Multi-layer laser cutting of electrical steel sheets applied to electric machine laminations.

With the move away from fossil fuels, the importance of electric machines is increasing. This is particularly the case within major engineering sectors such as the automotive industry. There is therefore a need to further develop processes which will allow for the diverse range of machining operations and large volume manufacture which will be required to overcome the inherent challenges in making this transition. Several critical components of an electric machine, such as the rotor and the stator, are made from electrical grade steel. This is a steel where the composition and processing acts to optimise the magnetic and other properties for the application. The steel is processed as thin sheet laminations and then stacked, to reduce the losses which occur within it due to the generation of eddy currents. The laminations need to be cut to shape, in an operation currently carried out most frequently by stamping from a sheet, but which could be done with greater flexibility by laser cutting (due, for example, to the absence of tooling). In laser cutting the possibility exists to perform cutting operations using what we call here a polystromata method, where several sheets are stacked and then cut simultaneously, increasing the efficiency of the operation. To date there have been few reports on this type of laser cutting process, and none that provide detail on the effect that the number of layers in a cutting stack has on critical parameters, such as the edge quality post cutting and the magnetic performance of the sheets. In this work we perform an experimental study of the process and report data in these measures, quantifying the decrease in performance as the stack increases in number of sheets.

Modelled optimisation approaches for laser cutting sheets simultaneously applied to EV component production.

This paper proposes that laser cutting has potential as a viable alternative to stamping for mass manufacture of thin steel components such as stator and rotor components in the electric automotive sector. Current laser cutting processes are much less efficient than stamping. However, laser cutting is much more flexible and is used for small batches and one-off production. This paper assesses the potential of performing laser cutting operations of multiple sheets or layers simultaneously. This method is referred to herein as polystromata cutting. A numerical model is used to assess the manufacturing performance of stamping, traditional laser cutting and polystromata laser cutting. Polystromata laser cutting is shown to be capable of producing parts at 37% less cost than stamping. However, polystromata remains slower than stamping, taking 79% more time to produce each stator stack. Through this research it has been identified that optimisation of polystromata processes is more complex and performance efficiency varies wildly dependent on manufacturing set-up. This work aims to provide a best practice optimisation methodology for polystromata laser cutting by assessing results using different manufacturing objectives.

Influence of Structural Porosity and Martensite Evolution on Mechanical Characteristics of Nitinol via In-Silico Finite Element Approach.

Nitinol (NiTi) alloys are gaining extensive attention due to their excellent mechanical, superelasticity, and biocompatibility properties. It is difficult to model the complex mechanical behavior of NiTi alloys due to the solid-state diffusionless phase transformations, and the differing elasticity and plasticity presenting from these two phases. In this work, an Auricchio finite element (FE) model was used to model the mechanical behavior of superelastic NiTi and was validated with experimental data from literature. A Representative Volume Element (RVE) was used to simulate the NiTi microstructure, and a microscale study was performed to understand how the evolution of martensite phase from austenite affects the response of the material upon loading. Laser Powder Bed Fusion (L-PBF) is an effective way to build complex NiTi components. Porosity being one of the major defects in Laser Powder Bed Fusion (L-PBF) processes, the model was used to correlate the macroscale effect of porosity (1.4-83.4%) with structural stiffness, dissipated energy during phase transformations, and damping properties. The results collectively summarize the effectiveness of the Auricchio model and show that this model can aid engineers to plan NiTi processing and operational parameters, for example for heat pump, medical implant, actuator, and shock absorption applications.

High Entropy Alloys as Filler Metals for Joining.

In the search for applications for alloys developed under the philosophy of the High Entropy Alloy (HEA)-type materials, the focus may be placed on applications where current alloys also use multiple components, albeit at lower levels than those found in HEAs. One such area, where alloys with complex compositions are already found, is in filler metals used for joining. In soldering (<450 °C) and brazing (>450 °C), filler metal alloys are taken above their liquidus temperature and used to form a metallic bond between two components, which remain both unmelted and largely unchanged throughout the process. These joining methods are widely used in applications from electronics to aerospace and energy, and filler metals are highly diverse, to allow compatibility with a broad range of base materials (including the capability to join ceramics to metals) and a large range of processing temperatures. Here, we review recent developments in filler metals relevant to High Entropy materials, and argue that such alloys merit further exploration to help overcome a number of current challenges that need to be solved for filler metal-based joining methods.

Incorporation of HA into porous titanium to form Ti-HA biocomposite foams.

