29 Search Results

This paper describes: 1) the use of feed rate scheduling software to predict the radial depth of cut variation for three-axis milling toolpaths and; 2) the use of the radial depth profile in a time-domain simulation to predict dynamic cutting forces. The time-domain simulation, which also includes the tool tip frequency response functions and force model (which relates the cutting force components to the chip geometry) as inputs, enables dynamic force profiles to be predicted and parameter combinations that cause chatter to be identified. A ramp geometry is selected that provides constantly varying radial depth and force predictions are completedmore » at multiple axial depths for comparison to measured forces. Both stable and unstable (chatter) milling conditions were observed with good agreement between time-domain simulation and measurement results. The value of combining the feed rate scheduling software and time-domain simulation is demonstrated.« less

Hybrid manufacturing consisting of metal additively manufactured preforms and computer numerical control (CNC) machining has been established to be an effective method for high material use rates. However, hybrid manufacturing introduces unique challenges. Near-net shape designs are typically selected, which result in a smaller margin for part placement within the stock and stringent requirements for work coordinate system identification. Additionally, less stock material reduces the preform stiffness, which limits the material removal rates during machining. This paper demonstrates a digital twin for CNC machining of a wire arc additively manufactured preform that implements: 1) structured light scanning for stock modelmore » identification and tool path generation; 2) a fused filament fabrication apparatus to attach temporary fiducials and scan targets to the preform that enable coordinate system definition for both the CAM and CNC machine; 3) preform and tool tip frequency response function measurements to enable stable milling parameter selection; and 4) post-manufacturing measurements of geometry, surface finish, and structural dynamics to confirm designer intent. These efforts define key components of the machining digital twin for hybrid manufacturing.« less

Low-Z nanocrystalline diamond (NCD) grids have been developed to reduce spurious fluorescence and avoid X-ray peak overlaps or interferences between the specimen and conventional metal grids. Here, the low-Z NCD grids are non-toxic and safe to handle, conductive, can be subjected to high-temperature heating experiments, and may be used for analytical work in lieu of metal grids. Both a half-grid geometry, which can be used for any lift-out method, or a full-grid geometry that can be used for ex situ lift-out or thin film analyses, can be fabricated and used for experiments.

Indium (In) and other low melting point metals are used as interconnects in a variety of hybridized circuits and a full understanding of the metallurgy of these interconnects is important to the reliability and performance of the devices. Here, this paper shows that room temperature focused ion beam (FIB) preparation of cross-sections, using Ga⁺ or Xe⁺ can result in artifacts that obscure the true In microbump structure. The use of modified milling strategies to minimize the increased local sample temperature are shown to produce cross-sections that are representative of the In bump microstructure in some sample configurations. Furthermore, cooling ofmore » the sample to cryogenic temperatures is shown to reliably eliminate artifacts in FIB prepared cross-sections of In bumps allowing the true bump microstructure to be observed.« less

Here, a direct comparison between electron transparent transmission electron microscope (TEM) samples prepared with gallium (Ga) and xenon (Xe) focused ion beams (FIBs) is performed to determine if equivalent quality samples can be prepared with both ion species. We prepared samples using Ga FIB and Xe plasma focused ion beam (PFIB) while altering a variety of different deposition and milling parameters. The samples’ final thicknesses were evaluated using STEM-EELS $$\textit{t/λ}$$ data. Using the Ga FIB sample as a standard, we compared the Xe PFIB samples to the standard and to each other. We show that although the Xe PFIB samplemore » preparation technique is quite different from the Ga FIB technique, it is possible to produce high-quality, large area TEM samples with Xe PFIB. We also describe best practices for a Xe PFIB TEM sample preparation workflow to enable consistent success for any thoughtful FIB operator. For Xe PFIB, we show that a decision must be made between the ultimate sample thickness and the size of the electron transparent region.« less

This paper describes the dynamic stability evaluation of a constrained-motion dynamometer (CMD) with passive damping. The CMD’s flexure-based design offers an alternative to traditional piezoelectric cutting force dynamometers, which can exhibit adverse effects of the complex structural dynamics on the measurement accuracy. In contrast, the CMD system’s structural dynamics are nominally single degree of freedom and are conveniently altered by material selection, flexure element geometry, and element arrangement. In this research, a passive damping approach is applied to increase the viscous damping ratio and, subsequently, the stability limit. Cutting tests were completed and the in situ CMD displacement and velocitymore » signals were sampled at the spindle rotating frequency. The periodic sampling approach was used to determine if the milling response was synchronous with the spindle rotation (stable) or not (chatter) by constructing Poincaré maps for both experiment and prediction (time-domain simulation). It was found that the viscous damping coefficient was increased by 130% and the critical stability limit was increased from 4.3 mm (no damping) to 15.4 mm (with damping).« less

