Advanced Surface Enhancement (eBook)

Proceedings of the 1st International Conference on Advanced Surface Enhancement (INCASE 2019)—Research Towards Industrialisation

Sho Itoh, Shashwat Shukla (Herausgeber)

eBook Download: PDF

2019
XII, 360 Seiten
Springer Singapore (Verlag)
9789811500541 (ISBN)

Infos

This book presents the proceedings of the first INCASE conference, organised by ARTC at A*STAR, Singapore. It provides a comprehensive review of recent advances in surface enhancement processes and strategies employed to assess their impact on materials properties and performance. As cyber-physical systems are becoming more and more relevant in manufacturing, it focuses on assessing the readiness of current technologies for future transformations, such as Industry 4.0, identifying the opportunities and challenges, and exploring ways to address them. 

Written by researchers, practising engineering and industry experts, the book bridges the gap between research and manufacturing, promoting technology adoption in industry and innovative ideas to prepare it for the future. 


Dr Sho Itoh is a Scientist at the Advanced Remanufacturing and Technology Centre (ARTC), Singapore. He received bachelor's/master's degree from Tokyo Institute of Technology and Ph.D. from Kyoto University. In 2010, he started R&D on laser processing of glass in Nippon Electric Glass Co., Ltd. From 2018, he has been working on metal surface enhancement processes such as stream finishing, laser peening, and the process monitoring and simulation in ARTC. As of 2019, he has published 9 journal papers, and 28 patents granted. 

Dr Shashwat Shukla is a Materials Scientist at the Advanced Remanufacturing and Technology Centre (ARTC), Singapore. He has over eight years of research experience in materials characterization and tailoring the structure and properties of engineering materials for advanced applications in data storage, catalysis, energy, metal processing, and aerospace industries. Prior to joining ARTC in April 2017, Dr Shukla worked at various global R&D centres of Seagate Technology and Johnson Matthey Plc for five years. Currently, he is involved with a range of research projects assessing materials performance and structural integrity issues in collaboration with partners from industry and academia in Singapore and abroad.

