) have become important materials for a variety of chemical technologies. The enhanced surface-area-to-volume ratio of NPs, making them excellent for use as catalyst, in analytical assays, and for antimicrobial applications.
Nickel NPs have exhibited immense potential as important catalyst for the Sabatier reaction, i.e. converting waste to energy via transformation of CO2 into CH4, and could replace the rare earth elements such as Ru, PT, or Rh. In this work we describe the solvothermal synthesis of monometallic and bimetallic nickel nanoparticles.
Monodisperse monometallic Ni NPs were synthesized using Oleylamin as solvent and reducing agent. The nanoparticles were investigated using small angle scattering (SAXS), scanning transmission electron microscopy (STEM) and energy dispersive X-ray spectroscopy (EDX), showing that the NPs are stable while the surface is not entirely covered. However, Ni has a high propensity to undergo oxidation, and becoming deactivated by coke formation. Hence, we further explore the preparation of bimetallic NPs, where a second metal is added to stabilize the Ni.
Bimetallic Cu-Ni NPs were synthesized by simultaneous solvothermal reduction. These bimetallic NPs exhibit excellent catalytic properties are promising candidates to be used as catalysts for efficient energy storage.
We present the synthesis of monodisperse monometallic Ni nanoparticles (NPs) and bimetallic NiCu respectively NiCo NPs. The NPs were investigated using SAXS, STEM, EDX, and XANES, showing that the NPs are size tunable and stable while the surface is not entirely covered. Nickel NPs have exhibited immense potential as important catalyst for the Sabatier reaction, i.e. converting waste to energy via transformation of CO2 into CH4.
Nanoparticles (NP) have become important materials for a variety of chemical technologies. The enhanced surface-area-to-volume ratio of NPs, making them excellent for use as catalyst, in analytical assays, and for antimicrobial applications.
Nickel NPs have exhibited immense potential as important catalyst for the Sabatier reaction, i.e. converting waste to energy via transformation of CO2 into CH4, and could replace the rare earth elements such as Ru, PT, or Rh. In this work we describe the solvothermal synthesis of monometallic and bimetallic nickel nanoparticles.
Monodisperse monometallic Ni NPs were synthesized using Oleylamin as solvent and reducing agent. The nanoparticles were investigated using small angle scattering (SAXS), scanning transmission electron microscopy (STEM) and energy dispersive X-ray spectroscopy (EDX), showing that the NPs are stable while the surface is not entirely covered. However, Ni has a high propensity to undergo oxidation, and becoming deactivated by coke formation. Hence, we further explore the preparation of bimetallic NPs, where a second metal is added to stabilize the Ni.
Bimetallic Cu-Ni NPs were synthesized by simultaneous solvothermal reduction. These bimetallic NPs exhibit excellent catalytic properties are promising candidates to be used as catalysts for efficient energy storage.
In this poster we will present some results of a research projects dealing with Arabic recipes of black inks [1-2]. To improve conservation practices of Arabic manuscripts we have assessed the feasibility of the recipes collected from many Arabic sources on bookmaking and reproduced the most common inks. Ink samples were then artificially aged and analysed using an array of analytical techniques, mostly non-invasive, in order to build a database of Arabic inks and their ingredients and also to verify the detection limits of the portable equipment employed.
We will show procedures and problems concerning the identification of ink types and ingredients using reflectography (in Vis, IR and UV), X-Ray Fluorescence, Infrared and Raman spectroscopy. The focus will be in particular on squid ink [3] and mixed inks – both in the form of carbon inks with the addition of tannins and of a mixture of carbon and iron gall inks – which are particularly difficult to detect [4]. We will also examine the results of iron gall inks made with iron filings or nails instead of vitriol, the various precursor used to extract gallic acid that are mentioned in the sources as surrogates of gall nuts.
