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This article contains an advanced analysis of the properties of solid wire electrical contacts produced by ultrasonic welding, both with and without varnish. The main disadvantage of ultrasonic welding of thin wires is the inability to achieve acceptable peel force and tensile strength, which is mainly due to the deformation and thinning of the wires. This study deals with ultrasonic welding using a ring of thin solid copper wires that minimises the deformation and thinning of the wires. The influence of welding parameters such as energy, pressure and amplitude were systematically analysed. Based on these parameters, the optimum welding programme and control method was determined to weld unvarnished and varnished wires. The investigations included electrical resistance tests, optical microscopy, micro-hardness measurements, peel tests and tensile tests, and the measurement of energy consumption. The results showed no significant differences in microstructure and hardness between varnished and unvarnished joints. Ultrasonic joints of varnished wires achieved lower electrical conductivity (by 38%), lower tensile strength (by 3%) and higher peel strength (by 7%), while the welding process was more sustainable in terms of energy (by 6.6%) and time consumption (without preprocessing). [ABSTRACT FROM AUTHOR]

Background: Despite the large variety of retainer wires available, no studies could be found comparing the micromechanical properties and surface roughness of different retainer wires. Such characteristics affect the survival of the fixed retainer in terms of both fracture resistance and resistance to debonding from the tooth. Therefore, the aim of the present study was to examine and compare those characteristics in popular retainer wires. Methods: six different popular orthodontic retainer wires were subjected to instrumental indentation based on the Oliver and Pharr method. The geometric surface structure was analysed using a non-contact profilometer. Results: stainless steel wires had a higher hardness and a higher elastic modulus compared to titanium wires and white gold chain. The titanium wire and the white gold chain showed much more roughness than other wires. Conclusions: stainless steel wires are the most resistant, considering both the shape retention capacity and the ability to resist abrasive wear. The titanium wire showed the lowest hardness and, thus, the highest susceptibility to deformation. Bond-a-braid, Retainium and Orthoflex white gold are more resistant to fracture than other steel wires. Titanium wire and chain retainer wires have more roughness, which is a great advantage in terms of mechanical adhesion to composite materials. [ABSTRACT FROM AUTHOR]

In this work, we show the in vitro anticancer potential of surgical wires, obtained from zinc (ZnMg0.004) or magnesium (MgCa0.7) alloys by spatial technology comprising casting, extrusion, and final drawing processes. We also present the selective anticancer effects of applied soluble multilayer nanocoatings of zinc and magnesium onto titanium surfaces using the pulse laser deposition method. In the latter, the titanium samples were produced via 3D printing using the selective laser melting method and coated with various combinations of zinc and magnesium layers. For cytotoxicity studies, human dental pulp-derived stem cells (hDPSCs) and human osteosarcoma SaOS-2 cell line were used as representatives of healthy and cancer cells. Cells were examined against the 0.3–3.0 cm2/mL material extract ratios obtained from experimental and steel surgical wires, the latter being the current clinical industry standard. The MgCa0.7 alloy wires were approx. 1.5 times more toxic to cancer cells at all examined extract ratios vs. the extracts from steel surgical wires that exhibited comparable toxicity towards healthy and cancer cells. The ZnMg0.004 alloy wires displayed increased toxicity towards cancer cells with decreasing extract ratios. This was also reflected in the increased anticancer effectiveness, calculated based on the viability ratio of healthy cells to cancer cells, from 1.1 to 4.0 times. Healthy cell viability remained at 80–100%, whereas cancer cell survival fluctuated at 20–75%, depending on the extract ratio. Furthermore, the culture of normal or cancer cells on the surface of Zn/Mg-coated titanium allowed us to select combinations of specific coating layers that yielded a comparable anticancer effectiveness to that observed with the experimental wires that ranged between 2 and 3. Overall, this work not only demonstrates the substantial anticancer properties of the studied wires but also indicates that similar anticancer effects can be replicated with appropriate nanocoatings on titanium samples. We believe that this work lays the groundwork for the future potential development of the category of new implants endowed with anticancer properties. [ABSTRACT FROM AUTHOR]

The main objective of this work was to propose and evaluate a methodology for shielding-gas selection in additive manufacturing assisted by wire arc additive manufacturing (WAAM) with an austenitic stainless steel as feedstock. To validate the proposed methodology, the impact of multi-component gases was valued using three different Ar-based blends recommended as shielding gas for GMA (gas metal arc) of the target material, using CMT (cold metal transfer) as the process version. This assessment considered features that potentially affect the building of the case study of thin walls, such as metal transfer regularity, deposition time, and geometrical and metallurgical characteristics. Different settings of wire-feed speeds were conceived to maintain a similar mean current (first constraint for comparison's sake) among the three gas blends. This approach implied different mean wire-feed speeds and simultaneously forced a change in the deposition speed to maintain the same amount of material deposited per unit of length (second comparison constraint). The composition of the gases affects the operational performance of the shielding gases. It was concluded that by following this methodology, shielding-gas selection decision-making is possible based on the perceived characteristics of the different commercial blends. [ABSTRACT FROM AUTHOR]

To receive a high-quality welding structure of high-strength S700MC steel for applications in the automotive industry, newly developed electrode wires with increased silicon and manganese content were used. The strength and structural tests of the obtained joints were performed. In the weld, we identified the beneficial oxides strengthening the joint structure and unfavorable MnS inclusions. The non-metallic inclusions were formed inside the weld. Their arrangement, morphology, and chemical composition is described. A view on the high-temperature mechanisms of the formations included during the welding process with new electrode wires is presented. It was found that the dominant mechanism of the inclusion formation and the temperature of the welding process impact the content and varied morphology of inclusions, thus determining the exploitation time of the welded joints obtained. The obtained MAG joints made S700MC steel, due to the formation mainly of oxide inclusions and a relatively small amount of MnS phase, were characterized by a high value of yield and tensile strength, which makes them a promising solution for the automotive industry, especially against the background of connections from the discussed steel grade presented in the literature. [ABSTRACT FROM AUTHOR]

Ag-Sn-In-Ni-Te alloy ingots were produced through a heating–cooling combined mold continuous casting technique; they were then drawn into wires. However, during the drawing process, the alloy wires tended to harden, making further diameter reduction challenging. To overcome this, heat treatment was necessary to soften the previously drawn wires. The study investigated how variations in heat treatment temperature and holding time affected the microstructure, microhardness and corrosion resistance of the alloy wires. The results indicate that the alloy wires subjected to heat treatment at 700 °C for 2 h not only exhibited a uniform microstructure distribution, but also demonstrated low microhardness and excellent corrosion resistance. [ABSTRACT FROM AUTHOR]

