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Wear behavior of innovative niobium carbide cutting tools in ultrasonic-assisted finishing milling
(2023)
The resources of niobium exceed the ones of tungsten by an order of magnitude. With 92%, Brazil is today the main global producer of niobium. Hence, niobium carbides (NbC) are a sustainable and economic alternative to conventionally used cutting materials, especially tungsten carbides (WC). Moreover, NbC can be used in Ni alloy matrix and thus offer significant advantages by substituting WC in Co matrix as cutting materials in terms of health risks and raw material price and supply risk. Based on recent studies which found an increased performance of NbC compared to WC cutting tools in machining higher strength steels, the composition NbC12Ni4Mo4VC was chosen for finish machining of a high-strength steel S960QL in this study. The experiments were carried out on an ultrasonic-assisted 5-axis milling machine using NbC tools specially made to benchmark them with commercially available coated WC cutting inserts. In addition, the influence of a coating system for the NbC inserts is tested and evaluated for its performance in the cutting process. Tool wear and cutting force analyses are implied to identify optimal parameter combinations as well as tool properties for the novel NbC tool. Together with the oscillation of ultrasonic-assisted milling, the loads on the component surface and the tool can be reduced and the wear behavior of the novel NbC tool can be refined. These milling tests are accompanied by standardized wear tests, i.e., pin-on-disc, between the aforementioned material combinations, and the results are correlated with each other. Finally, the behavior when using hard-to-cut materials such as Ni alloys, or innovative materials such as iron aluminide is also being tested, as these are constantly in the focus of machining optimization. With this strategy, comprehensive knowledge is achievable for future efficient application of NbC for milling tools, which have already been researched for decades using WC.
This study details a thorough analysis of leaky and waveguide modes in biperiodic diffractive nanostructures. By tuning diffraction orders and subsequently confining local density of optical states at two distinct resonance wavelengths, we present a highly sensitive refractive index biosensing platform that can resolve 35.5 to 41.3 nm/RIU of spectral shift for two separate biological analytes.
Additive manufacturing (AM) technologies are becoming increasingly important, not only for the manufacture of parts, but also as repair technology that complement existing production technologies. Powder bed fusion of metals by laser beam (PBF-LB/M) combines the freedom in design with high achievable accuracy, making it ideal as a repair approach. However, there are still challenges in adapting process for repair applications. When mounting parts inside PBF-LB/M machines, their real position within the build volume is unknown. One goal of a repair process is to minimize the offset between the base component and the additively manufactured structure to reduce additional rework. For a minimum offset between component and additively manufactured structure, the actual position of the component has to be identified with high precision within the machine coordinate system (MCS). In this work a process setup is presented that allows the actual position of a gas turbine blade to be detected inside a PBF-LB/M machine. A high resolution camera with 65 megapixel is used for this purpose. The presented setup is implemented on a SLM 280 HL PBF-LB/M machine. In addition to the setup, a novel repair workflow using PBF-LB/M is presented. The developed setup and workflow consider inaccuracies in the component and camera mounting, as well as process inaccuracies. This includes keystone distortion correction by homography. The machine setup and workflow are used to repair a real gas turbine blade. Subsequently the offset between the turbine blade and the additivley manufactured structure is validated by 3D scanning the repaired part. The maximum offset is 160 µm. The presented approach can be extended to other geometries and PBF-LB/M machine manufacturers. The high-resolution camera approach is platform independent, which facilates the market penetration of PBF-LB/M repair processes.
The main solidification parameters, namely the crystal axis, the growth rate, and the cross-sectional area of the columnar crystal control the primary microstructure and thus the final weld seam properties.
Limited understanding of solidification parameters due to complexities in experimental and theoretical weld pool boundary determination and
its mathematical description.
Application of local Lamé curves for efficient weld pool boundary reconstruction Derivation of general analytical solutions for the main solidification parameters of a two-dimensional columnar crystal growth during laser beam welding of thin steel sheets.
The Lamé curves approximation technique was successfully applied for the reconstruction of the rear part of the two-dimensional steady-state weld pool boundary. General analytical expressions for the main solidification parameters, namely the crystal axis, the growth rate and the cross-sectional area of the crystal were derived.
The derived expressions and herewith obtained results were verified and validated by comparing them to known theoretical solutions and experimental measurements. Dimensionless analysis of the influence of the size and shape of the rear weld pool boundary on the solidification parameters was provided.
The derived general solutions and the analysis provided allow for critical welding parameters to be estimated and adapted accordingly to improve the welding process.
Surface functionalized silica nanoparticles (SiO2-NP) gained great interest in the life and material sciences, as they can be used e.g. as drug carriers, fluorescent sensors, and multimodal labels in bioanalytical assays and imaging applications. They are highly stable, are easily produced and modified on a large scale at low cost and can be labeled or stained with a multitude of sensor dyes. These dye modified particle conjugates have several advantages as compared to conventional molecular probes like enhanced brightness, ease of designing ratiometric systems by combining analyte-sensitive and inert reference dyes, and increased photostability. Moreover, stained nanoparticles can enable the use of hydrophobic dyes in aqueous environments.
Here we present our work on multicolored sensors for the measurement of pH, oxygen and saccharides utilizing amorphous SiO2 NPs.