[1] A. Schopen, Tinten und Tuschen des arabisch-islamischen Mittelalters, Göttingen: Vandenhoeck & Ruprecht, 2004
[2] S. Fani, Le arti del libro secondo le fonti arabe originali. I ricettari arabi per la fabbricazione degli inchiostri (sec. IX-XIII): loro importanza per una corretta valutazione e conservazione del patrimonio manoscritto, PhD thesis, Napoli: Università L’Orientale, 2013
[3] S. Centeno, J. Shamir Journal of Molecular Structure, 873 (2008), 149-159
[4] C. Colini et. al, Manuscript cultures, 11 (2018) 43-50
Ink recipes from the islamic era: Texts, manuscripts, ink reproductions and scientific analyses
(2019)
Ink recipes can often be found in Arabic manuscripts. They may be included in treatises of diverse subjects – from handbooks for secretaries or calligraphers to books on arts and crafts, to alchemical and astrological essays. Recipes can also appear, with or without relation to the main text in the manuscript, in the form of lists or collections or even added in empty spaces as single entries. Why were these recipes written down? Were they used by the many professionals dealing with inks in their every-day work? Or were they part of the literary genre of adab with little or no practical application? To answer these questions a research project was set up: ink recipes have been collected from written Arabic sources, their feasibility has been assessed and some of them have been reproduced. These samples were artificially aged and analysed through an array of analytical techniques, most non-invasive and non-destructive, and the results compared to the data obtained by the application of the same analyses on concrete manuscripts. The codicological characteristics of the manuscripts have also been studied. My aim in this talk is to show how such an interdisciplinary approach could be beneficial for the study of material culture.
Fifty shades of black: Typologies and terminology of black inks in the light of new discoveries
(2019)
The identification of the materials constituting an artefact is the basis of any correct conservation project. For this reason (among others) in the last 50 years analytical techniques have been applied to the study of manuscripts. Unfortunately, the scientific investigation of Arabic books is still uncommon, focusing mainly on single case studies of illuminated manuscripts where the black media used to write the text is largely overlooked. This lack of knowledge prompted a recent research in which black ink recipes have been collected from written Arabic sources, their feasibility has been assessed, and some of them have been reproduced. These samples were artificially aged and analysed through an array of analytical techniques, mostly non-invasive and non-destructive, in order to build a database of Arabic inks and their ingredients and to verify the detection limits of the equipment employed. Finally, the results were compared to the data collected from historical manuscripts.
In this talk I will focus on the ink typologies and the terminology (ancient and modern) used to describe them. In particular I will highlight how even the modern classification fails to capture the variety encountered in both recipes and manuscripts, particularly in the light of recent discoveries. I will address especially the terminological and conceptual issues of mixed inks – in the form of carbon inks and tannins, of carbon and iron gall inks, and of carbon and metallic salts –, iron gall inks made without vitriol and iron gall inks made with sources of tannins different from gall nuts.
Papyrus was in use in the Islamic world until the 11th century and few ink recipes collected from treatises about the art of the books are dedicated to this support. But papyrus was also burnt in order to obtain soot used as an ingredient for a particular type of ink (midād al-qarāṭīs). In this talk I will give an overview of the recipes – in particular those by ar-Rāzī –, their context and transmission in order to evaluate this double nature of papyrus, which is considered at the same time a writing support and a material to be recycled. Moreover, I will discuss what kinds of ink are most likely to be found, according to these literary sources, on Arabic manuscripts and documents written on papyrus and compare them to the typologies mentioned for paper and parchment. These results are the premises of a research project starting at the beginning of 2019, in which a number of dated fragments from several European institutions will be analysed with non-destructive techniques in order to establish a profile of the main writing media used in the early centuries of the Islamic Era.
Statistically the mean time between damage events on rotor blades is 6 years (Deutscher Windenergie Report 2006). Due to imperfection in the production the shell structures get cracks after a few years fare before the designed life time. A shell test rig was built at BAM for efficient research on the effects of defects in production.
In-situ and ex-situ NDT give a better understanding from degradation processes in composite materials.
With advanced methods in the research on the fatigue behaviour of FRP it was found a load level of infinite life for GFRP and CFRP. This is in the range of typical strain values of airliners and rotor blades in normal operation.
Due to the fibre-composite nature NDT techniques have to be suitable to a wide length scale to image micro cracking as well as bigger defects. Therefore different techniques have to be applied and developed.
Even for the basic measurements of material data for design and engineering of composite structures there is a need to upgrade standards. With a new shear frame test rig more precise values can be obtained.
