Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (<em>invited</em>)

Xu Binshi; Dong Shiyun; Men Ping; Yan Shixing

doi:10.3788/IRLA201847.0401001

Volume 47 Issue 4

Apr. 2018

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Article Navigation > Infrared and Laser Engineering > 2018 > 47(4): 401001-0401001(9)

Xu Binshi, Dong Shiyun, Men Ping, Yan Shixing. Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)[J]. Infrared and Laser Engineering, 2018, 47(4): 401001-0401001(9). doi: 10.3788/IRLA201847.0401001

Citation:

Xu Binshi, Dong Shiyun, Men Ping, Yan Shixing. Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)[J]. Infrared and Laser Engineering, 2018, 47(4): 401001-0401001(9). doi: 10.3788/IRLA201847.0401001

Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

doi: 10.3788/IRLA201847.0401001

1.
National Key Laboratory for Remanufacturing,Academy of Army Armored Forces,Beijing 100072,China;
2.
The 92601 Troops of People's Liberation Army Navy,Zhanjiang 524009,China

Received Date: 2017-11-05
Rev Recd Date: 2017-12-15
Publish Date: 2018-04-25

Abstract

Nondestructive test(NDT) technology is the important technical support for laser additive manufacturing alloy steel components, the key technology to ensure laser additive manufacturing production quality and in-service safety and the important technical composition to the production safety guarantee through life cycle. The formation, texture and mechanics properties of alloy steel components made by laser additive manufacturing are different from those made by traditional technologies, so NDT technology faces many challenges. The forming quality characteristics of laser additive manufacturing alloy steel were summarized, including forming flaws and mechanics properties; Based on the development of NDT technologies, the applications of NDT technologies in laser additive manufacturing were reviewed, especially in applications of material mechanics properties and flaws; Based on ultrasonic and micro-magnetic techniques, micro-magnetic sensor design scheme, calibration method and principles of evaluating the material mechanics properties were outlined; Finally, the challenges and prospects of NDT in laser additive manufacturing alloy steel components were discussed.
- laser additive manufacture,
- nondestructive test,
- flaw,
- mechanics property,
- alloy steel component

