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The aim of this paper is to investigate the factors (build orientation, sample conditions, and R-ratio) that affect the cyclic response of laser powder-bed fusion stainless steel 316L and 17-4 PH parts. Initially, the data set was analyzed to confirm the normality assumption. The significant and insignificant factors that affect the fatigue life were identified using analysis of variance (ANOVA). Main effects for different sample conditions were also analyzed. Process and reproducibility assessment were performed to study the effect of process factors. Combining fatigue data sets was recommended as the best approach to accurately predict the fatigue behavior of LPBF 316L and 17-4 PH parts. Finally, the effect of sample conditions on fatigue life was quantified. The highest fatigue life was achieved with Machined-Polished surfaces.
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In this study, we compared the material properties of linearly and sharply graded Ti6Al4V additively manufactured samples to investigate whether the more severe discontinuities caused by sharp grading can reduce performance. We performed compression testing with digital image correlation (DIC) in two loading directions for each grading design to simulate iso-stress and iso-strain conditions. We extracted the elastic stiffness, yield strength, yield strain, and energy absorption capacity of each sample. In addition, we used micro-computed tomography (micro-CT) imaging to examine the printing quality and dimensional accuracy. We found that sharply graded struts have a 12.95% increase in strut cross-sectional areas, whereas linearly graded struts produced an average of 49.24% increase compared to design. However, sharply graded and linearly graded FGL samples do not have statistically significant differences in elastic stiffness and yield strength. For the iso-strain condition, the average DIC-corrected stiffnesses for linearly and sharply graded samples were 6.15 GPa and 5.43 GPa, respectively (p = 0.4466), and the yield stresses were 290.4 MPa and 291.2 MPa, respectively (p = 0.5734). Furthermore, we confirmed different types of printing defects using micro-CT, including defective pores and disconnected struts. These results suggest that the loss of material properties caused by manufacturing defects outweighs the adverse effects of discrete-grading-induced discontinuities.
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To maximize the performance and energy efficiency of Spiking Neural Network (SNN) processing on resource-constrained embedded systems, specialized hardware accelerators/chips are employed. However, these SNN chips may suffer from permanent faults which can affect the functionality of weight memory and neuron behavior, thereby causing potentially significant accuracy degradation and system malfunctioning. Such permanent faults may come from manufacturing defects during the fabrication process, and/or from device/transistor damages (e.g., due to wear out) during the run-time operation. However, the impact of permanent faults in SNN chips and the respective mitigation techniques have not been thoroughly investigated yet. Toward this, we propose RescueSNN, a novel methodology to mitigate permanent faults in the compute engine of SNN chips without requiring additional retraining, thereby significantly cutting down the design time and retraining costs, while maintaining the throughput and quality. The key ideas of our RescueSNN methodology are (1) analyzing the characteristics of SNN under permanent faults; (2) leveraging this analysis to improve the SNN fault-tolerance through effective fault-aware mapping (FAM); and (3) devising lightweight hardware enhancements to support FAM. Our FAM technique leverages the fault map of SNN compute engine for (i) minimizing weight corruption when mapping weight bits on the faulty memory cells, and (ii) selectively employing faulty neurons that do not cause significant accuracy degradation to maintain accuracy and throughput, while considering the SNN operations and processing dataflow. The experimental results show that our RescueSNN improves accuracy by up to 80% while maintaining the throughput reduction below 25% in high fault rate (e.g., 0.5 of the potential fault locations), as compared to running SNNs on the faulty chip without mitigation. In this manner, the embedded systems that employ RescueSNN-enhanced chips can efficiently ensure reliable executions against permanent faults during their operational lifetime.
