Enhancing Mechanical and Corrosion Properties of AISI 420 with Titanium-Nitride Reinforcement through High-Power-Density Selective Laser Melting Using Two-Stage Mixed TiN/AISI 420 Powder.

This study investigates the effect of laser volume energy density (VED) on the properties of AISI 420 stainless steel and TiN/AISI 420 composite manufactured by selective laser melting (SLM). The composite contained 1 wt.% TiN and the average diameters of AISI 420 and TiN powders were 45 µm and 1 µm, respectively. The powder for SLMing the TiN/AISI 420 composite was prepared using a novel two-stage mixing scheme. The morphology, mechanical, and corrosion properties of the specimens were analyzed, and their correlations with microstructures were investigated. The results showed that the surface roughness of both SLM samples decreases with increasing VED, while relative densities greater than 99% were achieved at VEDs higher than 160 J/mm3. The SLM AISI 420 specimen fabricated at a VED of 205 J/mm3 exhibited the highest density of 7.7 g/cm3, tensile strength (UTS) of 1270 MPa, and elongation of 3.86%. The SLM TiN/AISI 420 specimen at a VED of 285 J/mm3 had a density of 7.67 g/cm3, UTS of 1482 MPa, and elongation of 2.72%. The microstructure of the SLM TiN/AISI 420 composite displayed a ring-like micro-grain structure consisting of retained austenite on the grain boundary and martensite in the grain. The TiN particles strengthened the mechanical properties of the composite by accumulating along the grain boundary. The mean hardnesses of the SLM AISI 420 and TiN/AISI 420 specimens were 635 and 735 HV, respectively, which exceeded previously reported results. The SLM TiN/AISI 420 composite exhibited excellent corrosion resistance in both 3.5 wt.% NaCl and 6 wt.% FeCl3 solutions, with a resulting corrosion rate as low as 11 µm/year.

Effects of Laser Spot Size on the Mechanical Properties of AISI 420 Stainless Steel Fabricated by Selective Laser Melting.

The purpose of this study is to investigate the effects of laser spot size on the mechanical properties of AISI 420 stainless steel, fabricated by selective laser melting (SLM), process. Tensile specimens were built directly via the SLM process, using various laser spot diameters, namely 0.1, 0.2, 0.3, and 0.4 mm. The corresponding volumetric energy density (EV) is 80, 40, 26.7, and 20 J/mm3, respectively. Experimental results indicate that laser spot size is an important process parameter and has significant effects on the surface roughness, hardness, density, tensile strength, and microstructure of the SLM AISI 420 builds. A large laser spot with low volumetric energy density results in balling, un-overlapped defects, a large re-heated zone, and a large sub-grain size. As a result, SLM specimens fabricated by the largest laser spot diameter of 0.4 mm exhibit the roughest surface, lowest densification, and lowest ultimate tensile strength. To ensure complete melting of the powder and melt pool stability, EV of 80 J/mm3 proves to be a suitable laser energy density value for the given SLM processing and material system.

Effects of Build Direction on the Mechanical Properties of a Martensitic Stainless Steel Fabricated by Selective Laser Melting.

Mechanical properties and microstructure are investigated for a martensitic stainless steel (AISI 420) fabricated by selective laser melting (SLM) in three build directions. The tensile specimens built by SLM are classified into three groups. Group A is horizontally built in the thickness direction, Group B is horizontally built in the width direction, and Group C is vertically built in the length direction. The loading direction in tensile test is parallel to the build direction of Group C, but perpendicular to that of Groups A and B. Experimental results indicate build direction has significant effects on the residual stress, hardness, and tensile properties of SLM builds. Microstructural analyses indicate the as-fabricated SLM AISI 420 builds exhibit elongated cells and acicular structures which are composed of martensite and retained austenite phases growing along the build direction. Such anisotropy in the microstructure leads to anisotropic mechanical properties as Group C specimens (length direction) exhibit greater yield stress, ultimate tensile stress, and elongation than the specimens of Groups A (thickness direction) and B (width direction). The residual compressive stress in the gauge section also contributes to the superior tensile properties of Group C (length direction), as compared to Groups A (thickness direction) and B (width direction), which exhibit residual tensile stress in the gauge section.

Linear Displacement Calibration System Integrated with a Novel Auto-Alignment Module for Optical Axes.

