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- ItemFailure mechanism analysis based on laser-based surface treatments for aluminum-polyamide laser joining(Amsterdam [u.a.] : Elsevier, 2021) Elahi, Amne; Koch, Marcus; Bardon, Julien; Addiego, Frédéric; Plapper, PeterThe development of strong metal to polymer assemblies is currently an important research subject thanks to its prominence to develop lightweight structures. Furthermore, laser welding is known to be a fast, reliable, and versatile joining process, and it was demonstrated recently that it can be applied to such metal to polymer systems. To enhance the mechanical properties of the laser-joined aluminum-polyamide (Al-PA) specimens, laser polishing and laser ablation processes have been implemented on the aluminum surface before joining. The polyamide surface was also treated with the laser beam, separately. The surfaces were tested by several characterization techniques before and after each surface treatment. Then aluminum and polyamide samples with different surface treatments have been joined with an identical laser joining process. The mechanical properties of the joints in single lap shear configuration are reported and the failure mechanisms are discussed based on micro-computed x-ray tomography imaging of joined specimens and microscopic analysis before failure. Results show that both surface treatments of aluminum significantly improve the shear load of the joint; however, with different failure mechanisms. Polyamide surface treatment and increasing degree of crystallinity are effective when combined with the laser polishing of the Al surface. This combination is responsible for further enhancement of the shear load of the joint to the limit of base metal strength which is approximately 60 % improvement compared to the untreated samples. Finally, energy dispersive X-ray mapping shows the physicochemical bonding between aluminum oxide and polyamide at the interface.
- ItemAdhesion of a cylindrical punch with elastic properties that vary radially(Amsterdam [u.a.] : Elsevier, 2023) Kossa, Attila; Hensel, René; McMeeking, Robert M.The adhesion of a rigid substrate and an adhered straight cylindrical punch with a non-homogeneous elastic modulus is analyzed. The stress distributions are obtained along the interface for various elastic modulus gradients. The calculations are performed in the commercial finite element software Abaqus using a user material (UMAT) subroutine to control the dependence of Young's modulus on the radial position. The UMAT code is shared in the paper. The results reveal that the decreasing elastic modulus toward the perimeter of the punch can be used to significantly reduce the normal stress magnitudes in the singularity domain, which leads to stronger adhesion. The increase in the adhesion strength is characterized numerically. The effect of Poisson's ratio is also analyzed.
- ItemDevelopment and Implementation of a Guideline for the Combination of Additively Manufactured Joint Assemblies with Wire Actuators made of Shape Memory Alloys(Amsterdam [u.a.] : Elsevier, 2023) Löffler, Robin; Tremmel, Stephan; Hornfeck, RüdigerSmart Materials actuators in the form of wires made of shape memory alloys in combination with additively manufactured carrier components are used in a wide variety of prototype developments of innovative joint assemblies. This combination is relevant because of the same manufacturing costs of the additively manufactured components, which are independent of the quantity of parts, the free geometric design possibilities as well as the huge energy density of the aforementioned actuator technology. In particular, the focus is on the possibility of appropriately fitting large wire lengths on a compact part volume while taking into account acceptable force losses. Since there is no design guideline for such joint developments, each is individual, which results in unnecessarily long development times and a higher risk of errors. Based on selected in-house and third-party examples, integration possibilities of shape memory alloy wire actuators in additively manufactured carrier components are analysed and transferred into a universally applicable design guideline. These recommendations are brought into the framework of existing design guidelines of the VDI (Verein Deutscher Ingenieure – Association of German Engineers), namely VDI 2206 and VDI 2221 with extensions for additive manufacturing, for a better usability and integrability into existing processes. Finally, this results in a simplified access to the topic of the combination of additive manufacturing and shape memory alloys and a more efficient realisation of such joint developments.
- ItemSelf-cleaning stainless steel surfaces induced by laser processing and chemical engineering(Amsterdam [u.a.] : Elsevier, 2022) Lorenz, Pierre; Zajadacz, Joachim; Marquardt, Franka; Ehrhardt, Martin; Hommes, Gregor; Peter, Sebastian; Zimmer, KlausNanostructured surfaces show a variety of beneficial macroscopic effects. The combination of hierarchic nanostructures with a suitable chemical surface composition allows for the fabrication of surfaces with interesting fluidic properties beyond such effects. This approach enables the specification of nano/microstructure and chemical composition independent of each other. Various hierarchical micro- and nanostructures can be realized by laser texturing of stainless steel surfaces with infrared picosecond laser. Simultaneously, the surface is activated for chemical processing. The surface can now be tuned by bonding of a self-assembled monolayer on the laser-treated surface by chemical treatment. This two-step functionalization process allows the for separated adjusting of the surface topography and chemical composition and thus for the well-defined setting of the surface properties. The fabrication of superhydrophobic surfaces with self-cleaning properties are performed that can be functionalized further by subsequent laser-irradiation. Furthermore, the long-time stability of the surface functionalization in relation to the impact chemicals or radiation was investigated.
