Search Results (16)

In this work, micro-arc oxidation (MAO) under constant- and gradient-current modes was used to modify the surface of 6061 aluminum alloy. A black coating was created in situ on the alloy surface by controlling the spark discharge parameters during MAO. Using an electrochemical workstation (Metrohm Autolab, PGSTAT302 N, Herisau, Switzerland), energy-dispersive spectroscopy (EDS, JEOL, JSM-IT500A, Tokyo Metropolis, Japan), and scanning electron microscopy (SEM, JEOL, JSM-7900F, Tokyo Metropolis, Japan), the effects of the current output modes on the coating growth rate, energy consumption, colorimetric parameters (L*, a*, b*), microstructure, and corrosion resistance were methodically examined. The findings showed that the gradient-current mode (6 → 4 → 2 A/dm²) greatly lowered the micropore size (from 3.89 μm to 1.52 μm) and improved the coating compactness (porosity dropped by 40%), and all coatings satisfied the necessary blackness criterion (L* < 30). Additionally, this mode achieved excellent corrosion resistance, as demonstrated by a one-order-of-magnitude reduction in the corrosion current density (2.55 × 10⁻⁸ A/cm² vs. 2.34 × 10⁻⁷ A/cm²), while minimizing the energy consumption (2.37 kW·h/m²·μm vs. 3.45 kW·h/m²·μm for constant current). Full article

This research study aims to study and investigate the corrosion rate, hot tensile properties, and microstructures of SSDS 2507 and AISI 316 gas tungsten arc dissimilar weldments. Three separate samples were developed with frequencies of 2, 4, and 6 Hz using the pulse arc mode technique. The tensile characteristics were assessed at two distinct temperatures (27 °C and 350 °C) in order to examine the behavior of the welded structure. Mechanical characterization such as hardness measurement and corrosion behavior were studied. The metallurgical characteristics of pulsed and continuous current weldments were examined using microscopes (optical and scanning), revealing variations across different zones. At the 4 Hz pulse frequency, the material exhibited improved tensile qualities compared to constant arc welding. The microstructures indicated that the fusion zone in the pulsed arc weldment consisted of a balanced mixture of inter-granular austenite and ferrite phases. A better corrosion resistance rate of 0.0487 mm/year was observed in the pulsed arc weldment compared to both the SSDS2507 base metal and the constant arc weldment. Specifically, at a temperature of 27 °C, the ultimate tensile strength was 695 MPa, whereas at a temperature of 350 °C, the tensile strength was 475 MPa. The weld strength of the pulsed arc weldment exhibited a 15.8% improvement in comparison to the constant arc weldment. The surface hardness value increased to 240 HV compared to the constant arc weldment, which had an HV of 225. Full article

Through a three-factor, two-level orthogonal experiment, the effects of varying electrical parameters (voltage, frequency, and duty cycle) on the thickness, pressure resistance, corrosion resistance, morphology, and phase composition of the micro-arc oxidized film of aluminum foil in constant voltage mode were investigated. The aluminum foil was oxidized by micro-arc oxidation for 50 min. Eddy-current thickness gauges were used to measure the oxide film’s thickness, TV characterization testers were used to test the film’s resistance to pressure, kinetic potential polarization curves were used to examine the oxide film’s resistance to electrochemical corrosion, and SEM and XRD composition were used to examine the microstructures and phase compositions of the oxide films that were produced. The oxide film’s thickness was increased from 7 μm to 22 μm and the voltage was increased from 350 V to 450 V. The oxide film’s ramp-up time at a frequency and duty cycle of 2000 Hz and 15% could reach 3 s, and the resistance value could reach 98% of the micro-arc oxidation voltage. The oxide film’s i_corr decreased by an order of magnitude at high voltage compared to low voltage and the R_p value increased by an order of magnitude, which improved the corrosion resistance. The oxide film’s thickness increased as the voltage increased. Meanwhile, SEM was used to enhance the corrosion resistance. The oxide film thickens as the voltage increases. At the same voltage, the oxide film with a high frequency and low duty cycle has the best voltage resistance. The oxide film generated under high-voltage conditions has regular and dense surface holes, the oxide film’s α-Al₂O₃ phase increases, and the corrosion resistance in the NaCl medium is enhanced. Full article

