Longitudinal Cross Section Research Articles

Study on Mitigation of Interfacial Intermetallic Compounds by Applying Alternating Magnetic Field in Laser-Directed Energy Deposition of Ti6Al4V/AA2024 Dissimilar Materials

Brittle intermetallic compounds (IMCs) at the interface of dissimilar materials can seriously affect the mechanical properties of the dissimilar components. Introducing external assisted fields in the fabrication of dissimilar components is a potential solution to this problem. In this study, an alternating magnetic field (AMF) was introduced for the first time in the additive manufacturing of Ti6Al4V/AA2024 dissimilar alloy components by laser-directed energy deposition (L-DED). The effect of the AMF on the interfacial IMCs’ distribution was studied. The results indicate that the contents of the IMCs were different for different magnetic flux densities and frequencies, and the lowest content was obtained with a magnetic flux density of 10 mT at a frequency of 40 Hz. When an appropriate AMF was applied, the IMC layer was no longer continuous at the interface, and the thickness was notably decreased. In addition, the influence of the AMF on the temperature distribution and fluid flow in the melt pool was analyzed through numerical simulation. The simulation results indicate that the effect of the AMF on the temperature of the melt pool was not significant, but it changed the flow pattern inside the melt pool. The two vortices inside the cross-section that formed when the AMF was applied caused different orientations of club-shaped IMCs inside the deposition layer. A sudden change in the streamline direction at the bottom of the longitudinal cross-section of the melt pool can affect the formation of the IMC layer at the interface of dissimilar materials, resulting in inconsistent thickness and even gaps. This work provides a useful guidance for regulating IMCs at dissimilar material interfaces.

Large-scale investigation of dry orthogonal cutting experiments Ti6Al4V and Ck45

The numerical simulation of metal cutting processes requires material data for constitutive equations, which cannot be obtained with standard material testing procedures. Instead, inverse identifications of material parameters within numerical simulation models of the cutting experiment itself are necessary. This report presents the findings from a large-scale study of dry orthogonal cutting experiments on Ti6Al4V (Grade 5) and Ck45 (AISI 1045). It includes material characterization through microstructural analysis and tensile tests. The study details the measurement of cutting insert geometries and cutting edge radii, evaluates process forces, deduces friction coefficients and coefficients for Kienzle’s force model, and analyzes chip forms and thicknesses as well as built-up edge formation depending on the process parameters. The collected data, stored in pCloud, can support other researchers in the field, e.g. for recomputations within numerical models or inverse parameter identifications. The dataset includes force measurements, cutting edge scans, and chip images including longitudinal cross-sections of chips.

Atomic force microscopy-based nanoindentation technique for characterizing the transverse and shear moduli of flax fibers

Experimentally evaluating the elastic properties of flax fibers is challenging due to their complex hierarchical structure, and a standard test procedure for measuring their transverse and shear moduli is currently not reported in the literature. Hence, this study presents an atomic force microscopy (AFM) based nanoindentation technique to evaluate the transverse and shear moduli of flax fiber. A high-precision focused ion beam (FIB)-milling process was used to fabricate a flat surface for indentation along the longitudinal fiber cross-section of the fiber and transverse fiber cross-section by polishing the unidirectional (UD) lamina in order to evaluate the indentation modulus. Further, Swanson's numerical contour approach was adopted to evaluate the elastic properties of the fiber from the measured indentation modulus. The accuracy of the experimentally obtained fiber properties is verified by using it in a micromechanics model for predicting the elastic properties of the UD lamina and comparing it with experimental results reported in the literature.