- ItemSize, concentration, and origin of human exhaled particles and their dependence on human factors with implications on infection transmission(Amsterdam [u.a.] : Elsevier, 2022) Bagheri, Gholamhossein; Schlenczek, Oliver; Turco, Laura; Thiede, Birte; Stieger, Katja; Kosub, Jana M.; Clauberg, Sigrid; Pöhlker, Mira L.; Pöhlker, Christopher; Moláček, Jan; Scheithauer, Simone; Bodenschatz, EberhardUnderstanding infection transmission between individuals, as well as evaluating the efficacy of protective measures, are key issues in pandemics driven by human respiratory particles. The key is a quantitative understanding of the size and concentration of particles exhaled and their variability across the size range for a representative population of all ages, genders, and different activities. Here we present data from 132 healthy volunteers aged 5 to 80 years, measured over the entire particle size range for each individual. Conventional particle spectrometry was combined with in-line holography under well-controlled conditions for common activities such as breathing, speaking, singing, and shouting. We find age to be the most important parameter for the concentration of small exhale particles <5 µm (PM5), which doubles over a 7-year period in adolescents and over a 30-year period in adults. Gender, body mass index, smoking or exercise habits have no discernible effect. We provide evidence that particles with a diameter of <5 µm originate from the lower respiratory tract, 5–15 µm from the larynx/pharynx, and >15 µm from the oral cavity. PM5 concentration can vary by one order of magnitude within a person, while inter-person variability can span two orders of magnitude, largely explained by difference in age. We found no discernible inter-person variability for particles larger than 5 µm. Our results show that cumulative volume of PM5 is 2–8 times higher in adults than in children. In contrast, number and volume concentration of larger particles, which are produced predominantly in the upper respiratory tract, is largely independent of age. Finally, we examined different types of airborne-transmissible respiratory diseases and provided insights into possible modes of infection transmission with and without several types/fits of face masks.
- ItemProcess Monitoring of a Vibration Dampening CFRP Drill Tube in BTA deep hole drilling using Fibre-Bragg-Grating Sensors(Amsterdam [u.a.] : Elsevier, 2022) Summa, Jannik; Michel, Sebastian; Kurkowski, Moritz; Biermann, Dirk; Stommel, Markus; Herrmann, Hans-GeorgThe large tool length in BTA deep hole drilling often leads to strong torsional vibrations of the tool system, leading to a reduced bore hole quality failures. When substituting steel drill tubes with tubes from composite material, the laminate structure dampens these vibrations. Secondly, the integration of sensors allow to monitor process vibrations. This contribution introduces a new sensor platform to measure process vibrations, feed force and drilling torque using Fibre-Bragg Grating Sensors. The presented experimental results focus on characteristic frequency spectra with natural torsional and compression frequencies of the CFRP drill tube, which show variations due to changed feed.
- ItemSecondary electron yield engineering of copper surfaces by 532 nm ultrashort laser pulses(Amsterdam [u.a.] : Elsevier, 2022) Lorenz, Pierre; Bez, Elena; Himmerlich, Marcel; Ehrhardt, Martin; Taborelli, Mauro; Zimmer, KlausNanostructured surfaces exhibit outstanding properties and enable manifold industrial applications. In this study the laser surface processing of polycrystalline, flat copper surfaces by 532 nm picosecond laser irradiation for secondary electron yield (SEY) reduction is reported. The laser beam was scanned in parallel lines across the sample surface in order to modify large surface areas. Morphology and SEY are characterized in dependence of the process parameters to derive correlations and mechanisms of the laser-based SEY engineering process. The nano- and microstructure morphology of the laser-modified surface was characterized by scanning electron microscopy and the secondary electron yield was measured. In general, an SEY reduction with increasing accumulated laser fluence was found. In particular, at low scanning speed (1 mm/s - 10 mm/s) and “high” laser power (~ 1 W) compact nanostructures with a very low SEY maximum of 0.7 are formed.