Traditional ACSR overhead wires, which consist of a high-strength steel core and several layers of aluminium wires, are currently the most popular overhead line conductor (OHL) design globally. Operating conditions, particularly operating under varying stresses from Karman vortices, lead to the fatigue cracking of wires of the outer layer, followed by wires of the inner layers. Karman vortices are formed by the detachment of a laminar wind stream flowing around the conductor, which causes vibrations in the conductor called wind or aeolian oscillations. Aluminium wires are manufactured using standard batch material drawing technology. Although the fatigue strength of such wires is not standardised, there are various criteria for evaluating this characteristic, as well as established limits on the number of cycles needed to break the first wires of the outer layer. Fatigue strength also strongly depends on the geometric structure of the wire and its operating conditions. The article analyses the influence of the mechanical condition of aluminium wires used in ACSR cables on their fatigue strength. We then present results from aluminium wire fatigue tests conducted on a specially constructed test rig. In addition, fatigue cracks were interpreted using scanning microscopy. [ABSTRACT FROM AUTHOR]

Defect-free thin-walled samples were built using wire arc additive manufacturing (WAAM) combined with the "coldArc" deposition technique by feeding a Ti-6Al-4V welding wire and using two deposition strategies, namely with and without the welding torch weaving. The microstructures formed in these samples were examined in relation to mechanical characteristics. The arc torch weaving at 1 Hz allowed us to interfere with the epitaxial growth of the β-Ti columnar grains and, thus, obtain them a lower aspect ratio. Upon cooling, the α/α′+β structure was formed inside the former β-Ti grains, and this structure proved to be more uniform as compared to that of the samples built without the weaving. The subtransus quenching of the samples in water did not have any effect on the structure and properties of samples built with the arc torch weaving, whereas a more uniform grain structure was formed in the sample built without weaving. Quenching resulted also in a reduction in the relative elongation by 30% in both cases. [ABSTRACT FROM AUTHOR]

Electromagnetic wire is the carrier of energy and signal transmission. With the rapid development in aerospace, atomic energy, and other industrial fields, there is an increasing demand for the high-temperature-resistance of electromagnetic wires. In using traditional electromagnetic wires, it is difficult to meet the current temperature-resistance requirements. Therefore, the development of high-temperature-resistant electromagnetic wire has extremely important application value. In this paper, high-temperature-resistant electromagnetic wires are divided into organic insulated high-temperature-resistant electromagnetic wires, organic–inorganic insulated composite high-temperature-resistant electromagnetic wires, and inorganic insulated high-temperature-resistant electromagnetic wires. The method of improving the temperature-resistance level of organic insulated high-temperature-resistant electromagnetic wire is introduced. The selection principle of organic–inorganic and inorganic insulation high-temperature-resistant electromagnetic-wire conductor materials is analyzed. The current research status of organic–inorganic and inorganic insulated high-temperature-resistant electromagnetic wires is reviewed. The technical routes for preparing inorganic insulated high-temperature-resistant electromagnetic wire are compared. Finally, the challenges faced by the current high-temperature-resistant electromagnetic wire are pointed out, and the future development direction of organic–inorganic-composite insulation and inorganic insulation high-temperature-resistant electromagnetic wire is proposed. [ABSTRACT FROM AUTHOR]

Wire and arc additive manufacturing (WAAM), recognized for its capability to fabricate large-scale, complex parts, stands out due to its significant deposition rates and cost-effectiveness, positioning it as a forward-looking manufacturing method. In this research, we employed two welding currents to produce samples of 316 austenitic stainless steel utilizing the Cold Metal Transfer wire arc additive manufacturing process (CMT-WAAM). This study initially evaluated the maximum allowable arc travel speed (MAWFS) and the formation characteristics of the deposition bead, considering deposition currents that vary between 100 A and175 A in both CMT and CMT pulse(CMT+P) modes. Thereafter, the effect of the CMT+P mode arc on the microstructure evolution was analyzed using the EBSD technique. The findings indicate that the arc travel speed and deposition current significantly affect the deposition bead's dimensions. Specifically, an increase in travel speed or a reduction in current results in reduced bead width and height. Moreover, the employment of the CMT+P arc mode led to a reduction in the average grain size in the mid-section of the sample fabricated by CMT arc and wire additive manufacturing, from 13.426 μm to 9.429 μm. Therefore, the components of 316 stainless steel produced through the CMT+P-WAAM method are considered fit for industrial applications. [ABSTRACT FROM AUTHOR]

Electroplated diamond wire sawing is widely used as a processing method to cut hard and brittle difficult-to-machine materials. Currently, obtaining the sawing capability of diamond wire saw through the wire bow is still difficult. In this paper, a method for calculating the sawing capability of diamond wire saw in real-time based on the wire bow is proposed. The influence of the renewed length per round trip, crystal orientation of sapphire, wire speed, and feed rate on the wire sawing capability has been revealed via slicing experiments. The results indicate that renewing the diamond wire saw, and reducing the wire speed and feed rate can delay the reduction in sawing capability. Furthermore, controlling the value of renewed length per round trip can make the diamond wire saw enter a stable cutting state, in which the capability of the wire saw no longer decreases. The sawing capability of diamond wire saw cutting in the A-plane of the sapphire is smaller than that of the C-plane, and a suitable feed rate or wire speed within the range of sawing parameters studied in this study can avoid a rapid decrease in the sawing capability of the wire saw during the cutting process. The knowledge obtained in this study provides a theoretical basis for monitoring the performance of the wire saw, and guidance for the wire cutting process in semiconductor manufacturing. In the future, it may even be possible to provide real-time performance parameters of diamond wire saw for the digital twin model of wire sawing. [ABSTRACT FROM AUTHOR]

This work presents a test rig developed for testing the lifetime of electrically and cyclically activated shape memory alloy wires. This test rig is developed to provide information on the functional and structural fatigue of the wires. Therefore, electrical activation on the test rig can be carried out using different activation profiles, because it is of great research interest to determine whether those profiles have a significant influence on the wire's lifetime and functional behavior. The test rig monitors the process parameters such as stroke, current, voltage, and force. After presenting the electrical and mechanical design of the test rig, this publication evaluates an initial series of tests to demonstrate its functionality. Three different activation profiles are run in parallel on four identical test rig setups and are then evaluated. The functionality of the test rig is verified by a detailed evaluation of the process data on the one hand, and by comparing the results with existing literature on the other. The functionality of the test rig can thus be verified. At the same time, the strong influence of the different activation profiles on both the lifetime and the functional properties of the shape memory alloy wires becomes clear. [ABSTRACT FROM AUTHOR]

