Dynamic Mechanical Properties and Modified Johnson-Cook Model Considering Recrystallization Softening for Nickel-Based Powder Metallurgy Superalloys.

The material undergoes high temperature and high strain rate deformation process during the cutting process, which may induce the dynamic recrystallization behavior and result in the evolution of dynamic mechanical properties of the material to be machined. In this paper, the modified Johnson-Cook (J-C) model for nickel-based powder metallurgy superalloy considering dynamic recrystallization behavior in high strain rate and temperature is proposed. The dynamic mechanical properties of the material under different strain rates and temperature conditions are obtained by quasi-static compression test and split Hopkinson pressure bar (SHPB) test. The coefficients of the modified J-C model are obtained by the linear regression method. The modified model is verified by comparison with experimental and model prediction results. The results show that the modified J-C model proposed in this paper can accurately describe the mechanical properties of nickel-based powder metallurgy superalloys at high temperatures and high strain rates. This provides help for studying the cutting mechanism and finite element simulation of nickel-based powder metallurgy superalloy.

Chatter Stability Prediction for Deep-Cavity Turning of a Bent-Blade Cutter.

The bent-blade cutter is widely used in machining typical deep-cavity parts such as turbine discs and disc shafts, but few scholars have studied the dynamics of the turning process. The existing mechanism of regenerative chatter in the metal-cutting process does not consider the influence of bending and torsional vibration, the change of tool profile and the complex machining geometry, so it cannot be directly used to reveal the underlying cause of the chatter phenomena in the deep inner cavity part turning process. This paper attempts to investigate the dynamic problem of the bent-blade cutter turning process. The dynamic model of a bent-blade cutter is proposed by considering the regenerative chatter effect. Based on the extended Timoshenko beam element (E-TBM) theory and finite element method (FEM), the coupling between the bending vibrations and the torsional vibrations, as well as the dynamic cutting forces, are modeled along the turning path. The vibration characteristics of the bending-torsion combination of cutter board and cutter bar, together with the dynamical governing equation, were analyzed theoretically. The chatter stability of a bent-blade cutter with a bending and torsion combination effect is predicted in the turning process. A series of turning experiments are carried out to verify the accuracy and efficiency of the presented model. Furthermore, the influence of cutting parameters on the cutting process is analyzed, and the results can be used to optimize the cutting parameters for suppressing machining vibration and improving machining process stability.

An overview on state-of-art of micromixer designs, characteristics and applications.

Micromixers are characterized based on characteristics such as excellent mixing efficiency, low reagent cost and flexible controllability compared with conventional reactors in terms of macro size. A variety of designs and applications of micromixers have been proposed. The focus of current reviews is restricted to micromixer structures. Each type of micromixer has characteristics corresponding to its structure, which determines the suitable application areas. This paper provides an overview connecting micromixer designs and their applications. First, the typical designs and mixing mechanisms of both passive and active micromixers are summarized. Then, application cases of micromixers, including chemical, biological and medical applications, are presented. The characteristics, including the advantages and restrictions of different micromixers, are discussed. Finally, the future perspective of micromixer design is proposed. It is predictable that micromixers will have widespread applications by integrating two or more different mixing methods together. This review would be beneficial to guide the design of micromixers applied for specific purposes.

Preparation of a novel Bi9O7.5S6/SnS composite film with improved photoelectric properties.

Atomically thin two-dimensional (2D) bismuth oxychalcogenides have been considered as promising candidates for high-speed and low-power photoelectronic devices due to their high charge carrier mobility and excellent environmental stability. However, the photoelectric performance of their bulk materials still falls short of expectations. Herein, a novel Bi9O7.5S6/SnS composite film with a type-II heterojunction was successfully prepared by combining hydrothermal and knife-coating techniques. The crystal structure, morphology, and optical properties were systematically investigated. Under 1 V bias voltage, the photocurrent of the Bi9O7.5S6/SnS composite film can be obtained as 107 µA cm-2, which is about 29.9 times and 93.9 times higher than that of bare Bi9O7.5S6 and SnS, respectively. The type-II heterojunction has played a significant role in improving the photoelectric performance of the Bi9O7.5S6/SnS composite film by facilitating the separation and transfer of photo-generated carriers. This work sheds light on the design and development of new bismuth-based composite materials for advanced photoelectric and photocatalytic applications.

