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Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

《机械工程前沿（英文）》 2014年 第9卷 第2期   页码 106-119 doi: 10.1007/s11465-014-0301-2

摘要：

Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the tool wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

关键词： tool wear     nickel based super-alloy     wear mechanism    

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Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

ZHAO Qingliang, Brinksmeier Ekkard, Riemer Oltmann, Rickens Kai

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 350-355 doi: 10.1007/s11465-007-0061-3

摘要： In this paper, a novel conditioning technique using copper bonded diamond grinding wheels of 91 yD grain size and electrolytic in-process dressing (ELID) is first developed to precisely and effectively condition a nickel-electroplated monolayer coarse-grained diamond grinding wheel of 151 μm grain size. Under optimised conditioning parameters, the super abrasive diamond wheel was well conditioned in terms of a minimized run-out error and flattened diamond grain surfaces of constant peripheral envelope. The conditioning force was monitored by a force transducer, while the modified wheel surface status was in-situ monitored by a coaxial optical distance measurement system. Finally, the grinding experiment on BK7 was conducted using the well-conditioned wheel with the corresponding surface morphology and subsurface damage measured by atomic force microscope (AFM) and scanning electric microscope (SEM), respectively. The experimental result shows that the newly developed conditioning technique is applicable and feasible to ductile grinding optical glass featuring nano scale surface roughness, indicating the potential of super abrasive diamond wheels in ductile machining brittle materials.

关键词： ELID     peripheral     electrolytic in-process     nickel-electroplated monolayer     measurement    

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Nickel-based metal−organic framework-derived whisker-shaped nickel phyllosilicate toward efficiently

《化学科学与工程前沿（英文）》 2022年 第16卷 第10期   页码 1493-1504 doi: 10.1007/s11705-022-2168-9

摘要： Metal−organic framework-derived materials have attracted significant attention in the applications of functional materials. In this work, the rod-like nickel-based metal−organic frameworks were first synthesized and subsequently employed as the hard templates and nickel sources to prepare the whisker-shaped nickel phyllosilicate using a facile hydrothermal technology. Then, the nickel phyllosilicate whiskers were evaluated to enhance the mechanical, thermal, flammable, and tribological properties of epoxy resin. The results show that adequate nickel phyllosilicate whiskers can disperse well in the matrix, improving the tensile strength and elastic modulus by 13.6% and 56.4%, respectively. Although the addition of nickel phyllosilicate whiskers could not obtain any UL-94 ratings, it enhanced the difficulty in burning the resulted epoxy resin nanocomposites and considerably enhanced thermal stabilities. Additionally, it was demonstrated that such nickel phyllosilicate whiskers preferred to improve the wear resistance instead of the antifriction feature. Moreover, the wear rate of epoxy resin nanocomposites was reduced significantly by 80% for pure epoxy resin by adding 1 phr whiskers. The as-prepared nickel phyllosilicate whiskers proved to be promising reinforcements in preparing of high-performance epoxy resin nanocomposites.

关键词： metal−organic framework     nickel phyllosilicate     whisker     epoxy resin     mechanical response     tribological performance     flammable property    

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LCF behavior and life prediction method of a single crystal nickel-based superalloy at high temperature

Zhihua ZHANG,Huichen YU,Chengli DONG

《机械工程前沿（英文）》 2015年 第10卷 第4期   页码 418-423 doi: 10.1007/s11465-015-0362-x

摘要：

Low cycle fatigue tests were conducted on the single crystal nickel-based superalloy, DD6, with different crystallographic orientations (i.e., [001], [011], and [111]) and strain dwell types (i.e., tensile, compressive, and balanced types) at a certain high temperature. Given the material anisotropy and mean stress, both orientation factor and stress range were introduced to the Smith, Watson, and Topper (SWT) stress model to predict the fatigue life. Experimental results indicated that the fatigue properties of DD6 depend on both crystallographic orientation and loading types. The fatigue life of the tensile, compressive, and balanced strain dwell tests are shorter than those of continuous cycling tests without strain dwell because of the important creep effect. The predicted results of the proposed modified SWT stress method agree well with the experimental data.

