Residual stresses and white layer in electric discharge machining (EDM)

The effect of dielectric liquid and electrode type on white layer structure in electric discharge machined surfaces has been studied in terms of retained austenite and residual stresses using X-ray diffraction method. The machining tests were conducted by using two different tool electrodes (copper and graphite) and dielectric liquid (kerosene and de-ionized water) under same operational conditions. The present work suggests that the surface is saturated with carbon irrespective of the tool electrode material when machining with kerosene dielectric liquid. But, retained austenite is formed on the surface due to carbon uptake from graphite tool electrode when machining with de-ionized water dielectric liquid. On the other hand, even though surface residual stresses increase with structural non-homogeneities in the white layer, no clear consequences have been observed in residual stress distribution beneath the white layer.     

Morphology and Phase Composition of Particles Produced by Electro-Discharge-Machining of Iron

Towards producing metallic particles of controlled size and spherical shape, which are of technological importance, we have collected in the filters of an electro-discharge-machine (EDM) the material ejected from the surface of EDM iron pieces. The conditions of machining were varied for kerosene and water as dielectrics, using a discharge current of 25 A and duration times of 16 and 3072 μs for kerosene and of 32, 384 and 768 μs for water, respectively. Scanning electron microscopy was used to assess the effect of the time of discharge on the size of the particles. Mössbauer spectroscopy and X-ray diffraction revealed that for kerosene EDM particles only cementite-like carbides of diverse stoichiometry were formed. While no oxide was found for kerosene spheres, the analyses showed that besides the main fraction of α-Fe, a small percentage of wüstite (and traces of hematite for the 384 μs sample) formed on the water EDM ones.     

A new NLO Material: L-Asparagine thiocyanate (LATC) for opto-electronic applications

L-asparagine monohydrade thiocyanate (LATC), which is potentially a non-linear optical crystal, was grown by the conventional slow evaporation solution technique (SEST) using doubly de-ionized water at room temperature. The lattice parameters were found by using single crystal X-ray diffraction analysis. Perfection of the grown crystal was confirmed by powder X-ray diffraction. The various functional groups were identified from FT-IR analysis. The optical parameters, such as the optical absorption, the band gap, photoluminescence and second harmonic generation (SHG), were analyzed on the grown crystal. The induced surface laser damage threshold was measured using a Q-switched Nd:YAG laser. The thermal behavior and stability of the grown crystal was analyzed by TG/DTA analysis. The dielectric constant (ε_r) and dielectric loss (tanδ) as a function of frequency has been investigated at different temperatures. The mechanical property of the grown crystal was studied using the Vickers micro hardness method.     

Femtosecond laser induced nanostructuring of zirconium in liquid confined environment

The surface, structural, and mechanical properties of zirconium after irradiation with Ti: sapphire laser(800 nm, 30 fs,1 k Hz) have been investigated. The zirconium targets were exposed for a varying number of laser pulses ranging from 500 to 2000 at a fixed fluence of 3.6 J/cm~2 corresponding to an intensity of 1.2×10~(14)W/cm~2 in ambient environments of deionized water and propanol. A scanning electron microscope(SEM) was employed to investigate the surface morphology of the irradiated zirconium. The SEM analysis shows the formation of various kinds of features including nanoscale laser induced periodic surface structures(LIPSS), sponge like surface structure, flakes, conical structures, droplets, pores, and cavities. The energy dispersive x-ray spectroscopy(EDS) analysis exhibits the variation in chemical composition along with an enhanced diffusion of oxygen under both ambient conditions. The crystal structure and phase analyses of the exposed targets were explored by x-ray diffraction(XRD) and Raman spectroscopy techniques, respectively. The XRD analysis confirms the presence of various phases of zirconium hydride and zirconia after ablation in both de-ionized water and propanol. However, excessive hydrides are formed in the case of propanol. The Raman analysis supports the EDS and XRD results. It also reveals the presence of oxides(zirconia) after irradiation in both de-ionized water and propanol environments.The chemical reactivity of zirconium was significantly improved in the presence of liquids which were accountable for the growth of novel phases and modification in the chemical composition of the irradiated Zr. A nanohardness tester was employed to measure the nanohardness of the laser treated targets. The initial increase and then decrease in nanohardness was observed with an increase in the number of laser pulses in the de-ionized water environment. In the case of propanol,a continuous decrease in hardness was observed.     