An exact analytical solution for the weakly magnetized flow around an axially symmetric paraboloid, with application to magnetosphere models

Rotationally symmetric bodies with longitudinal cross sections of parabolic shape are frequently used to model astrophysical objects, such as magnetospheres and other blunt objects, immersed in interplanetary or interstellar gas or plasma flows. We discuss a simple formula for the potential flow of an incompressible fluid around an elliptic paraboloid whose axis of symmetry coincides with the direction of incoming flow. Prescribing this flow, we derive an exact analytical solution to the induction equation of ideal magnetohydrodynamics for the case of an initially homogeneous magnetic field of arbitrary orientation being passively advected in this flow. Our solution procedure employs Euler potentials and Cauchy's integral formalism based on the flow's stream function and isochrones. Furthermore, we use a particular renormalization procedure that allows us to generate more general analytical expressions modeling the deformations experienced by arbitrary scalar or vector-valued fields embedded in the flow as they are advected first toward and then past the parabolic obstacle. Finally, both the velocity field and the magnetic field embedded therein are generalized from incompressible to mildly compressible flow, where the associated density distribution is found from Bernoulli's principle.

Combined matrix-assisted laser desorption/ionisation-mass spectrometry imaging with liquid chromatography-tandem mass spectrometry for observing spatial distribution of lipids in whole Caenorhabditis elegans.

Matrix-assisted laser desorption/ionisation-mass spectrometry imaging (MALDI-MSI) is a powerful label-free technique for biomolecule detection (e.g., lipids), within tissue sections across various biological species. However, despite its utility in many applications, the nematode Caenorhabditis elegans is not routinely used in combination with MALDI-MSI. The lack of studies exploring spatial distribution of biomolecules in nematodes is likely due to challenges with sample preparation. This study developed a sample preparation method for whole intact nematodes, evaluated using cryosectioning of nematodes embedded in a 10% gelatine solution to obtain longitudinal cross sections. The slices were then subjected to MALDI-MSI, using a RapifleX Tissuetyper in positive and negative polarities. Samples were also prepared for liquid chromatography-tandem mass spectrometry (LC-MS/MS) analysis using an Exploris 480 coupled to a HPLC Vanquish system to confirm the MALDI-MSI results. An optimised embedding method was developed for longitudinal cross-sectioning of individual worms. To obtain longitudinal cross sections, nematodes were frozen at -80°C so that all worms were rod shaped. Then, the samples were defrosted and transferred to a 10% gelatine matrix in a cryomold; the worms aligned, and the whole cryomold submerged in liquid nitrogen. Using MALDI-MSI, we were able to observe the distribution of lipids within C. elegans, with clear differences in their spatial distribution at a resolution of 5μm. To confirm the lipids from MALDI-MSI, age-matched nematodes were subjected to LC-MS/MS. Here, 520 lipids were identified using LC-MS/MS, indicating overlap with MALDI-MSI data. This optimised sample preparation technique enabled (un)targeted analysis of spatially distributed lipids within individual nematodes. The possibility to detect other biomolecules using this method thus laid the basis for prospective preclinical and toxicological studies on C. elegans.

Structures in grain-refined directionally solidified hypoeutectic Al-Cu alloys: Benchmark experiments under microgravity on-board the International Space Station

Benchmark solidification experiments were successfully performed under microgravity conditions on-board the International Space Station (ISS) within the ESAprogramme CETSOL (Columnar-to-Equiaxed Transition in SOLidification Processing). Cylindrical samples of grain-refined Al-4wt.%Cu, Al-10wt.%Cu and Al-20wt.%Cu alloys were directionally solidified in a gradient furnace to investigate columnar and equiaxed dendritic growth structures as well as the columnar to equiaxed transition under diffusive conditions. The determination of temperature gradients; interface velocities; and cooling rates at liquidus, solidus, and eutectic front positions provides well-defined thermal experimental characterization. The evaluation of the flight samples demonstrates that no significant macrosegregation along the sample axis occurred and no radial effects were observed. Therefore, purely diffusive solidification behaviour without any residual melt convection can be assumed for these microgravity experiments. The analyses of the microstructure in longitudinal cross-sections show dendritic structures without any pore formation and the averaged eutectic fraction is largely constant along the sample. The samples of refined Al-4wt.%Cu alloy show a sharp CET from columnar dendrites to a fine equiaxed steady-state grain structure whereas in the samples of refined Al-10wt.%Cu and Al-20wt.%Cu alloy, only equiaxed dendritic grain growth is observed. A quantitative analysis of the equiaxed grain morphology shows, that the shapes of the equiaxed dendrites depend on the applied temperature gradient, but the grain sizes in radial and longitudinal directions are identical. Therefore, a fully equiaxed dendritic growth structure without dendrite elongation was obtained. Compared to experiments in microgravity with non-refined Al-Cu alloys the average equiaxed grain size is about three times smaller.