关键词： life prediction     single crystal superalloy     low cycle fatigue (LCF)     crystallographic orientation     strain dwell    

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Steam reforming of toluene as a tar model compound with modified nickel-based catalyst

Omeralfaroug KHALIFA, Mingxin XU, Rongjun ZHANG, Tahir IQBAL, Mingfeng LI, Qiang LU

《能源前沿（英文）》 2022年 第16卷 第3期   页码 492-501 doi: 10.1007/s11708-021-0721-8

摘要： Catalytic steam reforming is a promising route for tar conversion to high energy syngas in the process of biomass gasification. However, the catalyst deactivation caused by the deposition of residual carbon is still a major challenge. In this paper, a modified Ni-based Ni-Co/Al O -CaO (Ni-Co/AC) catalyst and a conventional Ni/Al O (Ni/A) catalyst were prepared and tested for tar catalytic removal in which toluene was selected as the model component. Experiments were conducted to reveal the influences of the reaction temperature and the ratio between steam to carbon on the toluene conversion and the hydrogen yield. The physicochemical properties of the modified Ni-based catalyst were determined by a series of characterization methods. The results indicated that the Ni-Co alloy was determined over the Ni-Co/AC catalyst. The doping of CaO and the presence of Ni-Co alloy promoted the performance of toluene catalytic dissociation over Ni-Co/AC catalyst compared with that over Ni/A catalyst. After testing in steam for 40 h, the carbon conversion over Ni-Co/AC maintained above 86% and its resistance to carbon deposition was superior to Ni/A catalyst.

关键词： catalytic steam reforming     tar model compound     Ni-based catalyst     carbon resistance    

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Topology optimization and seismic collapse assessment of shape memory alloy (SMA)-braced frames: Effectivenessof Fe-based SMAs

Aydin HASSANZADEH; Saber MORADI

《结构与土木工程前沿（英文）》 2022年 第16卷 第3期   页码 281-301 doi: 10.1007/s11709-022-0807-3

摘要： This paper presents a seismic topology optimization study of steel braced frames with shape memory alloy (SMA) braces. Optimal SMA-braced frames (SMA-BFs) with either Fe-based SMA or NiTi braces are determined in a performance-based seismic design context. The topology optimization is performed on 5- and 10-story SMA-BFs considering the placement, length, and cross-sectional area of SMA bracing members. Geometric, strength, and performance-based design constraints are considered in the optimization. The seismic response and collapse safety of topologically optimal SMA-BFs are assessed according to the FEMA P695 methodology. A comparative study on the optimal SMA-BFs is also presented in terms of total relative cost, collapse capacity, and peak and residual story drift. The results demonstrate that Fe-based SMA-BFs exhibit higher collapse capacity and more uniform distribution of lateral displacement over the frame height while being more cost-effective than NiTi braced frames. In addition to a lower unit price compared to NiTi, Fe-based SMAs reduce SMA material usage. In frames with Fe-based SMA braces, the SMA usage is reduced by up to 80%. The results highlight the need for using SMAs with larger recoverable strains.

关键词： topology optimization     shape memory alloy     Fe-based SMA     steel braced frames     performance-based seismic design     collapse assessment    

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Direct writing of electronics based on alloy and metal (DREAM) ink: A newly emerging area and its impact