With advanced methods in the research on the fatigue behaviour of FRP it was found a load level of infinite life for GFRP and CFRP. This is in the range of typical strain values of airliners and rotor blades in normal operation.
Statistically the mean time between damage events on rotor blades is 6 years (Deutscher Windenergie Report 2006). Due to imperfection in the production the shell structures get cracks after a few years fare before the designed life time. A shell test rig was built at BAM for efficient research on the effects of defects in production.
Test blades of ~10m are an efficient way for SHM research and evaluation of NDT-methods and blade geometry.
The Interdisciplinary Alchemist: Reproduction and Study of Black Inks from the Islamicate World
(2019)
The identification of the materials constituting an artefact is the basis of any correct conservation project, for this reason (among others) in the last 50 years analytical techniques have been applied to the study of manuscripts. Unfortunately, the scientific investigation of Arabic books is still uncommon, focusing mainly on single case studies, often producing unclear results, especially for black inks. This lack of knowledge prompted a recent research in which black ink recipes have been collected from written Arabic sources on bookmaking, their feasibility has been assessed, and finally some of them have been reproduced. These samples were artificially aged and analysed through an array of analytical techniques, mostly non-invasive and non-destructive, in order to build a database of Arabic inks and their ingredients and also to verify the detection limits of the portable equipment employed. In this talk I will present some instances of how this approach can help textual criticism, for example in evaluating variants and determining the competence of authors and compilers. At the same time the research highlights how much this scientific work depends on textual studies, especially concerning the identification of ingredients. Moreover, I will focus on some of the problematics I faced both during the textual interpretation and the actual reproduction of the recipes and how they influenced the results of the scientific analyses. In particular I’ll look into the role played by the degree of purity of the components and the function (real and perceived) of some of the ingredients.
In this poster we will present some results of a research projects dealing with Arabic recipes of black inks. To improve conservation practices of Arabic manuscripts we have assessed the feasibility of the recipes collected from many Arabic sources on bookmaking and reproduced the most common inks. Ink samples were then artificially aged and analysed using an array of analytical techniques, mostly non-invasive, in order to build a database of Arabic inks and their ingredients and also to verify the detection limits of the portable equipment employed.
First, we will provide an overview of the sources [1-2] employed in the study – dating from 9th to 14th century, although the manuscripts in which they can be found dates up to the 20th century – with an eye on the ink typologies (real and perceived by the compilers). Then we will show how, by reproducing the recipes, it was possible to shed light on some oddities in the procedures and the choice of ingredients. In the end we will discuss problems concerning the identification of ink types and ingredients using reflectography (in Vis, IR and UV), X-Ray Fluorescence, Infrared and Raman spectroscopy. The focus will be in particular on mixed inks – both in the form of carbon inks with the addition of tannins and of a mixture of carbon and iron gall inks – which are particularly difficult to detect [3]. We will also examine the results of iron gall inks made with iron filings or nails instead of vitriol and the various precursor used to extract gallic acid that are mentioned in the sources as surrogates of gall nuts.
[1] A. Schopen, Tinten und Tuschen des arabisch-islamischen Mittelalters, Göttingen: Vandenhoeck & Ruprecht, 2004
[2] S. Fani, Le arti del libro secondo le fonti arabe originali. I ricettari arabi per la fabbricazione degli inchiostri (sec. IX-XIII): loro importanza per una corretta valutazione e conservazione del patrimonio manoscritto, PhD thesis, Napoli: Università L’Orientale, 2013
[3] C. Colini et. al, Manuscript cultures, 11 (2018) 43-50
Functional materials for energy conversion are important technology drivers needed for the implementation of low carbon energy. Therefore, researchers commonly focus on improving the intrinsic properties of a functional material. However, for applications, the extrinsic properties are at least as important as the intrinsic ones. Consequently, it is important to investigate and understand the external and internal structure of semi-finished products and especially defect dependent properties. The extrinsic properties may change during application and the life cycle of the material as well as through processing and molding steps.