THE MEASUREMENT QUALITY EVALUATION OF AN ULTRASONIC FLOW SENSOR WITH A COMPLEX MEASURING PATH TRAJECTORY

Over the past ten years, ultrasonic measuring instruments have become most widespread in industrial measurements of the flow and quantity of various energy resources. Such instruments differ in design, method of obtaining the output signal, number and topology of acoustic waves propagation and, accordingly, have different metrological performances. The accuracy of the measured signal formation is determined by the quality of the flow sensor. At the same time, the components of quality are metrological performances, manufacturability of the design, ease of setup, cost and others. The purpose of the work is to compare, analyze and evaluate the quality of flow measurements when using a single-channel ultrasonic sensor with a complex trajectory of the measuring beam and a multi-path (multichord) ultrasonic sensor. As a result of simulation modeling, distributions of flow velocities in longitudinal sections and cross sections were obtained, correction factors for the measured signal were determined, and pressure losses were calculated. A comparative analysis of the measurement quality of the investigated flow sensors made it possible to identify the advantages of using a single-path flow transducer with acoustic wave reflection. We are talking about the possibility of accurately outputting a useful signal, higher metrological sensitivity, higher measurement accuracy, as well as minimal impact on the measured medium due to the creation of smaller geometrically sized local hydrodynamic resistance along the length of the measuring path. The further research prospect is the study of ultrasonic flow measuring sensors with different topologies of acoustic channels when measuring and recording flow and quantity for different flow regimes of the measured medium.

Microscopic mechanism of ultrasonically welded joints: The role of terminal roughness and wire diameter

The ultrasonic welding technology is widely promoted as a new connection approach in the field of current energy vehicle wiring harness connection. In this paper, three kinds of 25mm2 copper wire harnesses with different wire diameters and T2 copper terminals with different surface roughness were welded by ultrasonic welding. The mechanical properties of the joints were investigated by tensile experiments and the microstructure of joints was characterised using SEM and EBSD techniques. Excessive roughness increases plastic deformation at the weld interface during ultrasonic welding. This increases the dislocation density at the weld interface and refines the grain size. However, at the same time it inhibits recrystallisation to a certain extent. The lower roughness facilitates recrystallisation, but the low density of HAGBs makes the interface susceptible to slip in extended crystallographic plane and direction. Appropriate roughness allows the weld interface to generate fine equiaxed grains and a high density of HAGBs. This facilitates the obstruction of dislocation movement and improves the strength of joint. In addition, the high porosity of a longitudinal cross-section of the conductor with its small diameter was investigated. This results in a large number of wires remaining on the terminals when force is applied. It was determined that the larger a diameter of wire, the higher a cross-sectional porosity. The copper wire breaks at a weak point in cross-section when the force is applied, resulting in the entire wire being left on terminal. At a wire diameter of 0.2 mm, the porosity of a cross-section reaches an equilibrium and the strength of joint is even higher than the strength of material itself, resulting in the joint pulling off. The maximum strength reaches 4703.77 N.

Ultrasonic Non-Destructive Detection Method for Residual Stress in Rotary Forging Aluminum Alloy Plates.

Aluminum alloy plates are widely used to manufacture large-scale integral structure parts in the field of aerospace. During the forming and processing of aluminum alloy plates, different degrees of residual stress are inevitably produced. Fast and accurate detection of residual stress is very essential to ensuring the quality of these plates. In this work, the longitudinal critically refracted (LCR) wave detection method based on a one-transmitter and double-receiver (OTDR) transducer and the finite element simulation were employed to obtain the residual stress. Aluminum alloy plates with different deformation amounts were fabricated by rotary forging to obtain different residual stress states. Results reveal that the plate formed by rotary forging is in a stress state of central tension and edge compression. As the deformation increases from 20% to 60%, the peak residual tensile stress increases from 156 MPa to 262 MPa, and there is no significant difference in the peak compressive stress. When the deformation reaches 60%, the difference in the residual stresses at different depths is less than 13%, which indicates that the plastic deformation zone basically penetrates the entire longitudinal cross-section of the plate. The maximum deviation between measurement and FE is 61 MPa, which means the experimental data are in good agreement with the FE results.

