Pulsed laser micro polishing: Surface prediction model

The objective of this work is to predict the final roughness of metal surfaces that have undergone pulsed laser micro polishing. The motivation for pulsed laser micro polishing is to reduce the surface roughness of parts whose surface texture can approach the feature size. Being able to predict the magnitude of the polishing and frequency (wavelength) content of the surface will assist in the design of optimal processing parameters with minimal experiments. Laser pulses are used to create shallow melt pools with a controlled size (e.g., depth) and duration in order to allow surface tension forces to “pull down” asperities with small radius of curvature. There is no ablation occurring in the process being modeled. The melt depth and duration are predicted with a transient, two-dimensional axisymmetric heat transfer model with temperature-dependent material properties. The surface of the melt pool is analytically modeled as oscillations of stationary capillary waves with damping resulting from the forces of surface tension and viscosity. Above a critical spatial frequency, f_cr, a significant reduction in the amplitude of the spatial Fourier components is expected. The work described in this paper extends the concept of critical frequency to a physics-based prediction methodology for predicting the spatial frequency content and surface roughness after polishing, given the features of the original surface, the material properties, and laser parameters. The proposed prediction methodology was validated using line polishing data for stainless steel 316L and area polishing results for pure nickel, Ti6Al4V, and Al-6061-T6. The predicted average surface roughnesses were within 12% of the values measured on the polished surfaces.     

医疗垃圾焚烧飞灰的重金属浸出特性及其稳定化处理研究

通过对医疗垃圾飞灰的浸出特性和高温熔融处理实验,研究了浸出时间、液固比、pH值和颗粒尺寸对重金属浸出特性的影响以及飞灰熔融对重金属稳定化处理效果.结果表明,随着浸出时间的增加,飞灰绝大部分重金属的浸出浓度增高,浸出毒性增强;液固比(L/S)增加,大部分重金属的浸出率大大提高,其中重金属Cd的浸出率最大,在液固比为90时,飞灰中的Cd的浸出率达到70%以上;pH为中性左右的时候,医疗垃圾飞灰中的大部分重金属的浸出液浓度最低;颗粒尺寸在较大或者较小时,医疗垃圾飞灰中的大部分重金属浸出浓度较小,大部分重金属在颗粒尺寸250～900μm时,重金属的浸出浓度较高;飞灰高温熔融后,重金属的浸出毒性大大降低,说明熔融对重金属有很好的固化效果.     

A comparative study of the interaction between microhole sidewall and the plasma generated by nanosecond and femtosecond laser ablation of deep microholes

High-aspect-ratio microholes have many industrial applications, but are difficult to produce. Femtosecond (fs) and nanosecond (ns) laser ablation may produce potential manufacturing solutions. However, the laser-induced plasma–microhole sidewall interaction has not been well understood for laser ablation of deep microholes, which may significantly affect the hole size and/or quality. This interaction has been investigated in this paper. Due to the huge challenges involved in direct experimental observations, a physics-based model is applied as the research tool, which has been verified by measurements from literatures on laser ablation of flat targets (without deep microholes) that are relatively easy to perform. The study shows that under the same laser pulse fluence, the fs laser-induced plasma generates larger transient peak heat flux to the sidewall than the ns laser pulse. However, the high-heat-flux region moves up very rapidly in the hole, and hence the sidewall temperature is not significantly raised and sidewall melting does not occur under the studied conditions. On the other hand, for the ns laser pulse, the induced plasma maintains a relatively high heat flux to the sidewall near the hole bottom for a much longer time, which yields obvious sidewall melting and surface vaporization. The results are consistent with the previously observed sidewall surface morphology for microholes drilled by fs and ns laser pulses in air with the same pulse energy.     

典型不锈钢在淡化海水中的耐腐蚀性能研究

目的研究316L和2205在淡化海水中的耐腐蚀性能,并研究水处理药剂对不锈钢耐蚀性的影响。方法采用电化学试验、慢应变速率拉伸试验、扫描电镜等方法。结果在淡化海水中,316L临界点蚀温度为42.7℃,加入药剂后为70.2℃;2205的临界点蚀温度大于85℃。2205耐缝隙腐蚀性能明显好于316L,药剂对2205也具有一定的缓蚀作用。316L和2205在50℃淡化海水中具有高应力腐蚀抗力。结论 316L不适合直接在淡化海水中应用,但适合在加入药剂的淡化海水中使用;2205适合在淡化海水中应用。     