Synthesis of Cu2O Nanoparticles by Ellipse Curve Micromixer.

Micromixers offer the advantage of rapid and homogeneous mixing compared with conventional macroscale reaction systems, and thus they show great potential for the synthesis of nanoparticles. An ellipse curve serpentine micromixer, which had been proposed in our prior works was employed to synthesize Cu2O nanoparticles. Cu2O are excellent photocatalysts that have been widely utilized in the degradation of organic dyes. Owing to the excellent mixing performance, the reduction of Cu(OH)2 in micromixing synthesis was more sufficient than that in conventional stirring synthesis. The Cu2O nanoparticles synthesized by micromixing had smaller size and narrower size distribution compared with those synthesized by stirring in a beaker. The smallest Cu2O nanoparticles were obtained by micromixing with Re = 100 at T = 60 °C, while the most uniform Cu2O nanoparticles were obtained at T = 80 °C owing to Ostwald ripening. Through the photocatalytic degradation experiments of Rhodamine B, the Cu2O nanoparticles synthesized by micromixing were found to have better photocatalysis than those synthesized by stirring. The research results showed that the micromixing synthesis was a more suitable choice to produce Cu2O nanoparticles with excellent photocatalysis. The ellipse curve micromixer with a simple structure and high mixing performance can be applied in the synthesis of various nanoparticles.

Gallium-based liquid metal hybridizing MoS2 nanosheets with reversible rheological characteristics and enhanced lubrication properties.

Gallium-based liquid metal (GLM) is a promising lubricant candidate due to its high load capacity and high thermal stability. However, the lubrication performance of GLM is restricted by its metallic characteristics. Herein, this work proposes a facile method to obtain a GLM@MoS2 composite by integrating GLM with MoS2 nanosheets. The incorporation of MoS2 imparts GLM with different rheological properties. Since GLM is able to be separated from the GLM@MoS2 composite and agglomerates into bulk liquid metal again in alkaline solution, the bonding between GLM and MoS2 nanosheets is reversible. Moreover, our frictional tests demonstrate that the GLM@MoS2 composite exhibits enhanced tribological performance including reduction of friction coefficient and wear rate by 46% and 89%, respectively, in contrast to the pure GLM.

Comparison of Surface Morphology and Tool Wear in the Machining of Ti-6Al-4V Alloys with Uncoated and TiAlN Tools under Dry, Minimum Quantity Lubrication, Flood Cooling, and Low-Temperature Spray Jet Cooling Conditions.

TiAlN-coated carbide tools have been used to machine Ti-6Al-4V alloys in aviation workshops. However, the effect of TiAlN coating on surface morphology and tool wear in the processing of Ti-6Al-4V alloys under various cooling conditions has not been reported in the public published literature. In our current research, turning experiments of Ti-6Al-4V with uncoated and TiAlN tools under dry, MQL, flood cooling, and cryogenic spray jet cooling conditions were carried out. The machined surface roughness and tool life were selected as the two main quantitative indexes for estimating the effects of TiAlN coating on the cutting performance of Ti-6Al-4V under various cooling conditions. The results showed that TiAlN coating makes it hard to improve the machined surface roughness and tool wear of a cutting titanium alloy at a low speed of 75 m/min compared to that achieved by uncoated tools. The TiAlN tools presented excellent tool life in turning Ti-6Al-4V at a high speed of 150 m/min compared to that achieved by uncoated tools. From the perspective of obtaining finished surface roughness and superior tool life in high-speed turning Ti-6Al-4V, the selection of TiAlN tools is feasible and reasonable under the cryogenic spray jet cooling condition. The dedicative results and conclusions of this research could guide the optimized selection of cutting tools in machining Ti-6Al-4V for the aviation industry.