Cerium oxide and neodymium oxide phytoextraction by ryegrass in bioenhanced hydroponic environments

Sustainable technologies for the recovery of rare earth elements (REE) from waste need to be developed to decrease the volume of ore mining extractions and its negative environmental consequences, while simultaneously restoring previously impacted lands. This is critical due to the extensive application of REE in everyday life from electronic devices to energy and medical technologies, and the dispersed distribution of REE resources in the world. REE recovery by plants has been previously studied but the feasibility of REE phytoextraction from a poorly soluble solid phase (i.e., nanoparticles) by different plant species has been rarely investigated. In this study, the effect of biostimulation and bioaugmentation on phytorecovery of REE nanoparticles (REE-NP) was investigated by exposing ryegrass seeds to REE-NP in hydroponic environments. This was studied in two sets of experiments: bioaugmentation (using CeO2 nanoparticles and Methylobacterium extorquens AM1 pure culture), and biostimulation (using CeO2 or Nd2O3 nanoparticles and endogenous microorganisms). Addition of M. extorquens AM1 in bioaugmentation experiment including 500 mg/L CeO2 nanoparticles could not promote the nanoparticles accumulation in both natural and surface-sterilized treatments. However, it enhanced the translocation of Ce from roots to shoots in sterile samples. Moreover, another REE-utilizing bacterium, Bacillus subtilis, was enriched more than M. extorquens in control samples (no M. extorquens AM1), and associated with 52% and 14% higher Ce extraction in both natural (165 μg/gdried-plant) and surface-sterilized samples (136 μg/gdried-plant), respectively; showing the superior effect of endogenous microorganisms’ enrichment over bioaugmentation in this experiment. In the biostimulation experiments, up to 705 μg/gdried-plant Ce and 19,641 μg/gdried-plant Nd could be extracted when 500 mg/L REE-NP were added. Furthermore, SEM-EDS analysis of the surface and longitudinal cross-sections of roots in Nd2O3 treatments confirmed surface and intracellular accumulation of Nd2O3-NP. These results demonstrate stimulation of endogenous microbial community can lead to an enhanced REE phytoaccumulation.

Experimental Determination of a Strain State in a Bulk Forming of a Low Carbon Steel

An experimental metallographic method for determining strain distribution in a cold formed workpiece is presented in this paper. The method, based on the dependence of recrystallized grain size on prior deformation, was applied to a bulk formed element made of low carbon steel. Strain distribution was obtained by the calibration curve which gives the relation between recrystallized grain size and prior deformation. To determine strain values, the average grain size was measured in the longitudinal cross-section of the formed element. To accurately differentiate deformation zones, additional observation of carbides and nonmetallic inclusions morphology was utilized, also. The grain size and strain noticeably differ through the cross-section. It is observed that in the middle part, material flows freely through the die opening without significant deformation. From this zone, strain increases gradually, reaching the highest value at the contact surface of the die slope, while the top part flows radially having intermediate values of strain.

Teat morphology across five buffalo breeds: a multi-country collaborative study.