Ultra-thick offshore steel, known for its high strength, high toughness, and corrosion resistance, is commonly used in marine platforms and ship components. However, when offshore steel is in service for an extended period under conditions of high pressure, extreme cold, and high-frequency impact loads, the weld joints are prone to fatigue failure or even fractures. Addressing these issues, this study designed a narrow-gap laser wire filling welding process and successfully welded a 100-mm new type of ultra-thick offshore steel. Using finite element simulation, EBSD testing, SEM analysis, and impact experiments, this study investigates the weld's microstructure, impact toughness, and fracture mechanisms. The research found that at −80 °C, the welded joint exhibited good impact toughness (>80 J), with the impact absorption energy on the surface of the weld being 217.7 J, similar to that of the base material (225.3 J), and the fracture mechanism was primarily a ductile fracture. The impact absorption energy in the core of the weld was 103.7 J, with the fracture mechanism mainly being a brittle fracture. The EBSD results indicated that due to the influence of the welding thermal cycle and the cooling effect of the narrow-gap process, the grains gradually coarsened from the surface of the welded plate to the core of the weld, which was the main reason for the decreased impact toughness at the joint core. This study demonstrates the feasibility of using narrow-gap laser wire filling welding for 100-mm new type ultra-thick offshore steel and provides a new approach for the joining of ultra-thick steel plates. [ABSTRACT FROM AUTHOR]

Currently, MgB2 wires made by the powder-in-tube (PIT) method are most often used in the construction and design of superconducting devices. In this work, we investigated the impact of heat treatment under both low and high isostatic pressures on the formation of a layered structure in PIT MgB2 wires manufactured using the Mg coating method. The microstructure, chemical composition, and density of the obtained superconductive wires were investigated using scanning electron microscopy (SEM) with an energy-dispersive X-ray spectroscopy (EDS) analyzer and optical microscopy with Kameram CMOS software (version 2.11.5.6). Transport measurements of critical parameters were made by using the Physical Property Measurement System (PPMS) for 100 mA and 19 Hz in a perpendicular magnetic field. We observed that the Mg coating method can significantly reduce the reactions of B with the Fe sheath. Moreover, the shape, uniformity, and continuity of the layered structure (cracks, gaps) depend on the homogeneity of the B layer before the synthesis reaction. Additionally, the formation of a layered structure depends on the annealing temperature (for Mg in the liquid or solid-state), isostatic pressure, type of boron, and density of layer B before the synthesis reaction. [ABSTRACT FROM AUTHOR]

As a result of conventional wire-forming processes, the residual stress distribution in wires is frequently unfavorable for subsequent forming processes such as bending operations. High tensile residual stresses typically occur in the near-surface region of the wires and can limit further application and processability of the semi-finished products. This paper presents an approach for tailoring the residual stress distribution by modifying the forming process, especially with regard to the die geometry and the influence of the drawing velocity as well as the wire temperature. The aim is to mitigate the near-surface tensile residual stresses induced by the drawing process. Preliminary studies have shown that modifications in the forming zone of the dies have a significant impact on the plastic strain and deformation direction, and the approach can be applied to effectively reduce the process-induced near-surface residual stress distributions without affecting the diameter of the product geometry. In this first approach, the process variant using three different drawing die geometries was established for the metastable austenitic stainless steel X5CrNi18-10 (1.4301) using slow (20 mm/s) and fast (2000 mm/s) drawing velocities. The residual stress depth distributions were determined by means of incremental hole drilling. Complementary X-ray stress analysis was carried out to analyze the phase-specific residual stresses since strain-induced martensitic transformations occurred close to the surface as a consequence of the shear deformation and the frictional loading. This paper describes the setup of the drawing tools as well as the results of the experimental tests. [ABSTRACT FROM AUTHOR]

The 70/30 copper–nickel alloy is used mainly in critical parts with more demanding conditions in marine settings. There is a need for innovative methods that offer fast production and cost-effectiveness in order to supplement current copper–nickel alloy manufacturing processes. In this study, we employ wire arc additive manufacturing (WAAM) to fabricate the 70/30 copper–nickel alloy. The as-built microstructure is characterized by columnar grains with prominent dendrites and chemical segregation in the inter-dendritic area. The aspect ratio of the columnar grain increases with increasing travel speed (TS) at the same wire feed speed (WFS). This is in contrast with the equiaxed grain structure, with a more random orientation, of the conventional sample. The sample built with a WFS of 8 m/min, TS of 1000 mm/min, and a track distance of 3.85 mm exhibits superior corrosion properties in the 3.5 wt% NaCl solution when compared with the conventional sample, as evidenced by a higher film resistance and breakdown potential, along with a lower passive current density of the WAAM sample. The corrosion morphology reveals the critical roles played by the nickel element that is unevenly distributed between the dendrite core and inter-dendritic area. [ABSTRACT FROM AUTHOR]

In addition to cold drawing, the process of annealing is also essential in the preparation of Mg-4.7 wt%Gd (G4.7) alloy wires. The effect of annealing treatment on the recrystallized microstructure and texture of cold-drawn G4.7 wires was investigated. The results demonstrate that the uniformity and regularity of the recrystallized grains, as well as the annealing texture, impact the follow-up cold drawing performance. When the as-drawn G4.7 wires were annealed at 375 °C, the recrystallized grains were refined, accompanied by uniformity and regularity. Accordingly, the G4.7 wire had a good subsequent drawing deformability, with a maximum accumulative true strain (ATS) of 144%. Additionally, the evolution of the microstructure was consistent with the evolution of the texture. While annealing at a lower temperature (325 °C), the {0002} basal texture of the G4.7 wire was weak, forming the main texture component <10 1 ¯ 0>//DD (the drawing direction). With the increase in temperature, the basal texture was gradually strengthened and the texture component transformed from <10 1 ¯ 0>//DD to a recrystallized texture based on <11 2 ¯ 0>//DD. Even under high-temperature annealing, the G4.7 wire was still affected by the cold-drawn deformation texture and could not fully recover to the as-extruded texture, thus causing a decrease in the subsequent drawing performance. [ABSTRACT FROM AUTHOR]

A new composite with a core–shell structure based on magnesium hydride and finely dispersed aluminum powder with an aluminum oxide shell was mechanically synthesized. We used magnesium chips to produce magnesium hydride and aluminum wire after exploitation to produce nano-sized aluminum powder. The beginning of the hydrogen release from the composite occurred at the temperature of 117 °C. The maximum desorption temperature from the MgH2-EEWAl composite (10 wt.%) was 336 °C, compared to pure magnesium hydride—417 °C. The mass content of hydrogen in the composite was 5.5 wt.%. The positive effect of the aluminum powder produced by the electric explosion of wires method on reducing the activation energy of desorption was demonstrated. The composite's desorption activation energy was found to be 109 ± 1 kJ/mol, while pure magnesium hydride had an activation energy of 161 ± 2 kJ/mol. The results obtained make it possible to expand the possibility of using magnesium and aluminum waste for hydrogen energy. [ABSTRACT FROM AUTHOR]

