Machine Parts Research Articles

Design and optimization of annular gap in a nozzle for dyeing machines

The annular nozzle is an important part of the dyeing machine as its impact and traction performance directly affect the quality and efficiency of dyeing. The annular gap forms the core of the nozzle. In this paper, the performance differences between six nozzles with different annular gap shapes were analyzed under various conditions using numerical simulation. The results indicate that the performance of the cone straight nozzle is more stable than other nozzle shapes under various conditions. To further enhance the performance of the nozzle, a multi-objective optimization of the cone straight nozzle structure was performed using a backpropagation neural network and a non-dominated sorting genetic algorithm, thereby obtaining the optimal combination of structural parameters. Finally, the optimization results were verified via experiments and numerical simulations. The results show that the pulling force of the optimized cone straight nozzle is more than 10% higher than that before optimization.

Application of diamond abrasive tools in the processing of technical ceramics in parts of mining machines

Technological development of mining equipment is largely initiated by the improvement of technologies and tools for its production, including in the field of surface treatment quality, which, in turn, determines the reliability and productivity of machines. The use of technical ceramics in designing parts and assemblies of mining machines allows for significantly improved technical and produc-tion characteristics since the quality of the parts' surface treatment is traditionally carried out with diamond-containing tools. The dia-mond tools with ceramic bonds have the highest grinding perfor-mance at the abrasive shaping of ceramics. The tribotechnical characteristics of tools made of a material with a ceramic structure hardened with microdipersed diamond grains are investigated in this work. On the basis of the classical approach to the deformation of rough surfaces, a model has been constructed that makes it possible to estimate the influence of the structural components of a dia-mond mineraloceramic tool on the wear of technical ceramics. The relations for calculation of grinding productivity, diamond content in the worn layer of the abrasive tool and the value of specific dia-mond consumption have been obtained. Experimental studies con-firmed the theoretical conclusions. It has been established that the greatest influence on grinding productivity is exerted by diamond granularity, loading and speed modes; diamond concentration significantly determines the relative wear resistance of the abrasive tool. The obtained relations will be useful in the design of diamond-containing tools for processing technical ceramics, which is increas-ingly used in the design of mining machines since its market is grow-ing dynamically around the world.

Technological solutions for applying special coatings to increase wear resistance of machine parts and components

Subject of research: technology for applying alloyed diamond-like coating (DLC), the influence of the atmosphere of the working area on the results of work. Purpose of research: search for the optimal alloyed diamond-like coating for loaded parts of a car transmission in order to ensure the required service life of the unit. Methods of research: all coatings, the research results of which are described in this article, were obtained by reactive magnetron sputtering. Main results of research: an analysis of the structural-phase state of a number of coatings is provided: containing chromium, titanium and silicon, obtained by magnetron sputtering in argon-acetylene-nitrogen atmospheres. Data are presented on the phase composition and size of coherent scattering regions, as well as the relationship between the structure and mechanical properties of the APP. A basic scheme for tribological testing of coatings has been determined, and the obtained nanocomposite structures of the APP are analyzed.

Structure of software and hardware module for research of DC electrical machines. Part 1

The structure of a hardware and software complex for the study of DC electric machines and a mathematical model of its electromechanical part taking into account the influence of temperature on the resistance of the armature winding have been developed. The hardware and software complex is implemented on the Arduino Uno board. A distinctive feature of which is the modular structure, which allows conducting research on DC electric machines in various operating modes (start-up, armature speed control, reversing, braking). In addition, it is possible to implement various laws of changing the load moment. For this purpose, the hardware and software module include the studied and load DC electric machines, which are mechanically connected to each other by means of a coupling and operate in motor and generator modes, respectively. The proposed model makes it possible to describe electromagnetic processes in DC electric machines taking into account the influence of temperature on the resistance of the armature winding, as well as overheating of individual parts of the electric machine. The proposed hardware and software module can find practical application in research laboratories in the study of DC electric machines in various operating modes.