The buffalo (Bubalus bubalis) is a species of worldwide importance, raised to produce milk, meat, and hides, and often used as a working animal in rural contexts with low access to hi-tech solutions. In the present study, 100 lactating buffaloes (50 primiparous and 50 pluriparous) of five popular breeds were recruited to characterize and compare teat morphology. In particular, the focus was put on the Nili Ravi, Mediterranean, Egyptian, Bulgarian Murrah, and Azeri buffaloes raised in Pakistan, Italy, Egypt, Bulgaria, and Iran, respectively. In all countries, a longitudinal cross-section ultrasound was obtained before the milking to measure teat parameters at individual level: overall, teat canal length (TCL) averaged 24.13mm, teat diameter (TD) 30.46mm, cisternal diameter (CD) 17.80mm, and teat wall (TW) 7.12mm. The most variable trait across breeds was TCL which was positively correlated with CD and TD and negatively with TW, regardless of the teat position (front/rear or left/right). A strong negative correlation was found between TW and CD (- 0.43). The analysis of variance revealed that the fixed effect of breed significantly affected all the traits except TD. In fact, Bulgarian Murrah, Azeri, and Egyptian buffaloes presented the greatest estimate of TCL, whereas NR the smallest (14.70mm). The TW was maximum in Nili Ravi, Egyptian, and Mediterranean buffaloes, with estimates equal to 8.19, 7.59, and 8.74mm, respectively. Nili Ravi also showed the greatest TL (82.39mm). In terms of CD, the lowest least square mean was that of Mediterranean buffaloes (12.14mm). Primiparous and pluriparous buffaloes differed in terms of TD, TW, and TL, with older animals presenting the highest least square mean. In terms of position, instead, significant differences were observed for TD, CD, and TL when comparing front and rear teats, as left and right teats did not differ. Teat anatomy includes a set of heritable morphological features and is therefore breed-dependent. Differences presented in this study could be attributed to the divergent breeding objective and selective pressure across the five breeds; e.g., in some cases such as Mediterranean buffalo, selection for decades was oriented to improve milk production and milkability and achieve optimal conformation for mechanical milking. A better understanding of the mammary gland anatomical descriptors can be informative of the history of a breed and could provide useful insights to guide possible selection.

A superporous and pH-sensitive hydrogel from Salvia hispanica (chia) seeds: stimuli responsiveness, on-off switching, and pharmaceutical applications.

The use of plant seed-based hydrogels to design drug delivery systems (DDSs) has increased due to their swellable, pH-responsive, biocompatible, biodegradable, and non-toxic nature. Herein, the chia seeds hydrogel (CSH) was extracted through an aqueous extraction method to explore its pH and salt-responsive swelling behavior and sustained release potential. The CSH was characterized using Fourier transform infrared (FT-IR) and solid-state cross-polarization magic angle spinning carbon-13 nuclear magnetic resonance (solid/state CP-MAS 13C/NMR) spectra. Thermal analysis indicated that the CSH is a thermally stable material and decomposes in two steps. The scanning electron microscope (SEM) images of CSH witnessed the existence of microscopic channeling and a superporous nature with average pore sizes of 18 ± 11 μm (transverse cross-sections) and 23 ± 15 μm (longitudinal cross-sections). The CSH is a haemocompatible material. The CSH revealed pH and saline-responsive swelling in powder and compressed form (tablet) in the following order; distilled water (DW) > pH 7.4 > pH 6.8 > pH 1.2. Moreover, the swelling of CSH followed second-order kinetics. The swelling of CSH powder and tablets was decreased with increasing salt concentration. The pH, solvent, and saline responsive on/off switching (swelling/deswelling) results of the CSH and tablets disclosed its stimuli-responsive nature. The CSH prolonged the release of valsartan for 5 h at pH 7.4, whereas, negligible release (19.3%) was noted at pH 1.2. The valsartan release followed first-order kinetics and the non-Fickian diffusion. In conclusion, the CSH is a stimuli-responsive smart material with great potential to develop pH-sensitive and targeted DDSs.

Spatial variations in the osteocyte lacuno-canalicular network density and analysis of the connectomic parameters.

