New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways.

The aim of this study was to investigate the spall propagation mechanism in ball bearing raceways using physics-based models. Spalling is one of the most common types of bearing failures that can lead to catastrophic failure. This research takes a step forward toward developing a prognostic tool for ball bearings. It is first necessary to understand the spall progression process in order to formulate a constitutive law of spall deterioration and to estimate the amount of remaining useful life. Fragment formation in the vicinity of the spall edge was found to consist of surface and sub-surface cracks that eventually coalesce, and a fragment is released from the raceway, based on naturally-developed spalls. Here, we describe a physics-based model, integrating a dynamic model with a finite element one to simulate this process. A continuum damage mechanics (CDM) approach and fracture mechanics tools were embedded into the finite element model to simulate the damage propagation. The formation of cracks in the vicinity of the spall (surface and sub-surface cracks) were studied using this effective stress CDM model, and the propagation of the cracks was examined using two approaches: a fracture mechanics approach and an accumulated inelastic hysteresis energy CDM approach. The latter also predicts the overall process of a single fragment release. The simulation results of the spall propagation models are supported by experimental results of spalls from both laboratory experimental bearings and an in-service Sikorsky CH-53 helicopter swashplate bearing. The results obtained show that the impact of the ball on the spall edge affects the crack propagation and the appearance of the surface and sub-surface cracks. Both release the residual stresses and cause crack propagation until a fragment is released.

The Influence of Time, Atmosphere and Surface Roughness on the Interface Strength and Microstructure of AA6061-AA1050 Diffusion Bonded Components.

Diffusion bonding experiments followed by tensile testing were conducted on cylindrical pairs of AA6061-AA1050 aluminum alloys. The influence of bonding time, atmosphere and surface roughness on the resulting interface strength was studied. Metallurgical characterization was performed to study the quality of the bonded interface for different process conditions, and also to investigate the process of oxide formation on the specimen surface. Finite element analysis of the bonding experiments was used to study the thermo-mechanical fields during the bonding process. Using a cohesive zone approach for modelling the bonded interface, the bond strength for the different process parameters was quantified. The results demonstrate that high bond strength can be obtained even for specimens bonded in an air furnace, provided the surface roughness is low. When the surface roughness increases, specimens bonded in air show a reduction in interface strength, which is not observed for specimens bonded in vacuum. Inspection of the bonded interface suggests that this reduction in interface strength can be attributed to oxidation and pockets of air trapped between the asperities of the contact surface, which hinder diffusion and plastic flow.

Polycrystalline PbTe:In Films on Amorphous Substrate: Structure and Physical Properties.

Polycrystalline PbTe:In films on a polyimide substrate were obtained and investigated. Their structural and transport properties in a wide range of temperatures (10-300 K) were studied. The unique feature of In impurity in PbTe is the stabilization of the Fermi level (pinning effect) that allowed for the preparation polycrystalline films with the same carrier concentration. We found that heat treatment in an argon atmosphere does not change the average grain size and carrier concentration for as-grown films but greatly increases the Hall mobility and the electron mean free path. By comparing the mobility in the bulk and in the film after heat treatment, we extracted the value of the mobility that arises due to scattering at the grain boundary barriers. The ultimate goal of the present study is the development of these films in designing portable uncooled photodetectors for the mid-IR range.

Effect of Surface Dissolution on Dislocation Activation in Stressed FeSi6.5 Steel.

The effects of surface dissolution on dislocation activation in FeSi6.5 steel are quantitatively studied by analyzing the stress relaxation data using the thermal activation theory of dislocation. The stressed FeSi6.5 steel sample in acid solutions (H2SO4 or HCl) exhibits a much higher rate of stress reduction with time compared with that in air or deionized water. As the stress relaxation time is prolonged to 20 min, the relaxation rates are 0.055 MPa·min-1 in water and 0.074, 0.1, 0.11 MPa·min-1 in H2SO4 solutions with pH 4, 3, and 2, respectively. In a NaCl solution, a slight increase in the relaxation rate compared with air was found. Higher acidity (lower pH) of the solution inducing higher stress relaxation rate implies the softening is associated with the anodic dissolution of the surface layer and the accelerated (additional) flow of dislocations. The analyses using the thermal activation theory of dislocation during relaxation reveal the mechanism for the accelerated plastic flow induced by the corrosive medium. The variations of these parameters are related to the relaxation of the stress field of dislocations and the weakening of interaction between slip dislocations and short-range obstacles. The chemomechanical effect, including a reduction in apparent activation energy and a decrease in waiting time for dislocation to obtain sufficient thermal activation energy to cross obstacles, causes an increase in the stress relaxation rate (plastic strain rate). The study confirms that surface dissolution accelerates the plastic flow of metals and supports the view that surface dissolution facilitates dislocation slip. It is helpful to improve the formability of brittle metals.