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The mechanical properties of laser powder bed fused (LPBFed) Invar 36 alloy have been limited by the presence of manufacturing defects. It is imperative to investigate the influence of these defects on the mechanical behavior of LPBFed Invar 36 alloy. In this study, in-situ X-ray computed tomography (XCT) tests were conducted on LPBFed Invar 36 alloy fabricated at different scanning speeds to examine the relationship between manufacturing defects and mechanical behavior. For LPBFed Invar 36 alloy fabricated at a scanning speed of 400 mm/s, the manufacturing defects were randomly distributed and tended to be elliptical in shape. Plastic deformation behavior was observed, and failure initiated from defects inside the material resulting in ductile failure. Conversely, for LPBFed Invar 36 alloy fabricated at a scanning speed of 1000 mm/s, numerous lamellar defects were observed mainly located between deposition layers, and their quantity was significantly increased. Little plastic deformation behavior was observed, and failure initiated from defects on the shallow surface of the material resulting in brittle failure. The differences in manufacturing defects and mechanical behavior are attributed to changes in input energy during the laser powder bed fusion process.
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Voids in polymer matrix composites are one of the most common manufacturing defects, which may influence the mechanical properties and structural behavior of the final parts made of composites by various manufacturing methods. Therefore, numerous non-destructive testing (NDT) techniques were developed and applied for quality control and in-service testing of such structures. In this paper, the authors analyzed various alternatives to the reference technique, X-ray computed tomography (XCT) NDT, which is used for industrial testing of composite disks having defects in the form of the lower density areas. Different candidates, namely: vibration-based testing, infrared thermography, vibro-thermography, as well as ultrasonic testing were analyzed in terms of their sensitivity and technical feasibility. The quality of the results, the complexity of the testing procedure, time and labor consumption, and the cost of the equipment were analyzed and compared with the reference technique. Based on the conducted research the authors finally proposed a hybrid approach to quality control, using a combination of two NDT techniques-infrared thermography (for initial scanning and detection of near-surface defects) and ultrasonic testing (for a more detailed analysis of products that pass the first testing procedure). It allowed for replacing the costly XCT diagnostics with a much cheaper, but almost equally effective, alternative.
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This research presents a new technique using pulse echo ultrasound for sizing foreign objects within carbon fiber laminates. Carbon fiber laminates are becoming increasingly popular in a wide variety of industries for their desirable properties. It is not uncommon for manufacturing defects to occur within a carbon fiber laminates, causing waste, either in the discarding of failed parts or the overdesign of the initial part to account for these anticipated and undetected errors. One such manufacturing defect is the occurrence of a foreign object within the laminate. This defect will lead to a localized weakness within the laminate including, but not limited to, stress risers, delamination, and catastrophic failure. This paper presents a method to analyze high-resolution c-scan full waveform captured data to automatically capture the geometry of the foreign object with minimal user inputs without a-priori knowledge of the shape of the defect. This paper analyzes twelve samples, each a twelve-lamina carbon fiber laminate. Foreign objects are made from polytetrafluoroethylene (PTFE) measuring 0.05 mm (0.002 in.) thick and ranging in diameter from 12.7 mm (0.5 in) to 1.588 mm (0.0625 in), are placed within the laminates during fabrication at varying depths. The samples are analyzed with a custom high-resolution c-scan system and smoothing, and edge detection methods are applied to the collected c-scan data. Results are presented on the sizing of the foreign objects with an average error of 6% of the true area, and an average absolute difference in the estimation of the diameter of 0.1 mm (0.004 in), an improvement over recently presented ultrasonic methods by a factor of three.
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In recent years, most boat fabrication companies use 100% synthetic fiber-reinforced composite materials, due to their high performance of mechanical properties. In the new trend of research on the fabrication of boat structure using natural fiber hybrid with kevlar/fiberglass-reinforced composite, the result of tensile, bending, and impact strength showed that glass fiber-reinforced polyester composite gave high strength with increasing glass fiber contents. At some point, realizing the cost of synthetic fiber is getting higher, researchers today have started to use natural fibers that are seen as a more cost-effective option. Natural fibers, however, have some disadvantages, such as high moisture absorption, due to repelling nature; low wettability; low thermal stability; and quality variation, which lead to the degradation of composite properties. In recent times, hybridization is recommended by most researchers as a solution to natural fiber's weaknesses and to reduce the use of synthetic fibers that are not environmentally friendly. In addition, hybrid composite has its own special advantages, i.e., balanced strength and stiffness, reduced weight and cost, improved fatigue resistance and fracture toughness, and improved impact resistance. The synthetic-nature fiber hybrid composites are used in a variety of applications as a modern material that has attracted most manufacturing industries' attention to shift to using the hybrid composite. Some of the previous studies stated that delamination and manufacturing had influenced the performance of the hybrid composites. In order to expand the use of natural fiber as a successful reinforcement in hybrid composite, the factor that affects the manufacturing defects needs to be investigated. In this review paper, a compilation of the reviews on the delamination and a few common manufacturing defect types illustrating the overview of the impact on the mechanical properties encountered by most of the composite manufacturing industries are presented.