Inhalt

Preface 6
Organisation 8
Conference Chair 8
Organising Chair 8
Organising Committees 8
Technical Committees 9
Contents 10
Fatigue Life Enhancement 14
Optimization of Shot Peening for Titanium Alloys Ti 10-2-3 in CONDOR Project 15
Abstract 15
1 Introduction 15
2 Material and Experiments 16
2.1 Material 16
2.2 Design of Experiments 16
2.3 Specimens Preparation and Testing Conditions 16
3 Results 18
4 Conclusion 20
References 21
Mechanical Investigations on Composite Peened Aluminium 22
Abstract 22
1 Introduction 22
2 Experimental 23
2.1 Materials 23
2.2 Experimental Setup 23
3 Results 25
3.1 Microstructure 25
3.2 Surface Roughness 26
3.3 Penetration Depth 26
3.4 Mechanical Properties 27
4 Discussion 28
5 Conclusions 29
Acknowledgements 29
References 29
Influence of Wetblast Treatment on Fatigue Strength of Magnesium Alloy AZ31 31
Abstract 31
1 Introduction 31
2 Experimental Method 32
3 Result and Discussion 33
3.1 Experimental Result 33
3.2 Grain Measurement by EBSD (Electron Backscatter Diffraction) 35
4 Conclusions 36
References 37
Process Model for Evaluating the Peen Velocity in Shot Peening Machine 38
1 Introduction 38
2 Model Development 40
3 Model Validation 42
4 Applications 43
5 Concluding and Future Works 46
References 47
Experimental Study of Single Shot Process: Toward a Surface State Predictive Tool 48
Abstract 48
1 Introduction 48
2 Objectives 49
3 Methodology 49
3.1 Specimen and Shot Preparation 49
3.2 Experimental Data 50
4 Results and Discussions 51
4.1 Velocities and Kinetic Energies 51
4.2 Indent Profile 53
4.3 Process Signature Transfer 55
5 Conclusion 56
References 57
Microstructural Changes in Electroplated Chromium Coating–Substrate Interfaces Induced by Shot Peening 58
Abstract 58
1 Introduction 58
2 Experimental Procedure 59
3 Results and Discussions 61
3.1 Changes in Cr-Coated Steel Specimens Caused by SP 61
3.2 Quantitative Evaluation of Material Transport 63
4 Conclusions 66
References 66
Investigation on Theoretical Analysis of Residual Stress Distribution Induced by Shot Peening in 2397 Aluminum-Lithium Alloy 68
Abstract 68
1 Introduction 68
2 Theoretical Analysis 69
2.1 Hertz Contact Theory Between Elastic Shot and Semi-infinite Elastic Specimen 69
2.2 Elastic-Plastic Analysis of Loading Process 71
2.3 Analysis of Rebounding Process 74
2.4 Residual Stress Distribution in the Thin Plate 75
2.5 The Algorithm Corresponding to the Theoretical Model 75
3 Experimental Procedure 77
4 Conclusion 79
References 80
Effect of Shakedown on the Fatigue Limit of Ultrasonic Shot Peened Steel 81
Abstract 81
1 Introduction 81
2 Specimen and Experimental Procedure 82
2.1 Specimen 82
2.2 Experimental Procedure 83
3 Experimental Results 83
3.1 Hardness and Compressive Residual Stress Distribution 83
3.2 S-N Curve and Fracture Mechanism 83
3.3 Fatigue Limit Evaluation of USP Treated ASTM 309 Stainless Steel 84
4 Conclusions 86
References 87
Fundamentals and Applications of Cavitation Peening Comparing with Shot Peening and Laser Peening 88
Abstract 88
1 Introduction 88
2 Fundamental of Cavitation Peening 90
2.1 Cavitation and Cavitating Jet 90
2.2 Comparison Between Water Jet Peening and Cavitation Peening 92
3 Experimental Facilities and Procedures 94
4 Results 95
5 Conclusions 97
Acknowledgements 97
References 97
Effect of Mechanical Properties on Fatigue Life Enhancement of Additive Manufactured Titanium Alloy Treated by Various Peening Methods 100
Abstract 100
1 Introduction 100
2 Experimental Facilities and Procedures 102
3 Results 104
4 Conclusions 107
Acknowledgements 107
References 107
Influence of Burnishing Process on Microstructure and Corrosion Properties of Mg Alloy AZ31 109
Abstract 109
1 Introduction 109
2 Methodology 110
2.1 Burnishing Experiment 110
