Search Results for manufacturing defects

This study characterizes a historical Decauville narrow-gauge rail from Argentina (circa 1884) using metallographic analysis, chemical composition testing, and microhardness measurements. The rail, manufactured by French engineer Paul Decauville's company for portable agricultural and industrial transport, exhibited a hypoeutectoid steel composition (0.52% C) with ferrite-pearlite microstructure showing cold deformation patterns from service stress. Chemical analysis revealed a composition comparable to modern European rail steels, while microhardness values met current rail standards. Macrographic examination confirmed excellent material quality with no manufacturing defects. The study demonstrates that this 19th-century rail achieved contemporary quality standards through controlled manufacturing processes, with service-induced cold deformation enhancing mechanical strength and wear resistance.

Fire risk in electric vehicle batteries can be reduced by detecting flaws through nondestructive visualization. Industrial computed tomography (CT scanning) combined with advanced software that makes sense of CT-generated images, allows users to measure voids and particle sizes within electrode active material during the research and development phase, detect delamination and contamination during cell manufacturing, analyze electrical connections and electrolyte fill levels, and provide many other quality-assurance functions that were once impractical or even impossible to perform.

Increasing use of nonmetallic materials in wind turbine blades is driving the development of nondestructive microwave test methods.

This article explains how SEM, TEM, and atom probe tomography are being used in the development of additively manufactured high-entropy alloys (HEAs), revealing critical features such as anisotropic microstructure and metallurgical defects. It also discusses ongoing efforts to improve the predictability and analysis of HEA microstructure using data-driven approaches.

Structural features, spatial locations, and morphological measures not readily attainable with 2D methods are now accessible using 3D microstructure characterization techniques.

Developing a disciplined approach to standardizing special processes and introducing new technologies is key to eliminating defects in thermal spray applications.

The rapidly increasing complexity of microelectronic devices is necessitating the use of sophisticated imaging tools to analyze and correct defects. This article describes advanced analytical techniques in use at the Fraunhofer Center for Applied Microstructure Diagnostics.

Modeling and simulation are used to solve the problem of folded grooves, a common occurrence during aluminum wheel forging.

A novel framework including experimental and model-based techniques saves time and enables the introduction of new alloys for additive manufacturing. This article describes the first phase of the probabilistic machine learning framework that was successfully demonstrated to rapidly define optimum parameter sets for commercial high-temperature nickel superalloys, as well as to guide alloy design and selection for compatibility with laser powder bed fusion additive manufacturing.

In Germany, the Federal Institute for Materials Research and Testing (BAM) is addressing challenges in the implementation of additive manufacturing on the industrial landscape for safety-critical applications. This article provides an overview of BAM’s activities in additive manufacturing with a focus on safety (both for applications and the environment) and AM technology innovation for a wide range of materials and manufacturing locations.

Orion’s Exploration Flight Test 1 vehicle used four additively manufactured vent assemblies to equalize pressure between unpressurized portions of the spacecraft and the external environment.

This article is an informal discussion among three industry leaders about how additive manufacturing is impacted by new data-driven technologies. The panelists are Elizabeth A. Holm, James C. Williams, and Edward D. Herderick; the discussion is moderated by Hanchen Huang. The discussion is a preview for an IMAT 2020 panel session on the same topic organized by the ASM Emerging Technologies Awareness Committee.

Researchers at the Center for Heat Treating Excellence (CHTE) at Worcester Polytechnic Institute (WPI) are working with CHTE members to develop post-processing parameters to enhance the mechanical properties of additively manufactured (AM) steels. This article reports preliminary results based on characterization of AISI 8620 and 20MnCr5 powder, selective laser melted parts, and wrought parts.

Industrial computed tomography data analysis is harnessing deep learning to both accelerate in-line inspection and build better products. This article includes a case history involving deep learning industrial CT scan data analysis.

Determining the root cause of avionics failures requires a disciplined and systematic analytical process supported by sophisticated equipment. This article reviews some of the analytical tools and techniques used to understand and prevent avionics failures.

Physical cross-sectioning is commonly used on parts to reveal and study their internal features and defects. An alternative technology, acoustic cross-sectioning, produces equivalent results and images for small parts without damaging them. This article describes a new system for acoustic cross-sectioning and presents a case study of its use in integrated circuit analysis.

Nondestructive evaluation comprises a large family of specific test disciplines including visual inspection, dimensional metrology, ultrasound, radiography, penetrant tests, magnetic particle tests, leak tests, eddy current tests, potential drop tests, flash and vibrothermography, shearography, acoustic emissions, and many other methods. This article offers an overview of NDE science and discusses some key considerations for choosing specific techniques.

4D printing enables fabrication of complex objects that transform over time (the fourth dimension) when subjected to external stimuli. 4D printing of metallic functional materials is of special interest due to their capacity for self-assembly and multifunctionality, with the added benefit of higher actuation capability, in comparison with polymeric materials.

Ni-ion irradiated NiTi is nearly 50% harder, retains 85% recoverable deformation, and has reduced hysteresis. This work explores the feasibility of using ion beam modification to modulate the austenite to martensite phase transformation in NiTi, thereby achieving novel or localized properties in near-surface regions.

Resonant ultrasound spectroscopy (RUS) is an emerging ultrasonic measurement technique. By measuring the natural vibrational frequencies of test samples, RUS can determine Young's modulus, shear modulus, and Poisson's ratio for isotropic materials. By comparing the vibrational spectra of a test sample to those obtained from a standard, it is possible to infer the causes of the differences (if any) and detect various part defects, such as size variations, cracks, and pores. Thanks to advances in computer technology, codes and software are now available for data reduction, analysis, and interpretation. This article addresses fundamentals of the technology and applications in research and industry.