Our studies show how X-ray tomographic (XCT) investigations can contribute to structure investigations in composites and massive samples using the example of magnetic materials for energy conversion. The components are tested non-destructively in 3D in order to localize and characterize cracks, pores, inclusions as well as other defects and their influence on the functional properties and also “in-time” during the life cycle of the material. Exsitu and in-situ experiments performed with non-destructive XCT are predestinated to follow damaging mechanisms of materials under certain load conditions, atmospheres or liquids, e.g. went through several working cycles of a functional material. By combining microtomography with other methods of magnetic and classical material characterization, unique statements about the structure and the functional properties can be made.
From the applications point of view, sometimes complex, three-dimensional geometries are needed to fully exploit the functional properties of the materials, e.g. to ensure a high surface area for heat exchange. Since many functional materials are brittle and difficult to form, shaping is often a big challenge. In principle, additive manufacturing processes offer the possibility to produce complex, porous components from poorly formable alloys.
If all stages of additive manufacturing are accompanied by X-ray tomographic imaging, the process of finding the optimal parameters for material processing can be significantly accelerated.
Based on the quality control of the initial powder material used and also investigations of the shape and arrangement of defects within the molten structure and their relationship with the melting path scanning strategy, Xray tomography has proven to be an ideal tool for additive manufacturing, even for functional materials. Overall, tomographic methods are important tools for the development of functional materials to application maturity.
The deep penetration laser beam welding (LBW) has developed to one of the most promising metal joining methods in the modern manufacturing industry. It has well-known advantages of good penetration capacity, low heat input, high reachable welding speed and low welding distortion in comparison to conventional arc welding techniques. However, there are still challenges in LBW making the realization of the advantages difficult, such as porosity or inhomogeneous element distribution when using filler material. The magnetohydrodynamics technique is a promising way to solve these issues by introducing a suitable electromagnetic field, and correspondingly Lorentz force, to control the Transport phenomena in the weld pool.
The underlying physics in wire feed laser beam welding with electromagnetic stirring were investigated numerically and experimentally. A three-dimensional transient heat transfer and fluid flow model coupled with dynamic keyhole, magnetic induction and element transport was developed for the first time. The electromagnetic behaviour as well as the temperature and velocity profiles, solidification parameters, keyhole evolution and element transport are calculated.
The model is well tested against the experimental results. The beneficial effects from electromagnetic stirring (element homogenization and grain refinement) are explained quantitatively using the numerical data and the results from high-speed imaging, OM, EDX and EBSD.
A thorough characterization of starting materials is the precondition for further research, especially for cement, which contains various phases and presents quite a complex material for fundamental scientific investigation. In the paper at hand, the characterization data of the reference cement CEM I 42.5 R used within the priority program 2005 of the German Research Foundation (DFG SPP 2005) are presented from the aspects of chemical and mineralogical compositions as well as physical and chemical properties. The data were collected based on tests conducted by nine research groups involved in this cooperative program. For all data received, the mean values and the corresponding errors were calculated. The results shall be used for the ongoing research within the priority program.
In recent years, the improved understanding of the formation of laser-induced periodic surface structures (LIPSS) has led to an emerging variety of applications that modify the optical, mechanical and chemical properties of many materials. Such structures strongly depend on the laser beam polarization and are formed usually after irradiation with ultrashort linearly polarized laser pulses. The most accepted explanation for the origin of the structures is based on the interference of the incident laser radiation with electromagnetic surface waves that propagate or scatter at the surface of the irradiated materials. This leads to an intensity modulation that is finally responsible for the selective ablation in the form of parallel structures with periods ranging from hundreds of nanometers up to some micrometers. The versatility when forming such structures is based on the high reproducibility with different wavelength, pulse duration and repetition rate laser sources, customized micro- and nanometric spatial resolutions, and the compatibility with industrially relevant processing speeds when combined with fast scanning devices. In this contribution, we review the latest applications in the rapidly emerging field of surface functionalization through LIPSS, including biomimetic functionalities on fluid transport, control of the wetting properties, specific optical responses in technical materials, improvement of tribological performance on metallic surfaces and bacterial and cell growth for medical devices, among many others.