Electrocatalysis is and will continue to play a central role in the development of a new and modern sustainable economy, especially for chemicals and fuels. The storage of excess electrical energy into chemical energy by splitting water into hydrogen and oxygen is a feasible solution in this economic sector. A major drawback of electrical energy lies in the storage. Therefore, hydrogen is discussed as promising alternative. Fortunately, this issue can be effectively addressed through the implementation of chemical storage mechanisms. Due to their abundance on Earth and inherent stability in alkaline solutions, transition-metal oxides have become one of several viable alternatives to conventional noble-metal catalysts. Since FeNi oxide is one of the most active oxygen evolution reaction (OER) electrocatalysts for alkaline water electrolysis, it has been the subject of extensive research.
A series of different types of FeNi oxide nanoparticles (NPs) with atomic ratios covering a broad range, and various sizes with specific stoichiometric and non-stoichiometric iron and nickel ratios was synthesized and characterized by the combination of surface analysis techniques, such as time-of-flight secondary ion mass spectrometry (ToF-SIMS) and X-ray photoelectron spectroscopy (XPS). The morphology was studied using scanning electron microscopy (SEM) and transmission electron microscopy (TEM), which revealed the coexistence of mixed and unmixed iron and nickel NPs with comparable sizes in the range of 30–40 nm across all ratios. The synthesis technique displayed control over the iron-nickel ratio, as evidenced by energy dispersive X-ray spectroscopy (EDS) data. The presence of magnetite (Fe3O4) was detected in all samples investigated by X-ray diffraction (XRD). Furthermore, the existence of nickel ferrite (NiFe2O4) was shown in the Fe2Ni by XRD analysis. For the cyclic voltammetry (CV) measurements, the NPs were deposited onto glassy carbon electrodes using Nafion® as an ionomer, and 1 M KOH was employed as the electrolyte. Subsequently, the NPs/Nafion® electrode was transferred into the ToF-SIMS chamber to allow surface analysis and depth profiling.
The ToF-SIMS analysis revealed distinct peaks corresponding to Fe, Ni, and other peaks associated with Nafion®, whereas a straightforward correlation between the Ni.Fe ratio and the SIMS peak pattern is not possible.
The catalytic activity towards OER was evaluated through CV measurements, where the Fe2Ni3 ratio exhibited the most favorable performance, displaying a lower overpotential.
Engineered nanoparticles (NPs) with various chemical compositions and surface functionalities are routinely fabricated for industrial applications such as medical diagnostics, drug delivery, sensing, catalysis, energy conversion and storage, opto-electronics, and information storage which improve the quality of life and European prosperity. NP function, performance, interaction with biological species, and environmental fate are largely determined by their surface functionalities. Standardized repeatable surface characterization methods are therefore vital for quality control of NPs, and to meet increasing concerns regarding their safety. Therefore, industry, regulatory agencies, and policymakers need validated traceable measurement methods and reference materials. This calls for fit-for-purpose, validated, and standardized methods, and reference data and materials on the surface chemistry of engineered NPs. Here, we present a concept for the development of such standardized measurement protocols utilizing method cross-validation and interlaboratory comparisons (ILCs) with emphasis on both advanced measurement methods such as quantitative Nuclear Magnetic Resonance (qNMR), X-ray photoelectron spectroscopy (XPS) and secondary ion mass spectrometry (SIMS) and cost-efficient, non-surface specific methods like optical assays and electrochemical titration methods.
Electrocatalysis is and will continue to play a central role in the development of a new and modern sustainable economy, especially for chemicals and fuels. The storage of excess electrical energy into chemical energy by splitting water into hydrogen and oxygen is a feasible solution in this economic sector. A major drawback of electrical energy lies in the storage. Therefore, hydrogen is discussed as promising alternative. Fortunately, this issue can be effectively addressed through the implementation of chemical storage mechanisms. Due to their abundance on Earth and inherent stability in alkaline solutions, transition-metal oxides have become one of several viable alternatives to conventional noble-metal catalysts. Since FeNi oxide is one of the most active oxygen evolution reaction (OER) electrocatalysts for alkaline water electrolysis, it has been the subject of extensive research.
A series of different types of FeNi oxide nanoparticles (NPs) with atomic ratios covering a broad range, and various sizes with specific stoichiometric and non-stoichiometric iron and nickel ratios was synthesized and characterized by the combination of surface analysis techniques, such as time-of-flight secondary ion mass spectrometry (ToF-SIMS) and X-ray photoelectron spectroscopy (XPS). The morphology was studied using scanning electron microscopy (SEM) and transmission electron microscopy (TEM), which revealed the coexistence of mixed and unmixed iron and nickel NPs with comparable sizes in the range of 30–40 nm across all ratios. The synthesis technique displayed control over the iron-nickel ratio, as evidenced by energy dispersive X-ray spectroscopy (EDS) data. The presence of magnetite (Fe3O4) was detected in all samples investigated by X-ray diffraction (XRD). Furthermore, the existence of nickel ferrite (NiFe2O4) was shown in the Fe2Ni by XRD analysis. For the cyclic voltammetry (CV) measurements, the NPs were deposited onto glassy carbon electrodes using Nafion® as an ionomer, and 1 M KOH was employed as the electrolyte. Subsequently, the NPs/Nafion® electrode was transferred into the ToF-SIMS chamber to allow surface analysis and depth profiling.
The ToF-SIMS analysis revealed distinct peaks corresponding to Fe, Ni, and other peaks associated with Nafion®, whereas a straightforward correlation between the Ni.Fe ratio and the SIMS peak pattern is not possible.
The catalytic activity towards OER was evaluated through CV measurements, where the Fe2Ni3 ratio exhibited the most favorable performance, displaying a lower overpotential.