Qin ZHANG, Yi ZHENG, Jing LIU

《能源前沿（英文）》 2012年 第6卷 第4期   页码 311-340 doi: 10.1007/s11708-012-0214-x

摘要： Electronics, such as printed circuit board (PCB), transistor, radio frequency identification (RFID), organic light emitting diode (OLED), solar cells, electronic display, lab on a chip (LOC), sensor, actuator, and transducer etc. are playing increasingly important roles in people’s daily life. Conventional fabrication strategy towards integrated circuit (IC), requesting at least six working steps, generally consumes too much energy, material and water, and is not environmentally friendly. During the etching process, a large amount of raw materials have to be abandoned. Besides, lithography and microfabrication are typically carried out in “Cleanroom” which restricts the location of IC fabrication and leads to high production costs. As an alternative, the newly emerging ink-jet printing electronics are gradually shaping modern electronic industry and its related areas, owing to the invention of a series of conductive inks composed of polymer matrix, conductive fillers, solvents and additives. Nevertheless, the currently available methods also encounter some technical troubles due to the low electroconductivity, complex sythesis and sintering process of the inks. As an alternative, a fundamentally different strategy was recently proposed by the authors’ lab towards truly direct writing of electronics through introduction of a new class of conductive inks made of low melting point liquid metal or its alloy. The method has been named as direct writing of electronics based on alloy and metal (DREAM) ink. A series of functional circuits, sensors, electronic elements and devices can thus be easily written on various either soft or rigid substrates in a moment. With more and more technical progresses and fundamental discoveries being kept made along this category, it was found that a new area enabled by the DREAM ink electronics is emerging, which would have tremendous impacts on future energy and environmental sciences. In order to promote the research and development along this direction, the present paper is dedicated to draft a comprehensive picture on the DREAM ink technology by summarizing its most basic features and principles. Some important low melting point metal ink candidates, especially the room temperature liquid metals such as gallium and its alloy, were collected, listed and analyzed. The merits and demerits between conventional printed electronics and the new direct writing methods were comparatively evaluated. Important scientific issues and technical strategies to modify the DREAM ink were suggested and potential application areas were proposed. Further, digestions on the impacts of the new technology among energy, health, and environmental sciences were presented. Meanwhile, some practical challenges, such as security, environment-friendly feature, steady usability, package, etc. were summarized. It is expected that the DREAM ink technology will initiate a series of unconventional applications in modern society, and even enter into peoples’ daily life in the near future.

关键词： direct writing of electronics based on alloy and metal (DREAM) ink     direct writing of electronics     printed electronics     liquid metal ink     integrated circuit     consumer electronics     nano liquid metal    

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Characterization of the tensile properties of friction stir welded aluminum alloy joints based on axial

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 289-298 doi: 10.1007/s11465-016-0393-y

摘要：

Friction stir welding (FSW) process has gained attention in recent years because of its advantages over the conventional fusion welding process. These advantages include the absence of heat formation in the affected zone and the absence of large distortion, porosity, oxidation, and cracking. Experimental investigations are necessary to understand the physical behavior that causes the high tensile strength of welded joints of different metals and alloys. Existing literature indicates that tensile properties exhibit strong dependence on the rotational speed, traverse speed, and axial force of the tool that was used. Therefore, this study introduces the experimental procedure for measuring tensile properties, namely, ultimate tensile strength (UTS) and tensile elongation of the welded AA 7020 Al alloy. Experimental findings suggest that a welded part with high UTS can be achieved at a lower heat input compared with the high heat input condition. A numerical approach based on genetic programming is employed to produce the functional relationships between tensile properties and the three inputs (rotational speed, traverse speed, and axial force) of the FSW process. The formulated models were validated based on the experimental data, using the statistical metrics. The effect of the three inputs on the tensile properties was investigated using 2D and 3D analyses. A high UTS was achieved, including a rotational speed of 1050 r/min and traverse speed of 95 mm/min. The results also indicate that 8 kN axial force should be set prior to the FSW process.

关键词： tensile properties     ultimate tensile strength     tensile elongation     friction stir welding     tool rotational speed     genetic programming     welding speed    

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高酸性腐蚀气田用BG2250-125镍基合金油管开发

沈琛,张忠铧,张春霞

《中国工程科学》 2010年 第12卷 第10期   页码 35-38

摘要：

综述了高酸性腐蚀气田用BG2250镍基合金油井管国产化开发进展情况。通过与国外同类产品的实物质量分析以及成分、电弧炉冶炼、电渣重溶、锻造、热挤压、冷轧、特殊扣设计与加工、腐蚀评价等工艺技术的研究，宝钢开发的BG2250-125等镍基合金油管的产品质量达到了国际同类产品的先进水平，并已在普光气田成功下井使用，为我国高酸性气田的开发提供了重要的物资保障。

关键词： 镍基合金     油管     酸性井     产品性能    

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Experimental investigation of liquid metal alloy based mini-channel heat exchanger for high power electronic