三氧化二铝-聚苯乙烯复合微球的制备

 以Al₂O₃-PS复合材料为原料，采用乳液微封装法制备出掺杂Al₂O₃的PS空心微球。三相溶液分别是两个水相：蒸馏水（W₁相）、5wt%PVA水溶液（W₂相）和3wt%Al₂O₃-PS溶液（O相，苯和三氯甲烷混合物作溶剂）。所得微球表面粗糙度低于50nm。     

SiO_2/CH/Au复合黑腔诊断孔电火花加工技术

通过电火花加工技术,采用含碳较高的煤油作为电介质,利用导电性能及加工性能较好的紫铜作电极材料,实现了SiO2/CH/Au复合黑腔侧表面方形诊断孔的精密加工。采用OLYMPUS STM6测量显微镜对诊断孔尺寸,结果表明:孔的尺寸加工精度可控制在±10μm内,同一电极加工的诊断孔尺寸一致性可控制在±5μm内。采用扫描电镜能谱分析SiO2/CH/Au加工导电层的成分,结果表明:电火花加工过程中,由于电介质分解生成游离态的碳以及电极材料铜熔融后沉积在CH和SiO2层表面,形成辅助导电层。通过加工辅助导电层,产生的瞬时高温使SiO2和CH层熔融气化,从而实现对绝缘层的加工。     

单晶硅微纳构件加工表面性能的时变性研究

采用蒙特卡罗方法和分子动力学方法相结合, 模拟单晶硅微纳构件加工表面的时效过程, 研究其对加工表面质量和构件力学性能的影响. 模拟结果表明: 在时效过程中, 单晶硅微纳构件加工变质层的有序度显著提高, 残余应力大幅降低, 表面粗糙度略有增加, 此外还发现加工变质层中非晶硅原子在时效过程中大幅减少, 部分非晶硅出现了再结晶现象, 其中部分BCT5-Si以及金属相(Si-Ⅱ)结构原子转化为金刚石结构(Si-I). 时效作用对加工后单晶硅微纳构件表面性能具有重要的影响, 同时可以提高微纳构件的拉伸力学性能. 关键词： 蒙特卡罗方法 纳米加工 表面性能 时变性     

Analysis of machining characteristics in electrochemical etching using laser masking

Electrochemical etching using laser masking (EELM), which is a combination of laser beam irradiation for masking and electrochemical etching, allows the micro fabrication of stainless steel without photolithography technology. The EELM process can produce various micro patterns and multilayered structures. In this study, the machining characteristics of EELM were investigated. Changes in characteristics of recast layer formation and the protective effect of the recast layer according to the laser masking conditions and electrochemical etching conditions were investigated by field emission scanning electron microscopy (FE-SEM), focused ion beam (FIB) and X-ray photoelectron spectroscopy (XPS). The oxidized recast layer with a thickness of 500 nm was verified to yield a superior protective effect during electrochemical etching and good form accuracy. Finally, micro patterns and structures were fabricated by EELM.     

Electrical discharge machining of titanium alloy (Ti-6Al-4V)

In this study, the electrical discharge machining (EDM) of titanium alloy (Ti-6Al-4V) with different electrode materials namely, graphite, electrolytic copper and aluminium and process parameters such as, pulse current and pulse duration were performed to explore the influence of EDM parameters on various aspects of the surface integrity of Ti6Al4V. Scanning electron microscopy (SEM), X-ray diffraction (XRD), energy dispersive spectrograph (EDS) and hardness analysis were performed. The experimental results reveal that the value of material removal rate, surface roughness, electrode wear and average white layer thickness are tendency of increase with increasing current density and pulse duration. However, extremely long-pulse durations such as 200 μs led to decrease MRR and surface roughness. Furthermore, the surface hardness is increasing due to the Ti₂₄C₁₅ carbides formed on the surface and obvious cracks are always evident in re-solidified layer when machining copper electrode. The surface crack densities and critical crack lines were determined for the tested material. The graphite electrode is beneficial on material removal rate, electrode wear and surface crack density but relatively poorer surface finish.     

Nano-emulsification of oriental lacquer sap by ultrasonic wave propagation: Improvement of thin-film characteristics as a natural resin

Lacquer sap has received much attention as a traditional natural resin because it is a renewable and eco-friendly biopolymer resource unlike artificial coating materials. However, strict drying conditions and long drying times of lacquer sap should be modified to expand its applications. This study presents the first attempt to investigate the effect of different amplitudes of ultrasonic waves on the lacquer sap composed of water-in-oil (W/O) emulsion droplets and the mechanical properties of the resultant film by solvent evaporation. Acoustically induced cavitation via batch ultrasonication facilitates the generation of submicron-sized W/O emulsion. The drying time of sonicated lacquer sap was noticeably shortened as the amplitude of acoustic power increased. Interestingly, the transparency of the film cast from lacquer sap consisting of the smallest emulsion droplets increased significantly, weakening the degree of colour change from caramel-like yellow to dark brown as polymerisation progressed. These are attributed to the effective and frequent contact of laccase enzyme with urushiol at the increased interfacial area of nano-emulsified W/O droplets pulverised by ultrasonic waves. The quinone radical-generation in the interface layer and its transfer to the urushiol oil phase through water-insoluble glycoprotein emulsifier are greatly promoted, resulting in highly cross-linked, dense three-dimensional polymer networks, which also increased the lacquer film hardness after drying. As the emulsion droplet size decreased, the mutual interaction between the catechol moiety of urushiol and the substrates increased, resulting in improved adhesion. The nano-emulsification of the lacquer sap by ultrasonic waves can be used in a simple, effective, and eco-friendly way to shorten the drying time and improve the film characteristics of natural resins. This approach could pave the way for its wide range of applications in industrial fields, taking into account green and sustainable chemistry.     