The physical phenomena of submerged arc welding (SAW) conducted with a 1.6 mm flux-cored wire were investigated using X-ray imaging technique. Three kinds of metal transfer modes were confirmed in this paper, namely the front flux wall-guided droplet transfer, back flux wall-guided droplet transfer, and repelled droplet transfer, of which the corresponding percentages were 47.65%, 45.29%, and 7.06%, respectively. Although the average sizes of the droplets for SAW and FCAW (flux-cored wire welding) were 2.0 mm and 1.9 mm with an average droplet transfer time of 90.3 ms, it required 36.4% more time for the droplet of SAW to finish one metal transfer than it did in FCAW. In addition, the volume of the cavity was not constant but repeated a cycle mode of “expansion and contraction” during the whole process. Thus, the dynamics of the cavity and viscous resistance caused by the flux collectively slowed down the velocity of the droplets from the wire to the weld pool in SAW. Compared with FCAW, a smoother weld without pits and pores was manufactured during the SAW process. Due to the compression effect of the flux, the 14.5 mm average weld width of SAW was 2.9 mm shorter than that of the FCAW. Furthermore, the thickness of slag with a porous structure in SAW was 2.7 times of that in FCAW, indicating that it could provide better protection to the weld of SAW. Full article

An environmentally friendly alkaline electrolyte of silicate and borate, which contained the addition of carbohydrates (lactose, starch, and dextrin), was applied to produce micro-arc oxidation (MAO) coatings on AZ31B magnesium alloy surfaces in constant current mode. The effects of the carbohydrates on the performance of the MAO coatings were investigated using a scanning electron microscope (SEM), an X-ray diffractometer (XRD), energy-dispersive spectroscopy (EDS), the salt spray test, potentiodynamic polarization curves, and electrochemical impedance spectroscopy (EIS). The results show that the carbohydrates effectively inhibited spark discharge, so the anodized growth process, surface morphology, composition, and corrosion resistance of the MAO coatings were strongly dependent on the carbohydrate concentration. This is ascribed to the surface adsorption layer formed on the surface of the magnesium alloy. When the carbohydrate concentration was 10 g/L, smooth, compact, and thick MAO coatings with excellent corrosion resistance on the magnesium alloy were obtained. Full article

In this research, for a given time interval, which is the general period of melanoma treatment, a bilinear control model is considered, given by a system of differential equations, which describes the interaction between drug-sensitive and drug-resistant cancer cells both during drug therapy and in the absence of it. This model also contains a control function responsible for the transition from the stage of such therapy to the stage of its absence and vice versa. To find the optimal moments of switching between these stages, the problem of minimizing the cancer cells load both during the entire period of melanoma treatment and at its final moment is stated. Such a minimization problem has a nonconvex control set, which can lead to the absence of an optimal solution to the stated minimization problem in the classes of admissible modes traditional for applications. To avoid this problem, the control set is imposed to be convex. As a result, a relaxed minimization problem arises, in which the optimal solution exists. An analytical study of this minimization problem is carried out using the Pontryagin maximum principle. The corresponding optimal solution is found in the form of synthesis and may contain a singular arc. It shows that there are values of the parameters of the bilinear control model, its initial conditions, and the time interval for which the original minimization problem does not have an optimal solution, because it has a sliding mode. Then for such values it is possible to find an approximate optimal solution to the original minimization problem in the class of piecewise constant controls with a predetermined number of switchings. This research presents the results of the analysis of the connection between such an approximate solution of the original minimization problem and the optimal solution of the relaxed minimization problem based on numerical calculations performed in the Maple environment for the specific values of the parameters of the bilinear control model, its initial conditions, and the time interval. Full article