Experimental Investigation of the Spall Propagation Mechanism in Bearing Raceways.

This article investigates the spall propagation mechanism for ball bearing raceways by focusing on an experimental investigation of cracks that evolve in the vicinity of the spall edge. Understanding the spall propagation mechanism is an important step towards developing a physics-based prognostic tool for ball bearings. This research reflects an investigation of different spall sizes that propagate naturally both in laboratory experiments and in the field. By using a combined model of a rigid body dynamic model and a finite element model that simulates the rolling element-spall edge interaction, our results shed light on the material behavior (displacements, strains, and stresses) that creates an environment for crack formation and propagation. With the support of the experimental results and the rolling element-spall edge interaction model results, three stages of the mechanism that control fragment release from the raceway were identified. In Stage one, sub-surface cracks appear underneath the spall trailing edge. In Stage two, cracks appear in front of the trailing edge of the spall and, in Stage three, the cracks propagate until a fragment is released from the raceway. These stages were observed in all the tested bearings. In addition, other phenomena that affect the propagation of the cracks and the geometry of the fragment were observed, such as blistering and plastic deformation. We include an explanation of what determines the shape of the fragments.

Tailoring Microstructure and Mechanical Properties of Additively-Manufactured Ti6Al4V Using Post Processing.

Additively-manufactured Ti-6Al-4V (Ti64) exhibits high strength but in some cases inferior elongation to those of conventionally manufactured materials. Post-processing of additively manufactured Ti64 components is investigated to modify the mechanical properties for specific applications while still utilizing the benefits of the additive manufacturing process. The mechanical properties and fatigue resistance of Ti64 samples made by electron beam melting were tested in the as-built state. Several heat treatments (up to 1000 °C) were performed to study their effect on the microstructure and mechanical properties. Phase content during heating was tested with high reliability by neutron diffraction at Los Alamos National Laboratory. Two different hot isostatic pressings (HIP) cycles were tested, one at low temperature (780 °C), the other is at the standard temperature (920 °C). The results show that lowering the HIP holding temperature retains the fine microstructure (~1% ß phase) and the 0.2% proof stress of the as-built samples (1038 MPa), but gives rise to higher elongation (~14%) and better fatigue life. The material subjected to a higher HIP temperature had a coarser microstructure, more residual ß phase (~2% difference), displayed slightly lower Vickers hardness (~15 HV10N), 0.2% proof stress (~60 MPa) and ultimate stresses (~40 MPa) than the material HIP'ed at 780 °C, but had superior elongation (~6%) and fatigue resistance. Heat treatment at 1000 °C entirely altered the microstructure (~7% ß phase), yield elongation of 13.7% but decrease the 0.2% proof-stress to 927 MPa. The results of the HIP at 780 °C imply it would be beneficial to lower the standard ASTM HIP temperature for Ti6Al4V additively manufactured by electron beam melting.

Improved Formability of Mg-AZ80 Alloy under a High Strain Rate in Expanding-Ring Experiments.

Magnesium alloys offer a favored alternative to steels and aluminum alloys due to their low density and relatively high specific strength. Their application potentials are, however, impeded by poor formability at room temperature. In the current work, improved formability for the commercial magnesium AZ80 alloy was attained through the application of the high-rate electro-magnetic forming (EMF) technique. With the EMF system, elongation of 0.2 was achieved while only 0.11 is obtained through quasistatic loading. Systematic microstructural and textural investigations prior, during and post deformation under high strain-rate experiments were carried out using electron back-scattered diffraction (EBSD) and other microscopic techniques. The analysis indicates that enhanced elongation is achieved as a result of the combination of deformation, comprising basal and non-basal slip systems, twinning and dynamic recrystallization. An adopted EMF-forming technique is tested which results in enhanced elongation without failure and a higher degree of dynamically annealed microstructure.

The Mechanical Behavior of HAVAR Foils Using the Small Punch Technique.

Prediction of the mechanical behavior of thin foils (~25 µm) requires special characterization techniques. The current work is focused on the mechanical and microstructural characterization of 25 µm HAVAR alloy foils following annealing, cold rolling, and subsequent heat treatments, using small punch testing (SPT), X-ray diffraction (XRD), and transmission-scanning electron microscopy (TEM). The SPT technique revealed that the annealed specimens exhibited the largest maximal load to failure and deformation (more than two-fold), compared to the cold rolled and heat treated conditions. The microscopy observations revealed high dislocation density following cold rolling and subsequent heat treatments. Following annealing, a cubic crystallographic structure (FCC) with equiaxed grains and a limited dislocation population was observed. Following cold rolling and subsequent thermal treatment, a preferred orientation texture (i.e., 'deformation texture') was observed with a very high dislocation density. The correlation between the mechanical behavior and the microstructural observations is discussed in detail.

