Formation and Characterization of the Recast Layer Formed on Inconel 718 during Wire Electro Discharge Machining.

The present work investigates the formation and microstructural and micro-mechanical characterization of the recast layer that formed on Inconel 718 alloy in the course of the wire electro-discharge machining (WEDM). The as-machined surface contains globules, shallow cracks, and re-deposition of molten materials, together with the elements from the decomposition of wire electrode and electrolyte, which does not exceed beyond the surface of the recast layer. Under presently investigated machining parameters, the recast layer was about 6.2 ± 2.1 µm thick. There was no presence of a heat-affected zone (HAZ), as otherwise indicated for other hard-to-cut materials. The transmission electron microscopy (TEM) and electron back-scattered diffraction (EBSD) investigations show that the microstructure of the recast layer is similar to that of bulk alloy. Micro-mechanical characterizations of the recast layer were investigated via in-situ micro-pillar compression on the micro-pillars fabricated on the recast layer. The strength of the superficial layer (1151.6 ± 51.1 MPa) was about 2.2 times higher than that of the base material (523.2 ± 22.1 MPa), as revealed by the in-situ micro-pillar compression.

In-situ SEM micropillar compression of porous and dense zirconia materials.

The reduction of failure rates of small-sized zirconia devices depends on the understanding of their micromechanical properties. This paper reports the micromechanical behaviors of porous and dense zirconia materials using in-situ micropillar compression with a flat diamond indenter in a scanning electron microscope (SEM). Porous and dense zirconia micropillars were made using focused ion beam (FIB) milling technique in the SEM. They were then subject to in-situ SEM compression to identify their Young's moduli, yield stresses, plastic deformation, compressive and fracture strengths, damage accumulations, and failure mechanisms. We found that while both porous and dense zirconia microstructures exhibited plastic behaviors, the former had much lower Young's moduli, strengths (yield, compression and fracture), resilience and toughness but higher ductility, resulting in significant buckling than the latter. In plastic regions, alternative strain softening and hardening may have caused stress variations in porous zirconia while dislocation movement contributed to strain hardening in dense zirconia. Although both zirconia materials had quasi-brittle failures, there were different damage mechanisms. The quasi-brittle failure for porous state was due to mushrooming buckling damage driven by breaking of weak interconnected pore networks, resulting in severe compaction and pulverization, microcracks and material piling. The quasi-brittle failure for dense state was identified as plastic crushing damage, involving microcrack initiation and propagation, cleavage and intergranular fractures, and delamination. The mechanical properties of porous and dense zirconia micropillars investigated contributed to the knowledge on deformation and damage mechanisms of zirconia materials at the small scale.

Vacancy-Induced Temperature-Dependent Thermal and Magnetic Properties of Holmium-Substituted Bismuth Ferrite Nanoparticle Compacts.

Multiferroics have gained widespread acceptance for room-temperature applications such as in spintronics, ferroelectric random access memory, and transistors because of their intrinsic magnetic and ferroelectric coupling. However, a comprehensive study, establishing a correlation between the magnetic and thermal transport properties of multiferroics, is still missing from the literature. To fill the void, this work reports the temperature-dependent thermal and magnetic properties of holmium-substituted bismuth ferrite (BiFeO3) and their dependencies on oxygen vacancies and structural modifications. Two distinct magnetic transitions on temperature-dependent magnetic and heat capacity responses are identified. Experimental analysis suggests that the excess of oxygen vacancies shifts the magnetic transition temperature by ∼64 K. The holmium substitution-induced structural modification increases BiFeO3 heat capacity by 30% up to the antiferromagnetic phase transition temperature. Furthermore, an unsaturated heat capacity even at temperatures as high as 850 K is observed and is ascribed to anharmonicity and partial densification of the nanoparticles used during heat capacity measurements. The room-temperature thermal conductivity of BiFeO3 is ∼0.33 ± 0.11 W m-1 K-1 and remains unchanged at high temperatures due to defect scattering from porosities.

In-situ SEM cyclic nanoindentation of pre-sintered and sintered zirconia materials.

Efficient diamond machining of zirconia requires a comprehensive understanding of repetitive diamond indentation mechanics. This paper reports on in-situ cyclic nanoindentations of pre-sintered and sintered zirconia materials performed inside a scanning electron microscope (SEM). In-situ SEM imaging of cyclic indentation processes and high-magnification SEM mapping of indentation imprints were conducted. The elastic and plastic behaviors of pre-sintered and sintered zirconia materials were investigated as a function of the cyclic nanoindentation number using the Sakai and Sakai-Nowak models. For pre-sintered zirconia, cyclic nanoindentation induced quasi-plastic deformation, causing localized agglomeration of zirconia crystals with microcracks and large cracking along the indentation edge. Severely compressed, fragmented, and pulverized zirconia crystals and smeared surfaces were also observed. For sintered zirconia, shear bands dominated quasi-plastic deformation with the formation of edge pile-ups and localized microfractures occurred at indentation apex and diagonals. All elastic and plastic behaviors for pre-sintered and sintered zirconia materials revealed significantly microstructure-dependent. Pre-sintered zirconia yielded significantly lower contact hardness, Young's moduli, resistance to plasticity, elastic deformation components, and resistance to machining-induced cracking, and higher elastic and plastic displacements than sintered state. Meanwhile, all the behaviors for the two materials were independent from the cyclic nanoindentation number. A model was proposed for cyclic nanoindentation mechanics, revealing their cyclic indentation-induced microstructural changes in the two zirconia materials. This study advances the fundamental understanding of nanoindentation mechanics of zirconia materials.