Osteocyte lacuno-canalicular network (LCN) is comprised of micrometre-sized pores and submicrometric wide channels in bone. Accumulating evidence suggests multiple functions of this network in material transportation, mechanobiological signalling, mineral homeostasis and bone remodelling. Combining rhodamine staining and confocal laser scanning microscopy, the longitudinal cross-sections of six mouse tibiae were imaged, and the connectome of the network was quantified with a focus on the spatial heterogeneities of network density, connectivity and length of canaliculi. In-vivo loading and double calcein labelling on these tibiae allowed differentiating the newly formed bone from the pre-existing regions. The canalicular density of the murine cortical bone varied between 0.174 and 0.243 μm/μm3, and therefore is three times larger than the corresponding value for human femoral midshaft osteons. The spatial heterogeneity of the network was found distinctly more pronounced across the cortex than along the cortex. We found that in regions with a dense network, the LCN conserves its largely tree-like character, but increases the density by including shorter canaliculi. The current study on healthy mice should serve as a motivating starting point to study the connectome of genetically modified mice, including models of bone diseases and of reduced mechanoresponse.

CAD-RADS scoring of coronary CT angiography with Multi-Axis Vision Transformer: A clinically-inspired deep learning pipeline

Background and objectiveThe standard non-invasive imaging technique used to assess the severity and extent of Coronary Artery Disease (CAD) is Coronary Computed Tomography Angiography (CCTA). However, manual grading of each patient's CCTA according to the CAD-Reporting and Data System (CAD-RADS) scoring is time-consuming and operator-dependent, especially in borderline cases. This work proposes a fully automated, and visually explainable, deep learning pipeline to be used as a decision support system for the CAD screening procedure. The pipeline performs two classification tasks: firstly, identifying patients who require further clinical investigations and secondly, classifying patients into subgroups based on the degree of stenosis, according to commonly used CAD-RADS thresholds. MethodsThe pipeline pre-processes multiplanar projections of the coronary arteries, extracted from the original CCTAs, and classifies them using a fine-tuned Multi-Axis Vision Transformer architecture. With the aim of emulating the current clinical practice, the model is trained to assign a per-patient score by stacking the bi-dimensional longitudinal cross-sections of the three main coronary arteries along channel dimension. Furthermore, it generates visually interpretable maps to assess the reliability of the predictions. ResultsWhen run on a database of 1873 three-channel images of 253 patients collected at the Monzino Cardiology Center in Milan, the pipeline obtained an AUC of 0.87 and 0.93 for the two classification tasks, respectively. ConclusionAccording to our knowledge, this is the first model trained to assign CAD-RADS scores learning solely from patient scores and not requiring finer imaging annotation steps that are not part of the clinical routine.

Analysis of River Flow Velocity Using Current Meter with Six-Tenths Method and Two-Point Method (Case Study of Ampal River, Balikpapan City)

Rivers have cross-sectional sizes in the form of longitudinal profiles, valley slopes, and cross sections. The size can change according to the base material, cliffs, and water discharge so each river has different characteristics. The flow velocity will affect the flow rate. This study aims to determine the flow velocity of the Ampal River and determine the differences between the methods used. Measurement of flow velocity in this study using a current meter with the six-tenths method and the two-point method. The fastest flow velocity obtained on average is at the point z/b = 0.5 or in the middle of the river, with the maximum speed being at Cross Section 4, with a depth of 1.29 m and a speed of 0.474 m/s.

Characteristics of fires in coal mine roadways and comparative analysis of control effectiveness between longitudinal ventilation and cross-section sealing

Enhancing ventilation velocity and constructing sealing walls are prevalent strategies aimed at managing fires in coal mine roadways. To assess the efficacy of these control tactics, this study investigates the fire characteristics with varying heat release rates (HRR) using a 1:10 experiment and numerical simulations. Results reveal that an increase in the HRR corresponds to a decrease in ceiling temperature, alongside an increase in both smoke back-layering length and critical velocity. Longitudinal ventilation proves effective in lowering ceiling temperature and inhibiting upstream smoke propagation from fire source, but it does not extinguish the fire, instead reducing downstream visibility and escalating risk downstream of fire. When the actual velocity exceeds 3.1 m/s, it effectively prevents smoke backflow in a fire of 10 MW. Cross-section sealing works by reducing oxygen levels within roadway to suffocate the fire. As the sealing ratio increases, flame inclination angle and burning time decline, whereas ceiling temperature rises. When it exceeds 75%, CO concentration sharply rises and fire enters the extinguishment phase, if ratio is 100%, fire with higher HRR are extinguished more quickly. This study provides valuable insights into roadway fire control: longitudinal ventilation aids personnel evacuation, while cross-sectional sealing effectively extinguishes fires in unpopulated spaces.