Hierarchical Control in Mechatronic Technological Systems

The topic of hierarchical control of technological machines is one of the most relevant in mechanical engineering technology. The most difficult issue in this area is the organization of interactions between different control levels, on the one hand, and the choice of automatic control methods for each of these control levels (control by deviation, control by disturbance, mixed control, etc.), on the other. In this article, in relation to machining technology, a method and corresponding device are proposed that make it possible to implement the control of cutting force parameters (axial cutting force and cutting torque) in an automatic control system for the deviation of cutting torque by changing the axial cutting force (lower level of control). The lower-level control ensures the required quality of the surface layer (surface integrity) of the machined parts. At the same time, the required dimensional accuracy of parts is ensured at the upper level of control, which is implemented by the CNC system of the machine. At the upper level, automatic control is carried out based on the deviation of the kinematic parameters of the movement of the working parts of the CNC machine (acceleration, speed, displacement). Control switching from upper to lower level and back is carried out without using a spindle linear axial movement sensor. Instead of this expensive sensor, a limit switch (a closed and opened pair of contacts) is used, which fixes the lowest axial position of the spindle (and cutting tool). Based on the signal of closing the specified contacts of the limit switch, a transition from the lower control level to the upper one is carried out. Thus, the upper-level system operates only when these contacts are closed, and the lower-level system operates only when they are open. In relation to the upper-level system, the lower-level control system implements the control “by disturbance” principle, also known in control theory as the “disturbance compensation principle”.

An experimental analysis of mechanical properties for a dissimilar pattern structure in the 3-D printing of a PLA5F filament using the Taguchi method

Abstract Many automobile components and machine parts can be fabricated using the Fused Deposition Modeling (FDM) process with materials such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PET-G), and polymeric composite materials (e.g., PLA with carbon fiber, PLA with glass fiber). In this study, a new polymeric composite material was fabricated using Polylactic Acid and natural flax fiber was analysed for tensile stress, elongation, and impact load resistance using Taguchi Analysis. This analysis optimized the printing parameters, including layer thickness (0.15, 0.25, 0.35 mm), nozzle movement speed (80, 100, 120 mm s−1), filling structure (Lines - a, Triangular - b, and Octet - c), and occupancy rate (20%, 40%, 60%). The American Society for Testing and Materials (ASTM) standards for tensile strength (ASTM D638) and impact strength (ASTM D256) were used for evaluation. As a result, layer thickness was found to be the most effective variable for improving tensile characteristics, compared to extruder temperature, occupancy rate, or filling structure pattern. Mechanical properties including a layer thickness of 0.25 mm, an occupancy ratio of 20% for the bottom of the 2nd layer and 40% for the top of the 4th layer, triangular and octet filling structures, a nozzle speed of 100 mm s−1, and an extruder temperature of 200 °C are considered the most appropriate parameters for producing automotive parts in Three Dimensional (3D) Printing. Due to its tensile properties and impact strength resistance, these settings can be utilized in potential application in a wide variety of machine parts and vehicle components.

Batch-sizing and machinability data systems for milling operations: An optimal sustainable cost of quality approach

Nowadays, manufacturers make every effort to achieve a higher quality of their products at an attractive cost. With all the introduced legislation and incentives in the developed world to address global warming, machining shops in the West also strive to cut greenhouse emissions. This article offers an optimal approach to the micro Computer-Aided Process Planning (CAPP) problem to optimize the internal quality cost and buffering effect while keeping the environmental impact low. To optimize the machining parameters, the mathematical model is developed for different milling operations, face, side, and peripheral. cutting speed, feed rate, axial depth of cut, radial depth of cut, nose radius, and batch sizing while maximizing profit and meeting customer demand. A Mixed-Integer Nonlinear Programming (MINLP) model is formulated and solved using Classical Constrained Nonlinear Optimization (CCNO) and Genetic Algorithms (GAs). Surface roughness, used as a metric to evaluate the desired quality level of a finished machined part type, is modeled as a Gaussian random variable to model the surface roughness of the machined part utilizing a cumulative normal distribution. The ratio of rework and scrap is calculated in terms of the surface roughness of the machined part shifting away from the target and exceeding upper and lower specification limits. The internal failure cost model, addressing both scrap and rework, is developed based on Taguchi’s quadratic loss function. CCNO is employed to validate the results obtained by GAs, relaxing the lot-sizing integrality constraint and, thus, the convexity of the produced relaxed model. An iterative method employing a developed multi-regression model is used to solve for the expended power consumption (an inherent highly nonlinear environmental criterion of the developed model) within both GAs and CCNO. This study reveals that the machining parameters substantially impact the cost components of the objective function as well as the scrap and rework quantities. A stringent quality cost target can force the model to optimize the feed rate and nose radius to minimize the internal failure quality cost while improving the environmental impact, including direct and indirect power consumption and CO2 emissions considerations.