Tristructural isotropic (TRISO) fuel particles have been primarily developed for high-temperature gas-cooled nuclear reactors and can be subjected to oxidizing environments for extended periods in an off-normal accident scenario. Surrogate TRISO fuel particles were oxidized in air at 1,000 or 1,100 °C for up to 120 h. Here, the oxide scale morphology and thickness were studied via scanning electron microscopy, focused ion beam, and atomic force microscopy. TRISO particles oxidized at 1,100 °C exhibited a highly crystalline oxide scale, which led to significant cracking and irregularly shaped closed porosity, whereas those oxidized at 1,000 °C possessed a primarily amorphous oxidemore » scale, which contained small, rounded internal pores and no larger defects. The observed phenomena deviated from the expected behavior based on models for oxide growth on flat-plate and fiber SiC. The oxidation kinetics of TRISO fuel particles in high-temperature air were investigated without mechanically deforming the surface and were analyzed with respect to oxide morphology.« less

High-resolution imaging with secondary ion mass spectrometry (nanoSIMS) has become a standard method in systems biology and environmental biogeochemistry and is broadly used to decipher ecophysiological traits of environmental microorganisms, metabolic processes in plant and animal tissues, and cross-kingdom symbioses. When combined with stable isotope-labeling—an approach we refer to as nanoSIP—nanoSIMS imaging offers a distinctive means to quantify net assimilation rates and stoichiometry of individual cell-sized particles in both low- and high-complexity environments. While the majority of nanoSIP studies in environmental and microbial biology have focused on nitrogen and carbon metabolism (using ¹⁵N and ¹³C tracers), multiple advances have pushedmore » the capabilities of this approach in the past decade. The development of a high-brightness oxygen ion source has enabled high-resolution metal analyses that are easier to perform, allowing quantification of metal distribution in cells and environmental particles. New preparation methods, tools for automated data extraction from large data sets, and analytical approaches that push the limits of sensitivity and spatial resolution have allowed for more robust characterization of populations ranging from marine archaea to fungi and viruses. Further, NanoSIMS studies continue to be enhanced by correlation with orthogonal imaging and ‘omics approaches; when linked to molecular visualization methods, such as in situ hybridization and antibody labeling, these techniques enable in situ function to be linked to microbial identity and gene expression. Here we present an updated description of the primary materials, methods, and calculations used for nanoSIP, with an emphasis on recent advances in nanoSIMS applications, key methodological steps, and potential pitfalls.« less

Magnetocaloric alloys are an important class of materials that enable non-vapor compression cycles. One promising candidate for magnetocaloric systems is LaFeMnSi, thanks to a combination of factors including low-cost constituents and a useful curie temperature, although control of the constituents’ phase distribution can be challenging. In this paper, the effects of composition and high energy ball milling on the particle morphology and phase stability of LaFe11.71-xMnxSi1.29H1.6 magnetocaloric powders were investigated. The powders were characterized with optical microscopy, dynamic light scattering, X-ray diffraction (XRD), and differential scanning calorimetry (DSC). It was found that the powders retained most of their original magnetocaloricmore » phase during milling, although milling reduced the degree of crystallinity in the powder. Furthermore, some oxide phases (<1 weight percent) were present in the as-received and milled powders, which indicates that no significant contamination of the powders occurred during milling. Finally, the results indicated that the Curie temperature drops as Fe content decreases (Mn content increases). In all of the powders, milling led to an increase in the Curie temperature of ~3–6 °C.« less

High speed friction grinding has been used to grind plant and food substances in water but never been explored for grinding of thermoplastics like polylactic acid (PLA), low and high density polyethylene and polypropylene. Such grinding was investigated in this work and was made possible by using 0.5% guar gum solution instead of just water because increasing the viscosity of water reduced their settling and the speed of passing through the grinder. Additionally, tensile, flexural, and impact strengths of the plastics were studied and higher grinding efficiency of PLA could be explained by its low elongation-at-break compared to low densitymore » polyethylene, high density polyethylene, and polypropylene. The microplastics (2000–45 μm) were studied for mass and particle size distributions and by scanning electron microscopy, ¹³C CP/MAS NMR, Fourier transform infrared spectroscopy, differential scanning calorimetry, and thermogravimetric analysis. In addition, viscosity of guar gum and contact angles was measured. This new technology can produce finely ground microplastics (710–45 μm) for a variety of applications.« less