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Abstract: As part of a research into new techniques for purifying recycled aluminium, a novel electromagnetic apparatus had been developed for the purpose of investigating in real-time the separation mechanisms of detrimental inclusions in aluminium alloy melts under alternating magnetic fields. The magnetic coil was designed based on the Helmholtz coil design. A viewing gap was designed for in-situ imaging studies using synchrotron X-rays. The gap was designed to maintain a uniform magnetic field in the central region where a sample is positioned. The current setup for the magnetic coil pair is able to produce a peak magnetic flux density of ∼10 mT at a frequency of 25 kHz. A separate electrical resistance furnace, designed specifically to fit within the magnetic coil, was used to control the heating (up to ∼850°C) and cooling of the samples. After systematic tests, commissioning, the apparatus was used in a number of in-situ and ex-situ experiments.

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Abstract: The flow within the melt pool during welding is a major factor that dictates the formation of the final fusion zone shape, solidification microstructure and defects. In this paper, we report the evolution sequence of the arc weld pool flow that observed via fast in-situ synchrotron X-ray imaging. Varying flow regimes attribute to the dominance of characteristic forces within the weld pool during rapid solid-liquid-solid phase transformation. Our analysis indicates the general sequence in the arc, surface tension and gravity driven force domination. Welding process parameters appear to influence significantly in determining the domination interval and the intensity of individual force. In some instances, arc and surface tension driven forces can prevent pores, which causes porosity in final welded structures, escaping from the melt pool. Preliminary relations between power input levels, diffract force domination regimes, flow patterns and pool surface changes in fusion welds are suggested by considering the behavior of multiple weld pools.

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Abstract: Additive Manufacture (AM) of Ti-6Al-4V frequently leads to undesirable, coarse, columnar β-grain structures with a strong <100> fibre texture. In Wire-Arc AM (WAAM), it has been found that the application of a low plastic strain, by methods such as inter-pass rolling, can disrupt β columnar growth and produce a refined, equiaxed grain structure that is more randomly orientated. The origin of this desirable effect has been investigated by thermo-mechanical simulation, direct in-situ EBSD observation, as well as by real-time synchrotron X-ray diffraction (SXRD) during rapid heating. These complementary approaches have shown that, when starting with a WAAM microstructure, the grain refinement process produces a unique micro-texture represented by a four-pole motif symmetrically centred on the parent grain {100} orientations. These new β-grain orientations can be reproduced by a double {112}<111> twinning operation, which produces 12 new, unique, β-orientation variants. High-resolution orientation-mapping techniques and in-situ SXRD heating simulations suggest that the prior β does not twin during deformation, but rather the grain refinement and related texture may be caused by annealing twinning during β re-growth on rapid re-heating of the deformed AM microstructure. Although this is the first time such a unique texture has been observed in a deformed and β annealed Ti-6Al-4V material, it was only found to dominate under the unusual conditions that occur in AM of rapid heating – a fine, lightly deformed α transformation microstructure, with a very coarse starting β-grain structure.

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Abstract: There are several mechanisms contributing towards detrimental damage in wind turbine gearbox bearings, with sudden overload events believed to reduce their expected operational life. The generation of subsurface plasticity, followed by rolling contact fatigue, may lead to the initiation of either surface or subsurface cracking. This study presents a novel technique capable of measuring subsurface strain evolution in a rotating roller bearing, using energy dispersive X-ray diffraction. A pre-overloaded bearing was tested dynamically and consequently failed prematurely, supporting the hypothesis that overloads accelerate bearing failure. Throughout the test, an increase in compressive radial strain was observed, indicative of material softening, generally associated with the unstable stage of rolling contact fatigue, which occurs prior to definitive bearing failure.

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Abstract: Plastic effects during sheet metal forming can lead to undesirable distortions in formed components. Here, the three-stage work hardening and plastic strain recovery (“springback”) in a cold-rolled, α-phase commercially pure titanium is examined. Interrupted standard tensile tests with in situ x-ray diffraction and quasi- in situ electron backscatter diffraction show that twinning plays a minor role in both of these phenomena. The experiments give evidence that the observed work hardening plateau is the result of an abrupt activation and multiplication of  c + a  slip and a subsequent redistribution of load between grain families. The springback can be attributed to inelastic backwards motion and annihilation of dislocations, driven by backstresses from dislocation-based hardening during loading. The peak broadening behavior, observed by x-ray diffraction, suggests that the internal stress state is highest in the rolling direction, resulting in consistently higher springback magnitude along this direction.