References

[1]	Zhang Xuejun, Tang Siyi, Zhao Hengyue, et al. Research status and key technologies of 3D printing[J]. Journal of Materials Engineering, 2016, 44(2):122-128. (in Chinese)
[2]	Yang Yongqiang, Liu Yang, Song Changhui. The status and progress of manufacturing of metal parts by 3D printing technology[J]. Mechanical and Electrical Engineering Technology, 2013, 42(4):1-7. (in Chinese)
[3]	Li Huaixue, Sui Fan, Huang Baiying. Development and application of laser additive manufacturing for metal component[J]. Aeronautical Manufacturing Technology, 2012, 416(20):26-31. (in Chinese)
[4]	Lu Bingheng, Li Dichen. Development of the additive manufacturing(3D printing) technology[J]. Machine Building Automation, 2013, 42(4):1-4. (in Chinese)
[5]	Huang Weidong. Laser Solid Forming[M]. Xi'an:Northwestern Polytechnical University Press, 2007. (in Chinese)
[6]	Kumar S. Selective laser sintering/melting[J]. Comprehensive Materials Processing, 2014, 26(3):93-134.
[7]	Zhang Yuanliang, Zhang Hongchao, Zhao Jiaxu, et al. Review of non-destructive testing for remanufacturing of high-end equipment[J]. Journal of Mechanical Engineering, 2013, 49(7):80-90. (in Chinese)
[8]	Xu Binshi, Dong Shiyun. Laser Remanufacturing Technology[M]. Beijing:National Defense Industry Press, 2016. (in Chinese)
[9]	Khairallah S A, Anderson A T, Rubenchik A, et al. Laser powder-bed fusion additive manufacturing:Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones[J]. Acta Materialia, 2016, 108:36-45.
[10]	Murr L E, Gaytan S M, Medina F, et al. Characterization of Ti-6Al-4V open cellular foams fabricated by additive manufacturing using electron beam melting[J]. Materials Science Engineering A, 2010, 527(7-8):1861-1868.
[11]	Yong H, Ming C L, Mazumder J, et al. Additive manufacturing:current state, future potential, gaps and needs, and recommendations[J]. Journal of Manufacturing Science Engineering, 2015, 137(1):014001.
[12]	Brown D W, Bernardin J D, Carpenter J S, et al. Neutron diffraction measurements of residual stress in additively manufactured stainless steel[J]. Materials Science Engineering A, 2016, 678(15):291-298.
[13]	Sander J, Hufenbach J, Giebeler L, et al. Microstructure and properties of FeCrMoVC tool steel produced by selective laser melting[J]. Materials Design, 2016, 89(15):335-341.
[14]	Gu D, Hong C, Jia Q, et al. Combined strengthening of multi-phase and graded interface in laser additive manufactured TiC/Inconel 718 composites[J]. Journal of Physics D Applied Physics, 2014, 47(4):45309-45319.
[15]	Cox S C, Jamshidi P, Eisenstein N M, et al. Adding functionality with additive manufacturing:Fabrication of titanium-based antibiotic eluting implants[J]. Materials Science Engineering C, 2016, 533(64):407-415.
[16]	Kim T B, Yue S, Zhang Z, et al. Additive manufactured porous titanium structures:through-process quantification of pore and strut networks[J]. Journal of Materials Processing Technology, 2014, 214(11):2706-2715.
[17]	Ibrahim K A, Wu B, Brandon N P. Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering[J]. Materials Design, 2016, 106(15):51-59.
[18]	Benedetti M, Cazzolli M, Fontanari V, et al. Fatigue limit of Ti6Al4V alloy produced by selective laser sintering[J]. Procedia Structural Integrity, 2016(2):3158-3167.
[19]	Cerniglia D, Scafidi M, Pantano A, et al. Inspection of additive-manufactured layered components[J]. Ultrasonics, 2015, 62(7):292-298.
[20]	Mengucci P, Barucca G, Gatto A, et al. Effects of thermal treatments on microstructure and mechanical properties of a Co-Cr-Mo-W biomedical alloy produced by laser sintering[J]. Journal of the Mechanical Behavior of Biomedical Materials, 2016, 60(March):106-117.
[21]	Li P. Constitutive and failure behaviour in selective laser melted stainless steel for microlattice structures[J]. Materials Science Engineering A, 2015, 622(12):114-120.
[22]	Sun Z, Tan X, Shu B T, et al. Selective laser melting of stainless steel 316L with low porosity and high build rates[J]. Materials Design, 2016, 104(15):197-204.
[23]	Baek S W, Song E J, Kim J H, et al. Hydrogen embrittlement of 3-D printing manufactured austenitic stainless steel part for hydrogen service[J]. Scripta Materialia, 2017, 130(15):87-90.
[24]	Liu Bin. Ultrasonic and metal magnetic memory testing method for quality nondestructive evaluation of remanufacturing coating[D]. Harbin:Harbin Institute of Technology, 2013. (in Chinese)
[25]	American Society for Nondestructive Testing. American NDT Manual[M]. Beijing:World Book Publishing Company, 1999. (in Chinese)
[26]	Hu Mulin, Xie Changsheng, Huang Kaijin. Measurement of residual stress in multi-track laser-clad coating[J]. Laser Technology, 2006, 30(3):262-264. (in Chinese)