Study of Variation in Physiochemical Properties of a Worm Gearbox Lubricant by Blending Castor Oil in the Base Lubricant

In both industrial & heavy-duty applications, oil analysis can be a very effective strategy for preventing gearbox failure, cutting downtime, and managing maintenance costs. In any application, gearboxes are essential to production, the unplanned downtime and the resulting productivity losses can prove to be extremely expensive. Used oil analysis is a preventative maintenance procedure that can point out and pinpoint mechanical breakdown inside the system before it gets serious or becomes too expensive to fix. A thorough oil examination can identify wear, corrosion, and other changes that could be harmful to the health and durability of the machinery. To reduce machine wear, prevent contamination, or optimize working conditions in challenging environments, lubricants are carefully formulated by mixing additives in the base oil. A lubricant with a high acid content can cause varnish and sludge to accumulate, which can clog oil filters and cause machine parts to corrode. When a lubricant degrades, acidic byproducts are produced because of the base stock and additives' process of decomposition in the presence of heat and air. To assess the presence of acidic constituents in the oil or its acid concentration, Total Acid Number (TAN) oil testing is employed. The present work studies the effects on Total Acid Number (TAN) and Total Base Number (TBN) properties of commercial lubricant (EP 90) when castor oil is mixed in percentage concentration in it. The findings of this research have unveiled that the acidic characteristics of the base lubricant (EP90 commercial gear oil) increases as the percentage of castor oil additive is increased in the base lubricant oil.

Comparison of the Torsional Strength of Material Samples Made Using Selected Rapid Prototyping Methods

In recent years, there has been a marked increase in the use of rapid prototyping techniques that support industrial processes. The analysis of studies on strength tests of parts manufactured using additive techniques from model materials and hybrid composites usually includes tests of material and strength parameters based on uniaxial tension, bending, and compression tests. For elements manufactured from polymeric materials using traditional methods (e.g. injection moulding), data obtained from these tests are sufficient to determine the strength of the material and to apply the results in the product design process. In the case of the layered extrusion method, due to the model construction process, strength data based on standard samples do not have a direct transposition on the strength of machine parts operating under various load ranges, especially torsional loads. The publication presents the results of tests on the torsional strength of cylindrical samples with splines produced by layered extrusion, vacuum casting technology, and hybrid technology, which combines both technologies. The test samples were made using a Prusa i3 MK3 3D printer and the plasticised plastic modelling (fused filament fabrication, FFF) method, while PolyJet technology was used to create a reference model. The findings indicate that hybrid technology, in which a thin-walled mould is filled with a chemically hardened polymer, achieves the desired strength for the manufactured parts while maintaining dimensional accuracy and shape. The research results show that producing rotating elements using the hybrid technology reduces the sample core’s ability to undergo plastic deformation due to the adhesion between the materials and the occurrence of notches resulting from the model production process using the layered extrusion method.

