Active vacuum brazing of CNT films to metal substrates for superior electron field emission performance.

The joining of macroscopic films of vertically aligned multiwalled carbon nanotubes (CNTs) to titanium substrates is demonstrated by active vacuum brazing at 820 °C with a Ag-Cu-Ti alloy and at 880 °C with a Cu-Sn-Ti-Zr alloy. The brazing methodology was elaborated in order to enable the production of highly electrically and thermally conductive CNT/metal substrate contacts. The interfacial electrical resistances of the joints were measured to be as low as 0.35 Ω. The improved interfacial transport properties in the brazed films lead to superior electron field-emission properties when compared to the as-grown films. An emission current of 150 µA was drawn from the brazed nanotubes at an applied electric field of 0.6 V µm-1. The improvement in electron field-emission is mainly attributed to the reduction of the contact resistance between the nanotubes and the substrate. The joints have high re-melting temperatures up to the solidus temperatures of the alloys; far greater than what is achievable with standard solders, thus expanding the application potential of CNT films to high-current and high-power applications where substantial frictional or resistive heating is expected.

Characterization of the Fe-rich corner of Al-Fe-Si-Ti.

The quaternary system Al-Fe-Si-Ti was studied in the iron-rich corner for sections at 50, 60 and 70 at.% Fe at 900 °C. Isothermal phase equilibria were investigated by a combination of optical microscopy, X-ray powder diffraction (XRD) followed by Rietveld refinement and Electron Probe Microanalysis (EPMA). Phase boundaries of the phases, in particular of the Laves phase (Fe2Ti) and of the extended phase field of A2/B2/D03, were investigated. Selected samples containing the Laves phase and the B2 phase were characterized by microhardness measurements at different compositions throughout the quaternary homogeneity range of the phases.

Phase equilibria and structural investigations in the Ni-poor part of the system Al-Ge-Ni.

The ternary phase diagram Al-Ge-Ni was investigated between 0 and 50 at.% Ni by a combination of differential thermal analysis (DTA), powder- and single-crystal X-ray diffraction (XRD), metallography and electron probe microanalysis (EPMA). Ternary phase equilibria and accurate phase compositions of the equilibrium phases were determined within two partial isothermal sections at 400 and 700 °C, respectively. The two binary intermediate phases AlNi and Al3Ni2 were found to form extended solid solutions with Ge in the ternary. Three new ternary phases were found to exist in the Ni-poor part of the phase diagram which were designated as τ1 (oC24, CoGe2-type), τ2 (at approximately Al67.5Ge18.0Ni14.5) and τ3 (cF12, CaF2-type). The ternary phases show only small homogeneity ranges. While τ1 was investigated by single crystal X-ray diffraction, τ2 and τ3 were identified from their powder diffraction pattern. Ternary phase reactions and melting behaviour were studied by means of DTA. A total number of eleven invariant reactions could be derived from these data, which are one ternary eutectic reaction, six transition reactions, three ternary peritectic reactions and one maximum. Based on the measured DTA values three vertical sections at 10, 20 and 35 at.% Ni were constructed. Additionally, all experimental results were combined to a ternary reaction scheme (Scheil diagram) and a liquidus surface projection.

A parametric neutron Bragg edge imaging study of additively manufactured samples treated by laser shock peening.

Laser powder bed fusion is an additive manufacturing technique extensively used for the production of metallic components. Despite this process has reached a status at which parts are produced with mechanical properties comparable to those from conventional production, it is still prone to introduce detrimental tensile residual stresses towards the surfaces along the building direction, implying negative consequences on fatigue life and resistance to crack formations. Laser shock peening (LSP) is a promising method adopted to compensate tensile residual stresses and to introduce beneficial compressive residual stress on the treated surfaces. Using neutron Bragg edge imaging, we perform a parametric study of LSP applied to 316L steel samples produced by laser powder bed fusion additive manufacturing. We include in the study the novel 3D-LSP technique, where samples are LSP treated also during the building process, at intermediate build layers. The LSP energy and spot overlap were set to either 1.0 or 1.5 J and 40[Formula: see text] or 80[Formula: see text] respectively. The results support the use of 3D-LSP treatment with the higher LSP laser energy and overlap applied, which showed a relative increase of surface compressive residual stress (CRS) and CRS depth by 54[Formula: see text] and 104[Formula: see text] respectively, compared to the conventional LSP treatment.