Physical and chemical characteristics of ultrasonically-prepared water-in-diesel fuel: Effects of ultrasonic horn position and water content

An ultrasonic technique was applied to preparation of two-phase water-in-oil (W/O) emulsified fuel of water/diesel oil/surfactant. In this study, an ultrasonic apparatus with a 28 kHz rod horn was used. The influence of the horn tip position during ultrasonic treatment, sonication time and water content (5 or 10 vol%) on the emulsion stability, viscosity, water droplet size and water surface area of emulsion fuels prepared by ultrasonication was investigated. The emulsion stability of ultrasonically-prepared fuel significantly depended on the horn tip position during ultrasonic irradiation. It was found that the change in the stability with the horn tip position was partly related to that in the ultrasonic power estimated by calorimetry. Emulsion stability, viscosity and sum of water droplets surface area increased and water droplet size decreased with an increase in sonication time, and they approached each limiting value in the longer time. The maximum values of the viscosity and water surface area increased with water content, while the limiting values of the emulsion stability and water droplet size were almost independent of water content. During ultrasonication of water/diesel oil mixture, the hydrogen and methane were identified and the cracking of hydrocarbon components in the diesel oil occurred. The combustion characteristics of ultrasonically-prepared emulsion fuel were studied and compared with those of diesel oil. The soot and NOx emissions during combustion of the emulsified fuel with higher water contents were significantly reduced compared with those during combustion of diesel oil.     

Microstructures and properties of electrical discharge strengthened layers on 65Mn steel

Here, we reported the successful surface modification with silicon electrode via electrical discharging. During the modification procedure, metallurgy reaction occurred between silicon electrode and workpiece materials, in which kerosene was discomposed and a strengthened layer was obtained on the surface of workpiece materials. The influence of processing parameters on the modified layer was also investigated. Our experimental results elucidated that an amorphous nano-crystalline alloy layer can be fabricated on the surface of 65Mn steel (ASTM:1566) in a controllable way. By forming a strengthened nano-layer, the hardness of 65Mn steel as well as the wear and corrosion resistance was obviously enhanced. In addition, a homogenous strengthened nano-layer can be formed by utilizing ultrasonic vibration of silicon electrode.     

用消除夹带溶胀的新液膜法测定汞

夹带溶胀分为包裹溶胀和再液化溶胀,消除液膜操作中的夹带溶胀对液膜的工业化具有重要意义。文章从油膜和水膜的寿命出发,讨论了夹带溶胀形成的过程,结果表明,不论何种表面活性剂,油膜寿命均比水膜寿命高出20～88倍,把油滴分散到水中,上浮聚集后不发生乳化;把乳状液滴分散到水中,上浮聚集后不发生溶胀。这样本法的溶胀率大大低于搅拌池操作法的溶胀率。作者用这种消除夹带溶胀的新液膜法与火焰原子吸收法相结合测定汞,方法的精密度为1.9%～2.3%,回收率为99.8%～101.1%,可富集测定ng·g-1级的汞。本方法已用于废水中汞的分析。     

微热光电系统原型的设计制造和测试

本文首次描述了一种新颖的微热光电(微TPV)系统原型的设计、加工过程和测试结果。该系统由一个SiC发射极、一个简单的9层绝缘过滤器和一个GaSb光电池环路组成。当H2流率为3.4439 g/h,H2/O2比为1.8时,微TPV 系统能在一个容积为0.091 cm3的微型燃烧室内产生0.562 W的电力输出。相应的开路电压和短路电流分别为1.14 V和0.65 A。该项工作使得我们在不久的将来用微TPV系统代替电池作为微机械装置的动力源成为可能。     