In diamond wire saw cutting monocrystalline silicon (mono-Si), the material brittleness removal can cause microcrack damage in the subsurface of the as-sawn silicon wafer, which has a significant impact on the mechanical properties and subsequent processing steps of the wafers. In order to quickly and non-destructively obtain the subsurface microcrack damage depth (SSD) of as-sawn silicon wafers, this paper conducted research on the SSD prediction model for diamond wire saw cutting of mono-Si, and established the relationship between the SSD and the as-sawn surface roughness value (SR) by comprehensively considering the effect of tangential force and the influence of the elastic stress field and residual stress field below the abrasive on the propagation of median cracks. Furthermore, the theoretical relationship model between SR and SSD has been improved by adding a coefficient considering the influence of material ductile regime removal on SR values based on experiments sawing mono-Si along the (111) crystal plane, making the theoretical prediction value of SSD more accurate. The research results indicate that a decrease in wire speed and an increase in feed speed result in an increase in SR and SSD in silicon wafers. There is a non-linear increasing relationship between silicon wafer SSD and SR, with SSD = 21.179 Ra4/3. The larger the SR, the deeper the SSD, and the smaller the relative error of SSD between the theoretical predicted and experimental measurements. The research results provide a theoretical and experimental basis for predicting silicon wafer SSD in diamond wire sawing and optimizing the process. [ABSTRACT FROM AUTHOR]

The aim of this study was to investigate the load deflection characteristics of Gummetal® wires in comparison to nickel–titanium (NiTi) wires. Four different NiTi wires and one Gummetal® archwire were analyzed in two dimensions (0.014″ (0.36 mm) and 0.016″ × 0.022″ (0.41 mm × 0.56 mm)) and in two different orientations (edgewise and ribbonwise) using three-point bending tests at T = 37 °C. Force–displacement curves were recorded and analyzed. The Gummetal® 0.014″ wires exhibited higher forces compared to the NiTi wires at 2.0 mm deflection. At 1.0 mm deflection, the opposite pattern was observed. For the 0.016″ × 0.022″ Gummetal® wires, the forces were within the force interval of the NiTi wires at 2.0 mm deflection. At a deflection of 1.0 mm, no residual force was measurable for the Gummetal® wires. All the NiTi wires investigated showed hysteresis and a superelastic plateau. However, the Gummetal® did not form a plateau, but hysteresis was present. An easier plastic deformability compared to the NiTi wires was observed for all the tested geometries. [ABSTRACT FROM AUTHOR]

The current article presents an advanced analysis of the properties of solid-wire electric contacts produced with ultrasonic welding and soldering. Soldering is generally used to join thin, solid copper wires to produce electrical contacts in small-volume production, as ultrasonic welding does not provide acceptable peel force and tensile strength due to the deformation and thinning of the wires. In this article, ultrasonic welding of thin, solid copper wires using a ring before and after a thermal shock test is discussed and compared with the standard soldering technique. The thermal shock test was carried out in the temperature range from −30 to 150 °C. Half of the samples, for both the joining techniques and the wires, were subjected to the thermal shock test; the other half were not. Investigations included electrical resistance tests, optical and SEM microscopy, XRD, microhardness measurements, peel tests, tensile tests, and fractographic analysis. The electrical resistance test, microscopy, microhardness measurements, and fracture examinations showed no differences between the thermal shock-exposed and the non-exposed samples with the same joining process. In mechanical tests, the ultrasonic joint demonstrated superior strength compared to the soldered joint. [ABSTRACT FROM AUTHOR]

In the present study, the effects of varying heating and cooling rates during the solution treatment process on the microstructure and properties of AA7050 alloy wires were investigated using tensile tests, metallographic microscopy, electron backscattered diffraction, and transmission electron microscopy. It was found that the recrystallized grain size of the alloy, subjected to method of rapid heating, exhibited a smaller and more uniform distribution in comparison to method of slow heating. The low density of η′ strengthening phases after the artificial aging treatment was formed using air cooling method. Meanwhile, by using the water quenching method sufficient solute atoms and more nucleation sites were provided resulting in a large number of η′ strengthening phases being formed. In addition, the alloy processed using the water quenching method displayed higher strength than that treated using the air cooling method for the T6 and T73 states. Furthermore, coarse precipitates formed and less clusters were observed in the matrix, while high density nanoscale clusters and no continuous precipitation are formed when using the water quenching method. [ABSTRACT FROM AUTHOR]

This paper presents the mechanical behavior of thermally sprayed coatings produced using an arc wire coating material. The produced coatings were cut and subjected to strength resistance tests in static and in dynamic loading. The compressive behavior for the strain rates between 0.001 1/s and 2612 1/s was examined. The strain rate sensitivity of the material was recognized in the material during dynamic loading using the SHPB technique. Microstructural observations were made, and properties such as changes in porosity and the microhardness of the coatings tested were examined. A significant reduction in coating porosity was demonstrated after static loading (90%) and dynamic loading (86%). The result of porosity reduction is the strengthening of the coatings through an increase in the microhardness of these coatings after loading in the static test (160 HV 0.3/8) and the dynamic test (278 HV 0.3/8). As a result of the tests, the coatings retain their cohesion and remain consistent. At the same time, they can absorb a significant amount of mechanical energy due to plastic deformation and porosity reduction. The presented results concern a completely new coating material created from a core wire. [ABSTRACT FROM AUTHOR]

Wire bonding, one of the methods for electrically connecting a semiconductor chip with a substrate, involves attaching thin metal wires to pads. It is the oldest electrical connection method that exhibits high compatibility with other processes. The metal wires used for electrical connection in wire bonding are mainly made of Au, Cu, and Ag. After the wire bonding, molding is performed using the epoxy molding compound (EMC). However, EMC inevitably contains ions such as halogen elements. In addition, it absorbs moisture due to its hydrophilicity, creating a corrosive environment with electrolytes. In this study, we evaluated the influence of hydrochloric acid concentration on corrosion behavior between Au or Cu bonding wires and sputtered Al bond pads. The electrochemical factors such as corrosion potential difference (ΔE), galvanic corrosion current density (ig), and anodic and cathodic Tafel slopes were found to influence galvanic corrosion behavior. Galvanic corrosion tendency in first bond and second bond areas of PCB unit specimen was confirmed. [ABSTRACT FROM AUTHOR]