板料激光弯曲成形及其数值模拟

介绍了一种利用激光扫描板料时形成的不均匀温度场所诱发的热应力进行弯曲变形的技术。采用非耦合模型,用有限元法对成形过程中的三维瞬态温度场及形变场进行了数值模拟,定量地解释了板料激光弯曲的变形机理。文中还介绍了动态边界热流的引入方法及改进热弹塑有限元计算精度和收敛性的措施。模拟值与实测值吻合。     

过电位抛光增材制造双极板流道结构及性能研究

目的 研究过电位抛光对不锈钢异形截面微流道内壁成形性及双极板性能的影响。方法 采用电化学实验、扫描电子显微镜（SEM）、粗糙度测试分别对激光粉末床熔融技术成形异形截面微流道进行测试分析,研究抛光时间对微流道内壁表面形貌、典型缺陷、表面粗糙度及双极板耐腐蚀性的影响。结果 在抛光前10 min,微流道内壁的质量得到有效提升,随着抛光时间的延长,其表面粗糙度达到稳定值,同时典型缺陷也由黏粉、半熔金属颗粒等局部缺陷逐渐变化到球化、挂渣、阶梯效应等大范围缺陷,直至出现点蚀现象。抛光时间在5～15 min内,LPBF成形316L不锈钢表面质量提升,随着抛光时间的增加,其耐腐蚀性下降。结论 采用过电位抛光工艺并选择适当的过电位抛光时间,能有效提升微流道内壁成形质量及双极板耐腐蚀性能。     

融冰过程中铁离子和锰离子的迁移规律

为探究融冰过程中重金属离子的迁移规律,选择铁离子和锰离子为研究对象,开展了室内模拟融冰实验,探讨其在融冰过程中的迁移规律,并分析初始浓度和冷冻温度对其迁移过程的影响.结果表明：在不同的初始浓度和冷冻温度条件下,铁离子和锰离子在冰中各层的浓度分布关系皆为：中层 < 上层 < 下层;融冰过程中,51.17%~71.67%的铁离子和锰离子均在冰体融化前期（0~25%）集中释放,中后期相对平稳均匀释放,此外初始浓度对冰融化时铁离子和锰离子的迁移规律影响不大,而冷冻温度较低时,融1中铁离子和锰离子的浓度基本在增加;融冰过程中,随着累积融水体积的增加,融水中铁离子和锰离子的浓度与冰体初始浓度之比逐渐降低,它们之间呈指数函数衰减模式.     

垃圾焚烧炉飞灰的低温玻璃固化初步研究

在研究我国城市生活垃圾焚烧炉飞灰的毒性特征和高温灼烧特性的基础上，试验了几种常用玻璃熔制助溶剂、烟气净化产物中的成分对飞灰的溶融温度和熔融减量的影响，以实现低温玻璃固化。实验发现受热温度越高、时间越长，飞灰减量越大；B2O3、硼砂、CaF2对飞灰助溶效果明显，而废玻璃、CaO、CaCl2能使悄灰溶融后形成的玻璃态物质地均匀、少孔。按一定比例同时加入硼砂、CaF2、废玻璃、CaO、CaCl2于飞灰中，混合物的熔融温度降到1000℃以下，大大低于飞灰自身的熔融温度（1200℃）。对该熔融物在空气中淬火形成的玻璃态物质按标准方法浸沥，选择测量了浸出液中铅、汞、镉、砷的浓度，初步发现低温玻璃态物质对重金属铅和镉具有较好的固化效果，而对汞有砷的固化效果尚不确定。     

30CrMnSiNi2A超强钢激光熔覆修复试验研究

目的研究激光熔覆技术,解决30CrMnSiNi2A钢制部件表面腐蚀、划伤、裂纹等缺陷的修复问题。方法利用光纤激光器在30CrMnSiNi2A钢表面进行同基体相近成分的合金粉末熔覆试验,优化激光熔覆工艺参数,开展熔覆层的微观组织、硬度、力学性能等方面试验研究,并对拉伸试样的断口进行分析。结果熔覆层与基体呈现牢固的冶金结合,基体热影响区域小,熔覆区的抗拉强度大于基体强度的80%,熔覆区材质的脆性较基材有所增加。结论激光熔覆可用于修复30CrMnSiNi2A钢制零件表面的腐蚀、划伤、裂纹等局部缺陷。     