Effects of surface morphology and composition of titanium implants on osteogenesis and inflammatory responses: a review.

Titanium and its alloys have been widely used in bone tissue defect treatment owing to their excellent comprehensive properties. However, because of the biological inertness of the surface, it is difficult to achieve satisfactory osseointegration with the surrounding bone tissue when implanted into the body. Meanwhile, an inflammatory response is inevitable, which leads to implantation failure. Therefore, solving these two problems has become a new research hotspot. In current studies, various surface modification methods were proposed to meet the clinical needs. Yet, these methods have not been classified as a system to guide the follow-up research. These methods are demanded to be summarized, analyzed, and compared. In this manuscript, the effect of physical signal regulation (multi-scale composite structure) and chemical signal regulation (bioactive substance) generated by surface modification in promoting osteogenesis and reducing inflammatory responses was generalized and discussed. Finally, from the perspective of material preparation and biocompatibility experiments, the development trend of surface modification in promoting titanium implant surface osteogenesis and anti-inflammatory research was proposed.

Effect of Ball Burnishing Pressure on Surface Roughness by Low Plasticity Burnishing Inconel 718 Pre-Turned Surface.

The low plasticity burnished surface roughness is significantly affected by the low plasticity burnishing (LPB) parameters. This research proposed the analytical prediction model to predict the LPBed surface roughness and optimal LPB pressure based on Hertz contact mechanics and the slip-line field theory. In this study, the surface formatted process was divided into the smoothing stage (SS) and the indentation stage (IS). The smoothing mechanism of SS and the deterioration mechanism of IS were analyzed theoretically. The analytical prediction model for the LPBed surface roughness was proposed based on Hertz contact mechanics and slip-line field theory. The proposed analytical prediction model was validated by the LPBed surface roughness of AISI 1042, and the error of the analytically predicted results was less than 13.3%. After validation, the proposed model was applied to predict the LPBed surface roughness of Inconel 718. The single-factor experiments were conducted. The error between the proposed model prediction results and experimental results was less than 7% for the LPBed surface roughness of Inconel 718. The optimal LPB pressure interval was calculated to be [12.2 MPa, 17.5 MPa], corresponding to the experimental one as [12 MPa, 18 MPa]. It indicated that the proposed model could accurately predict the LPBed surface roughness and conduct the LPB processing.

Fabrication and enhanced photoelectric properties of a novel Bi9O7.5S6/CdS composite film.

Layered bismuth oxychalcogenides have been demonstrated as potential candidates for high-speed and low-power electronics due to their outstanding environmental stability and high carrier mobility, but the photoelectric performance of bulk species is still far from satisfactory. Herein, a novel Bi9O7.5S6/CdS composite film with a type-II heterojunction has been successfully prepared by combining chemical bath deposition (CBD) and spin-coating technologies. The structure, morphology, optical and photoelectric properties of the samples were investigated systematically. The photoelectric current of the Bi9O7.5S6/CdS composite film was obtained as 32.49 µA cm-2 at 1 V, which is about 13.9-fold and 3.3-fold higher than those of bare Bi9O7.5S6 and CdS. An enhanced photoelectric response and photostability were achieved in the Bi9O7.5S6/CdS composite film, and can be appropriately attributed to the improved separation and transfer of photogenerated carriers driven by the type-II heterojunction. This work offers a promising route to develop high-performance visible-light photoelectric devices with type-II heterojunctions.

Studies on the Microstructural Evolution and Mechanical Properties of Superalloy Inconel 718 Induced by Low Plasticity Burnishing Coupled with Turning.