Investigating the Efficacy of Adhesive Tape for Drilling Carbon Fibre Reinforced Polymers.

In the present research work, an effort has been made to explore the potential of using the adhesive tapes while drilling CFRPs. The input parameters, such as drill bit diameter, point angle, Scotch tape layers, spindle speed, and feed rate have been studied in response to thrust force, torque, circularity, diameter error, surface roughness, and delamination occurring during drilling. It has been found that the increase in point angle increased the delamination, while increase in Scotch tape layers reduced delamination. The surface roughness decreased with the increase in drill diameter and point angle, while it increased with the speed, feed rate, and tape layer. The best low roughness was obtained at 6 mm diameter, 130° point angle, 0.11 mm/rev feed rate, and 2250 rpm speed at three layers of Scotch tape. The circularity error initially increased with drill bit diameter and point angle, but then decreased sharply with further increase in the drill bit diameter. Further, the circularity error has non-linear behavior with the speed, feed rate, and tape layer. Low circularity error has been obtained at 4 mm diameter, 118° point angle, 0.1 mm/rev feed rate, and 2500 RPM speed at three layers of Scotch tape. The low diameter error has been obtained at 6 mm diameter, 130° point angle, 0.12 mm/rev feed rate, and 2500 rpm speed at three layer Scotch tape. From the optical micro-graphs of drilled holes, it has been found that the point angle is one of the most effective process parameters that significantly affects the delamination mechanism, followed by Scotch tape layers as compared to other parameters such as drill bit diameter, spindle speed, and feed rate.

Microstructural responses of Zirconia materials to in-situ SEM nanoindentation.

Development of optimal shaping processes for pre-sintered and sintered zirconia materials requires a fundamental understanding of damage and deformation mechanisms at small-scale contacts with diamond tools. This paper reports on responses of zirconia materials with distinct microstructures to nanoindentation associated with diamond machining using a Berkovich diamond indenter. In-situ nanoindentation was performed in a scanning electron microscope (SEM) and in-process filmed to record small contact events. Indentation morphology was SEM-mapped at high-magnifications. Although both pre-sintered porous and sintered dense zirconia materials mechanically revealed the quasi-plastic behavior in indentation, there were distinct responses of the two materials to quasi-plasticity at the microstructural level. For pre-sintered porous zirconia, the quasi-plasticity was attributed to shear faults resulting from breaking pore networks as microstructurally discrete interfaces, to lead to compression, fragmentation, pulverization and microcracking of zirconia crystals in indentation imprints. In contrast, sintered dense zirconia had shear band-induced quasi-plastic deformation, accompanied with localized tensile microfracture. A material index associated with the mechanical properties ranked the lower quasi-plasticity for pre-sintered porous zirconia than its sintered dense state, predicting more machining-induced damage in the former than the latter. Significantly higher indentation imprint volumes induced in indented pre-sintered porous zirconia than sintered dense state previses higher machining efficiency for the former than the latter. The microstructure-dependent indentation mechanisms provide the fundamental knowledge into micromechanics of abrasive machining of zirconia materials and may lead to a new microstructural design for zirconia materials to achieve a balanced machining efficiency and damage control.

Tribological Properties of Chromium Nitride on the Cylinder Liner under the Influence of High Temperature.

The chromium nitride coating is a hard coating used to improve the sliding friction and wear behavior and is applied to engine components in various operating conditions even at an elevated temperature. In this study, chromium nitride was deposited by a physical vapor deposition process onto the cast iron substrate. All tribological tests were performed on linear reciprocating tribometer with a stroke length of 5 mm in a dry condition at variable temperature levels of 28 °C, 100 °C, 200 °C, and of 300 °C corresponding to loads of 10 N, 20 N, 30 N, and 40 N against the cylinder liner material. The worn surfaces of chromium nitride(CrN) coatings after friction tests were analyzed by scanning electron microscope (SEM) and energy-dispersive spectroscopy (EDS). The results showed that friction coefficients (COF) ranged from 0.93 to 0.34 from room temperature to 300 °C against the cylinder liner material as a counter-body of 6 mm in diameter; higher temperature results in the positive tribological performance of CrN, with at least 0.34 COF at 300 °C. The wear mechanisms of CrN and counter-body surfaces are abrasive wear accompanied by the slight oxidation. This study guides the wear behavior of cylinder liner coatings in an environment similar to the engine.