Milton Sergio Fernandes de Lima

Laser Surface Remelting and Hardening of an Automotive Shaft Sing a High-power Fiber Laser

An automotive shaft was surface-remelted and hardened using a 2 kW fiber laser and an adapted linear axis whose rotating axis produced helical tracks at 120 RPM. The process variable was the laser power, ranging from 300 to 1100 W, which produced two regions in the material: a martensitic region (MR) and a partially transformed region (PTR). The MR is formed after rapid solidification or austenitization followed by rapid cooling (107 K.s-1). The PTR is composed of martensite, unchanged pearlite and proeutectoid ferrite. The maximum case depth was about 0.3 mm. The microhardness inside the martensitic regions are at least double that of the base material, i.e. between 800 than 600 HV compared to 300 HV. Thermal simulations using a modified Rosenthal formalism help elucidate the phase transformation inside the material and show good agreement with experimental results. The experimental laser-steel absorptivities were measured; they ranged between 38 and 59% depending on the laser power and the amount of liquid at the surface.

Cracking susceptibility of aluminum alloys during laser welding

The influence of laser parameters in welding aluminum alloys was studied in order to reduce hot cracking. The extension of cracks at the welding surface was used as a cracking susceptibility (CS) index. It has been shown that the CS changes with changing welding velocity for binary Al-Cu alloys. In general, the CS index increased until a maximum velocity and then dropped to zero, generating a typical l-curve. This curve is due to two different mechanisms: 1) the refinement of porosities with increasing velocity and 2) the changes in the liquid fraction due to decreasing microsegregation with increasing velocities.

Surface Hardening of an AISI D6 Cold Work Steel Using a Fiber Laser

Laser surface treatments represent some of the most advanced and versatile processes for enhanced materials applications. Laser hardening is a technique to generate a hard wear-resistant surface microstructure in metals due to the rapid heating and cooling cycles imposed by a laser beam. This work intends to understand the influence of the laser variables on hardness after laser hardening of an AISI D6 steel. A fiber laser, which is a new source available for industrial applications, has been used. The overall absorptivity measured was ∼37 % and the laser treatment produced two different zones: Remelted and heat-affected. The surface layer was remelted and composed of martensite and retained austenite. The region next to the free surface is composed of primary austenite dendrites with martensite plates with hardness between 400 and 500 HV. The region called the heat-affect zone is composed of martensite, retained austenite, and carbides and has a hardness up to 800 HV. The case depth in laser treated samples was between 1 and 2 mm.

Laser beam welding of titanium nitride coated titanium using pulse-shaping

A new welding method which allows the assembly of two titanium nitride coated titanium parts is proposed. The welding procedure utilizes the possibility for pulse-shaping in order to change the energy distribution profile during the laser pulse. The pulse-shaping is composed of three elements: a) a short high power pulse for partial ablation at the surface; b) a long pulse for thermal penetration; and c) a quenching slope for enhanced weldability. The combination of these three elements produces crack-free welds. The weld microstructure is changed in comparison to normal welding, i.e. with a rectangular pulse, as the nitrogen and the microhardness are more homogenously distributed in the weld under pulse-shaping conditions. This laser pulse dissolves the TiN layer and allows nitrogen to diffuse into the melt pool, also contributing to an enhanced weldability by providing suitable thermal conditions.

A multi-objective green UAV routing problem

Introduce a new time-dependent UAV heterogeneous fleet routing problem.Consider several objective functions and respect drones operational requirements.Design a MILP model in order to find sets of non-dominated solutions.Consider a model able to tackle multi-layer scenarios with package exchanging points.Integrate UAV into the new concepts of mini/microgrid systems inside smart cities. This paper introduces an Unmanned Aerial Vehicle (UAV) heterogeneous fleet routing problem, dealing with vehicles limited autonomy by considering multiple charging stations and respecting operational requirements. A green routing problem is designed for overcoming difficulties that exist as a result of limited vehicle driving range. Due to the large amount of drones emerging in the society, UAVs use and efficiency should be optimized. In particular, these kinds of vehicles have been recently used for delivering and collecting products. Here, we design a new real-time routing problem, in which different types of drones can collect and deliver packages. These aerial vehicles are able to collect more than one deliverable at the same time if it fits their maximum capacity. Inspired by a multi-criteria view of real systems, seven different objective functions are considered and sought to be minimized using a Mixed-Integer Linear Programming (MILP) model solved by a matheuristic algorithm. The latter filters the non-dominated solutions from the pool of solutions found in the branch-and-bound optimization tree, using a black-box dynamic search algorithm. A case of study, considering a bi-layer scenario, is presented in order to validate the proposal, which showed to be able to provide good quality solutions for supporting decision making.