2.2 Microstructure Observation 112
2.3 Corrosion Test 112
3 Result and Discussion 113
3.1 Work-Hardened Layer Thickness 113
3.2 Grain Size 115
3.3 Corrosion Test 116
4 Conclusions 118
Acknowledgements 118
References 118
Effects of Machine Hammer Peened Surface Textures on the Tribological Behavior of Stamping Tools 120
Abstract 120
1 Introduction 121
2 Approach 121
3 Experimental Setup 122
4 Results and Discussion 126
5 Conclusion and Outlook 131
Acknowledgements 131
References 132
Mechanical Properties Enhancement of Additive Manufactured Ti-6Al-4V by Machine Hammer Peening 133
Abstract 133
1 Introduction 134
2 Experimental Work 135
2.1 Manufacturing and Setup of WAAM Samples 135
2.2 Material Characterization and Testing 137
3 Results and Discussion 138
3.1 Effect of MHP on Grain Refinement 138
3.2 Effect of MHP on Mechanical Properties 138
3.3 Strength and Fatigue from ? Lamellae Size and Prior-Beta Refinement 141
4 Conclusions 142
Acknowledgments 142
References 143
An Automated Deposition Procedure for Cold Spray Additive Manufacturing Process Modeling Based on Finite Element Simulation 145
Abstract 145
1 Introduction 145
2 Progressive Build-Up Technique 146
2.1 FE Simulation of Cold Spraying Process Using Eulerian Method 146
2.2 Variable Extraction and Averaging 148
2.3 Heat Transfer Analysis 150
2.4 Structural Analysis 152
3 Conclusion 154
References 154
Bonding Strength Improvement Through Numerical Simulation of Particle Impact Process During Metal Cold Spray 156
Abstract 156
1 Introduction 156
2 Methodology 157
2.1 Finite Element Simulation 157
2.2 Experimental Setup 159
3 Results and Discussion 159
3.1 Single Particle Impact Model Validation 159
3.2 Derivation of the Bonding Stress from the Nodal Temperature Profile 160
4 Conclusion 163
References 163
Product Verification and Material Characterisation 165
Surface Texture Evaluation on Mirror Finish Surface Using Patterned Area Illumination Method 166
Abstract 166
1 Introduction 167
2 Materials and Method 167
2.1 Test Samples 167
2.2 Coherence Correlation Interferometer 168
2.3 Patterned Area Illumination System 168
3 Results and Discussion 169
3.1 Luminance Contrast Measurement 169
3.2 Surface Uniformity Measurement 171
4 Conclusion and Future Work 172
References 173
Sliding Behavior of Secondary Phase SiC Embedded Alloyed Layer Doped Ti6Al4V Surfaces Ensuing Electro Discharge Machining 174
Abstract 174
1 Introduction 174
2 Experimental Methodology 175
2.1 Materials 175
2.2 Sample Preparation 176
2.3 Development of ETi64 Sample Surfaces 176
2.4 Tribo-Test 177
3 Results and Discussion 177
3.1 Friction and Wear Behavior 177
3.2 Surface Morphology Analyses 181
4 Conclusions 182
Acknowledgement 182
References 182
Measurement of Residual Stresses on Deep Rolled Round Aluminum Samples Using Hole Drilling Strain Gage Method 184
Abstract 184
1 Introduction 184
2 Derivation of Calibration Matrices 185
2.1 Finite Element Models 186
2.2 Derived Calibration Matrices 188
3 Residual Stress Measurements 189
3.1 Measurement of Flat Workpiece 190
3.2 Measurement of Cylindrical Workpiece 190
4 Summary 191
Acknowledgement 192
References 192
Mechanical Stress Relaxation of a Laser Peened and Shot Peened Ni-Based Superalloy 193
Abstract 193
1 Introduction 193
2 Materials and Methods 194
2.1 Materials and Specimen Preparation 194
2.2 Work Hardening Characterization 195
2.3 Residual Stress Measurement 195
3 Results 196
3.1 Work Hardening 196
3.2 Stress Profiles and Relaxation 197
4 Discussion 198
5 Conclusion 199
Acknowledgment 199
References 199
Incorporation of Evaluation Technology into Shot Peening Equipment 201
Abstract 201
1 Introduction 201
2 Quality Control of Shot Peening 202
2.1 Conventional Quality Control Method for Shot Peening 202