Basic Approach to a Prediction System for Burr Formation in Face Milling

Geometric parameters and material properties are the two major categories of factors affecting burr formation in the milling process. Geometric parameters such as tool geometry, workpiece geometry, or process condition influence workpiece edge quality at the tool-chip interface. This study identifies a unified criterion to analyze burr formation for different tool engagements. The criterion exploits the exit order of cutting edges of the tool along the workpiece edge, which essentially includes the 3-D nature of the process. The criterion correlates the cutting mechanism and burr formation using the exit order sequence (EOS) as an approximation of chip flow angle. The impact of different possible exit order sequences on burr formation is analyzed. Previously observed phenomena are explained based on the EOS. Also, experiments are done with three different materials (with different ductilities) to analyze the impact of material properties on burr formation for a given EOS. Although burr sizes are different quantitatively with different material, the ranking of burr size for different EOS remained the same. An algorithm for the prediction of burr formation in face milling based on EOS is developed and tested and validated on two different profiles of an automotive part.     

几种典型金属材料西沙海洋全浸区腐蚀行为规律研究

目的研究几种典型金属材料在西沙海洋全浸区的腐蚀行为规律。方法通过外场暴露试验,分析EH36和CM690船用钢、316L不锈钢以及5083铝合金材料暴露0.5、1、2a后的腐蚀形貌与动力学规律。结果CM690腐蚀速率要大于EH36,而点蚀深度规律相反。316L不锈钢发生较为严重缝隙腐蚀,5083铝合金则以局部腐蚀为主。结论试验条件下,EH36与CM690钢腐蚀质量损失与点蚀最为严重,316L不锈钢与5083铝合金生物污损严重,伴有局部腐蚀。     

Scattering of ground based lasers by aerosols in an atmosphere with enhanced particle content

A component of the proposed Strategic Defense Initiative may be a high power ground based laser system. In scenarios which may lead to a nuclear winter, the aerosol content and composition of the atmosphere is altered. Within this environment, this paper examines the effect of scattering of the ground based laser by aerosols in order to determine the degree of deterioration of the laser beam. The thermodynamics of aerosol and ambient medium heating by pulsed high energy lasers is calculated to determine the time-dependent temperature variations of the aerosol surface and surrounding medium. The resulting temperature variations give rise to non-uniformities in the index of refraction which act as scattering centers for the laser beam. The scattering of the laser beam from these non-uniform index of refraction centers is calculated by the use of the Born approximation. The range of aerosol and laser beam variables that may cause significant deterioration of the ground based laser is discussed.     

316L不锈钢在淡化海水中的耐腐蚀性能研究

目的评价316L不锈钢在淡化海水中的耐蚀性能。方法利用电化学和慢应变速率拉伸（SSRT）,并结合扫描电镜（SEM）的方法。结果电化学阻抗测试结果表明,随着温度的升高,材料的耐蚀性能下降;循环伏安实验结果表明,随着温度的升高,点蚀击破电位负移;SSRT实验结果表明,316L不锈钢在淡化海水中具有一定的应力腐蚀敏感性（SCC）,随着温度升高,敏感性增大,在35℃和50℃,316L不锈钢在淡化海水中的断裂为韧性断裂,在70℃时,断口微观形貌呈现韧窝＋少量准解理形貌。结论在淡化海水中,随着温度的升高,不锈钢的耐点蚀性能下降,SCC敏感性增强。     

废弃印刷线路板热解过程传热特性实验研究

为了改善印刷线路板热解过程中的传热性能、提高废弃印刷线路板热解效率和产率、减少热解过程对环境的二次污染,本文设计并搭建了一套固定床热解实验装置,在高温氮气渗流条件下对3种不同尺寸废弃印刷线路板颗粒料层的热解过程进行了对比实验;测试了颗粒料层热解过程沿轴向和径向的温度分布,分析了线路板颗粒尺寸对物料层温度场和对热解区域迁移速度的影响,阐明了沿热解炉高度方向物料温度参数随时间的变化特征,揭示了热解区域和热解状态对于沿轴向的温升速率和温度梯度的影响规律.结果表明:较大颗粒料层的热解区域纵向迁移速度要快于小颗粒料层,当颗粒尺寸分别为1.5、2.5和3.5 cm时,热解区域的纵向迁移速度分别为0.47、0.50和0.63 m·h~(-1);热解区域和热解状态对于沿轴向的温升速率和温度梯度有显著影响;废弃印刷线路版热解过程的能源利用效率较低,只有29.50%～37.13%,主要损失为热解装置和物料的蓄热损失.研究结果对印刷线路板热解装置的设计和运行具有重要的指导意义.     