In this work, analyses focus on understanding the effects of the scanning pattern and speed on the thermal profile, phase transformation, and residual stress generation in the WAAM deposition. An FE numerical model is constructed that takes into account the phase evolution and transformation plasticity using the ABAQUS user subroutine, UMAT. The results show that the scanning pattern significantly affects the heat accumulation and the cooling rate during the AM deposition, and, eventually, the generation of residual stresses. According to the simulation results, the highest residual stress is generated in the case of the out–in scanning, while the alternate pattern leads to the lowest residual stress. The influence of the scanning speed on the thermal profiles and residual stress are also examined. The analyses show that an increase in the scan speed leads to a decrease in the peak temperature and an increase in the cooling rate, which result in an increase in the martensite volume fraction of the deposition. [ABSTRACT FROM AUTHOR]

This study investigates the mechanical properties of exceptionally high-strength steel produced by wire and arc additive manufacturing (WAAM), using the 304 stainless steel wire and the low carbon wire (LCS). The study found that annealing treatment can enhance the steel's mechanical properties. The microstructure in the LCS layer changed from ferrite to bainite and then to a mixture of austenite, pearlite, and bainite with increasing annealing temperature. In contrast, the SS layer retained its martensitic structure, albeit with altered lath sizes. The annealing treatment also improved the orientation of the grains in the steel. The optimal annealing temperature observed for the steel was 900 ℃, which resulted in a maximum tensile strength of 1176 MPa along the Y direction and 1255 MPa along the Z direction. Despite the superior mechanical properties, the LCS layer still exhibited failure during tensile testing due to its lower hardness. The study suggests that annealing treatment can be a useful technique for enhancing the mechanical properties of high-strength steel in WAAM applications. [ABSTRACT FROM AUTHOR]

Welded resistance slotted screens, also known as slotted screens, are a special type of screen primarily used for the filtration and separation of liquids and dust. They are characterized by slots with parallel geometry and precisely defined sizes. The quality of the side surfaces and edges of welded wires determines the durability of the slotted screens made from them. This article presents the results of tests for four types of wires: two types of working profile wires made from austenitic-ferritic steel (duplex) and two types of supporting cross wires made from ferritic steel. The wire surfaces were characterized using a profilometer and atomic force microscopy. Basic roughness parameters Ra, Rz, and SAD (surface area difference) were determined. Surface observations of the working profiles were conducted using scanning electron microscopy. These studies allowed for the characterization of the working wire surfaces used in the production of slotted screens. At work, the results of surface roughness were analyzed based on three measurement methods for wires used in the production of welded slot screens. These results allowed for the identification of the most reliable method for characterizing the surface condition of such products. [ABSTRACT FROM AUTHOR]

The superconducting joints of superconducting in situ MgB2 wires have been of great interest since the first MgB2 wires were manufactured. The necessity of joining fully reacted wires in applications such as NMR brings complexity to the methodology of connecting already reacted wires sintered under optimised conditions via a mixture of Mg + 2B and subsequential second heat treatment to establish fully superconducting MgB2 joints. Some of the data in the literature resolved such a procedure by applying high cold pressure and sintering at a low temperature. A topical review publication did not address in depth the question of whether cold sintering is a potential solution, suggesting that hot pressing is the way forward. In this paper, we discuss the potential joint interfacial requirements, suggesting a thermo-mechanical procedure to successfully form a superconductive connection of two in situ reacted wires in the presence of Mg + 2B flux. The critical current at 25 K of the researched junction achieved 50% Ic for an individual in situ wire. [ABSTRACT FROM AUTHOR]

In this study, the effect of heat treatment parameters on the optimized performance of Ni-rich nickel–titanium wires (NiTi/Nitinol) were investigated that were intended for application as actuators across various industries. In this instance, the maximum recovery strain and actuation angle achievable by a nitinol wire were employed as indicators of optimal performance. Nitinol wires were heat treated at different temperatures, 400–500 °C, and times, 30–120 min, to study the effects of these heat treatment parameters on the actuation performance and properties of the nitinol wires. Assessment covered changes in density, hardness, phase transition temperatures, microstructure, and alloy composition resulting from these heat treatments. DSC analysis revealed a decrease in the austenite transformation temperature, which transitioned from 42.8 °C to 24.39 °C with an increase in heat treatment temperature from 400 °C to 500 °C and was attributed to the formation of Ni4Ti3 precipitates. Increasing the heat treatment time led to an increase in the austenite transformation temperature. A negative correlation between the hardness of the heat-treated samples and the heat treatment temperature was found. This trend can be attributed to the formation and growth of Ni4Ti3 precipitates, which in turn affect the matrix properties. A novel approach involving image analysis was utilized as a simple yet robust analysis method for measurement of recovery strain for the wires as they underwent actuation. It was found that increasing heat treatment temperature from 400 °C to 500 °C above 30 min raised recovery strain from 0.001 to 0.01, thereby maximizing the shape memory effect. [ABSTRACT FROM AUTHOR]

This paper presents the influence of the Hot Isostatic Pressing (HIP) process on the structure, mechanical properties and corrosion resistance of padding welds made using the TIG method from aluminium bronzes—CuAl7 and CuAl2 (a composite bundled wire). The tested CuAl7 material was a commercial welding wire, while the CuAl2 composite was an experimental one (a prototype of the material produced in multiwire technology). The wire contains a bundle of component materials—in this case, copper in the form of a tube and aluminium in the form of rods. The padding welds were manufactured for both the CuAl7 wire and the CuAl2 multiwire. The prepared samples were subjected to the Hot Isostatic Pressing (HIP) process, chemical composition tests were performed, and then the samples were subjected to observations using light microscopy, Vickers hardness testing, electrical conductivity tests, and apparent density determination using Archimedes' Principle. Tribological tests (the 'pin on disc' method) and neutral salt spray corrosion tests were conducted. The padding weld made of CuAl2 multifiber material subjected to the HIP process is characterized by an improvement in density of 0.01 g/cm3; a homogenization of the hardness results across the sample was also observed. The average hardness of the sample after the HIP process decreased by about 15HV, however, the standard deviation also decreased by about 8HV. The electrical conductivity of the CuAl2 welded sample increased from 16.35 MS/m to 17.49 MS/m for the CuAl2 sample after the HIP process. As a result of this process, a visible increase in electrical conductivity was observed in the case of the wall made of the CuAl2 multiwire—an increase of 1.14 MS/m. [ABSTRACT FROM AUTHOR]