Organized assembly from biosurfactants

The formation of higher order aggregates in aqueous media from naturally occurring surfactants (biosurfactants) and its mechanism have been studied. A liposome (vesicle), as a kind of artificial cell, is prepared according to a newly developed microencapsulation technique from phospholipids by mimicking the molecular structure of biomembranes. Secondly, the surface active properties of alkaline salts of spiculisporic acid depend on the kinds of alkali as its gegen ions; these have been studied for the purpose of a detailed understanding of vesicle formation of the alkylamine salts of spiculisporic acid in the binary system consisting of spiculisporates and water. Thirdly, the solution behavior of the ternary system of spiculisporates-oil-water is examined. Divalent cationic salts of spiculisporic acid formed oil-in-water (O/W) emulsion gels due to ionic-bonding network formation of spiculisporates around emulsified oil droplets and these are important for their gelling properties. These gelling systems may have potential to be O/W emulsion-type paints and safe fuels.     

Laser controlled melting of pre-treated zirconia surface

Laser treatment of pre-prepared zirconia surface is carried out. The pre-prepared surface, prior to laser treatment, consists of 50 μm carbon film and 7% titanium carbide particles, which are imbedded in the carbon film. The microstructural and morphological changes in the laser treated surface layer are examined using optical and scanning electron microscopes, energy dispersive spectroscopy, and X-ray diffraction. The fracture toughness of the laser treated surface is measured and the residual stress formed at the surface vicinity is determined from the X-ray diffraction technique. It is found that the microhardness of the laser treated surface increased slightly due to the dense layer formed at the surface vicinity. However, the laser treatment process reduces the fracture toughness of the surface due to improved surface hardness and the residual stress formed in the surface vicinity.     

Выделение меченых соединений методом препаративной хроматографии

Mica Track Microfilters (MTM) are successful applied to separate two different and strongly mixed liquid phases (emulsion). The organic and the inorganic phase of the emulsion were 30% tributyl phosphate (TBP) in kerosene and 2 N HNO₃ (or H₂O), respectively. Mica filters with sharp edges (i.e. etched with H₂F₂) and having pore sizes k of 8 μm > k > 2 μm are used to get under some well defined conditions a rather complete extraction of the aqueous phase out of the emulsion. The system was calibrated with the pure phases (water as well as TBP in kerosene), and the liquid throughput is shown as a function of the pore size of the filter. The throughput depends mainly on the pore size and not that much on the kind of liquid, it is slightly larger for water as compared to that of TBP in kerosene.     

Preparation and application of the 3C–SiC substrate to piezoelectric micro cantilever transducers

This study examines the fabrication process and mechanical properties of piezoelectric films with the substrate, which is made from silicon carbide. After depositing the PZT thick film on silicon carbide substrate and silicon substrate respectively, it was shown that silicon carbide substrate formed a stable interface with PZT thick film up to 950?°C, compared with silicon substrate. In addition, the dielectric constant of the PZT thick film sintered at 950?°C on a silicon carbide substrate was 843, and this value was about over 25 % improved value compared with that on a silicon substrate. A thick film piezoelectric micro transducer of a micro cantilever type was fabricated by using a multifunctional 3C–SiC substrate. The fabricated micro cantilever was a micro cantilever with multiple thin films on either silicon or silicon carbide substrate. The piezoelectric thick-film micro cantilever that was fabricated by using a SiC substrate showed excellent mechanical and thermal properties. The piezoelectric micro cantilever on the SiC substrate shows an excellent sensitivity towards the change of mass compared with the piezoelectric micro cantilever on the Si substrate.     

金黑腔方形诊断孔电火花铣削加工技术

通过电火花加工技术,采用分层铣削加工方法,利用形状简单的圆柱电极,实现了Au黑腔侧表面方形诊断孔的加工。通过对分层厚度的控制,将放电区域控制在电极底部,避免了电极侧面放电对诊断孔尺寸的影响。通过扫描电镜对诊断孔形貌进行检测,采用奥林巴斯测量显微镜测量诊断孔尺寸,结果表明:孔的尺寸加工精度可控制在±5μm,诊断孔边缘清晰,无毛刺及锯齿形状。     

绝缘层修饰对喷墨打印有机场效应晶体管形貌和性能的影响

通过对OTFT绝缘层SiO_2表面分别采用十八烷基三氯硅烷(OTS)处理和原子层沉积薄层氧化铝的修饰方式,制备了喷墨打印有机薄膜晶体管并研究了修饰前后绝缘层的表面形貌、接触角及有源层的物相结构。虽然绝缘层的表面形貌在修饰前后变化不大,但是表面接触角和打印后有源层的物相结构有较大差别。OTS处理和沉积氧化铝修饰后,器件的迁移率比修饰前分别增大了4倍和9倍,而开关比则分别增大了1个和4个数量级。修饰后的最大迁移率可达0.35 cm~2/(V·s),开关比可达6.0×10~6。