Photocatalytic degradation of Chicago Sky Blue 6B and Benzopurpurin 4B using titanium dioxide thin film

Aqueous solutions of azo dyes undergo degradation to form harmless intermediates and colorless products following irradiation by visible light in the presence of titanium dioxide thin films. The dyes that were studied in this work are： Chicago Sky Blue 6B and Benzopurpurin 4B. Results obtained indicated that complete mineralization of the dyes took place under the experimental conditions. There was an increase in conductivity after the complete mineralization experiments possibly indicating the formation of ions such as NO3^- and SO4^2-. Chemical oxygen demand（COD） measurements show a decrease in organic matter for both dyes following complete degradation. The effect of how changing experimental conditions such as pH, temperature and starting concentrations of dyes affected the rate of dye degradation was measured. There was an increase in the rate of disappearance of the dye color at lower pH. High concentrations of dye solutions reauired Iona dearadation time.     

Bending of Titanium Sheet Using Laser Forming

Laser forming, a novel manufacturing method for bending sheet metal first reported in 1985, has been investigated as an alternative to hot brake forming (industry standard) of titanium sheet parts for the aircraft industry. Laser forming involves scanning a focused or partially defocused laser beam over the surface of a titanium workpiece to cause localized heating along the bend line and angular deflection toward the beam. The main advantage that laser forming has over conventional brake forming is increased process flexibility. An experimental investigation of this process (primarily designed experiments) met the following objectives: identified the response variables related to change in geometry (bend angle) and material microstructure; characterized the influence of process variables (scanning speed, beam diameter, laser power) on these response variables; determined the degree of controllability over the process variables; and evaluated the suitability of laser forming for the aircraft industry (most important), all with respect to titanium sheet. It has been determined that laser forming with an Nd:YAG laser is a controllable, flexible manufacturing process for titanium sheet bending. Unfortunately, these advantages over traditional hot brake forming are overshadowed by the fact that, with regard to forming with titanium, laser forming is significantly slower and more labor and energy intensive, and results in unacceptable material properties at the bend line according to aircraft industry standards. These findings cast doubt over the assertions of some researchers that laser forming may be a viable manufacturing process for parts made in small batches. Instead, it appears that it may be best suited for rapid prototyping of sheet metal parts.     

辅助燃料对垃圾熔融炉炉温影响的分析研究

文章计算了在不同焦炭加入量及不同焦炭和煤的配比条件下处理城市生活垃圾时气化熔融炉的炉温。计算结果表明,用焚烧法处理重庆市的生活垃圾时,在常温鼓风条件下,要使垃圾灰渣完全熔融,焦炭配比至少应在42％以上;在一定的条件下,可以用煤部分或全部代替焦炭,同时配以高温鼓风,可使炉温达到并超过垃圾灰渣的熔融温度,从而使得垃圾灰渣熔融。     

316L与X65在模拟流动地层水中电偶腐蚀行为

目的研究316L与X65在模拟流动地层水中电偶腐蚀行为,方法进行复合管材料X65和316L耦合在模拟流动地层水饱和CO2环境中的浸泡实验,通过电化学工作站测量电偶电流、电偶电位、开路电位及试样在不同温度和流速下极化曲线和交流阻抗图谱,另外通过电子扫描显微镜观察腐蚀形貌,对复合管电偶腐蚀行为进行分析。结果在模拟流速为0,0.2 m/s地层水中,X65耦合后的腐蚀速率分别为0.883,1.169 mm/a。结论 X65阳极反应极化程度较小,316L的阴极反应过程是整体反应速度的控制步骤。X65表面不仅发生阳极溶解,还伴随阴极反应。     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

316L不锈钢在海洋深水环境中的局部腐蚀规律

目的研究316L不锈钢在海洋深水环境中的局部腐蚀规律。方法利用自行设计的实验装置在南海170 m水深位置开展316L不锈钢腐蚀模拟实验,并通过电化学测试方法与扫描电子显微镜(SEM)、能谱仪(EDS)等测试手段进行分析。结果浸泡7天时,316L不锈钢表面发生局部腐蚀,但微生物吸附会形成保护性的微生物膜,引起其自腐蚀及击穿电位正移,耐点蚀性能会升高。随着浸泡时间的延长,溶解氧含量逐渐降低,试样表面吸附的微生物膜性质发生变化,导致钝化膜在微生物与Cl-的作用下破裂,自腐蚀电位及击穿电位负移,耐点蚀性能下降。结论 316L不锈钢在海洋深水环境中的耐点蚀性能随着浸泡时间的延长,先降低而后增加。