Browse Topic: Coating processes
As “point of need” additive manufacturing emerges as a priority for the Department of Defense (DoD), Australian 3D printing provider SPEE3D is one of several companies demonstrating that its machines can rapidly produce castings, brackets, valves, mountings and other common replacement parts and devices that warfighters often need in an on-demand schedule when deployed near or directly within combat zones. DoD officials describe point of need manufacturing as a concept of operations where infantry and squadron have the equipment, machines, tools and processes to rapidly 3D print parts and devices that are being used in combat. Based in Melbourne, Australia, SPEE3D provides cold spray additive manufacturing (CSAM) machines that use a combination of robotics and high-speed kinetic energy to assemble and quickly bind metal together into 3D-printed parts without the need for specific environmental conditions or post-assembly cooling or temperature requirements. Over the last two years, the
Graphene has been called “the wonder material of the 21st century.” But graphene has a dirty little secret: it’s dirty. Now, engineers at Columbia University and colleagues at the University of Montreal and the National Institute of Standards and Technology are poised to clean things up with an oxygen-free chemical vapor deposition (OF-CVD) method that can create high-quality graphene samples at scale. Their work, published in Nature, directly demonstrates how trace oxygen affects the growth rate of graphene and identifies the link between oxygen and graphene quality for the first time
University of Wisconsin–Madison engineers have used a spray coating technology to produce a new workhorse material that can withstand the harsh conditions inside a fusion reactor
This study delves into the innovative realm of synthesizing surface alloyed materials by utilizing copper-based metamorphic powders subjected to high-intensity electron beam irradiation. The process involves depositing metamorphic particles onto a stainless-steel substrate, and subsequently exposing the assembly to a powerful electron beam, resulting in the development of distinct surface alloyed layers. A notable advancement was achieved by introducing a second layer of metamorphic powders over the existing alloyed layer, followed by further treatment with the electron beam. The alloyed layers, characterized by a volumetric concentration ranging from 60 to 67%, exhibited a fascinating phenomenon— the formation of abundant borate crystals with the chemical formula Al2.56Fe1.75Ni0.84. This crystal presence significantly elevated the hardness of the surface alloyed layers, showcasing an impressive five to sevenfold increase compared to the substrates. Importantly, the alloyed layers
This specification covers the requirements for vacuum deposited cadmium
Naval Air Systems Command Naval Air Station North Island, CA (619) 545-3415
Simulation tools play a significant role in the automotive industry due to their cost-reducing capabilities in new model development. Computational Fluid Dynamics (CFD) is extensively utilized in various applications, such as vehicle aerodynamics and engine thermal management. However, its application in manufacturing engineering is not yet widespread. One crucial process in automotive manufacturing is the application of the base coat, which provides protection for the final paint layer. This process involves three key steps: bodywork immersion, electrophoretic deposition (E-coat), and bodywork removal from the bath. Each of these steps can be evaluated using appropriate CFD models. During the immersion step, the primary objective is to minimize the presence of trapped air. In the E-coat step, the focus is on controlling the paint layer thickness on the Body-in-white (BIW). Lastly, the drainage analysis aims to minimize the retention of bath fluid, thereby preventing contamination in
NASA instrumentation is at risk for contamination from dusty space environments. Additionally, contamination from water and ice buildup can affect instrumentation function. Researchers at the Goddard Space Flight Center have developed a viable dust, water, and ice mitigation optical coating for space flight, aeronautical, and ground applications. The innovation of the LOTUS coating prevents contamination on sensitive surfaces, like optics, that cannot be cleaned during space missions
This specification covers engineering requirements for the grinding of tungsten carbide high velocity oxygen/fuel (HVOF) thermal spray coatings applied to high strength steels (220 ksi and above
Engineers, managers, technicians and other automation professionals at most manufacturers understand the value of pretreating metal surfaces of parts to remove corrosion, grease, residue, old coatings, or to roughen the surface of metals prior to coating. By ensuring the items are cleaned down to bare metal, manufacturers can avoid costly warranty issues that result when coatings peel, flake, bubble, or otherwise fail prematurely
Chemical Vapor Deposition (CVD) and Atomic Layer Deposition (ALD) processes deposit material on all surfaces in a process chamber. Over time, the thickness of these deposits increases to the point that material begins to delaminate, producing gas-phase particulates that negatively impact process yield. Remote and in situ chemical etching processes are used to periodically remove these deposits from chamber walls, maintaining chamber cleanliness
Electroplating is a process whereby an object is coated with one or more relatively thin, tightly adherent layers of one or more metals. It is accomplished by placing the object to be coated on a plating rack or a fixture, or in a basket or in a rotating container in such a manner that a suitable current may flow through it, and then immersing it in a series of solutions and rinses in planned sequence. The advantage to be gained by electroplating may be considerable; broadly speaking, the process is used when it is desired to endow the basis material (selected for cost, material conservation, and physical property reasons) with surface properties it does not possess. It should be noted that although electroplating is the most widely used process for applying metals to a substrate, they may also be applied by spraying, vacuum deposition, cladding, hot dipping, chemical reduction, mechanical plating, etc. The purpose for applying an electroplate and the metals used for various
This specification covers nonfluorescent magnetic particles in the form of a mixed, ready-to-use suspension in an odorless oil vehicle and packaged in aerosol cans
This specification covers a mold release agent in the form of a liquid
