Adam T. Clare

Development of quadrupole mass spectrometers using rapid prototyping technology

In this report, we present a prototype design of a quadrupole mass filter (QMF) with hyperbolic electrodes, fabricated at the University of Liverpool using digital light processing (DLP), a low-cost and lightweight 3D rapid prototyping (RP) technique. Experimental mass spectra are shown for H2+, D2+, and He+ ions to provide proof of principle that the DLP mass filter is working as a mass analyzer in the low-mass range (1 to 10 amu). The performance of the DLP QMF has also been investigated for individual spectral peaks. Numerical simulations of the instrument were performed by coupling CPO and Liverpool QMS-2 programs to model both the ion source and mass filter, respectively, and the instrument is shown to perform as predicted by theory. DLP thus allows miniaturization of mass spectrometers at low cost, using hyperbolic (or other) geometries of mass analyzer electrodes that provide optimal ion manipulation and resolution for a given application. The potential of using RP fabrication techniques for developing miniature and microscale mass analyzers is also discussed.

Laser Deposition of Ti-6Al-4V Wire with WC Powder for Functionally Graded Components

In this study, metal matrix ceramic (MMC) functionally graded components are fabricated using a method based upon shape metal deposition. Laser deposition provides a suitable means for metallic coating and surface alloying for many applications. New functionally graded components can be built with surface and bulk properties locally modified. Tailoring to meet location specific demands such as modified tribological, corrosion, and thermal properties is achievable. This article investigates the cladding of Ti-6Al-4V wire and WC powder concurrently fed into the laser generated melt pool on a Ti-6Al-4V substrate. The addition of WC particles promotes its hardness and improves wear resistance. Results obtained showed the micrograph of the functionally graded area coating of Ti-6Al-4V/WC matrix in which WC particles are dissolved resulting in TiC/W two phase nodules. Scanning electron microscope (SEM), energy dispersive X-ray (EDX), X-ray diffraction (XRD), and microhardness characterization is presented for the coating. Fiber laser deposition is demonstrated as a means to produce titanium matrix ceramic composite structures with a demonstrator part is presented.

Linear ion trap fabricated using rapid manufacturing technology

This article presents the design, construction, and test results of a linear ion trap, fabricated using digital light processing (DLP), which is a low-cost 3D layer-based manufacturing technique. The ion trap was incorporated into a portable mass spectrometer system and experimental mass spectrum was obtained for methamphetamine (m/z 182), cocaine (m/z 304), and rhodamine B (m/z 443), with a maximum observed resolution (FWHM) of 260. For rhodamine B, tandem MS capability is also demonstrated. The mass range (and resolution at higher m/z) of the instrument is also demonstrated by spectrum obtained from Ultramark (m/z 1621). The spectra obtained for the DLP trap occur at a considerably lower rf voltage than a rectilinear ion trap of similar size, which is a consequence of the hyperbolic electrode geometry and, hence, smaller r0 in the DLP case. High mass range with low voltage operation is especially important with regard to ‘in the field’ applications requiring low power consumption for extended periods of operation.

Concurrent Inconel 625 wire and WC powder laser cladding: process stability and microstructural characterisation

Abstract The microstructure and hardness property of WC powder–Inconel 625 wire single tracks deposited by laser cladding at varying processing parameters were investigated using a combination of scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffraction, image processing software and hardness testing. The results include the generation of process maps that predict the cladding process characteristics at varying processing conditions. High dissolution of WC particles at high energy input resulted in a decrease in retained WC volume fraction with increasing laser power. The negative dependence of the retained WC volume fraction on the transverse speed and wire feedrate showed that the decreasing powder catchment efficiency with increasing the two parameters is primarily significant to the amount of WC contained in a track. The dissolution of WC in the matrix resulted in the formation of W2C and Fe3W3C hard phases, which mainly contributed to high hardness (540–690 HV0·3) of the composite matrix.

Laser cladding of rail steel with Co–Cr

Abstract Degradation and subsequent failure of rail tracks are commonly caused by rolling contact fatigue among other mechanisms of wear. Rail crossings are known to exhibit more of these failures due to increased localised traffic and environmental conditions. A high proportion of the costs associated with the repair of rail tracks was due to the rolling contact fatigue phenomenon. In order to mitigate these costs, laser cladding of worn regions has been proposed for the repair of used tracks in situ to limit the need for them to be replaced and for the preservice protection of newly rolled rails and cast crossings. A Co–Cr, Stellite 6, alloy is chosen to demonstrate repair and also surface coating/protection of R260 rail steel. Results showed that cladded Stellite 6 possessed improved hardness, good tribological performance and excellent workhardening ability when compared with rail steel. These demonstrate laser cladding as a viable solution for repair worn rail track.