Ti foams are advanced materials with great potential for biomedical applications as they can promote bone ingrowth, cell migration and attachment through providing interconnected porous channels that allow the penetration of the bone-forming cells and provide them with anchorage sites. However, Ti is a bio-inert material and thus only mechanical integration is achieved between the porous implant and the surrounding tissue, not the chemical integration which would be desirable. In this work particles of a biologically active material (Hydroxyapatite, HA) are blended with titanium powder, and used to produce Ti foams through the use of Metal Injection Moulding (MIM) in combination with a space holder. This produces titanium foams with incorporated HA, potentially inducing more favourable bone response to an implant from the surrounding tissue and improving the osseointegration of the Ti foams. To be able to do this, samples need to show sufficient mechanical and biocompatibility properties, and the foams produced were assessed for their mechanical behaviour and in vitro biological response. It was found that the incorporation of high levels of HA into the Ti foams induces brittleness in the structure and reduces the load bearing ability of the titanium foams as the chemical interaction between Ti and HA results in weak ceramic phases. However, adding small amounts of HA (about 2 vol%) was found to increase the yield strength of the Ti foams by 61% from 31.6 MPa to 50.9 MPa. Biological tests were also carried out in order to investigate the suitability of the foams for biomedical applications. It was found that Ti foams both with and without HA (at the 2 vol% addition level) support calcium and collagen production and have a good level of biocompatibility, with no significant difference observed between samples with and without the HA addition.

Selective laser melting processed Ti6Al4V lattices with graded porosities for dental applications.

Dental implants need to support good osseointegration into the surrounding bone for full functionality. Interconnected porous structures have a lower stiffness and larger surface area compared with bulk structures, and therefore are likely to enable better bone-implant fixation. In addition, grading of the porosity may enable large pores for ingrowth on the periphery of an implant and a denser core to maintain mechanical properties. However, given the small diameter of dental implants it is very challenging to achieve gradations in porosity. This paper investigates the use of Selective Laser Melting (SLM) to produce a range of titanium structures with regular and graded porosity using various CAD models. This includes a novel 'Spider Web' design and lattices built on a diamond unit cell. Well-formed interconnecting porous structures were successfully developed in a one-step process. Mechanical testing indicated that the compression stiffness of the samples was within the range for cancellous bone tissue. Characterization by scanning electron microscopy (SEM) and X-ray micro-computed tomography (µCT) indicated the designed porosities were well-replicated. The structures supported bone cell growth and deposition of bone extracellular matrix.

The Effect of Electronic Structure on the Phases Present in High Entropy Alloys.

Multicomponent systems, termed High Entropy Alloys (HEAs), with predominantly single solid solution phases are a current area of focus in alloy development. Although different empirical rules have been introduced to understand phase formation and determine what the dominant phases may be in these systems, experimental investigation has revealed that in many cases their structure is not a single solid solution phase, and that the rules may not accurately distinguish the stability of the phase boundaries. Here, a combined modelling and experimental approach that looks into the electronic structure is proposed to improve accuracy of the predictions of the majority phase. To do this, the Rigid Band model is generalised for magnetic systems in prediction of the majority phase most likely to be found. Good agreement is found when the predictions are confronted with data from experiments, including a new magnetic HEA system (CoFeNiV). This also includes predicting the structural transition with varying levels of constituent elements, as a function of the valence electron concentration, n, obtained from the integrated spin-polarised density of states. This method is suitable as a new predictive technique to identify compositions for further screening, in particular for magnetic HEAs.

Casting protocols for the production of open cell aluminum foams by the replication technique and the effect on porosity.

Metal foams are interesting materials from both a fundamental understanding and practical applications point of view. Uses have been proposed, and in many cases validated experimentally, for light weight or impact energy absorbing structures, as high surface area heat exchangers or electrodes, as implants to the body, and many more. Although great progress has been made in understanding their structure-properties relationships, the large number of different processing techniques, each producing material with different characteristics and structure, means that understanding of the individual effects of all aspects of structure is not complete. The replication process, where molten metal is infiltrated between grains of a removable preform material, allows a markedly high degree of control and has been used to good effect to elucidate some of these relationships. Nevertheless, the process has many steps that are dependent on individual "know-how", and this paper aims to provide a detailed description of all stages of one embodiment of this processing method, using materials and equipment that would be relatively easy to set up in a research environment. The goal of this protocol and its variants is to produce metal foams in an effective and simple way, giving the possibility to tailor the outcome of the samples by modifying certain steps within the process. By following this, open cell aluminum foams with pore sizes of 1-2.36 mm diameter and 61% to 77% porosity can be obtained.

Formation of microporous NiTi by transient liquid phase sintering of elemental powders.

Porous metallic structures are attractive for biomedical implant applications as their open porosity simultaneously improves the degree of fixation and decreases the mismatch in stiffness between bone and implant, improving bonding and reducing stress-shielding effects respectively. NiTi alloys exhibit both the shape memory effect and pseudoelasticity, and are of particular interest, though they pose substantial problems in their processing. This is because the shape memory and pseudoelastic behaviours are exceptionally sensitive to the presence of oxygen, and other minor changes in alloy chemistry. Thus in processing careful control of composition and contamination is vital. In this communication, we investigate these issues in a novel technique for producing porous NiTi parts via transient liquid phase sintering following metal injection moulding (MIM) of elemental Ni and Ti powders, and report a new mechanism for pore formation in the powder processing of metallic materials from elemental powders.