PREDICTION OF STRENGTH DEPENDING ON THE INFLUENCE OF THE CHEMICAL COMPOSITION IN THE 40КХНМ ALLOY

Introduction. The study is devoted to the analysis of the influence of the chemical composition of the 40КХНМ alloy on its hardness. The relevance of the work lies in the fact that mechanical tests require significant material and time costs. For the operational assessment of metal quality criteria, it is proposed to apply mathematical modeling in the work. Materials and methods. A study of the effect of the chemical composition on the hardness of the 40KHNM alloy, which meets the requirements of the state standard 51397, was carried out. The results of the experiment. In the course of research, it was found that changes in the chemical composition of the 40КХНМ alloy significantly affect its mechanical properties, including hardness and resistance to shock loads. An increase in the content of carbon, molybdenum and chromium in the alloy leads to an increase in its hardness. This is with the formation of stronger carbide and molybdenum phases in the structure of the alloy, which leads to an improvement in its mechanical properties. Increased hardness makes the alloy more resistant to wear and increases its durability in operating conditions. An increase in the nickel content in the alloy leads to an increase in its resistance to shock loads. This is caused by an increase in plasticity and impact toughness of the alloy with an increased nickel content. Higher resistance to shock loads makes the alloy suitable for use in conditions that require high resistance to shocks, for example, in the production of machine parts and equipment. A mathematical model of the dependence of the strength of the alloy on the percentage content of the components of the chemical composition was built, which allows to control the indicators of the strength of the alloy in the process of its manufacture. Conclusions. The research results confirm that changes in the chemical composition of the 40КХНМ alloy have a significant impact on its mechanical properties. As a result of the experiments, it was established that the chemical composition of the metal significantly affects the hardness of the material. By changing the composition of the metal, it was possible to achieve a significant increase in hardness to levels that meet the requirements of quality standards. These results are an important step in optimizing the production processes and improving the properties of the final products from the 40КХНМ alloy.

Tailoring of Self-Healable Polydimethylsiloxane Films for Mechanical Energy Harvesting.

Triboelectric nanogenerators (TENGs) have emerged as potential energy sources, as they are capable of harvesting energy from low-frequency mechanical actions such as biological movements, moving parts of machines, mild wind, rain droplets, and others. However, periodic mechanical motion can have a detrimental effect on the triboelectric materials that constitute a TENG device. This study introduces a self-healable triboelectric layer consisting of an Ecoflex-coated self-healable polydimethylsiloxane (SH-PDMS) polymer that can autonomously repair mechanical injury at room temperature and regain its functionality. Different compositions of bis(3-aminopropyl)-terminated PDMS and 1,3,5-triformylbenzene were used to synthesize SH-PDMS films to determine the optimum healing time. The SH-PDMS films contain reversible imine bonds that break when the material is damaged and are subsequently restored by an autonomous healing process. However, the inherent stickiness of the SH-PDMS surface itself renders the material unsuitable for application in TENGs despite its attractive self-healing capability. We show that spin-coating a thin layer (≈32 μm) of Ecoflex on top of the SH-PDMS eliminates the stickiness issue while retaining the functionality of a triboelectric material. TENGs based on Ecoflex/SH-PDMS and nylon 6 films show excellent output and fatigue performance. Even after incisions were introduced at several locations in the Ecoflex/SH-PDMS film, the TENG spontaneously attained its original output performance after a period of 24 h of healing. This study presents a viable approach to enhancing the longevity of TENGs to harvest energy from continuous mechanical actions, paving the way for durable, self-healable mechanical energy harvesters.

Recent Progress in Laser Powder Bed Fusions Processes of Advanced High-Strength Steels

This review is focused on the perspectives of the application of Advanced High Strength Steels (AHSSs) in the field of additive technologies directed at the laser powder bed fusion/selective laser melting processes. In principle, AHSSs require significant attention due to their promising mechanical properties for usage in the automotive industry towards reducing the weight of vehicles. Although additive manufacturing represents a promising perspective towards expanding the industrialization of AHSSs in a wider area of their applications, they have not been sufficiently investigated concerning their usage in LPBF/SLM processes. AM techniques enable the fabrication of complex machine parts, including those with a cellular structure, which can contribute to further reducing the weight of vehicles or structures. Maraging steels have recently attracted the attention of researchers, and today are a common grade of steel produced by LPBF techniques. The other group of AHSSs are high-Mn steels with an austenitic matrix characterized by the TRIP and TWIP effects. Less published research has been conducted on medium-Mn steels, which require additional intercritical annealing and preheating during printing. Moreover, the advanced bainitic steels and low-density, high-strength steels represent a new window for further research into the use of the LPBF processes for their fabrication.

Static Loading of Different Intraradicular Preparation Depths of Trinia Endocrowns in Maxillary Canines.