Manli LUO, Jing LIU

《能源前沿（英文）》 2013年 第7卷 第4期   页码 479-486 doi: 10.1007/s11708-013-0277-3

摘要： There is currently a growing demand for developing efficient techniques for cooling integrated electronic devices with ever increasing heat generation power. To better tackle the high-density heat dissipation difficulty within the limited space, this paper is dedicated to clarify the heat transfer behaviors of the liquid metal flowing in mini-channel exchangers with different geometric configurations. A series of comparative experiments using liquid metal alloy Ga68%In20%Sn12% as coolant were conducted under prescribed mass flow rates in three kinds of heat exchangers with varied geometric sizes. Meanwhile, numerical simulations for the heat exchangers under the same working conditions were also performed which well interpreted the experimental measurements. The simulated heat sources were all cooled down by these three heat dissipation apparatuses and the exchanger with the smallest channel width was found to have the largest mean heat transfer coefficient at all conditions due to its much larger heat transfer area. Further, the present work has also developed a correlation equation for characterizing the Nusselt number depending on Peclet number, which is applicable to the low Peclet number case with constant heat flux in the hydrodynamically developed and thermally developing region in the rectangular channel. This study is expected to provide valuable reference for designing future liquid metal based mini-channel heat exchanger.

关键词： heat exchanger     liquid metal     mini-channel     heat dissipation     heat transfer coefficient    

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长大公路隧道火灾安全疏散性能化设计与分析

陈长坤,徐志胜

《中国工程科学》 2007年 第9卷 第9期   页码 78-83

摘要：

基于性能化防火设计方法， 分析火灾条件下长大公路隧道内人 员疏散行为的特点，给出隧道内人 员疏散的安全判据，并结合某隧道 的结构及车流特征对人员疏散过程 进行了数值模拟研究，分析隧道在 正常通车和局部行车堵塞时，不同 火源位置、横通道间距与横通道宽 度对人员疏散时间及安全状态的影 响。结果表明,与建筑内人员疏散不 同，长大公路隧道内火灾的可用安 全疏散时间(ASET)与需要的安全疏 散时间(RSET)均为沿隧道长度方向 位置的函数。隧道内人员安全疏散 的时间曲线在各横通道疏散口出现 峰值，这主要是受到横通道通行能 力的限制，各疏散口人员集聚等待 所致。当隧道发生局部堵塞时，横 通道口需要的安全疏散时间显著增 加，危险性也急剧增大。隧道内人 员疏散的性能化防火设计应综合考 虑火源位置对人员载荷及疏散口位 置可用安全疏散时间的影响。该研 究为公路隧道火灾安全疏散设施的 优化设计提供依据。

关键词： 疏散     火灾     隧道     横通道     性能化防火设计    

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Activated carbon induced oxygen vacancies-engineered nickel ferrite with enhanced conductivity for supercapacitor

《化学科学与工程前沿（英文）》 2023年 第17卷 第12期   页码 2088-2100 doi: 10.1007/s11705-023-2352-6

摘要： Activated carbon induced oxygen vacancies-engineered nickel ferrite with enhanced conductivity for supercapacitor application

关键词： nickel ferrite conductivity     carbon oxygen vacancies    

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Enabling nickel ferrocyanide nanoparticles for high-performance ammonium ion storage

《化学科学与工程前沿（英文）》 2023年 第17卷 第2期   页码 226-235 doi: 10.1007/s11705-022-2198-3

摘要： Prussian blue and its analogs are extensively investigated as a cathode for ammonium-ion batteries. However, they often suffer from poor electronic conductivity. Here, we report a Ni2Fe(CN)6/multiwalled carbon nanotube composite electrode material, which is prepared using a simple coprecipitation approach. The obtained material consists of nanoparticles with sizes 30–50 nm and the multiwalled carbon nanotube embedded in it. The existence of multiwalled carbon nanotube ensures that the Ni2Fe(CN)6/multiwalled carbon nanotube composite shows excellent electrochemical performance, achieving a discharge capacity of 55.1 mAh·g–1 at 1 C and 43.2 mAh·g–1 even at 15 C. An increase in the ammonium-ion diffusion coefficient and ionic/electron conductivity based on kinetic investigations accounts for their high performance. Furthermore, detailed ex situ characterizations demonstrate that Ni2Fe(CN)6/multiwalled carbon nanotube composite offers three advantages: negligible lattice expansion during cycling, stable structure, and the reversible redox couple. Therefore, the Ni2Fe(CN)6/multiwalled carbon nanotube composite presents a long cycling life and high rate capacity. Finally, our study reports a desirable material for ammonium-ion batteries and provides a practical approach for improving the electrochemical performance of Prussian blue and its analogs.