Mechanical surface treatments are needed to perform on components for fatigue life enhancement by introducing beneficial compressive residual stress and material strengthening. In this study, the combined turning with low plasticity burnishing (LPB) surface modification process was performed for the sake of improving mechanical properties of Inconel 718. Firstly, the evolution of microstructure and residual stress after the LPB process were analyzed with the aid of electron backscatter diffraction (EBSD) and X-ray diffraction (XRD), respectively. Secondly, the tensile behavior of treated samples was investigated through tension tests. Finally, the micro-strengthening mechanism of Inconel 718, induced by the LPB process, was revealed. The results show that the peak compressive stress is increased by a factor of 4.2 after the LPB process. The grain refinement induced by the LPB process is attributed to the increase of average misorientation and the formation of high angle grain boundaries (HAGBs). The enhanced yield strength depends on the decreased average spacing and the increased HAGBs.

Coating-thickness-dependent physical properties and cutting temperature for cutting Inconel 718 with TiAlN coated tools.

Introduction: Coating-thickness-dependent physical properties can induce different cutting temperatures with physical vapor deposition (PVD) titanium aluminum nitride (TiAlN) ceramic-coated tools. The determination of the optimal TiAlN coating thickness is important to obtain superior coating physical properties and decrease the cutting temperature of Inconel 718 alloy. Objectives: The present study investigates the effects of coating thickness on the physical properties of TiAlN coatings and the cutting temperature during the machining of Inconel 718 alloy. The optimal coating thickness is also determined. Methods: First, the direct-current-arc method was utilized to deposit PVD Ti0.55Al0.45N coatings with thickness of 1.6 µm, 2 µm, 2.5 µm, and 3 µm, onto a cemented carbide substrate. Second, the coating-thickness-dependent physical properties were characterized and estimated with a radar chart. Third, the effects of coating thickness on coating antifriction were analyzed with the tool-chip friction coefficient when cutting Inconel 718 with PVD TiAlN coated tools. Both the maximum cutting temperature generated in the chip and the cutting temperature of the tool bodies were measured for analyzation of the thermal barrier effect of coating. Finally, the topographies of the deformed chip and tool-chip contact area were obtained and investigated to determine the effects of coating thickness on the cutting temperature. Results: The tool-chip friction coefficient and coating thermal barrier effect were affected by the coating thickness. Ti0.55Al0.45N coated tools with moderate coating thickness had fine antifriction effect with Inconel 718. The thermal barrier effect of Ti0.55Al0.45N coating was positively related to the coating thickness. Conclusions: The optimal TiAlN coating thickness was determined as 2 µm, which resulted in superior physical properties and reduced the cutting temperature of Inconel 718.

The Fabrication of Porous Metal-Bonded Diamond Coatings Based on Low-Pressure Cold Spraying and Ni-Al Diffusion-Reaction.

A porous metal-bonded diamond grinding wheel has an excellent performance in precision grinding. In this research, a novel manufacturing process of porous metal-bonded diamond coating was presented. Firstly, the diamond/Ni/Al coatings (400-600 µm) were fabricated via low-pressure cold spraying and their microstructures were studied. The diamond particles in the feedstock had a core-shell structure. Secondly, the post-spray heat-treatments were set at 400 °C and 500 °C to produce pores in the cold-sprayed coatings via Ni-Al diffusion. The porosities of 400 °C and 500 °C heated coating were 8.8 ± 0.8% and 16.1 ± 0.7%, respectively. Finally, the wear behavior of porous heated coating was tested in contrast with cold-sprayed coating under the same condition via a ball-on-disc tribometer. The wear mechanism was revealed. The porous heated coating had better wear performance including chip space and slight clogging. The surface roughness of wear counterpart ground by the porous heated coating was smaller (Sa: 0.30 ± 0.07 µm) than that ground by cold-sprayed coating (Sa: 0.37 ± 0.09 µm). After ultrasonic clean, the average exposure height of diamond particles in the wear track of porous heated coating was 44.5% higher than that of cold-sprayed coating. The presented manufacturing process can contribute to fabricate high performance grinding wheels via cold spraying and porous structure controlling through Ni-Al diffusion-reaction.