Toxoplasma gondii (T. gondii) is a zoonotic parasite that is widely distributed and seriously endangers public health and human health. Therefore, accurate and effective detection of T. gondii is crucial. This study proposes a microfluidic biosensor using a thin-core microfiber (TCMF) coated with molybdenum disulfide (MoS₂) for immune detection of T. gondii. The single-mode fiber was fused with the thin-core fiber, and the TCMF was obtained by arc discharging and flame heating. In order to avoid interference and protect the sensing structure, the TCMF was encapsulated in the microfluidic chip. MoS₂ and T. gondii antigen were modified on the surface of TCMF for the immune detection of T. gondii. Experimental results showed that the detection range of the proposed biosensor for T. gondii monoclonal antibody solutions was 1 pg/mL to 10 ng/mL with sensitivity of 3.358 nm/log(mg/mL); the detection of limit was calculated to be 87 fg/mL through the Langmuir model; the dissociation constant and the affinity constant were calculated to be about 5.79 × 10⁻¹³ M and 1.727 × 10¹⁴ M⁻¹, respectively. The specificity and clinical characteristics of the biosensor was explored. The rabies virus, pseudorabies virus, and T. gondii serum were used to confirm the excellent specificity and clinical characteristics of the biosensor, indicating that the proposed biosensor has great application potential in the biomedical field. Full article

Gas metal arc welding-based additive manufacturing (GMA–AM) is a promising, low-cost approach to fabricate large-scale and complex geometry components using layer-by-layer deposition of metals. However, the low forming accuracy of GMA–AM still limits its one-off industrial application due to the strong and nonlinear interactions between arc–droplet transfer and molten pool. To fully understand the influential mechanism of this inherent interaction in the GMA–AM process to precisely control the part accuracy, the arc–droplet transfer behavior in the GMA–AM process with different current waveforms was firstly studied experimentally. The phenomena of the arc swing and the differing droplet transfer with the increase in deposited height were interpreted. The thermal force status of the molten pool and its balance boundary conditions were also theoretically analyzed. Finally, the microstructure and the hardness of the AM parts with different cooling times were tested and analyzed. The experimental results demonstrate that using the spray droplet transfer mode can generate a stable AM process under direct current application conditions, but it easily ends the AM process at the third or fourth layer deposition owing to excessive heat input. A more highly accurate deposition morphology can be obtained in one droplet per pulse mode under pulsed current application conditions, which also indicates that the AM process with a constant current welding supply is stabler and easily produces better deposition than the process with a constant voltage welding supply. With the increase in cooling time, the microstructure evolved from fine ferrite to equiaxed ferrite and to columnar ferrite combined with acicular ferrite with a lower proportion of pearlite in the vertical direction of the part, and the average hardness changed to ~168 HV (bottom), ~175 HV (middle), and ~250 HV (top). The analysis indicates that the heat accumulation of the molten pool is a critical factor that affects the deposition accuracy. To this end, a novel strategy that uses the heat accumulation to compensate for the energy formed in the molten pool is proposed to further reduce the arc heat input and weaken the heat accumulation, and its feasibility is discussed. Full article

We proposed a high-sensitivity optical fiber sensor based on a dual-resonance helical long-period fiber grating (HLPG). The grating is fabricated in a single-mode fiber (SMF) by using an improved arc-discharge heating system. The transmission spectra and the dual-resonance characteristics of the SMF-HLPG near the dispersion turning point (DTP) were studied through simulation. In the experiment, a four-electrode arc-discharge heating system was developed. The system can keep the surface temperature of optical fiber relatively constant during the grating preparation process, which shows an advantage in preparing high-quality triple- and single-helix HLPGs. In particular, benefiting from this manufacturing system, the SMF-HLPG operating near the DTP was successfully prepared directly by arc-discharge technology, without secondary processing of the grating. As a typical application example of the proposed SMF-HLPG, physical parameters such as temperature, torsion, curvature and strain can be measured with high sensitivity by monitoring the variation of the wavelength separation in the transmission spectrum. Therefore, the proposed sensor and its fabrication technology have potential application prospects in practical sensing measurement. Full article