2.2 Subject and Countermeasure of Quality Control 202
3 Experiment for the Application of Inspection of SP Products 203
3.1 High-Speed X-ray Stress Measurement Method 203
3.2 Eddy Current Measurement Method 205
4 Conclusion 208
References 208
Influence of the Feed Rate in the Single-Lip Deep Hole Drilling Process on the Surface Integrity of Steel Components 209
Abstract 209
1 Introduction 209
2 Experimental Setup 212
3 Results and Discussion 215
3.1 Analysis of the Feed Force Ff and Drilling Torque Md 215
3.2 Influence on the Surface Roughness 215
3.3 Influence on the Micro-hardness and Microstructure 216
3.4 Analysis of the Micro-magnetic Barkhausen Noise 220
4 Conclusions and Outlook 221
Acknowledgments 222
References 222
Surface Finishing and Machining 224
Improvement of Chipping Phenomena for Crustaceous Materials Rounding by Centrifugal Barrel Finishing 225
Abstract 225
1 Introduction 225
2 Conventional Method 226
3 Investigation About Causes of the Chipping by Behavior Observation in Tank 227
4 Examination of a New Chipping Reduction Method 229
4.1 Hypothesis and Observation of the Chipping Reduction Method 229
4.2 Confirming the Effect of Chipping Reduction Method Through Tests 230
5 Results and Discussions 232
6 Conclusions 234
References 235
In Situ Measurement of Granular Pressure and Velocity on Component Surfaces in Stream Finishing 236
Abstract 236
1 Introduction 236
1.1 Post Processing of Additively Manufactured (AM) Components 236
1.2 Objectives 237
2 Experimental 238
2.1 Stream Finishing System 238
2.2 Measurement Tools 239
3 Results and Discussions 239
3.1 Pressures 239
3.2 Velocities 241
3.3 Discussions 242
4 Conclusions 242
References 243
Development of Rheology and Computational Flow Model for Robotized External Finishing on Additively Manufactured Components 244
Abstract 244
1 Introduction 244
2 Rheology Model, Methodology and Experimental Set-up 245
2.1 Rheology Model and Simulation Methodology 245
2.2 Experimental Set-up 246
3 Calibration of the Rheology Model 247
4 Flow Dynamics and Velocity Comparison 250
5 Conclusions 252
References 253
Effects of Combined Wear Mechanisms in Internal Surface Finishing Using Controlled Hydrodynamic Cavitation Abrasive Finishing Process 254
Abstract 254
1 Introduction 254
2 Machine, Method and Materials 256
2.1 Experimental Setup 256
2.2 Experimental Procedure 257
3 Results 258
3.1 Effect of Combined Wear Mechanisms in Material Removal 258
3.2 Effect of Combined Wear Mechanisms in Surface Enhancement 259
4 Discussion 260
5 Conclusion 262
Acknowledgement 262
References 263
Surface Integrity Characteristics of NiTiHf High Temperature Shape Memory Alloys 264
Abstract 264
1 Introduction 264
2 Experimental Details 265
3 Results and Discussions 267
4 Conclusions 271
Acknowledgments 271
References 272
The Effect of Finish-Milling Operation on Surface Quality and Wear Resistance of Inconel 625 Produced by Selective Laser Melting Additive Manufacturing 273
Abstract 273
1 Introduction 273
2 Experimental Details 274
3 Results and Discussions 275
3.1 Surface Quality 275
3.2 Microhardness and Wear Performance 277
4 Conclusions 280
References 281
Toolpath Generation for Robot Filleting 283
Abstract 283
1 Introduction 283
2 Experimental Setup 285
3 Filleting Framework 285
3.1 Lissajous Curves 285
3.2 Experiments 288
4 Conclusion 289
Acknowledgment 289
References 290
Laser Processes 291
Effect of Bubble Radius on Ability of Submerged Laser Peening 292
Abstract 292
1 Introduction 292
2 Numerical Method 294
2.1 Governing Equation in Fluid 294
2.2 Governing Equation in Material 294
2.3 Numerical Scheme of Analyzing Method 294
3 Results and Discussion 295
3.1 Initial Condition and Calculation Area 295