An effective method for evaluating the fatigue strength of thick unidirectional composite laminates of wing spar caps has been presented here. A typical width-tapered bending specimen has been developed for a four-point loading set up. Static and fatigue loading was performed at a load ratio R = -1. The complex stress state has been investigated numerically by finite element analysis. Finally, the concept is proven experimentally on specimens made of pultruded fibre rods.
The fatigue behavior of the continuously tapered width by water Jet cutting has been compared to discrete tapering via rod-drop. The new method enables a screening of material fatigue behavior caused by normal and shear loading.
In this presentation the main requirements of BAM-GGR 016 regarding maintenance and periodic inspections were explained. BAM ensures during acceptance of the quality management program that specific and relevant instructions for maintenance and periodic inspections are developed and handed to the operator of the packaging. Examples are given.
It was found for inorganic/polymer nanocomposites that a so-called Rigid Amorphous Phase (RAF) is formed in the interfacial region by adsorption of polymer segments onto the nanoparticles. The segmental dynamics of RAF is expected to be altered, as compared to the pure matrix, which might percolate into the entire system, affecting the overall nanocomposite properties. Here, the structure and molecular mobility of epoxy-based PNCs with different nanofillers (layered double hydroxide and boehmite) was studied by a combination of calorimetric and X-Ray scattering techniques. Temperature modulated DSC (TMDSC) showed that depending on the nanofiller, RAF can reach up to 40 wt % of the system or, on the contrary, the overall mobility of the matrix might increase due to the presence of particles. Such contrasting results, including the high amount of RAF, which was never shown before for epoxy-based PNCs, emphasize the importance of interfaces. Additionally, glass transition and glassy dynamics were investigated by a novel technique, Flash DSC (heating rates up to 10 kK/s) employed for the first time to a thermosetting system and electrospun fibers, which did not result in their degradation. It was used to study both the vitrification kinetics and glassy dynamics of the PNCs, for instance further confirming the presence of RAF and its impact on the overall material properties.
In summary, we report a highly modular solid TTA-UC system comprising of a crystalline, thermally stable PCN222(Pd) MOF with CA-coated MOF channels and with a DPA annihilator embedded in a solution-like environment in the MOF channels. This solid material displays blue upconverted delayed emission with a luminescence lifetime of 373 us, a threshold value of 329 mW*cm-2 and a triplet–triplet energy transfer efficiency of 82%. This optical application adds another facet to the versatile chemistry of PCN-222 MOFs. The design concept is also applicable to other TTA-UC pairs and enables tuning of the UCL color, for example, by replacing DPA with other dyes as exemplarily shown for 2,5,8,11-tetra-tert-butyl-perylene, that yields UCL at 450 nm. Current work aims to reduce the oxygen sensitivity and to increase the retention of the trapped annihilators in organic environments, for example, by tuning the chain length of the carboxylic acid and by coating the MOF surface. In addition, the TTA-UC efficiency will be further enhanced by reducing the reabsorption of the UC emission caused by Pd(TCPP) and by optimizing the sensitizer/annihilator interface.
Challenges in Traceable Size Measurement of Non-Spherical, Non-Monodisperse Nanoparticles - nPSize
(2019)
Size measurement of nanoparticles (NP) becomes a challenging analytical problem when non-spherical shapes must be traceably measured. However, most industrial NPs have irregular shapes and broad size distribution making it often more complex to follow European regulatory to identify a material as a nanomaterial according to which accurate measurement of the smallest dimension and its size Distribution is necessary.
The European research project nPSize - Improved traceability chain of nanoparticle size measurements aims to fill this gap by developing potential non-spherical reference nanoparticles, measurement procedures and physical modelling to improve the traceability chain, comparability and compatibility for NP size measurements between different methods. Therefore, new model NP with well-controlled shape has been synthesized and are supposed to be systematically characterized using the traceable methods scanning/transmission electron microscopy, atomic force microscopy and small angle X-ray scattering.