The aim of this study is to compare the fracture resistance of canine teeth restored using TRINIA Endocrowns with three different types of preparations (2, 3, and 4 intracanal preparations). Thirty maxillary-extracted canines were collected. All teeth were fixed in orthodontic acrylic resin and decapitated at the level of the proximal cemento-enamel junction (CEJ). After being endodontically treated, specimens were distributed equally between 3 groups (n = 10) with different preparation depths (GT: 2 mm Intraradicular Preparation, GH: 3 mm Intraradicular Preparation, GF: 4 mm Intraradicular Preparation). Thirty TRINIA endocrowns were dry milled. After surface treatment, all endocrowns were bonded to their corresponding roots using Permaflo a dual-cure resin cement. Each specimen was then fixed in the lower part of a universal testing machine with a load cell of 5 KN, at an angle of 45 degrees to the tooth long-axis at 0.5 mm/min crosshead speed. Failure loads were recorded in Newton's. Data were recorded, organized, and statistically investigated. Shapiro-Wilk tests revealed that the data were not normally distributed. Descriptive statistics revealed a high mean fracture resistance of GH (647 N), then GT (475.6 N), and finally GF (353.9 N). The Kruskal-Wallis test revealed a significant difference that existed between the groups being studied (p = 0.036). TRINIA endocrowns with intracanal preparations of 2 and 3 mm provide more promising fracture resistance than those with intracanal preparations of 4 mm as a way of treating of root-canal-treated maxillary canines. TRINIA endocrowns (2 and 3 mm intracanal preparations) are as promising as fiber posts and all ceramic crowns in terms of fracture resistance. TRINIA endocrowns with 2 mm intracanal preparations are mostly reparable after failure, but those of 3 and 4 mm are mostly irreparable after failure. Modifying endocrowns to have intraradicular projections, simulating Nayyar core, may improve the success and longevity of endocrowns in anterior teeth. How to cite this article: Alahmad AM, Alenezi AY, Rayyan M, et al. Static Loading of Different Intraradicular Preparation Depths of Trinia Endocrowns in Maxillary Canines. J Contemp Dent Pract 2024;25(6):575-580.

Progressive technologies of laser surfacing and gas‑thermal spraying

The article notes the experience of Yantai Huaheng Energy Conservation Technology Co., Ltd in applying protective anti‑corrosion polymer coatings and discusses the most promising modern recovery and strengthening technologies of thermal spraying (PAPS, AS, HVAF, HVOF) and laser cladding (LASC). Examples of installations that the company has and typical restored machine parts with protective wearand corrosion‑resistant coatings and the microstructure of coatings are given. The main stages of a typical technological process for applying coatings are noted. Using the example of the company, the feasibility and effectiveness of the development of this area in China is noted.

Design and Technological Aspects of Integrating Multi-Blade Machining and Surface Hardening on a Single Machine Base

Modern mechanical engineering faces high competition in global markets, which requires manufacturers of process equipment to significantly reduce production costs while ensuring high product quality and maximum productivity. Metalworking occupies a significant part of industrial production and consumes a significant share of the world’s energy and natural resources. Improving the technology of manufacturing parts with an emphasis on more efficient use of metalworking machines is necessary to maintain the competitiveness of the domestic machine tool industry. Hybrid metalworking systems based on the principles of multi-purpose integration eliminate the disadvantages of monotechnologies and increase efficiency by reducing time losses and intermediate operations. The purpose of this work is to develop and implement a hybrid machine tool system and an appropriate combined technology for manufacturing machine parts. Theory and methods. Studies of the possible structural composition and layout of hybrid equipment at integration of mechanical and surface-thermal processes were carried out, taking into account the basic provisions of structural synthesis and componentization of metalworking systems. Theoretical studies were carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, methods of finite elements, and mathematical and computer modeling. The mathematical modeling of thermal fields and structural-phase transformations during HEH HFC was carried out in ANSYS (version 19.1) and SYSWELD (version 2010) software packages using numerical methods of solving differential equations of unsteady heat conduction (Fourier equation), carbon diffusion (2nd Fick’s law) and elastic–plastic behavior of the material. The verification of the modeling results was carried out using in situ experiments employing the following: optical and scanning microscopy; and mechanical and X-ray methods of residual stress determination. Formtracer SV-C4500 profilograph profilometer was used in the study for simultaneous measurement of shape deviations and surface roughness. Surface topography was assessed using a Walter UHL VMM 150 V instrumental microscope. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD. Results and discussion. The original methodology of structural and kinematic analysis for pre-design studies of hybrid metalworking equipment is presented. Methodological recommendations for the modernization of multi-purpose metal-cutting machine tool are developed, the implementation of which will make it possible to implement high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and provide the formation of knowledge-intensive technological equipment with extended functionality. The innovative moment of this work is the development of hybrid metalworking equipment with numerical control and writing a unique postprocessor to it, which allows to realize all functional possibilities of this machine system and the technology of combined processing as a whole. Special tooling and tools providing all the necessary requirements for the process of surface hardening of HEH HFC were designed and manufactured. The conducted complex of works and approbation of the technology of integrated processing in real conditions in comparison with traditional methods of construction of technological process of parts manufacturing allowed to obtain the following results: increase in the productivity of processing by 1.9 times; exclusion of possibility of scrap occurrence at finishing grinding; reduction in auxiliary and preparatory-tasking time; and reduction in inter-operational parts backlogs.