Effect of Longitudinal Circular Hollows on the Flexural Strength of Reinforced Concrete Beams

In this study, the effect of hollows passing through reinforced concrete (RC) beams in the longitudinal direction on flexural strength was examined. 4 RC beams were designed to satisfy the conditions for implementation. One of the beams was fabricated as a reference specimen and 3 of the remaining beams were fabricated with total of 5 pipes in the tension, neutral axis and compression regions. All experimental beam specimens were subjected to 4-point axial flexural tests with the request for constant flexural moments at the limits of loading. Experimental beams with pipes in the compression region, tensile region and neutral axis regions were confronted with the reference beam in terms of initial stiffness, ductility, load-bearing capacity and energy absorption capacity. It was verified that to provide that both the sufficient stiffness and sufficient ductility conditions for the reinforced concrete beams, do not establish any structural discontinuity, the longitudinal orbicular cross-section hollows created by pipes should be passed through the neutral axis region as much as possible. The results of the present study not only align with those of previous research (e.g., the correlative results) but also extend the current state of research (e.g., the revealed differences) and provide starting points for future research. Conclusions are drawn from these results at the end of the paper.

Cracking mechanisms in additively manufactured pure tungsten from printing single tracks, thin walls and cubes

Cracking is a critical issue in the additive manufacturing of pure tungsten (W). To eliminate crack formation, it is imperative to gain an in-depth understanding of the underlying mechanisms behind this process. In this study, we systematically investigated the crack behaviors of single tracks, thin walls, and cubes fabricated using powder bed fusion–laser beam (PBF–LB) technology with nonrotational parallel-hatching scanning. The energy framework was employed to elucidate the mechanism of crack formation. The longitudinal cracks appearing in the microstructures of single tracks and the through cracks existing in thin walls and cubes were characterized. Notably, periodic through cracks extended upward across the sample, appearing at every single hatch in unidirectional samples and at every other hatch in bidirectional samples. The horizontal, longitudinal, and transverse cross sections of cubes were studied to clarify the correlation between through crack arrangement and solidification microstructure. Based on a comprehensive analysis of grain boundaries, we proposed a deformation-cracking competition mechanism in PBF–LB tungsten. Geometric effects in the crack and microstructure were also revealed. This study could provide valuable insights into the formation of cracks in PBF–LB tungsten and serve as a foundation for future investigations aimed at eliminating cracks.

A Metallurgical Inspection Method to Assess the Damage in Performance-Limiting Nb3Sn Accelerator Magnet Coils

The design and production of Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn-based dipole and quadrupole magnets is critical for the realization of the High-Luminosity Large Hadron Collider (HL-LHC) at the European Organization for Nuclear Research (CERN). Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn superconducting coils are aimed at enhancing the bending and focusing strengths of accelerator magnets for HL-LHC and beyond. Due to the brittle nature of Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn, the coil fabrication steps are very challenging and require very careful QA/QC. Flaws in the Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn filaments may lead to quenches, and eventually, performance limitation below nominal during magnet testing. A novel inspection method, including advanced non-destructive and destructive techniques, was developed to explore the root-causes of quenches occurring in performance-limiting coils. The most relevant results obtained for MQXF coils through this innovative inspection method are presented. This approach allows for precise assessment of the physical events associated with the quenches experienced by magnet coils, mainly occurring in the form of damaged strands with transversely broken sub-elements. Coil-slice preparation, micro-optical observations of transverse and longitudinal cross-sections, and a deep etching technique of copper will be illustrated in the present work, with a focus on the results achieved for a CERN coil from a non-conforming quadrupole magnet prototype, and two coils fabricated in the US, in the framework of the Accelerator Upgrade Project (AUP) collaboration, from two different non-conforming quadrupole magnets, respectively. The results obtained through the proposed inspection method will be illustrated.