Exquisite Energy Savings at Cold Metal Forming of Threads through the Application of Polymers.

One of the global problems today is energy-its production and distribution. As the human population grows, the consumption of energy rises simultaneously. However, the natural sources are limited, and so the focus on power savings becomes more and more important. One of the ways to reduce consumption is the use of effective lubricants and tribological fluids in industry, especially in processes with high demands on energy but high quality of products as well. Forming is a typical example of such technology, and the application of polymers seems to be a very important challenge, because the application of straight oils or lubricant with extreme pressure additives seems to be prevailing in that field. Nevertheless, the polymer lubricant should fulfill all European standards as well as the environmental and ecological limitations with respect to health and the natural environment and its recycling and disposal. This paper is focused on the forming technology of threads and the application of selected polymers to the forming process. The measured and quantified criteria are torque and force loadings, energy consumption, and quality of the produced surfaces. Kistler dynamometers, scanning electron microscopy, and advanced surface topography with the use of Alicona IF-G5 were applied to assess all aspects of the tribological and energy aspects of six modern process fluids, three lubricating pastes, and two fluid modifications. The results show that the polymer synthetic lubricant (at volume concentration 20% in water) can reduce the total energy consumption by up to 40% per forming cycle (in mean values) at average surface roughness below 0.8 µm.

Assessment of Retained Austenite in Fine Grained Inductive Heat Treated Spring Steel.

Advanced thermomechanical hot rolling is becoming a widely used technology for the production of fine-grained spring steel. Different rapid phase transformations during the inductive heat treatment of such steel causes the inhomogeneous mixture of martensitic, bainitic, and austenitic phases that affects the service properties of the steel. An important task is to assess the amount of retained austenite and its distribution over the cross-section of the inductive quenched and tempered wire in order to evaluate the mechanical properties of the material. Three different analytical methods were used for the comparative quantitative assessment of the amount of retained austenite in both the core and rim areas of the sample cross-section: neutron diffraction-for the bulk of the material, Mössbauer spectroscopy-for measurement in a surface layer, and the metallographic investigations carried by the EBSD. The methods confirmed the excessive amount of retained austenite in the core area that could negatively affect the plasticity of the material.

Fatigue Life of 7475-T7351 Aluminum After Local Severe Plastic Deformation Caused by Machining.

The fatigue properties of thermo-mechanically treated and machined aluminum alloy 7475-T7351 have been studied. The applied advanced machining strategy induced intensive plastic deformation on the machined surface under defined cutting conditions. Therefore, a detailed study of 3D surface topography was performed. Advanced characterization of the material structure and electron back scattered diffraction mapping of selected chemical phases were performed, as well as energy dispersive X-ray analysis of the surface. Advanced mechanical properties of the material were investigated in situ with a scanning electron microscope that was equipped with a unique tensile fixture. The fatigue results confirmed an evident dispersion of the data, but the mechanism of crack nucleation was established. Fracture surface analysis showed that the cracks nucleated at the brittle secondary particles dispersed in the material matrix. The surface topography of samples that had been machined in wide range of cutting/deformation conditions by milling has not proved to be a decisive factor in terms of the fatigue behavior. The incoherent interface and decohesion between the alumina matrix and the brittle secondary phases proved to significantly affect the ultimate strength of the material. Tool engagement also affected the fatigue resistance of the material.

Mitigating Curtaining Artifacts During Ga FIB TEM Lamella Preparation of a 14 nm FinFET Device.

We report on the mitigation of curtaining artifacts during transmission electron microscopy (TEM) lamella preparation by means of a modified ion beam milling approach, which involves altering the incident angle of the Ga ions by rocking of the sample on a special stage. We applied this technique to TEM sample preparation of a state-of-the-art integrated circuit based on a 14-nm technology node. Site-specific lamellae with a thickness <15 nm were prepared by top-down Ga focused ion beam polishing through upper metal contacts. The lamellae were analyzed by means of high-resolution TEM, which showed a clear transistor structure and confirmed minimal curtaining artifacts. The results are compared with a standard inverted thinning preparation technique.

Ultrasmooth metallic foils for growth of high quality graphene by chemical vapor deposition.

Synthesis of graphene by chemical vapor deposition is a promising route for manufacturing large-scale high-quality graphene for electronic applications. The quality of the employed substrates plays a crucial role, since the surface roughness and defects alter the graphene growth and cause difficulties in the subsequent graphene transfer. Here, we report on ultrasmooth high-purity copper foils prepared by sputter deposition of Cu thin film on a SiO2/Si template, and the subsequent peeling off of the metallic layer from the template. The surface displays a low level of oxidation and contamination, and the roughness of the foil surface is generally defined by the template, and was below 0.6 nm even on a large scale. The roughness and grain size increase occurred during both the annealing of the foils, and catalytic growth of graphene from methane (≈1000 °C), but on the large scale still remained far below the roughness typical for commercial foils. The micro-Raman spectroscopy and transport measurements proved the high quality of graphene grown on such foils, and the room temperature mobility of the graphene grown on the template stripped foil was three times higher compared to that of one grown on the commercial copper foil. The presented high-quality copper foils are expected to provide large-area substrates for the production of graphene suitable for electronic applications.