A stiffness switch in human immunodeficiency virus.

After budding from the cell, human immunodeficiency virus (HIV) and other retrovirus particles undergo a maturation process that is required for their infectivity. During maturation, HIV particles undergo a significant internal morphological reorganization, changing from a roughly spherically symmetric immature particle with a thick protein shell to a mature particle with a thin protein shell and conical core. However, the physical principles underlying viral particle production, maturation, and entry into cells remain poorly understood. Here, using nanoindentation experiments conducted by an atomic force microscope (AFM), we report the mechanical measurements of HIV particles. We find that immature particles are more than 14-fold stiffer than mature particles and that this large difference is primarily mediated by the HIV envelope cytoplasmic tail domain. Finite element simulation shows that for immature virions the average Young's modulus drops more than eightfold when the cytoplasmic tail domain is deleted (930 vs. 115 MPa). We also find a striking correlation between the softening of viruses during maturation and their ability to enter cells, providing the first evidence, to our knowledge, for a prominent role for virus mechanical properties in the infection process. These results show that HIV regulates its mechanical properties at different stages of its life cycle (i.e., stiff during viral budding versus soft during entry) and that this regulation may be important for efficient infectivity. Our report of this maturation-induced "stiffness switch" in HIV establishes the groundwork for mechanistic studies of how retroviral particles can regulate their mechanical properties to affect biological function.

Measurement of the mechanical properties of isolated tectorial membrane using atomic force microscopy.

The tectorial membrane (TM) is an extracellular matrix situated over the sensory cells of the cochlea. Its strategic location, together with the results of recent TM-specific mutation studies, suggests that it has an important role in the mechanism by which the cochlea transduces mechanical energy into neural excitation. A detailed characterization of TM mechanical properties is fundamental to understanding its role in cochlear mechanics. In this work, the mechanical properties of the TM are characterized in the radial and longitudinal directions using nano- and microindentation experiments conducted by using atomic force spectroscopy. We find that the stiffness in the main body region and in the spiral limbus attachment zone does not change significantly along the length of the cochlea. The main body of the TM is the softest region, whereas the spiral limbus attachment zone is stiffer, with the two areas having averaged Young's modulus values of 37 +/- 3 and 135 +/- 14 kPa, respectively. By contrast, we find that the stiffness of the TM in the region above the outer hair cells (OHCs) increases by one order of magnitude in the longitudinal direction, from 24 +/- 4 kPa in the apical region to 210 +/- 15 kPa at the basilar end of the TM. Scanning electron microscopy analysis shows differences in the collagen fiber arrangements in the OHC zone of the TM that correspond to the observed variations in mechanical properties. The longitudinal increase in TM stiffness is similar to that found for the OHC stereocilia, which supports the existence of mechanical coupling between these two structures.

Mechanical properties of murine leukemia virus particles: effect of maturation.

After budding from the host cell, retroviruses undergo a process of internal reorganization called maturation, which is prerequisite to infectivity. Viral maturation is accompanied by dramatic morphological changes, which are poorly understood in physical/mechanistic terms. Here, we study the mechanical properties of live mature and immature murine leukemia virus particles by indentation-type experiments conducted with an atomic force microscope tip. We find that both mature and immature particles have an elastic shell. Strikingly, the virus shell is twofold stiffer in the immature (0.68 N/m) than the mature (0.31 N/m) form. However, finite-element simulation shows that the average Young's modulus of the immature form is more than fourfold lower than that of the mature form. This finding suggests that per length unit, the protein-protein interactions in the mature shell are stronger than those in the immature shell. We also show that the mature virus shell is brittle, since it can be broken by application of large loading forces, by firm attachment to a substrate, or by repeated application of force. Our results are the first analysis of the mechanical properties of an animal virus, and demonstrate a linkage between virus morphology and mechanical properties.

Self-assembled peptide nanotubes are uniquely rigid bioinspired supramolecular structures.

We recently presented a novel class of self-assembled diphenylalanine-based peptide nanotubes. Here, for the first time, we present their mechanical properties, which we directly measured through indentation type experiments using atomic force microscopy. We find that the averaged point stiffness of the nanotubes is 160 N/m, and that they have a correspondingly high Young's modulus of approximately 19 GPa, as calculated by finite element analysis. This high value places these peptide nanotubes among the stiffest biological materials presently known, making them attractive building blocks for the design and assembly of biocompatible nanodevices.