This specification establishes requirements for pressure-sensitive adhesive tape designed for masking and color separation during aircraft painting operations
Laser crystals can be considered the “engines” of solid-state lasers. They are used for gain media, for frequency conversion, and to manage laser characteristics and performance. Like the engine of a car, if laser crystals are clean and working properly, they allow the larger system to operate at a higher level. In the case of a laser system, operating at a high level means creating a stable beam and reaching high optical powers. Some advantages of laser crystals over other solid-state gain media are that they typically offer less absorption, a narrower emission bandwidth, higher transition cross-sections, and higher thermal conductivity. Laser crystals are critical for enabling a wide variety of applications including laser materials processing, laser surgery, sensing, defense applications like rangefinding, and more
This specification covers the material and process requirements for fabricating sandwich radomes having hot-melt, addition-reaction polyimide-resin-impregnated quartz cloth shells and polyimide-resin syntactic foam cores
This specification covers the material and process requirements for fabricating sandwich radomes having polyimide-resin-impregnated quartz cloth shells and polyimide-resin syntactic foam cores
Engineers have created a highly effective way to paint complex 3D-printed objects, such as lightweight frames for aircraft and biomedical stents, that could save manufacturers time and money and provide new opportunities to create “smart skins” for printed parts
In recent years, bearing electrical failures have been a significant concern in electric cars, restricting electric engine life. This work aims to introduce a coating approach for preventing electrical erosion on 52100 alloy steel samples, the most common material used on manufacturing bearings. This paper discusses the causes of shaft voltage and bearing currents, and summarizes standard electrical bearing failure mechanisms, such as morphological damages and lubrication failures. Alumina coatings are suitable for insulating the 52100 alloy steel samples because alumina coatings provide excellent insulation, hardness, and corrosion resistance, among other characteristics. The common method to coat an insulated alumina coating on the bearing is thermal spraying, but overspray can cause environmental issues, and the coating procedures are costly and time-consuming. Based on the research, this article briefly discusses employing plasma electrolytic aluminating to coat 52100 alloy steel
With the improvement of vehicle comfort requirements of market users, NVH performance has been paid more and more attention. Especially the pure electric passenger vehicle is lack of combustion engine noise masking effect, it is more likely to cause the drivers attention for any abnormal noise. In the steering operation under the low speed acceleration of pure electric vehicles, the cabin interior noise derived from the road and the wind is relatively low, and there is not marketing effect of traditional internal combustion engine noise, any slight abnormal noise is more likely for the drivers and passengers feel unsafe and complain. However, there is lack of systematic analysis and research on the untypical NVH problem in the automotive industry. This paper systematically expounds the test and analysis process of abnormal noise. According to the correlation comparison between the full vehicle and the drivetrain subsystem platform, it is found that the differential assembly is the
The carbon footprint calculation of a catalytic converter coating process at Heraeus Precious Metals is presented in this publication. The emission hot spots are identified and discussed. Heraeus Precious Metals is a German world-wide leading company in the field of precious metal products and Tier-1 Supplier of emission catalytic converter coatings. In the first step of the carbon footprint calculation, all relevant raw materials and production process steps of the coating process are collected and modelled by use of a flowchart. In this case study the manufacturing of the metal honeycomb carrier is not included in the calculation. Transport emissions from the origin of the raw materials to the manufacturing plant of Heraeus Precious Metals in Germany are also considered in the carbon footprint calculation. Included activities for the production of the washcoat dispersion are the mixing of all components by use of an electric agitator and the grinding of the mixture by use of an
This specification covers tungsten carbide-cobalt chrome in the form of powder
The critical components in earlier were manufactured by mild steel but due to low corrosion resistance, stainless steel and aluminium alloy are being utilised. However a component of aluminium alloy has to be enriched by anodizing for long durability and better corrosion resistance. But peel off, pit formation, low adhesion and white rust formation are still the downfalls faced by the industries in the coated components over cyclic duration. High-Velocity Oxy-Fuel (HVOF) thermal spraying is an adaptable method that can produce high-density coating with less than 1% porosity, high resistant to chemical environment providing better adhesion and increase the life of mating components. Though stainless steel and anodized aluminium alloy offers far superior life span and corrosion resistance but still more expensive than mild steel. This work evaluates the behaviour of HVOF thermal sprayed with tungsten, nickel and chromium containing WC-Cr3C2-Ni coating material over mild steel were found
In the present work, a system approach to the tribological optimization of passenger car engines is demonstrated. Experimental data and simulation results are presented to demonstrate the role of surface specifications, ring pack, and lubricant on the piston/bore tribology. The importance of in-design “pairing” of low-viscosity motor oils with the ring pack and the cylinder bore characteristics in order to achieve maximum reduction in GHG emissions and improvement in fuel economy without sacrificing the endurance is elucidated. Earlier motored friction data for two different gasoline engines - Ford Duratec and Mercedes Benz M133 - using motor oils of different viscosity grades are now rationalized using AVL EXCITE® piston/bore tribology simulations. The main difference between the engines was the cylinder bore surface: honed cast iron vs thermally sprayed, and the valve train type: direct-acting mechanical bucket (DAMB) vs roller finger follower (RFF). The simulation data show that
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