关键词： nickel ferrocyanides     NH4+     electrochemistry     Prussian blue     aqueous ammonium ion batteries    

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Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

《化学科学与工程前沿（英文）》 2023年 第17卷 第12期   页码 2114-2126 doi: 10.1007/s11705-023-2357-1

摘要： In this study, nickel phyllosilicate was synthesized based on molybdenum disulfide (MoS2@NiPS) by the sol-gel method, and then MoS2@NiPS was used to prepare epoxy composites. The thermal stability, flame retardancy, and frictional performances of epoxy composites were studied. With the addition of 3 wt% MoS2@NiPS, the epoxy composite increased the limiting oxygen index from 23.8% to 26.1% and reduced the vertical burning time from 166 s for epoxy resin to 35 s. The residual char of the epoxy composite increased from 11.8 to 20.2 wt%. MoS2@NiPS promoted the graphitization of the residual char, and facilitated the formation of a dense and continuous char layer, thereby improving the fire safety of epoxy resin. The epoxy composite with 3 wt% MoS2@NiPS had excellent wear resistance property with a wear rate of 2.19 × 10−5 mm3·N–1·m–1, which was 68.8% lower than that of epoxy resin. This study presented a practical approach to improve the frictional and fire resistance of epoxy composites.

关键词： molybdenum disulfide     nickel phyllosilicate     epoxy resin     flame retardancy    

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A novel shape memory alloy actuated soft gripper imitated hand behavior

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0700-8

摘要： The limited length shrinkage of shape memory alloy (SMA) wire seriously limits the motion range of SMA-based gripper. In this paper, a new soft finger without silicone gel was designed based on pre bent SMA wire, and the finger was back to its original shape by heating SMA wire, rather than relying only on heat exchange with the environment. Through imitating palm movement, a structure with adjustable spacing between fingers was made using SMA spring and rigid spring. The hook structure design at the fingertip can form self-locking to further improve the load capacity of gripper. Through the long thin rod model, the relationship of the initial pre bent angle on the bending angle and output force of the finger was analyzed. The stress-strain model of SMA spring was established for the selection of rigid spring. Three grasping modes were proposed to adapt to the weight of the objects. Through the test of the gripper, it was proved that the gripper had large bending amplitude, bending force, and response rate. The design provides a new idea for the lightweight design and convenient design of soft gripper based on SMA.

关键词： shape memory alloy (SMA)     pre bent     wire     gripper     grasping mode     lightweight    

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标题 作者 时间 类型 操作

Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

期刊论文

Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

ZHAO Qingliang, Brinksmeier Ekkard, Riemer Oltmann, Rickens Kai

期刊论文

Nickel-based metal−organic framework-derived whisker-shaped nickel phyllosilicate toward efficiently

期刊论文

LCF behavior and life prediction method of a single crystal nickel-based superalloy at high temperature

Zhihua ZHANG,Huichen YU,Chengli DONG

期刊论文

Steam reforming of toluene as a tar model compound with modified nickel-based catalyst

Omeralfaroug KHALIFA, Mingxin XU, Rongjun ZHANG, Tahir IQBAL, Mingfeng LI, Qiang LU

期刊论文

Topology optimization and seismic collapse assessment of shape memory alloy (SMA)-braced frames: Effectivenessof Fe-based SMAs

Aydin HASSANZADEH; Saber MORADI

期刊论文

Direct writing of electronics based on alloy and metal (DREAM) ink: A newly emerging area and its impact

Qin ZHANG, Yi ZHENG, Jing LIU

期刊论文

Characterization of the tensile properties of friction stir welded aluminum alloy joints based on axial

Biranchi PANDA,A. GARG,Zhang JIAN,Akbar HEIDARZADEH,Liang GAO

期刊论文

高酸性腐蚀气田用BG2250-125镍基合金油管开发

沈琛,张忠铧,张春霞

期刊论文

Experimental investigation of liquid metal alloy based mini-channel heat exchanger for high power electronic

Manli LUO, Jing LIU

期刊论文

长大公路隧道火灾安全疏散性能化设计与分析

陈长坤,徐志胜

期刊论文

Activated carbon induced oxygen vacancies-engineered nickel ferrite with enhanced conductivity for supercapacitor

期刊论文

Enabling nickel ferrocyanide nanoparticles for high-performance ammonium ion storage

期刊论文

Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

期刊论文

A novel shape memory alloy actuated soft gripper imitated hand behavior

期刊论文