Following NP candidates are under investigation with respect to their homogeneity and stability: (i) titania nanoplatelets (10-15 nm thickness x 50-100 nm lateral), (ii) titania bipyramides (~60 nm length x 40 nm width), (iii) titania acicular particles (100 nm length x 15-20 nm width; aspect ratio 5.5/6), (iv) gold nanorods (~10 nm width x 30 nm length), and (v) gold nanocubes (~55 nm x 55 nm x 55 nm). In addition, sample preparation procedures as well as measurement analysis procedures with evaluation of appropriate measurands and descriptors for each material class and method are being developed to support standardization. To underpin the traceability of the size measurement of nonspherical NP, physical modelling of the signals in e.g. electron microscopy techniques will be used and in combination, the implementation of machine learning is aimed to facilitate measurement Analysis procedures, especially regarding the accurate thresholding/segmentation of the NPs.zeige mehr
When assessing the performance of welded components residual stresses are vital. The possibilities of transferring the real boundary conditions of welding, which influence the residual stress, into the laboratory are highlighted in this contribution. The potentials of a test system specially developed for this purpose are demonstrated. The component design induces global process-, geometry- and material-dependent stresses, which can be simulated and quantified in the system. In addition, the resulting local residual stress distribution can be exactly determined with high spatial resolution with the aid of X-ray diffraction. Examples are presented of how the conditions to be found during production are simulated in the laboratory.
The potential of lowered surface features as well as the application of wear resistant coatings have been known for many years to improve the tribological behavior of forming tools. More recent studies also discuss the capability of protruded microfeatures for adjusting the tribological behavior between contacting surfaces. The demand for a high wear resistance of such structures as well as their economical and reliable production, however, often limits the industrial application. The laser implantation process can overcome these limitations. In contrast to conventional cw-laser dispersing processes, where the formation of uniform metal matrix composite layers is intended, this surface engineering technique aims to improve the tribological behavior of contacting surfaces by a localized dispersing of pre-placed hard ceramic particles. This enables the formation of deterministic textures composed of separated wear resistant dome- or ring-shaped microstructures (implants).
Since TaC shows very promising material properties for improving the wear resistance of tools exposed to severe operating conditions, this paper analyzes its suitability for pulsed laser implantation on X38CrMoV5-3 tool steel for the first time. In the experiments, the influence of the particles and the laser parameters (pulse power, pulse duration and focal diameter) on the material properties of the localized dispersed zones was studied by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy and X-ray diffraction. The composite´s (micro-) hardness was measured and calculated by using a rule of mixture. Additionally, the influence of the laser parameters and the TaC particles on the geometrical properties of the implants was studied by optical microscopy and white light interferometry.
The results showed that defect-free implants with hardness values of ~900 HV1 can be obtained at the focal spot, since a localized dispersing of the TaC particles is possible using a pulsed millisecond laser. However, in dependence of the laser intensity, also a partial dissolution of the initial particles occurs. This leads to the precipitation of new dendritic TaC nanoparticles and to varying contents of retained austenite in the matrix. Both effects have a strong influence on the implant hardness and must be considert by the rule of mixture. Regarding the geometrical response it was pointed out that protruded microfeatures with heights up to 10 µm can be created. In comparison to laser remelted zones, the implanted zones showed significantly altered weld pool profiles due to the influence of the particles on the melt convection. A transition of the implant shape from predominantly dome-shaped to predominantly ring-shaped was observed for intensities >1.7∙106 W/cm2 due to the onset of the keyhole effect.