The quality of processed workpieces is affected directly by the precision of the linear stage. Therefore, the linear displacement calibration of machine tools must be implemented before delivery and after employment for a period of time. How to perform a precise calibration with high inspection efficiency is a critical issue in the precision mechanical engineering industry. In this study, the self-developed system integrated by the measurement module based on the common path Fabry-Pérot interferometer for linear displacement and the auto-alignment module for optical axes was proposed to realize the automatic linear displacement calibration of the linear stages. The measurement performance of the developed structure was verified experimentally. With the auto-alignment module, the cosine error was reduced to 0.36 nm and the entire procedure accomplished within 75 s without the limitation of the perceived resolution of the human eye, operational experience, and the risk of misalignment and broken cable. According to the comparison of experimental results for the linear displacement, the repeatability of the proposed measurement module was less than 0.171 µm. After the compensation procedure according to the linear displacement calibration, the systematic positional deviation, repeatability, and accuracy of the linear axis could be improved to 4 µm, 1 µm, and 5 µm respectively. Hence, the calibration efficiency can be improved by 80% with the proposed compact system, which is beneficial for the linear displacement calibration of machine tools in the precision mechanical engineering industry.

Modified Fabry-Perot interferometer for displacement measurement in ultra large measuring range.

Laser interferometers have demonstrated outstanding measuring performances for high precision positioning or dimensional measurements in the precision industry, especially in the length measurement. Due to the non-common-optical-path structure, appreciable measurement errors can be easily induced under ordinary measurement conditions. That will lead to the limitation and inconvenience for in situ industrial applications. To minimize the environmental and mechanical effects, a new interferometric displacement measuring system with the common-optical-path structure and the resistance to tilt-angle is proposed. With the integration of optomechatronic modules in the novel interferometric system, the resolution up to picometer order, high precision, and ultra large measuring range have been realized. For the signal stabilization of displacement measurement, an automatic gain control module has been proposed. A self-developed interpolation model has been employed for enhancing the resolution. The novel interferometer can hold the advantage of high resolution and large measuring range simultaneously. By the experimental verifications, it has been proven that the actual resolution of 2.5 nm can be achieved in the measuring range of 500 mm. According to the comparison experiments, the maximal standard deviation of the difference between the self-developed Fabry-Perot interferometer and the reference commercial Michelson interferometer is 0.146 µm in the traveling range of 500 mm. With the prominent measuring characteristics, this should be the largest dynamic measurement range of a Fabry-Perot interferometer up till now.

Multi-interferometric displacement measurement system with variable measurement mirrors.

Laser interferometers have been widely implemented for the displacement sensing and positioning calibration of the precision mechanical industry, due to their excellent measuring features and direct traceability to the dimensional definition. Currently some kinds of modified Fabry-Perot interferometers with a planar mirror or a corner cube prism as the measurement mirror have been proposed. Each optical structure of both models has the individual particularity and performance for measuring applications. In this investigation, a multi-interferometric displacement system has been proposed whose measurement mirror can be quickly and conveniently altered with a planar mirror or a corner cube reflector depending on the measuring demand. Some experimental results and analyses about the interpolation error and displacement measurements with both reflectors have been demonstrated. According to the results, suggestions about the choice of a measuring reflector and interpolation model have been presented. With the measuring verifications, the developed system with a maximum standard deviation less than 0.2081 µm in measuring range of 300 mm would be a compact and robust tool for sensing or calibrating the linear displacement of mechanical equipment.

A robust disturbance reduction scheme for linear small delay systems with disturbances of unknown frequencies.

A robust disturbance reduction scheme for linear small delay systems with disturbances of unknown frequencies is presented in this paper. Unlike other methods, the proposed scheme does not require disturbance frequencies to be known. The linear systems modeled in this study are nominally stable and minimum phase systems with relative degree. The control structure is an integration of Astrom's modified Smith predictor and the proposed scheme. The proposed scheme consists of an input disturbance reduction controller (IDRC) and a residual disturbance reduction controller (RDRC). The IDRC using an artificial neural network (ANN) is proposed to reduce unknown load disturbances and modeling uncertainties in stable systems and unstable systems. The ANN can appropriately approximate the product of an inverse time delay and a nonnegative gain in the IDRC. The residual signals including residual disturbances and residual uncertainties are suppressed by the RDRC based on a disturbance observer. Simulation examples are illustrated to show the effectiveness of the proposed robust disturbance reduction scheme for linear delay uncertain systems with periodic or non-periodic unknown load disturbances.

Data analysis using a combination of independent component analysis and empirical mode decomposition.

A combination of independent component analysis and empirical mode decomposition (ICA-EMD) is proposed in this paper to analyze low signal-to-noise ratio data. The advantages of ICA-EMD combination are these: ICA needs few sensory clues to separate the original source from unwanted noise and EMD can effectively separate the data into its constituting parts. The case studies reported here involve original sources contaminated by white Gaussian noise. The simulation results show that the ICA-EMD combination is an effective data analysis tool.