Additive manufacturing has garnered significant interest in various industries due to its flexibility and capability to produce parts with complex shapes. However, issues related to surface quality, such as roughness and microstructural defects, necessitate the use of post-processing techniques to achieve the desired properties. Ti6Al4V alloy, produced additively, was finished using low-energy discharges, and the new surface integrity properties resulting from the induced heat energy were investigated. To further understand the influence of discharge energy on the formation of the new layer, roughness parameters and power spectral density were used to characterize the surface topography. SEM and EDS analyses were performed to examine the morphology and microstructural defects such as microcracks. The results indicate that the heat energy induced by the discharge improved the properties of the surface. SEM analysis revealed that the new layer was characterized by a reduction in defects such as unmelted particles, the balling effect, and microcracks. At the lowest investigated discharge energy of E = 0.21 mJ, surface roughness, Sa, was reduced by about 69%, which is equal to about 2 μm, accompanied by a significant decrease in microcracks. EDS analysis indicated that the diffusion of copper and zinc from the electrode to the top surface was related to the discharge energy. Furthermore, prediction models of the influence of wire electrical discharge polishing parameters, including discharge energy, wire speed, and time interval, on the surface roughness and material removal rate (MRR) were developed using the response surface methodology. [ABSTRACT FROM AUTHOR]

Double-pulsed gas metal arc welding (DP-GMAW) is a high-performance welding method with low porosity and high frequency. Periodic shrinkage and expansion of the melt pool during DP-GMAW leads to unusual remelting, and the re-solidification behavior of the weld metal can significantly refine the weld structure. The advantages of DP-GMAW have been proven. In order to better apply DP-GMAW to aluminum alloy arc additive manufacturing, in this paper, the single-pass deposition layer parameters (double-pulse amplitude, double-pulse frequency and travel speed) of DP-GMAW will be optimized using the response surface method (RSM) with the width, height, and penetration of the deposition layer as the response values to find the superior process parameters applicable to the additive manufacturing of aluminum alloy DP-GMAW. The results show that the aluminum alloy components made by DP-GMAW additive are well formed. Due to the stirring of double-pulse arc and the abnormal remelting and solidification of metal, the microstructures in the middle and top areas show disordered growth. The average ultimate tensile strength of the transverse tensile specimen of the member can reach 175.2 MPa, and the elongation is 10.355%. [ABSTRACT FROM AUTHOR]

The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed. [ABSTRACT FROM AUTHOR]

Temperature rise of a specimen is a significant issue in drawing industries for wire, rod, and bar products, because an excessive increase in temperature during the drawing process can deteriorate the product quality and die life. The influence of the strain hardening exponent (n) of a wire on the temperature and strain distributions during wire drawing is investigated to understand its effect and to improve the quality of drawn wire. Finite element analysis and experiments are conducted to analyze the temperature and strain distributions of wires with n values of 0.0, 0.1, 0.5, and 1.0. The temperature increase of the wire augments as the n of the wire increases, despite the same amount of ideal plastic deformation, which is associated closely with the redundant work. The shear strain increases with the n of the specimen, which generates redundant work, leading to a high temperature rise. Similarly, drawing force increases with the n of the specimen, owing to the increase in redundant work with the n of the wire. In addition, the drawing force presents a linear relationship with the temperature rise of the wire. The drawing speed should be reduced and/or the cooling of wire and die should be strengthened during wire drawing, with increasing n value of the wire, because product quality and die wear are highly associated with the temperature rise of the wire in the deformation zone. [ABSTRACT FROM AUTHOR]

To study the effects of Fe content and cold drawing strain on the microstructure and properties, Cu-Fe alloys were prepared via powder metallurgy and hot extrusion. Scanning electron microscopy was applied to observe the Fe phase, and the ultimate tensile strength was investigated using a universal material testing machine. Alloying with an Fe content below 10 wt.% formed a spherically dispersed Fe phase via the conventional nucleation and growth mechanism, whereas a higher Fe content formed a water-droplet-like Fe phase via the spinodal decomposition mechanism in the as-extruded Cu-Fe alloy. Further cold drawing induced the fiber structure of the Fe phase (fiber strengthening), which could not be destroyed by subsequent annealing. As the Fe content increased, the strength increased but the electrical conductivity decreased; as the cold drawing strain increased, both the strength and the electrical conductivity roughly increased, but the elongation roughly decreased. After thermal–mechanical processing, the electrical conductivity and strength of the Cu-40Fe alloy could reach 51% IACS and 1.14 GPa, respectively. This study can provide insight into the design of high-performance Cu-Fe alloys by tailoring the size and morphology of the Fe phase. [ABSTRACT FROM AUTHOR]

Using the CMT (Cold Metal Transfer, F. Fronius, Upper Austria) welding process, wire arc additive manufacturing (WAAM) enables companies to fabricate steel components in a resource-saving manner (additive vs. subtractive) by properly reinforcing existing steel components. Two fundamental questions are discussed in the current work. The first focus is on the general geometric possibilities offered by this process. The influence of various parameters, such as wire feed speed, travel speed, and torch inclination on the seam shape and build-up rate are presented. The microstructure of the manufactured components is evaluated through metallography and hardness testing. Based on the first results, print strategies are developed for different requirements. Moreover, suitable process parameter sets are recommended in terms of energy input per unit length, weld integrity and hardness distribution. The second focus is on testing and determining joint properties by analyzing the microhardness of the welded structures. The chosen parameter sets will be investigated, and steel quality equivalents according to ÖNORM EN ISO 18265 will be defined. [ABSTRACT FROM AUTHOR]

In this paper, the response characteristics of wave propagation in entangled metallic wire materials (EMWMs) are investigated by acoustic emission. The frequency, amplitude of wave emission, and the pre-compression force of the specimen can be adjusted in the experimental setup. EMWM specimens fabricated from stainless steel wires and with different design parameters are tested in this work. The results show that waves of different amplitudes propagate in EMWMs with approximate linear characteristics and the fluctuation coefficient of wave passing ratios is calculated below 15%. The response spectrum of passing waves shows a distinct single-peak characteristic, with the peak response at approximately 14 kHz. The parameters of pre-compression force, porosity, wire diameter, helix diameter, specimen height, and the layered structure of specimens have no significant effect on the frequency characteristics but moderately affect the wave passing ratios. Notably, EMWMs exhibit a lower wave passing ratio (ranging from 0.01 to 0.18) compared to aluminum alloy and natural rubber. The characteristics of response spectrums can be successfully reproduced by the finite element simulation. This work demonstrates EMWMs' potential as an acoustic frequency vibration isolation material, offering excellent performance and engineering design convenience. [ABSTRACT FROM AUTHOR]