Laser Powder Bed Fusion of Metal Coated Copper Powders.

Laser powder bed fusion (L-PBF) of copper alloys with high copper content is difficult due to the high infrared reflectivity and thermal conductivity of these alloys. In this study a simple and scalable method for coating copper powder with tin and nickel is presented, and suggested as an alloying strategy for such alloys. The coated powders were processed in a commercial L-PBF-machine at various scanning speeds. The samples made from coated powders show a lower amount of porosity compared to samples made from in-situ alloyed powders of similar composition.

Supervised deep learning for real-time quality monitoring of laser welding with X-ray radiographic guidance.

Laser welding is a key technology for many industrial applications. However, its online quality monitoring is an open issue due to the highly complex nature of the process. This work aims at enriching existing approaches in this field. We propose a method for real-time detection of process instabilities that can lead to defects. Hard X-ray radiography is used for the ground truth observations of the sub-surface events that are critical for the quality. A deep artificial neural network is applied to reveal the unique signatures of those events in wavelet spectrograms from the laser back-reflection and acoustic emission signals. The autonomous classification of the revealed signatures is tested on real-life data, while the real-time performance is reached by means of parallel computing. The confidence of the quality classification ranges between 71% and 99%, with a temporal resolution down to 2 ms and a computation time per classification task as low as 2 ms. This approach is a new paradigm in the digitization of industrial processes and can be exploited to provide feedbacks in a closed-loop quality control system.

In Situ and Ex Situ Characterization of the Microstructure Formation in Ni-Cr-Si Alloys during Rapid Solidification-Toward Alloy Design for Laser Additive Manufacturing.

Laser beam-based deposition methods such as laser cladding or additive manufacturing of metals promises improved properties, performance, and reliability of the materials and therefore rely heavily on understanding the relationship between chemical composition, rapid solidification processing conditions, and resulting microstructural features. In this work, the phase formation of four Ni-Cr-Si alloys was studied as a function of cooling rate and chemical composition using a liquid droplet rapid solidification technique. Post mortem x-ray diffraction, scanning electron microscopy, and in situ synchrotron microbeam X-ray diffraction shows the present and evolution of the rapidly solidified microstructures. Furthermore, the obtained results were compared to standard laser deposition tests. In situ microbeam diffraction revealed that due to rapid cooling and an increasing amount of Cr and Si, metastable high-temperature silicides remain in the final microstructure. Due to more sluggish interface kinetics of intermetallic compounds than that of disorder solid solution, an anomalous eutectic structure becomes dominant over the regular lamellar microstructure at high cooling rates. The rapid solidification experiments produced a microstructure similar to the one generated in laser coating thus confirming that this rapid solidification test allows a rapid pre-screening of alloys suitable for laser beam-based processing techniques.

Author Correction: Supervised deep learning for real-time quality monitoring of laser welding with X-ray radiographic guidance.

An amendment to this paper has been published and can be accessed via a link at the top of the paper.

Fatigue and cyclic deformation behaviour of surface-modified titanium alloys in simulated physiological media.

In this investigation, the cyclic deformation behaviour of the binary titanium alloys Ti-6Al-4V and Ti-6Al-7Nb was characterized in axial stress-controlled constant amplitude and load increase tests as well as in rotating bending tests. The influence of different clinically relevant surface treatments (polishing, corundum grit blasting, thermal and anodic oxidizing) on the fatigue behaviour was investigated. All tests were realized in oxygen-saturated Ringer's solution. The cyclic deformation behaviour was characterized by mechanical hysteresis measurements. In addition, the change of the free corrosion potential and the corrosion current during testing in simulated physiological media indicated surface damages such as slip bands, intrusions and extrusions or finally microcracks. Microstructural changes on the specimen surfaces were examined by scanning electron microscopy (SEM).