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We are developing a flexible and general methodology for real-time monitoring of acoustic emissions in machining applications. The goal of this work is to develop an approach to in-process monitoring which allows continuous assessment of tool wear and early warning of process exceptions. The nature of metal removal processes creates short-lived vibrations that carry information about the condition of the cutting tool and quality of cut. We wish to extract and represent these transient events without loss of important spectral structure. Other challenges include the need for system training data selection in the absence of expert labeled data, the modeling of short-term time evolution, and efficient real-time operation on an inexpensive computing platform.

Oil extracted from microalgae has the potential to offset demand for petroleum, if conditions of cost and scale can be met. In this paper, we present the compositional differences of fatty acid methyl esters (FAMEs) obtained by solvent extraction from two different oleaginous microalgae. Oil samples were extracted from a proprietary alga (Alga X) and a more common Nannochloropsis oculata (NC) using the Soxhlet process with n-hexane. The neutral lipids contained in Alga X comprised approximately 40 to 60% of the algal dry weight, and the oil was mostly converted to methyl esters using a transesterification process. On the other hand, NC produced approximately 25% lipids, but the yield of methyl esters was often less than 1% and subject to high variation. FAMEs were analyzed using gas chromatography and the average chain lengths for NC were shown to be greater than the average chain lengths for Alga X.

Minimizing the stress concentrations around cutouts in a plate is often a design problem, especially in the Aerospace industry. A problem of optimizing spatially varying fiber paths in a symmetric, linear orthotropic composite laminate with a cutout, so as to achieve minimum stress concentration under remote unidirectional tensile loading is of interest in this study. A finite element (FE) model is developed to this extent, which constraints the fiber angles while optimizing the fiber paths, proving essential in manufacturing processes. The idea to be presented could be used to derive fiber paths that would drastically reduce the Stress Concentration Factor (SCF) in a symmetric laminate by using spatially varying fibers in place of unidirectional fibers. The model is proposed for a four layer symmetric laminate, and can be easily reproduced for any number of layers.

An experimental study of waterjet peening on 7075-T6 aluminum alloy was conducted to investigate the effects of waterjet conditions. Erosion surface features caused by high velocity jet impingement were evaluated as functions of standoff distance, jet pressure, and jet velocity. Surface characteristics were evaluated in terms of subsurface work hardening, surface finish and a degree of surface residual stresses. Results show that waterjet peening induces the same level of plastic deformation at the surface layer as shot peening.

A composite of an aluminum matrix reinforced by short TiNi shape memory alloy (SMA) fibers was fabricated. The processing and thermomechanical behaviors of the composite TiNi/Al6061 were investigated experimentally and analytically. Optimal hot-pressing conditions of TiNi/Al6061 processing were identified. The shape memory effect (SME) was activated by prestraining the composite at the temperature between Ms and As, followed by heating up to Af. SME on mechanical properties, such as microhardness, yield stresses of the composite, were investigated. A computational model for the strengthening mechanism of the short fiber metal matrix composite was utilized to analyze SME on yield stress of the composite. Yield stress of the composite as a function of prestrain was predicted numerically and verified experimentally.

A new method for improving the fatigue lives of holes in metal structures has been developed. The StressWave® process provides compressive residual stresses and fatigue life improvement factors that are similar to or exceed those produced by legacy mandrel cold working processes. StressWave creates the stresses prior to machining the hole, without any pre- or extra post-processing operations. The process has been applied in a variety of alloys (aluminum, steel, titanium and cast iron) and section thickness (0.8 to 25 mm). Fatigue testing has shown life improvement factors typically five to twenty times greater than untreated open-hole specimens. Residual stress distributions have been measured by neutron diffraction and photo-elastic techniques and compared with FEA analysis to verify process parameters. Crack growth measurements and fractography have revealed the beneficial compressive residual stresses extend fatigue crack growth life.

A new, patented process for improving the fatigue lives of holes in metal structures has been developed. The process, known as StressWaveTM, produces residual compressive stresses and fatigue performance comparable to, or better than, those produced by legacy cold working methods and is designed primarily for automated manufacturing, fastening and assembly environments. Eliminating the need for close-tolerance starting holes, consumable sleeves, liquid lubricant cleanup and off-line processing increases speed of operation. These process benefits and associated cost savings satisfy many aspects of lean and continuous improvement program initiatives.

To improve the fatigue properties of additive manufactured (AM) titanium alloy Ti6Al4V, cavitation abrasive surface finishing (CASF) was proposed. With CASF, a high-speed water jet with cavitation, i.e. a cavitating jet, was injected into a water-filled chamber, to which abrasives were added. Abrasives accelerated by the jet created a smooth surface by removing un-melted particles on the surface. Simultaneously, cavitation impacts induced by the jet introduced compressive residual stress and work hardening into the surface, similar to cavitation peening. In this study, to demonstrate the improvement of the fatigue properties of AM Ti6Al4V owing to CASF, Ti6Al4V specimens manufactured through direct metal laser sintering (DMLS) and electron beam melting (EBM) were treated using CASF and cavitation peening, and tested using a plane bending fatigue test.