Due to its exceptional electrical and thermal conductivity, pure copper is frequently employed in industry as the base metal for thermal management and electromagnetic applications. The growing need for complicated and efficient motor designs has recently accelerated the development of copper additive manufacturing (AM). The present work aims to improve the power density of the copper laser powder bed fusion (Cu-LPBF) coil by increasing the slot-filling factor (SFF) and the electrical conductivity. Firstly, the dimensional limitation of Cu-LPBF fabricated parts was identified. Sample contouring and adjusting beam offset associated with optimum scan track morphology upgraded the minimum feature spacing to 80 μm. Accordingly, the printed winding's slot-filling factor increased to 79% for square wire and 63% for round wire. A maximum electrical conductivity of 87% (IACS) was achieved by heat treatment (HT). The electrical impedance of full-size Cu-LPBF coils, newly reported in this study, was measured and compared with solid wire. It can reflect the performance of Cu-LPBF coils (power factor) in high-frequency applications. Furthermore, surface quality benefited from either sample contouring and HT, where the side surface roughness was lowered by 45% and an additional reduction of 25% after HT. [ABSTRACT FROM AUTHOR]

Hardfacing is one of the techniques used for part lifecycle elongation. Despite being used for over 100 years, there still is much to discover, as modern metallurgy provides more and more sophisticated alloys, which then have to be studied to find the best technological parameters in order to fully utilize complex material properties. One of the most efficient and versatile hardfacing approaches is Gas Metal Arc Welding technology (GMAW) and its cored-wire equivalent, known as FCAW (Flux-Cored/Cored Arc Welding). In this paper, the authors study the influence of heat input on the geometrical properties and hardness of stringer weld beads fabricated from cored wire consisting of macrocrystalline tungsten carbides in a nickel matrix. The aim is to establish a set of parameters which allow to manufacture wear-resistant overlays with high deposition rates, preserving all possible benefits of this heterogenic material. This study shows, that for a given diameter of the Ni-WC wire, there exists an upper limit of heat input beyond which the tungsten carbide crystals may exhibit undesired segregation at the root. [ABSTRACT FROM AUTHOR]

Steel-wire rope is a mechanical component that has versatile uses and on which human lives depend. One of the basic parameters that serve to describe the rope is its load-bearing capacity. The static load-bearing capacity is a mechanical property characterized by the limit static force that the rope is able to endure before it breaks. This value depends mainly on the cross-section and the material of the rope. The load-bearing capacity of the entire rope is obtained in tensile experimental tests. This method is expensive and sometimes unavailable due to the load limit of testing machines. At present, another common method uses numerical modeling to simulate an experimental test and evaluates the load-bearing capacity. The finite element method is used to describe the numerical model. The general procedure for solving engineering tasks of load-bearing capacity is by using the volume (3D) elements of a finite element mesh. The computational complexity of such a non-linear task is high. Due to the usability of the method and its implementation in practice, it is necessary to simplify the model and reduce the calculation time. Therefore, this article deals with the creation of a static numerical model which can evaluate the load-bearing capacity of steel ropes in a short time without compromising accuracy. The proposed model describes wires using beam elements instead of volume elements. The output of modeling is the response of each rope to its displacement and the evaluation of plastic strains in the ropes at selected load levels. In this article, a simplified numerical model is designed and applied to two constructions of steel ropes, namely the single strand rope 1 × 37 and multi-strand rope 6 × 7-WSC. [ABSTRACT FROM AUTHOR]

Hard and brittle materials such as monocrystalline silicon still occupy an important position in the semiconductor industry, but hard and brittle materials are difficult to process because of their physical properties. Fixed-diamond abrasive wire-saw cutting is the most widely used method for slicing hard and brittle materials. The diamond abrasive particles on the wire saw wear to a certain extent, which affects the cutting force and wafer surface quality in the cutting process. In this experiment, keeping all the given parameters unchanged, a square silicon ingot is cut repeatedly with a consolidated diamond abrasive wire saw until the wire saw breaks. The experimental results show that the cutting force decreases with the increase in cutting times in the stable grinding stage. The wear of abrasive particles starts at the edges and corners, and the macro failure mode of the wire saw is fatigue fracture. The fluctuation of the wafer surface profile gradually decreases. The surface roughness of wafer is steady during the wear steady stage, and the large damage pits on the wafer surface are reduced in the whole process of cutting. [ABSTRACT FROM AUTHOR]

This article deals with the effect of strain-assisted tempering (SAT) on the fatigue properties of 54SiCr6 steel used for spring steel wires in a wide variety of automotive applications, including coil springs. This steel spring wire is extremely strong, having a high elastic limit and yield point, giving the steel excellent energy accumulation and fatigue properties. This combination opens up new possibilities in helical and cylindrical coil spring design, resulting in the reduction of both size and weight. Lightweight coil springs lead to improvements in fuel consumption, stability and vehicle traction. A large plastic deformation and SAT were applied to enhance the yield point of the study material. Improvements in the static and cyclic properties of steel springs were investigated using tensile tests and 3PB fatigue tests at ambient temperature. In addition, an advanced laser shock peening (LSP) process was employed to increase the fatigue resistance of the SAT material. The results presented here show great improvements in the static and fatigue properties over commercial steel treatment. The material quality of the wires was evaluated to be insufficient for further processing with cold coiling. [ABSTRACT FROM AUTHOR]

This study aimed to clarify the effect of wire structure and alkaline elements in wire composition on metal transfer behavior in metal-cored arc welding (MCAW). A comparison of metal transfer in pure argon gas was carried out using a solid wire (wire 1), a metal-cored wire without an alkaline element (wire 2), and another metal-cored wire with 0.084 mass% of sodium (wire 3). The experiments were conducted under 280 and 320 A welding currents, observed by high-speed imaging techniques equipped with laser assistance and bandpass filters. At 280 A, wire 1 showed a streaming transfer mode, while the others showed a projected one. When the current was 320 A, the metal transfer of wire 2 changed to streaming, while wire 3 remained projected. As sodium has a lower ionization energy than iron, the mixing of sodium vapor into the iron plasma increases its electrical conductivity, raising the proportion of current flowing through metal vapor plasma. As a result, the current flows to the upper region of the molten metal on the wire tip, with the resulting electromagnetic force causing droplet detachment. Consequently, the metal transfer mode in wire 3 remained projected. Furthermore, weld bead formation is the best for wire 3. [ABSTRACT FROM AUTHOR]

Joining wires made of NiTi alloys with shape memory effect and pseudoelasticity causes many technical and structural problems. They result from unwanted phase interactions that occur in high temperatures and negatively affect the characteristics of these materials. Such obstacles are challenging in terms of welding. Hence, an attempt was made to join NiTi wires via an economical and reliable basic laser welding technique which does not require complicated equipment and gas protection. The parameters such as spot diameter and pulse time were constant and only the laser power, calculated as a percentage of the total power, was optimized. The wires were parallelly connected with overlapping seam welds 10 mm long. The welds were examined regarding their microstructure, chemical and phase composition, reversible martensitic transformation, microhardness, and pseudoelasticity. The obtained results showed that the joint was completed at the 12–14% power. The weld revealed good quality with no voids or pores. As the laser power increased, the microhardness rose from 282 (for 4%) to 321 (for 14%). The joint withstood the stress-inducing reversible martensitic transformation. As the transformation was repeated cyclically, the stress value decreased from 587 MPa (initial wire) to 507 MPa (for the 14% power welded wire). [ABSTRACT FROM AUTHOR]