Active dosimetry for VHEE FLASH radiotherapy using beam profile monitors and charge measurements

The discovery of the FLASH effect has revealed a high potential for treating cancer more efficiently by sparing healthy tissue. The surge in related medical research activities over the last couple of years has triggered a demand for technology with the capability of generating and measuring ionizing radiation at ultra-high dose-rates (UHDR). A reliable dosimetry system is an integral part of a radiotherapy machine. Because existing active dosimetry methods are unable to handle the dose-rates required for FLASH, UHDR dosimetry has emerged as an important area of research. In this paper we present an active dosimetry method based on a scintillating screen and an integrating current transformer. This method provides a simultaneous measurement of the absolute dose delivery as well as the 2D dose distribution. The measurements have been correlated with corresponding readings from radiochromic films (RCFs), and a procedure for image processing has been established. Moreover, different methods of calibrating the active dosimetry system against RCFs have been introduced and evaluated. Lastly, we present results which demonstrate that an agreement with RCFs of better than 5% can be realistically expected if camera parameters are carefully optimized.

Thrust ball bearing fault identification from visualized data using optimized deep network

Bearings are the most common components employed in machine parts. The bearings' movement facilitates the smooth motion. They also help with friction reduction. The faults in bearings are often caused by tribological parameters. Various methods have been developed to identify faults in bearings, but they often fail to predict these accurately. This work has concentrated on designing an effective fault-recognizing model. Therefore, a framework, the Zebra-based Radial Basis Prediction Mechanism (ZbRBPM), was proposed in this work. Initially, the bearing datasets are collected, and mineral oil (MO) lubrication is added to minimize wear and friction. The primary goal of the work is to detect and classify the fault in the thrust ball bearing. The bearing vibration data included a normal vibration signal, a ball fault, and inner and outer race faults. Hence, Zebra fitness is enhanced for the optimization of tribological parameters and fault identification. The proposed model is executed in the MATLAB system. Finally, performance criteria like accuracy, precision, recall, F-score, error rate, computation time, speed, specific wear rate, friction torque, and energy consumption are validated. The performance of the proposed ZbRBPM gains better accuracy rate as 99.5 %, 99 % of precision and f-score and 99.4 % of recall. Also it significantly reduced the prediction error rate into 0.5 % with lower computation time and very low wear and friction.

Fourier Features and Machine Learning for Contour Profile Inspection in CNC Milling Parts: A Novel Intelligent Inspection Method (NIIM)

