William O’Neill

Bio: William O’Neill is an academic researcher from University of Cambridge. The author has contributed to research in topics: Laser & Gas dynamic cold spray. The author has an hindex of 30, co-authored 155 publications receiving 3345 citations. Previous affiliations of William O’Neill include University of Liverpool.

Cold gas dynamic manufacturing: A non-thermal approach to freeform fabrication

Abstract: This paper reports on the development of a novel freeform fabrication technique using a cold spray (CS) system. In the CS process, metallic powder particles are accelerated in a supersonic gas jet and impacted with a substrate at speeds in excess of 600 m/s. The non-melting nature of its deposition mechanism ensures that the sprayed material is free from thermally induced tensile stresses, while the underlying substrate remains unchanged. The process is seen as a viable method for additive manufacturing because of its high deposition rates and controllable spray jet. A process was developed to investigate the potential of non-thermal freeform fabrication and was coined Cold Gas Dynamic Manufacturing (CGDM). Here, additive and subtractive techniques were combined to enable the production of complex geometries. Whereas most CS facilities concentrate on the application of wear or corrosion-resistant coatings, CGDM is dedicated to the production of freeform components, whilst still retaining an inherent coating ability. The process can produce functional forms using novel manufacturing strategies that are unique to CS. This paper presents information on the process, and details the various strategies employed during component fabrication. It was possible to construct components from many materials, including titanium, which exhibited freeform surfaces, internal channels and embedded devices. A breakdown of the process economics is also provided, with and without helium recycling.

Standoff distance and bow shock phenomena in the Cold Spray process

Abstract: Cold Spray involves the deposition of metallic powder particles using a supersonic gas jet. When the nozzle standoff distance is small, a bow shock is formed at the impingement zone between the supersonic jet and the substrate. It has long been thought that this bow shock is detrimental to process performance as it can reduce particle impact velocities. By using computational fluid dynamics, Particle Image Velocimetry and Schlieren imaging it was possible to show that the bow shock has a negative influence on deposition efficiency as a result of a reduction in particle velocity. Furthermore, the existence of the bow shock was shown to be dependent on the length of the nozzle's supersonic potential core. Experiments were carried out with aluminium, copper and titanium powders using a custom-made helium nozzle, operating at 2.0 MPa and 20 °C, and a commercial nitrogen nozzle operating at 3.0 MPa and 300 °C. In all cases, it was found that there is a direct relationship between standoff distance and deposition efficiency. At standoff distances less than 60 mm, the bow shock reduced deposition efficiencies by as much as 40%.

Deposition of metallic coatings on polymer surfaces using cold spray

Abstract: Current coating technologies such as plasma spray, High Velocity Oxygen Fuel (HVOF) or laser cladding involve the delivery of molten materials during the deposition process However, such techniques are not well suited to the deposition of metallic coatings on polymers and composites Cold spray (CS) has attracted much industrial interest over the past two decades In this method, a material in powder form is accelerated on passage through a converging–diverging nozzle to high speeds via a high pressure coaxial carrier gas jet The high impact kinetic energy deforms the particles, which creates effective bonding to the substrate This paper presents the results of an initial study on the potential of the CS process to produce metallic coatings on non-metallic surfaces such as polymers and composites for engineering applications Experimental and Computational Fluid Dynamics (CFD) results when spraying copper, aluminium and tin powder on a range of substrates such as PC/ABS, polyamide-6, polypropylene, polystyrene and a glass-fibre composite material are presented and analyzed

Density analysis of direct metal laser re-melted 316L stainless steel cubic primitives

Abstract: This paper reports on the density of cubic primitives made by Direct Metal Laser Re-Melting, a process variant of selective laser sintering (SLS). Here, stainless steel 316L powder fractions are scanned and fused by a 90 W Nd:YAG laser in consecutive 100 μm layers in order to build a 3-Dimensional object. The effects of Q-Switch pulsing frequency, scanning speed and scan spacing on sample density are described. The samples are measured by two methods: a weight/volume analysis and a xylene impregnation technique. The results are supported by microscopy analysis for qualitative arguments. The results show the significant influence of pulsing the beam on the density of the fabricated material. Also reported is the relationship of material density with energy density (as a function of the process parameters; power, scan speed and scan spacing). Optical analysis of material cross sections shows a periodic occurrence of porosity across the whole range of samples. Causes for this are discussed.

Carbon Nanostructure-Based Field-Effect Transistors for Label-Free Chemical/Biological Sensors

Abstract: Over the past decade, electrical detection of chemical and biological species using novel nanostructure-based devices has attracted significant attention for chemical, genomics, biomedical diagnostics, and drug discovery applications. The use of nanostructured devices in chemical/biological sensors in place of conventional sensing technologies has advantages of high sensitivity, low decreased energy consumption and potentially highly miniaturized integration. Owing to their particular structure, excellent electrical properties and high chemical stability, carbon nanotube and graphene based electrical devices have been widely developed for high performance label-free chemical/biological sensors. Here, we review the latest developments of carbon nanostructure-based transistor sensors in ultrasensitive detection of chemical/biological entities, such as poisonous gases, nucleic acids, proteins and cells.

Graphene photonics and optoelectronics

Abstract: The richness of optical and electronic properties of graphene attracts enormous interest. Graphene has high mobility and optical transparency, in addition to flexibility, robustness and environmental stability. So far, the main focus has been on fundamental physics and electronic devices. However, we believe its true potential lies in photonics and optoelectronics, where the combination of its unique optical and electronic properties can be fully exploited, even in the absence of a bandgap, and the linear dispersion of the Dirac electrons enables ultrawideband tunability. The rise of graphene in photonics and optoelectronics is shown by several recent results, ranging from solar cells and light-emitting devices to touch screens, photodetectors and ultrafast lasers. Here we review the state-of-the-art in this emerging field.

Science and technology roadmap for graphene, related two-dimensional crystals, and hybrid systems

Abstract: We present the science and technology roadmap for graphene, related two-dimensional crystals, and hybrid systems, targeting an evolution in technology, that might lead to impacts and benefits reaching into most areas of society. This roadmap was developed within the framework of the European Graphene Flagship and outlines the main targets and research areas as best understood at the start of this ambitious project. We provide an overview of the key aspects of graphene and related materials (GRMs), ranging from fundamental research challenges to a variety of applications in a large number of sectors, highlighting the steps necessary to take GRMs from a state of raw potential to a point where they might revolutionize multiple industries. We also define an extensive list of acronyms in an effort to standardize the nomenclature in this emerging field.

Laser additive manufacturing of metallic components: materials, processes and mechanisms

Abstract: Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...