3.2 Definition of Stress Effective Volume 296
3.3 Relationship Between Maximum Pressure in Fluid, Maximum Equivalent Stress in Material and Bubble Radius 296
3.4 Evaluation of Effect of Bubble Radius on Materials by Stress Effective Volume 298
4 Conclusion 299
Acknowledgments 299
References 300
Crack Retardation of Damage Through Enhanced Crack Closure Effect Induced by Laser Peening 301
Abstract 301
1 Introduction 301
2 Experiments 302
3 Results and Discussion 304
4 Conclusions 306
Acknowledgements 306
References 306
Application of Laser Peening for Cold Work Steel 307
Abstract 307
1 Introduction 307
2 Experimental Method 308
2.1 Specimens 308
2.2 Peening Condition 309
2.3 Evaluation Method of Fatigue Strength 309
3 Experimental Result 310
3.1 Rotary Bend Fatigue Test Result 310
3.2 Fractography Result 310
4 Discussion 311
4.1 Effect of Surface for Laser Peening 311
4.2 Residual Stress Distribution 312
5 Conclusion 313
References 313
Influence of Laser Shock Peening (LSP) on the Material Properties of Additive Manufactured IN718 314
Abstract 314
1 Introduction 314
2 Experimental Procedure 315
2.1 Materials and Direct Metal Laser Sintering 315
2.2 Laser Shock Peening Process 316
2.3 Residual Stress Measurements 316
2.4 Surface Roughness Measurements 317
2.5 Microstructure Characterisation Measurements 317
3 Results and Discussion 317
3.1 Residual Stress 317
3.2 Surface Roughness 319
3.3 Microstructure 319
4 Conclusions 321
References 322
A Comparison of Surface and Sub-surface Features Induced by Shot Peening vs. Laser Peening on a Duplex Aged Beta Ti Alloy 323
Abstract 323
1 Introduction 323
2 Material and Method 324
3 Results and Discussions 325
3.1 Surface Topography 325
3.2 Microstructure 325
3.3 Micro-hardness Profile 327
4 Conclusions 327
Acknowledgement 328
References 328
Effect of Laser-Induced Microstructure in Cavitation Erosion Performance of Martensitic Stainless Steel 330
Abstract 330
1 Introduction 330
2 Materials and Methodology 331
3 Results and Discussion 332
3.1 Characterization of Laser Hardened Surface 332
3.2 Cavitation Erosion Performance 335
4 Conclusions 337
Acknowledgements 337
References 337
Effect of In-Situ Laser Remelting on the Microstructure of SS316L Fabricated by Micro Selective Laser Melting 339
Abstract 339
1 Introduction 339
2 Experimental Setup 340
3 Results and Discussions 341
3.1 Microstructure of Micro SLM Samples 341
3.2 Effects of Laser Remelting on Porosity 341
3.3 Effects of Laser Remelting on Microstructure 342
4 Conclusions 345
References 345
Tailoring Surface Roughness of Micro Selective Laser Melted SS316L by In-Situ Laser Remelting 346
Abstract 346
1 Introduction 346
2 Materials and Methods 347
3 Results and Discussion 348
3.1 Samples Without Laser Remelting 348
3.2 Laser Remelting Samples 349
4 Conclusions 351
References 352
Surface Structuring of Multilayer Coated Cutting Tool Using Nd: YVO4 Nanosecond Laser 353
Abstract 353
1 Introduction 353
2 Experimental Details 354
3 Results and Discussion 357
3.1 The Laser Surface Structuring Results 357
3.2 Discussion on the Laser Structuring 359
3.3 Cutting Tests Results and Discussion 362
4 Conclusion 364
References 365
Author Index 367

Produkt-Details

• Erscheint lt. Verlag: 30.8.2019
• Reihe/Serie: Lecture Notes in Mechanical Engineering
• Reihe/Serie: Lecture Notes in Mechanical Engineering
• Zusatzinfo: XII, 360 p. 278 illus., 211 illus. in color.
• Sprache: englisch
• Themenwelt: Naturwissenschaften ► Physik / Astronomie
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: ARTC A*ASTAR • Automation in Remanufacturing • INCASE • Industry 4.0 • Rapid Characterisation • Surface Enhancement Mechanism • Surface Integrity • Surface Mechanical Treatments
• ISBN-13: 9789811500541 / 9789811500541