Form deviation generated during the milling profile process challenges the precision and functionality of industrial fixtures and product manufacturing across various sectors. Inspecting contour profile quality relies on commonly employed contact methods for measuring form deviation. However, the methods employed frequently face limitations that can impact the reliability and overall accuracy of the inspection process. This paper introduces a novel approach, the novel intelligent inspection method (NIIM), developed to accurately inspect and categorize contour profiles in machined parts manufactured through the milling process by computer numerical control (CNC) machines. The NIIM integrates a calibration piece, a vision system (RAM-StarliteTM), and machine learning techniques to analyze the line profile and classify the quality of contour profile deformation generated during CNC milling. The calibration piece is specifically designed to identify form deviations in the contour profile during the milling process. The RAM-StarliteTM vision system captures contour profile images corresponding to curves, lines, and slopes. An algorithm generates a profile signature, extracting Fourier descriptor features from the contour profile to analyze form deviations compared to an image reference. A feed-forward neural network is employed to classify contour profiles based on quality properties. Experimental evaluations involving 60 machined calibration pieces, resulting in 356 images for training and testing, demonstrate the accuracy and computational efficiency of the proposed NIIM for profile line tolerance inspection. The results demonstrate that the NIIM offers 96.99% accuracy, low computational requirements, 100% inspection capability, and valuable information to improve machining parameters, as well as quality classification.

Phase composition and microstructure of intermetallic alloys obtained using electron-beam additive manufacturing

The paper investigates the microstructure and phase composition of nickel- and aluminum-based intermetallic alloys obtained using two-wire electron-beam additive manufacturing (EBAM). Relevance of the research is related to the widespread use of intermetallic alloys based on nickel and aluminum (mainly Ni3Al) in various high-temperature applications and the need to use modern production methods when creating machine parts and mechanisms from these alloys. Using EBAM, the billets from intermetallic alloys with different ratios of the content of main components were obtained. Change in concentrations of the basic elements was carried out varying the ratio of feed rates of nickel and aluminum wires during additive manufacturing in the range from 1:1 to 3:1, respectively. The results of microscopic studies of the obtained alloys showed that, regardless of nickel content, the obtained alloys are characterized by a large–crystalline structure with grain sizes in the range of 100 – 300 μm for alloys with a component ratio of 1:1 and 150 – 400 μm for alloys with a component ratio of 2:1 and 3:1. At the same time, the alloy with an equal content of base components is characterized by more uniform grain and microstructure compared to those with high content of Ni. By changing the concentration ratio of the components, phase composition of the resulting billet can be purposefully controlled. In the case of an “equiatomic” content of the base components in the alloy, a NiAl-based compound with a small phase content based on the intermetallides Ni3Al5 and Ni3Al is formed. At high concent­rations of nickel, the intermetallic Ni3Al phase is formed, and at a component ratio of 3:1, structure of the resulting billet consists mainly of Ni3Al phase and the γ solid substitutional solution based on nickel. The paper demonstrates the possibility of direct production of intermetallic alloys with a given phase composition during electron-beam additive manufacturing.

Thermodynamic aspects of WO3 tungsten oxide reduction by carbon, silicon, aluminum and titanium

The development and research of new materials for machine parts of the mining and metallurgical complex by the method of surfacing with flux cored wire has a lot of attention nowadays. Flux cored wires are widely used for surfacing of steels with high wear resistance, in which reduced tungsten in the form of ferroalloys, ligatures and metal powder of various degrees of purity are used as fillers. However, due to the scarcity and high cost of tungsten, its rational use is an urgent task. For practical application, the technology of surfacing with tungsten-containing flux cored wire is of interest; using it the maximum extraction of tungsten into the deposited layer is achieved due to reduction processes in the arc. In order to increase the beneficial use of tungsten, the technologies of indirect alloying with tungsten during surfacing under the flux of flux cored wires, in which tungsten oxide is used as a filler on the one hand, and reducing agent – on the other, deserve consideration. It can be expected that during arc discharge, tungsten and (or) chemical compounds of tungsten with reducing agents can be formed during the surfacing process. This paper presents the results of a comparative analysis of the thermodynamic processes of tungsten oxide reduction by carbon, silicon, aluminum and titanium during arc discharge occurring during surfacing with flux cored wires under a layer of flux. The thermodynamic analysis of 41 reactions in standard states showed that the presence of reducing agents (carbon, silicon, aluminum, titanium) in the flux cored wire used for surfacing will contribute to the formation of silicides and tungsten carbides, and, possibly, tungsten itself. It was determined that the best state for the participation of tungsten oxide in reactions in the arc is WO3(g) gaseous state.