The ultrasonic-frequency pulse underwater wet welding (UFP-UWW) process was achieved through a constant-voltage-mode power source connecting an ultrasonic-frequency pulse power source in parallel. The arc voltage and welding current waveforms, sound signal variations, microstructural characteristics and mechanical properties at different parameters were investigated. The results showed that the ultrasonic-frequency pulse voltage and current of the UFP-UWW process displayed a periodic high-frequency oscillation on the based values of the conventional UWW process. The arc stability of the UFP-UWW process improved owing to the fact that the proportions of the unstable arc burning region could be reduced to 1.56% after the introduction of the ultrasonic-frequency pulse current. No significant changes in weld width and penetration were observed while the weld dilution rate increased to 54.2% for the combination of 40 V–30 kHz, compared with the results of the conventional UWW process. The flux-cored arc (FCA) welding arc in the air had the same frequency response to the ultrasonic excitation signal, which verified the existence of the ultrasonic-frequency vibration induced by the periodic high-frequency electromagnetic forces. The application of the ultrasonic-frequency pulse produced finer columnar grains in the welds with an average length of 315 μm, although the amount of pro-eutectoid ferrite and acicular ferrite varied little. The mechanical properties of the welded joints were also noticeably enhanced with the application of different ultrasonic excitation frequencies. The optimum tensile strength and impact toughness of the welded joint were improved by 6.7% and 21.7% when the applied ultrasonic excitation voltage was 40 V for a pulsed frequency of 30 kHz. These results facilitate the application of ultrasonic arc welding technology in the marine field. Full article

Flower-like ZnO architectures assembled with many nanorods were successfully synthesized through Thermionic Vacuum Arc, operated both in direct current (DC-TVA) and a pulsed mode (PTVA), and coupled with annealing in an oxygen atmosphere. The prepared coatings were analysed by scanning-electron microscopy with energy-dispersive X-ray-spectroscopy (SEM-EDX), X-ray-diffraction (XRD), and photoluminescence (PL) measurements. By simply modifying the TVA operation mode, the morphology and uniformity of ZnO nanorods can be tuned. The photocatalytic performance of synthesized nanostructured ZnO coatings was measured by the degradation of methylene-blue (MB) dye and ciprofloxacin (Cipro) antibiotic. The ZnO (PTVA) showed enhancing results regarding the photodegradation of target contaminants. About 96% of MB molecules were removed within 60 min of UV irradiation, with a rate constant of 0.058 min⁻¹, which is almost nine times higher than the value of ZnO (DC-TVA). As well, ZnO (PTVA) presented superior photocatalytic activity towards the decomposition of Cipro, after 240 min of irradiation, yielding 96% degradation efficiency. Moreover, the agar-well diffusion assay performance against both Gram-positive and Gram-negative bacteria confirms the degradation of antibiotic molecules by the UV/ZnO (PTVA) approach, without the formation of secondary hazardous products during the photocatalysis process. Repeated cyclic usage of coatings revealed excellent reusability and operational stability. Full article

Dual phase (DP) steels have high strength, while maintaining outstanding elongation capacities. This is possible using a well-controlled thermomechanical process that produces a perfect phase combination in the DP microstructures. However, automotive makers are required to weld the DP steels, which generates a soft zone in the microstructure. In this work, 1.6 mm-thick DP980 steel sheets were welded by gas metal arc welding process to analyze the response of the welded soft zone to cyclic loading conditions. Conducted macrographic and metallography analyses revealed good quality in the appearance of the welded joints, with a complete fusion of the DP980 joint and without the presence of discontinuities. Low cycle fatigue tests of the DP welded joints were conducted under a constant amplitude strain control mode. The welded joints experienced a fatigue life reduction with respect to the DP980 steel of ~16% at strain amplitudes of 0.2, 0.3, and 0.4%. For strain amplitudes larger than 0.6%, the fatigue life of the welded joint was reduced by 39%. Weld thermal cycles combined with metallography analysis indicated that a tempered process of the martensite during the welding was responsible for the soft-zone formation and the poor fatigue response. Full article