Laser beam welding of aluminum die casting is challenging. A large quantity of gases (in particular hydrogen) is absorbed by aluminum during the die-cast manufacturing process and is contained in the base material in solved or bound form. After re-melting by the laser, the gases are released and are present in the melt as pores. Many of these metallurgic pores remain in the weld seam as a result of the high solidification velocities. The natural (Archimedean) buoyancy is not sufficient to remove the pores from the weld pool leading to process instabilities and poor mechanical properties of the weld. Therefore, an electromagnetic (EM) system is used to apply an additional buoyancy component to the pores. The physical mechanism is based on the generation of Lorentz forces, whereby an electromagnetic pressure is introduced into the weld pool. The EM system exploits the difference in electrical conductivity between poorly conducting pores (inclusions) and the comparatively better conducting aluminum melt to increase the resulting buoyancy velocity of the pores. Within the present study, the electromagnetic supported degassing is investigated in dependence on the laser beam power, welding velocity and electromagnetic flux density. By means of a design of experiments a systematic variation of these parameters is carried out for partial penetration laser beam welding of 6 mm thick sheets of wrought aluminum alloy AlMg3 and die-cast aluminum alloy AlSi12(Fe) where the wrought alloy serves as a reference. The proportion of pores in the weld seams is determined using X-ray images, computed tomography (CT-) images and cross-section images. The results prove a significant reduction of the porosity up to 70 % for both materials as a function of the magnetic flux density
The paper describes a systematic investigation of the EM influenced laser beam welding of the aluminum die casting alloy AlSi12(Fe) in comparison to a reference material, a wrought aluminum alloy AlMg3. By using of a face centred CCD test plan, the influencing variables laser power, welding velocity and magnetic flux density are varied with regard to their influence on the remaining porosity. The global pore fraction of the weld seams was analyzed by X-ray images with ImageJ. This enabled a qualitatively very good regression model to be derived for the respective material, which identifies the dominant influencing variables. The results prove, statistically verified, for the investigated parameter range, that
- the magnetic flux density is the main cause for the porosity reduction,
- the porosity rises with increasing laser power the porosity in the weld seams rises,
- the influence of the welding velocity is negligible,
- the pore quantity in wrought alloy is more strongly minimized by the magnetic flux density than in die casting,
- the porosity decreases due to the EM influence by approx. 70 % compared to the unaffected welds. This effect is emphasized by the contour line charts, which illustrate the relationship between laser power and magnetic flux density.
With the exception of the quadratic influence of B at the wrought alloy, the statistical correlation shows a linear development of the respective influence variables for both aluminum alloys. In order to investigate these deviations, further simulations with a focus on weld pool geometry and weld pool flow are to be performed. In addition, the welding results can be classified in accordance with DIN EN ISO 13919-2 in the highest evaluation group B for AlMg3 and in evaluation group C for AlSi12(Fe) by applying a magnetic flux density of 350 mT. The analysis of the CT images at constant laser power and welding velocity allows a direct comparison both between the two alloys and also as a function of the magnetic flux density with regard to the number and size of pores. An increase in the magnetic flux density leads to a significant decrease in the number and volume of pores, which can be seen more clearly in wrought alloy than in die casting. Very acceptable results can be achieved for both materials and different welding parameters. This successfully demonstrates the desired process robustness and functionality of the EM system for practical applications. For subsequent investigations of overlap joints, the lowest possible laser power and a high magnetic flux density are recommended.
Friction stir welding (FSW) of high-melting temperature alloys, such as steel and Inconel, requires tooling that can survive under the applied loads at the elevated temperatures. Tungsten-Rhenium (W-Re) alloys are a suitable candidate for this application; however, the costs typically associated with achieving the required densities and grain structure for the tooling are high due to the lengthy traditional processing required. Further costs are incurred in machining the starting bar stock to the final FSW tooling configuration. An alternate processing method is used in this study to shorten the fabrication time using direct current sintering which rapidly consolidates the starting powders at lower temperatures than used in traditional powder metallurgy. Although this process enables retention of the fine grain size, the sintering time is too short to form the desired single, solid phase. Therefore, the specimens were subjected to a post-consolidation heat treatment to fully solutionize the W matrix. Once the desired density and solid solution phase was verified in coupons, the final processing parameters were used to consolidate a net shape tool for FSW.
Diffraction-based experimental determination of Residual Stress in AM parts: A critical discussion
(2019)
Additive manufacturing (AM) technologies have experienced an exceedingly rapid growth, not always paralleled by the knowledge about the materials properties and performance. In particular, residual stress (RS) has been soon recognized as an issue in AM parts, so that parts are always post-heat-treated. Moreover, much effort has been spent on simulating RS, especially using finite element methods.
The experimental determination of RS has thereby become increasingly important, and even simple data constitute (to date) a piece of knowledge to fill the above-mentioned gap. In particular, diffraction methods, which are basically non-destructive, offer enormous possibilities to gain knowledge on real components, since neutrons and synchrotron radiation can penetrate even heavy metals up to several millimeters (or even centimeters). Indeed, some success has been obtained, and the knowledge about the origins of the RS fields, as well as their variation as a consequence of heat or mechanical treatments, has been greatly expanded.