A Novel Unsupervised Machine Learning-Based Method for Chatter Detection in the Milling of Thin-Walled Parts.

Data-driven chatter detection techniques avoid complex physical modeling and provide the basis for industrial applications of cutting process monitoring. Among them, feature extraction is the key step of chatter detection, which can compensate for the accuracy disadvantage of machine learning algorithms to some extent if the extracted features are highly correlated with the milling condition. However, the classification accuracy of the current feature extraction methods is not satisfactory, and a combination of multiple features is required to identify the chatter. This limits the development of unsupervised machine learning algorithms for chattering detection, which further affects the application in practical processing. In this paper, the fractal feature of the signal is extracted by structure function method (SFM) for the first time, which solves the problem that the features are easily affected by process parameters. Milling chatter is identified based on k-means algorithm, which avoids the complex process of training model, and the judgment method of milling chatter is also discussed. The proposed method can achieve 94.4% identification accuracy by using only one single signal feature, which is better than other feature extraction methods, and even better than some supervised machine learning algorithms. Moreover, experiments show that chatter will affect the distribution of cutting bending moment, and it is not reliable to monitor tool wear through the polar plot of the bending moment. This provides a theoretical basis for the application of unsupervised machine learning algorithms in chatter detection.

Effects of Machined Surface Integrity on High-Temperature Low-Cycle Fatigue Life and Process Parameters Optimization of Turning Superalloy Inconel 718.

Machined surface integrity characteristics, including surface stresses, physical-mechanical properties and metallographic structures, play important roles in the fatigue performance of machined components. This work aimed at investigating the effects of machined surface integrity on high-temperature low-cycle fatigue life. The process parameters were optimized to obtain required surface integrity and fatigue life of the turning superalloy Inconel 718. The relationships between low-cycle fatigue life and machined surface integrity characterization parameters were established based on the low-cycle fatigue tests at a high temperature (650 °C). The sensitivities of turning process parameters to high-temperature low-cycle fatigue life were analyzed, and the optimization parameters were proposed with the goal of antifatigue manufacturing. Experimental results indicated that the impact order of the characterization parameters of machined surface integrity on the high-temperature low-cycle fatigue life were the degree of work hardening RHV, the residual stress in the cutting speed direction S22, the fatigue stress concentration factor Kf, the degree of grain refinement RD and the residual stress in the feed direction S33. In the range of turning parameters of the experiments in this research, the cutting speeds could be 80~110 m/min, and the feed rate could be 0.10~0.12 mm/rev to achieve a longer high-temperature low-cycle fatigue life. The results can be used for guiding the fatigue-resistant manufacturing research of aeroengine superalloy turbine disks.

A cost-effective serpentine micromixer utilizing ellipse curve.

Due to high mixing performance and simple geometry structure, serpentine micromixer is one typical passive micromixer that has been widely investigated. Traditional zigzag and square-wave serpentine micromixers can achieve sufficient mixing, but tend to induce significant pressure drop. The excessive pressure drop means more energy consumption, which leads to low cost-performance of mixing. To mitigate excessive pressure drop, a novel serpentine micromixer utilizing ellipse curve is proposed. While fluids flowing through ellipse curve microchannels, the flow directions keep continuous changing. Therefore, the Dean vortices are induced throughout the whole flow path. Numerical simulation and visualization experiments are conducted at Reynolds number (Re) ranging from 0.1 to 100. Dean vortices varies with the changing curvature in different ellipse curves, and local Dean numbers are calculated for quantitative evaluation. The results suggest that the ellipse with a larger eccentricity induces stronger Dean vortices, thus better mixing performance can be obtained. A parameter, named mixing performance cost (Mec), is proposed to evaluate the cost-performance of micromixers. Compared with the zigzag, square-wave and other improved serpentine micromixers, the ellipse curve micromixer produces lower pressure drop while have the capability to maintain excellent mixing performance. The ellipse curve micromixer is proved to be more cost-effective for rapid mixing in complex microfluidic systems.

Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling.

Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

The biomechanical effects of Ti versus PEEK used in the PLIF surgery on lumbar spine: a finite element analysis.

Titanium (Ti) and polyetheretherketone (PEEK) are commonly used in posterior lumbar interbody fusion (PLIF). The study investigated biomechanical effects of Ti versus PEEK used as materials of cage and rods on the lumbar spine. Four different configurations of PLIF were constituted. Stiff Ti rods provided satisfactory initial stability but increased the stress on rods significantly under simulated physiological load conditions. Ti cage increased the stress on bone endplates significantly. Materials of cage and rods had insignificant effects on the nucleus pressure and facet joint force of non-instrumented segments. Further clinical studies and follow-up observations are essential for corroborating these findings.

3D Printed Ti-6Al-4V Implant with a Micro/Nanostructured Surface and Its Cellular Responses.

Three-dimensional (3D) printing technology has been proved to be a powerful tool for the free-form fabrication of titanium (Ti) implants. However, the surface quality of 3D printed Ti implants is not suitable for clinical application directly. Therefore, surface modification of 3D printed Ti implants is required in order to achieve good biocompatibility and osseointegration. In this study, a novel surface modification method of 3D printed Ti-6Al-4V implants has been proposed, which combined acid etching with hydrothermal treatment to construct micro/nanostructures. Polished TC4 sheets (P), electron beam melting Ti sheets (AE), and micro/nanostructured Ti sheets (AMH) were used in this study to evaluate the effects of different surface morphologies on cellular responses. The surface morphology and 3D topography after treatment were detected via scanning electron microscopy and laser scanning microscopy. The results illustrated that a hierarchical structure comprising micro-valleys and nanowires with a surface roughness of 14.388 µm was successfully constructed. Compared with group P samples, the hydrophilicity of group AMH samples significantly increased with a reduced water contact angle from 54.9° to 4.5°. Cell culture experiments indicated that the micro/nanostructures on the material surface could enhance the cell adhesion and proliferation of MC3T3s. The microstructure could enhance bone-to-implant contact, and the nanostructure could directly interact with some cell membrane receptors. Overall, this study proposes a new strategy to construct micro/nanostructures on the surface of 3D printed Ti-6Al-4V implants and may further serve as a potential modification method for better osteogenesis ability.

Porous fusion cage design via integrated global-local topology optimization and biomechanical analysis of performance.

Porous fusion cage is considered as a satisfactory substitute for solid fusion cage in transforaminal lumbar interbody fusion (TLIF) surgery due to its interconnectivity for bone ingrowth and appropriate stiffness reducing the risk of cage subsidence and stress shielding. This study presents an integrated global-local topology optimization approach to obtain porous titanium (Ti) fusion cage with desired biomechanical properties. Local topology optimizations are first conducted to obtain unit cells, and the numerical homogenization method is used to quantified the mechanical properties of unit cells. The preferred porous structure is then fabricated using selective laser melting, and its mechanical property is further verified via compression tests and numerical simulation. Afterward, global topology optimization is used for the global layout. The porous fusion cage obtained by the Boolean intersection between global structural layout and the porous structure decreases the solid volume of the cage by 9% for packing more bone grafts while achieving the same stiffness to conventional porous fusion cage. To eliminate stress concentration in the thin-wall structure, framework structures are constructed on the porous fusion cage. Although the alleviation of cage subsidence and stress shielding is decelerated, peak stress on the cage is significantly decreased, and more even stress distribution is demonstrated in the reinforced porous fusion cage. It promises long-term integrity and functions of the fusion cage. Overall, the reinforced porous fusion cage achieves a favorable mechanical performance and is a promising candidate for fusion surgery. The proposed optimization approach is promising for fusion cage design and can be extended to other orthopedic implant designs.