Laser beam welding aerospace aluminum using fiber lasers

This work intends to contribute towards the knowledge of AA6013 aluminum alloy weldability, autogenously welded with a high-power fiber laser. The quality and metallurgical characterization of the welds were done considering laser speed and power as process parameters. The present study shown that is possible to obtain welds with good macroscopic quality; i.e. with regular welds borders and without the presence of holes, cracks or porosities in speeds around 5 m/min using 1 kW laser power. Additionally, it had been verified that the liquation zone is well confined around 50 μm. The presence of porosities in longitudinal cuts was linked to keyhole instabilities, which could be appropriately controlled by the process parameters. Although this alloy is known for some propensity for solidification cracking, any cracking was verified. This could be linked to an appropriate thermal cycle during welding due to the high quality laser beam, which produces short solidification interval. The present results indicate that other difficult-to-weld Al-based alloys could be properly joined using the fiber laser.

Comparing mechanical behaviour of aluminium welds produced by laser beam welding (LBW), friction stir welding (FSW), and riveting for aeronautical structures

Abstract Three welding processes for aluminium parts have been considered for aircraft fabrication: riveting, friction stir welding (FSW) and laser beam welding (LBW). These processes have advantages and threats, which were analysed in the present work focusing on T-pull and Hoop tensile properties. Concerning T-pull tests, LBW coupons presented higher ability to withstand the applied loads. This was due to the better distribution of loads when the strain is done in the stringer direction. In the case of the Hoop tests, which stress only the skin, the results obtained after FSW were notably higher in terms of ultimate tensile stress, yield stress and maximum strain. It was concluded that both LBW and FSW could replace riveting usually applied for commercial aircraft manufacturing.

Discontinuity Detection in the Shield Metal Arc Welding Process

This work proposes a new methodology for the detection of discontinuities in the weld bead applied in Shielded Metal Arc Welding (SMAW) processes. The detection system is based on two sensors—a microphone and piezoelectric—that acquire acoustic emissions generated during the welding. The feature vectors extracted from the sensor dataset are used to construct classifier models. The approaches based on Artificial Neural Network (ANN) and Support Vector Machine (SVM) classifiers are able to identify with a high accuracy the three proposed weld bead classes: desirable weld bead, shrinkage cavity and burn through discontinuities. Experimental results illustrate the system’s high accuracy, greater than 90% for each class. A novel Hierarchical Support Vector Machine (HSVM) structure is proposed to make feasible the use of this system in industrial environments. This approach presented 96.6% overall accuracy. Given the simplicity of the equipment involved, this system can be applied in the metal transformation industries.

Mechanical and Corrosion Properties of a Duplex Steel Welded using Micro-Arc or Laser

Duplex stainless steels have been extensively used in parts that are subject to corrosive environments and that have high mechanical strength requirements. Welding usually distorts the well-balanced austenite-ferrite ratio, and can produce brittle intermetallic phases; therefore, post-welding heat treatments are usually required. For applications where post-welding treatments are not possible, low heat input methods, such as micro-tungsten inert gas welding (TIG) and laser beam welding (LBW), can be used. The present investigation analyzed the microstructure, mechanical, and corrosion properties of 2507-classduplex steel tubes after welding. The microstructures of the heat-affected zones and the fusion zones contained variable amounts of ferrite and austenite. In the heat-affected and fusion zones in the TIG samples, the microstructures were primarily composed of ferrite grains with allotriomorphic austenite at the grain boundaries, intragranular Widmanstatten needles and plate-like precipitates. The LBW samples showed much finer microstructures, which contained austenite in the grain boundaries and fine austenite precipitates in the ferrite grains. Deleterious intermetallic phases, such as σ-phases, were not observed using X-ray diffraction. The tensile strength properties were very similar for the TIG and LBWsamples, reaching tensile strengths of approximately 840 MPa and total elongations between 61 and 87%. The heat-affected zone of the TIG welds were particularly susceptible to corrosion (0.05 mm/year) compared to the base metal (0.007 mm/year) and the laser welds (0.01 mm/year). Therefore, laser welding is a promising technique for the welding of 2507-class duplex tubes.

Elimination of Lubricants from Aluminum Cold Rolled Products Using Short Laser Pulses

This work presents a new technique to remove the surface impurities from the aluminum cold-worked sheets. The method consists to concentrate a short-time high-power pulsed laser on the materials surface and scan it in order to cover a desired area. Incrustations ablation is obtained as long as the fluency and the peak power are high enough to produce vaporization of the contaminated layer without affecting the material surface properties. The present problem consists in eliminating a desiccated soap of about 1 g/m2 from the surface of a 6016-class aluminum alloy sheet. The soap is originated from the rolling process. The present laser method is intended to replace water washing when the piece cannot be soaked, when drying is difficult due to the geometry, or when environmental restrictions apply. Best results were obtained when the pulse length was 100 ns and the average laser power was 95 W. In these conditions, the surface was completely cleaned and the aluminum alloy did not suffer any structural modification.