In this talk, a few success stories will be outlined. It will be shown how the determination of RS in metallic parts (with focus on those produced by laser powder bed fusion) has even allowed showing that process parameters that were considered unimportant play a major role in the onset of stress.
However, while RS is starting to be considered in the part design, deposition strategy (e.g. build plate temperature), and even in the definition of the relevant metric to assess the quality of a part, much is still to be investigated about the hypotheses underlying its experimental determination. Therefore, some aspects to be aware of, or even to date unclear will also be discussed, such as the determination of the reference unstrained samples and of the principal axes of stress. All these aspects will draw the path towards a comprehensive understanding of the process-structure-performance relationships in AM materials and parts.
The second edition of this textbook on physical electrochemistry, written by two experienced teachers of physical chemistry, corrosion engineering and materials science and engineering, covers the current knowledge which should be transferred to students of these fields.
In 20 chapters the fundamentals of electrochemistry, the most important electrochemical measurement techniques and applications of electrochemistry are covered.
It can be concluded that this study fulfills its intension of “serving as a key textbook in undergraduate courses” dealing with electrochemistry and being “a reference source for graduated students, researchers and engineers” interested in this field. Teachers will find sufficient content for preparing lectures on this topic. Even self‐learning is well supported by the clear structure, presented content and provided sources for further reading.
The laser-based direct energy deposition (DED) as a technology for additive manufacturing allows the production of near net shape components. Industrial applications require a stable process to ensure reproducible quality. Instabilities in the manufacturing process can lead to faulty components which do not meet the required properties.
The DED process is adjusted by various parameters such as laser power, velocity, powder mass flow and spot diameter, which interact with each other. A frequently used comparative parameter in welding is the energy per unit length and is calculated from the laser power and the velocity in laser welding. The powder per unit length comparative parameter in the DED process has also be taken into account, because this filler material absorbs energy in addition to the base material.
This paper deals with the influence of mass energy as a comparative parameter for determining the properties of additively manufactured parts. The same energy per unit length of 60 J/mm as well as the same powder per unit length of 7.2 mg/mm can be adjusted with different parameter sets. The energy per unit length and the powder per unit length determine the mass energy. The laser power is varied within the experiments between 400 W and 900 W. Energy per unit length and powder per unit length are kept constant by adjusting velocity and powder mass flow. Using the example of Inconel 718, experiments are carried out with the determined parameter sets. In a first step, individual tracks are produced and analyzed by means of micro section. The geometry of the tracks shows differences in height and width. In addition, the increasing laser power leads to a higher dilution of the base material. To determine the suitability of the parameters for additive manufacturing use, the individual tracks are used to build up parts with a square base area of 20x20 mm². An investigation by Archimedean principle shows a higher porosity with lower laser power. By further analysis of the micro sections, it can be seen that at low laser power, connection errors occur between the tracks.
The results show that laser power, velocity and powder mass flow have to be considered in particular, because a constant mass energy can lead to different geometric as well as microscopic properties.
Ferritic spheroidal graphite cast iron (SGI) materials have a remarkable technical poten-tial and economic impact in modern industry. These features are closely related to the question of how the cast materials can be produced without structural defects and graphite degenerations such as for example chunky graphite. Although the chunky graphite degeneration superficially seems to be well known, its metallurgical background is still controversially discussed, appropriate field-tested non-destructive tools for its quantification in castings are lacking and the knowledge on its impact on material properties is fairly limited. Addressing this status, the article is providing a current overview on the subject. Existing theories on formation and growth mechanisms of chunky graphite are briefly reviewed. Furthermore, from a metallurgical point of view, causes for the appearance of chunky graphite as well as preventive measures are concisely summarized. Particular attention is paid to the morphology of chunky graphite and how it can be characterized by destructive and non-destructive techniques. Special emphasis was laid on providing a comprehensive overview on the impact of chunky graphite on strength, ductility, fatigue limit, fatigue crack growth rate as well as fracture tough-ness of ferritic SGI materials based on experimental data. Moreover, conclusions for the assessment of castings affected by chunky graphite are drawn.