This experimental study was conducted to evaluate the deflection performance of wire-integrated steel deck plates with various end details subjected to cumulative gravity loads. In general, when deck plates are installed in the Republic of Korea, vertical bars are mounted at the ends of the wire-integrated deck plates. However, this process can extend the construction time, thus incurring additional costs. Consequently, this study aimed to examine the structural performance of a deck plate when a lattice foot—rather than a vertical bar—is installed at the end of it. A total of nine specimens were prepared; the experimental variables included the end details, height of the lattice truss girder, and structure type. To evaluate the deflection performance, the cumulative gravity load (as a construction load) and a concrete self-weight were applied to the specimens, and the deflections of each specimen were measured. In the experimental results, the deflection values of the specimen with vertical bars were 0.9~6.1 mm, while those for the specimen without vertical bars were 0.8~5.0 mm. This means that a lattice foot exhibits better deflection performance than conventional end details. Additionally, the deflection of the specimens satisfied the deflection limits required in the relevant standards. [ABSTRACT FROM AUTHOR]

Welding and the behavior of the weldments are important, since welding of high strength low alloy (HSLA) steels is a conventional method for manufacturing industrial parts. This work conducts a comparative investigation of microstructural characteristics and mechanical properties for joints of 16-mm-thick HSLA Q890 steel produced by multi-layer multi-pass shielded metal arc welding (SMAW) with filler wire and single-layer autogenous laser beam welding (LBW). The mechanical properties of the welded joints were assessed in terms of tensile and impact using butt joints. The results show that tensile failure occurred in the base metal during the tensile tests for most of the trials. The ultimate tensile strength and percent elongation of the LBW welded joint (973.5 MPa and 10%) are higher than those of the SMAW joint (951 MPa and 2.9%) due to the filler filling process of the SMAW process. The Charpy impact energy of the weld metal (16.4 J and 15.1 J) is lower than that of the heat-affected zone (18.5 J and 19.5 J) in the LBW joint and the SMAW joint. [ABSTRACT FROM AUTHOR]

Wire and arc additive manufacturing (WAAM) technology has recently become attractive due to the fact of its high production capacity and flexible deposition strategy. One of the most prominent drawbacks of WAAM is surface irregularity. Therefore, WAAMed parts cannot be used as built; they require secondary machining operations. However, performing such operations is challenging due to the fact of high waviness. Selecting an appropriate cutting strategy is also challenging, because surface irregularity makes cutting forces unstable. The present research determines the most suitable machining strategy by assessing the specific cutting energy and local machined volume. Up- and down-milling are evaluated by calculating the removed volume and specific cutting energy for creep-resistant steel, stainless steel, and their combination. It is shown that the main factors that affect the machinability of WAAMed parts are the machined volume and specific cutting energy rather than the axial and radial depths of the cut due to the fact of high surface irregularity. Even though the results were unstable, a surface roughness of 0.1 µm was obtained with up-milling. Despite a two-fold difference in the hardness between the two materials in the multi-material deposition, it is found that hardness should not be used as a criterion for as-built surface processing. In addition, the results show no machinability difference between multi- and single-material components for a low machined volume and low surface irregularity. [ABSTRACT FROM AUTHOR]

Electrical Impedance Tomography (EIT) is a detection imaging technology developed 30 years ago. When the conventional EIT measurement system is used, the electrode and the excitation measurement terminal are connected with a long wire, which is easily affected by external interference, and the measurement result is unstable. In this paper, we developed a flexible electrode device based on flexible electronics technology, which can be softly attached to the skin surface for real-time physiological monitoring. The flexible equipment includes an excitation measuring circuit and electrode, which eliminates the adverse effects of connecting long wires and improves the effectiveness of measuring signals. At the same time, the design also uses flexible electronic technology to make the system structure achieve ultra-low modulus and high tensile strength so that the electronic equipment has soft mechanical properties. Experiments have shown that when the flexible electrode is deformed, its function is completely unaffected, the measurement results remain stable, and the static and fatigue performances are satisfactory. The flexible electrode has high system accuracy and good anti-interference. [ABSTRACT FROM AUTHOR]

This paper studies the drawing-induced intercolonial microdamage (ICMD) in pearlitic microstructures. The analysis was performed from the direct observation of the microstructure of the progressively cold-drawn pearlitic steel wires associated with the distinct steps (cold-drawing passes) of a real cold-drawing manufacturing scheme, constituted by seven cold-drawing passes. Three types of ICMD were found in the pearlitic steel microstructures, all affecting two or more pearlite colonies, namely: (i) intercolonial tearing; (ii) multi-colonial tearing; and (iii) micro-decolonization. The ICMD evolution is quite relevant to the subsequent fracture process of cold-drawn pearlitic steel wires, since the drawing-induced intercolonial micro-defects act as weakest links or fracture promoters/initiators, thereby affecting the microstructural integrity of the wires. [ABSTRACT FROM AUTHOR]

Direct energy deposition with arc and wire (DED-AW) is a versatile, low-cost, and energy-efficient technology for additive manufacturing of medium- and large-sized metallic components. In this study, the effects of arc energy and shielding gas in cold metal transfer (CMT) welding of walls and blocks on cooling time, mechanical properties, and macro- and microstructure have been studied using precipitation-hardenable Ni-based superalloy Haynes® 282®. The arc energy and consequently the cooling rate were varied by changing the wire feed rate and the travel speed. As expected, increasing the arc energy leads to higher cooling times for the walls. Due to the 2D thermal conduction, the thin walls cool down much slower than multi-layer welded blocks, but this reduces the strength values only very slightly. While the walls have no sensitivity to the occurrence of unacceptable seam irregularities, the multi-layer blocks show isolated seam defects, such as hot cracks or lack of fusion. Despite shielding gas variation, the as-welded blocks show acceptable strength properties at room temperatures (RT) and impact values at RT and −196 °C. However, the use of an N-containing shielding gas results in lower elongation and notched bar impact energy. Precipitation-hardened specimens tested at 871 °C exhibit a similar strength level to transverse tensile specimens of gas metal arc welding (GMAW) welded joints on 12.7 mm thick plates with fracture in the weld metal. [ABSTRACT FROM AUTHOR]