Commercial coin cells with LiNi_0.6Mn_0.2Co_0.2O₂ positive electrode material were investigated using an accelerating rate calorimeter and a Tian-Calvet calorimeter. After cycling and charging to the selected states of charge (SOCs), the cells were studied under thermal abuse conditions using the heat-wait-seek (HWS) method with the heating step of 5 K and a threshold for self-heating detection of 0.02 K/min. The onset temperature and the rate of the temperature rise, i.e., the self-heating rate for thermal runaway events, were determined. The morphology of the positive electrode, negative electrode and the separator of fresh and tested cells were compared and investigated with scanning electron microscopy (SEM). Furthermore, the microstructure and the chemical compositions of the individual components were investigated by X-ray diffraction (XRD) and inductively coupled plasma with optical emission spectrometry (ICP-OES), respectively. In the Tian-Calvet calorimeter, the coin cells with the selected SOCs and the individual components (positive electrode, negative electrode and separator) were heated up with a constant heating rate of 0.1 °C/min (ramp heating mode). Simultaneously, the heat flow signals were recorded to analyze the heat generation. The combination of the three different methods—the HWS method using the ES-ARC, ramp heating mode on both cells and the individual components using the Tian-Calvet calorimeter—together with a post-mortem analysis, give us a complete picture of the processes leading to thermal runaway. Full article

The relation among microstructure and fatigue behavior of 2205/316L stainless steel dissimilar welded joints was investigated. Plates of 6.35 mm in thickness with a single-V joint configuration were gas metal arc welded (GMAW) in a single pass by feeding at 6 m/min an ER2209 filler wire with a heat input of 1.2 kJ/mm. Grain growth in the high temperature-heat affected zone (HT-HAZ) occurred mostly at the mid-height of the plates, delimiting the width of this region up to ~1.28 and ~0.73 mm of the 2205 and 316L plates, respectively. Dilution of the 316L plate with the ER2209 filler altered the solidification mode in this side of the weld and led to a significant content of austenite along the fusion line. Fatigue tests were performed using sinusoidal waveform at room temperature applying uniaxial cyclic loading, between constant stress limits within the elastic deformation of tension and compression (Δσ) with stress ratio R = −0.3. With stress ranges of 98% and 95% the fatigue specimens rapidly failed in much less than 10⁶ cycles. The failure crack initiated at the surface of the 316L in the HT-HAZ near the weld toe. Surface analyses of unbroken specimens before and after fatigue testing revealed a significant increment in roughness of the 316L base material owing to the formation of intrusions and extrusions. Full article

Keyhole-mode plasma arc welding (PAW) has a good prospect in the manufacturing industry. Unified models of plasma arc and workpiece help to reveal the physical mechanism in PAW for a better application. Previous unified models either deal with a constant keyhole situation or take too much computational time to display the dynamic keyhole process with a two-phase flow method. In view of the convenience for industrial application as well as good accuracy, a convenient unified model was developed to describe the mobile keyhole-mode PAW. With a simplified technique, the multiphase heat and force effect between plasma arc and workpiece was turned into a single-phase problem at each individual domain. Thus, it takes less computational time than previous unified models. The temperature field and weld pool during the mobile keyhole-mode PAW process were revealed, the arc flow and pool flow were displayed and the electric potential was predicted. The experiment was conducted on a stainless-steel plate, and the weld pool image and the measured arc pressure agree well with the calculated result. The calculated electric potential drop also coincides with the experiment. The model provides a convenient and accurate method to display the mobile keyhole-mode arc welding process. Full article