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Automated fiber placement (AFP) is an advanced manufacturing method for composites, which is especially suitable for large-scale composite components. However, some manufacturing defects inevitably appear in the AFP process, which can affect the mechanical properties of composites. This work aims to investigate the recent works on manufacturing defects and their online detection techniques during the AFP process. The main content focuses on the position defect in conventional and variable stiffness laminates, the relationship between the defects and the mechanical properties, defect control methods, the modeling method for a void defect, and online detection techniques. Following that, the contributions and limitations of the current studies are discussed. Finally, the prospects of future research concerning theoretical and practical engineering applications are pointed out.
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Various manufacturing defects of endotracheal tubes are encountered in anaesthesia practice. One of the important defects of an endotracheal tube is that a partial or complete obstruction can be potentially life-threatening. Manufacturing defects may not be ascertainable by routine inspection. In this case report, we report a partial airway obstruction caused by a plastic membrane in the connector of an endotracheal tube as a manufacturing defect.
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During endodontic therapy, cleaning of root canals is performed using endodontic files and auxiliary chemical substances, and it is important that the endodontist be familiar with the instruments used in daily practice. This study evaluated, under scanning electron microscopy (SEM), the quality of the surface finishing of unused rotary endodontic instruments. Fifty sizes 20, 25 and 30 rotary files from different commercial brands (ProFile, Protaper, Race, Hero and K3 Endo) were removed directly from their packages and had their final 3 mm examined with a scanning electron microscope at x190 magnification with no previous preparation. The images were evaluated by 3 skillful, calibrated, blinded observers according to the following criteria: cutting edge, debris, grooves, microcavities, tip shape, tip position, scraping and transition angle. Data were recorded in worksheets designed for the study. Irregular edges were observed in 50-100 percent of the files. Except for ProFile, all commercial brands presented surface debris in 100 percent of samples. Only Race files showed no grooves or microcavities. K3 Endo files presented the best tip centralization. Excetp for ProTaper files, all commercial brands presented blunt-cutting edges in 100 percent of samples. All types of files presented surface scraping. K3 Endo files and Protaper had a high percentage of transition angle. Based on the evaluation criteria used in the present study, most samples presented a minimum of 2 alterations and a maximum of 7 alterations per instrument. Under the tested conditions, the quality of the surface finishing of the examined instruments was not as expected, given that no instrument was free of imperfections and most of them presented at least 2 and up to 7 types of surface defects. These results suggest that the manufacturing process and the packaging conditions of rotary endodontic instruments are far from ideal.
Durante a terapia endodôntica, a ação de limpeza é realizada com os instrumentos endodônticos auxiliada por substâncias químicas. Sendo assim, é importante que o endodontista conheça como são os instrumentos. Este trabalho visou avaliar a qualidade do acabamento de superfície de instrumentos endodônticos rotatórios por meio de microscopia eletrônica de varredura. Foram selecionados, 50 instrumentos endodônticos rotatórios nos números de 20, 25 e 30, das marcas Profile, Protaper, Race, Hero e K3 Endo, da forma como são encontradas no mercado e sem nenhum preparo prévio. Os instrumentos tiveram seus 3 milímetros finais fotomicrografados em microscópio eletrônico de varredura com ampliação de x190. As imagens foram avaliadas por três profissionais especialistas, e os resultados anotados em planilhas. A metodologia aplicada permitiu concluir que todos os instrumentos das marcas comerciais avaliadas apresentaram inadequações no acabamento da superfície. Cabe aclarar que, observando os critérios selecionados utilizados para avaliação a maioria das amostras apresentaram o mínimo de duas alterações e o máximo de sete por instrumento avaliado.