Soluble Abrasives for Waterjet Machining

The addition of hard abrasives to the jet in waterjet machining can improve machining rate, however, embedding of particles in machined surfaces is a limitation, which results in reduced fatigue life, and limits the application of well adhered subsequent coatings to the surface. In this study, softer soluble abrasives were investigated as a potential solution. Soluble abrasives yielded a higher material removal rate compared to plain waterjet, although were not as effective as traditional hard abrasives. Soluble abrasives reduced grit embedment on all four workpiece materials. A post-machining surface cleaning operation demonstrated that any remaining soluble abrasive could be removed.

Laser cladding for railway repair and preventative maintenance

Rolling contact fatigue, amongst other mechanisms of wear, between railway track and train wheel ensures that periodic replacement of worn track and other key components such as switches must be undertaken. The cost associated with repairing/replacing track is significant. This places a financial burden upon the rail network provider, creates a significant carbon footprint associated with remanufacture of track, and also interruption to train services. It is proposed that laser cladding, when deployed strategically, can reduce the costs associated with replacing worn track by enhancing the longevity of new rail components (preservice) and also for the repair of sections of track which are prone to excessive wear (in service). This will lead to a cheaper, more reliable, and sustainable rail network. This paper details a series of investigations undertaken to laser clad with premium wear resistant alloys (nickel alloy, Stellite 6, maraging steel, and hadfield steel) to much cheaper rail material substrates....

Enhanced sensing and conversion of ultrasonic Rayleigh waves by elastic metasurfaces

Recent years have heralded the introduction of metasurfaces that advantageously combine the vision of sub-wavelength wave manipulation, with the design, fabrication and size advantages associated with surface excitation. An important topic within metasurfaces is the tailored rainbow trapping and selective spatial frequency separation of electromagnetic and acoustic waves using graded metasurfaces. This frequency dependent trapping and spatial frequency segregation has implications for energy concentrators and associated energy harvesting, sensing and wave filtering techniques. Different demonstrations of acoustic and electromagnetic rainbow devices have been performed, however not for deep elastic substrates that support both shear and compressional waves, together with surface Rayleigh waves; these allow not only for Rayleigh wave rainbow effects to exist but also for mode conversion from surface into shear waves. Here we demonstrate experimentally not only elastic Rayleigh wave rainbow trapping, by taking advantage of a stop-band for surface waves, but also selective mode conversion of surface Rayleigh waves to shear waves. These experiments performed at ultrasonic frequencies, in the range of 400–600 kHz, are complemented by time domain numerical simulations. The metasurfaces we design are not limited to guided ultrasonic waves and are a general phenomenon in elastic waves that can be translated across scales.

Loose powder detection and surface characterization in selective laser sintering via optical coherence tomography.

Defects produced during selective laser sintering (SLS) are difficult to non-destructively detect after build completion without the use of X-ray-based methods. Overcoming this issue by assessing integrity on a layer-by-layer basis has become an area of significant interest for users of SLS apparatus. Optical coherence tomography (OCT) is used in this study to detect surface texture and sub-surface powder, which is un-melted/insufficiently sintered, is known to be a common cause of poor part integrity and would prevent the use of SLS where applications dictate assurance of defect-free parts. To demonstrate the capability of the instrument and associated data-processing algorithms, samples were built with graduated porosities which were embedded in fully dense regions in order to simulate defective regions. Simulated in situ measurements were then correlated with the process parameters used to generate variable density regions. Using this method, it is possible to detect loose powder and differentiate between densities of ±5% at a sub-surface depth of approximately 300 μm. In order to demonstrate the value of OCT as a surface-profiling technique, surface texture datasets are compared with focus variation microscopy. Comparable results are achieved after a spatial bandwidth- matching procedure.

Focussed arc tungsten inert gas brazing of zinc-coated steels:

The brazeability of automotive zinc-coated steels depends on several factors. These include the morphology of the joint and the welding parameters selected. However, more fundamental material factors such as the composition of the coating, method of coating and coating thickness also have a significant effect. In this study, five commercially available and widely used automotive zinc-coated steels are investigated to assess brazeability. Surface zinc content and the coating type are shown to have a marked effect on the quality of the resulting joint. This is shown by surface analysis of the joint to determine evenness and bridging capability of the filler material and a cross-sectional analysis of the joints. Differences in wettability and contact length of the filler material and zinc-coated steel substrate are observed. It was found that electro-galvanised steel exhibited the best brazeability of the materials investigated here. Wettability of spreading angles as low as 17.3°, most uniform contact length and best bridging capability due to the filler material forming a metallic bond with the substrate were observed. However, pores were present in cross-sections. Galvannealed steel also showed good wetting with no embedded defects. Other steels used (galvanised and magnesium–aluminium zinc steels) presented problems with uniformity, high spreading angles of the filler material and poor bridging characteristics.