[27]	Dong Shiyun, Yan Xiaoling, Xu Binshi. Influence of microstructure and residual stress on surface stress measurement of laser cladding layer by Rayleigh wave[J]. Journal of Mechanical Engineering, 2015, 51(24):50-56. (in Chinese)
[28]	Liu Bin, Dong Shiyun. Stress measurement of laser cladding coating with critically refracted longitudinal wave method[J]. Transactions of the China Welding Institution, 2014, 35(9):53-56. (in Chinese)
[29]	Liu B, Dong S. Stress evaluation of laser cladding coating with critically refracted longitudinal wave based on cross correlation function[J]. Applied Acoustics, 2016, 101(1):98-103.
[30]	Haat G, Calmon P, Lasserre F. Application of ultrasonic modeling to the positioning of defects in a cladded component[C]//American Institute of Physics Conference Proceeding, 2004(2):1.1711612.
[31]	Fang Yan, Chen Xichen. Research on key techniques of defect detection for laser remanufacturing[J]. Chinese Journal of Lasers, 2012, 39(4):54-59. (in Chinese)
[32]	Yan Xiaoling. Numerical simulation and experimental study on ultrasonic testing for laser cladding[D]. Beijing:Beijing Institute of Technology, 2015. (in Chinese)
[33]	Liu Bin, Gong Kai, Qiao Yanxin, et al. Evaluation of influence of preset crack burial depth on stress of laser cladding coating with metal magnetic memory[J]. Acta Metallurgica Sinica, 2016, 52(2):241-248. (in Chinese)
[34]	Dong Shiyun, Yan Shixing, Xu Binshi, et al. Laser cladding remanufacturing technology of cast iron cylinder head and its quality evaluation[J]. Journal of Academy of Armored Forces Engineering, 2013, 27(1):90-93. (in Chinese)
[35]	Shi Changliang. Metal magnetic memory and ultrasonic complex method for damage degree evaluation of used ferromagnetic component before remanufacturing[D]. Harbin:Harbin Institute of Technology, 2011. (in Chinese)
[36]	Chinese Society for Nondestructive Testing. 2016 China NDT annual report[R]. Shanghai:Nondestructive Testing Editorial Department, 2016. (in Chinese)
[37]	Deng Ziyun, Ma Bing, Yi Yinghui, et al. Microstructure and properties of nickel-based super alloys valve by laser cladding remanufacturing[J]. Ordnance Material Science and Engineering, 2013, 36(3):101-104. (in Chinese)
[38]	Wang Xiao, Shi Yiwei, Liang Jing, et al. The method for nondestructive testing additive manufacturing parts on line by laser ultrasonic:China, CN106018288A[P]. 2016-10-12. (in Chinese)
[39]	Men Ping, Dong Shiyun, Kang Xueliang, et al. Material early damage diagnosis with nonlinear ultrasound[J]. Chinese Journal of Scientific Instrument, 2017, 38(5):1101-1118. (in Chinese)
[40]	Chen Yunpeng, Li Mangmang, Tang Chenglong. Progression of online detection technologies of mechanical property of cold-rolled strip steels[J]. Physical Testing and Chemical Analysis Part A:Physical Testing, 2017, 53(12):859-865. (in Chinese)
[41]	Ukomski T, Stepinski T. Steel hardness evaluation based on ultrasound velocity measurements[J]. Insight-Non-Destructive Testing and Condition Monitoring, 2010, 52(11):592-596.
[42]	Freitas V L D A, Albuquerque V H C D, Silva E D M, et al. Nondestructive characterization of microstructures and determination of elastic properties in plain carbon steel using ultrasonic measurements[J]. Materials Science Engineering A, 2010, 527(16):4431-4437.
[43]	Rayes M M E, El-Danaf E A, Almajid A A. Ultrasonic characterization of heat-treatment effects on SAE-1040 and -4340 steels[J]. Journal of Materials Processing Tech, 2015, 216(2):188-198.
[44]	Wiskel J B, Kennedy J, Ivey D G, et al. Ultrasonic velocity and attenuation measurements in l80 steel and their correlation with tensile properties[C]//19th World Conference on Non-Destructive Testing, 2016(7):1-9.
[45]	Murthy G V S, Ghosh S, Das M, et al. Correlation between ultrasonic velocity and indentation-based mechanical properties with microstructure in Nimonic 263[J]. Materials Science Engineering A, 2008, 488(1-2):398-405.

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通讯作者: 陈斌, bchen63@163.com

1.
沈阳化工大学材料科学与工程学院沈阳 110142

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Proportional views

Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

1. National Key Laboratory for Remanufacturing,Academy of Army Armored Forces,Beijing 100072,China;

2. The 92601 Troops of People's Liberation Army Navy,Zhanjiang 524009,China

Received Date: 2017-11-05

Rev Recd Date: 2017-12-15

Publish Date: 2018-04-25

Key words:

Abstract: Nondestructive test(NDT) technology is the important technical support for laser additive manufacturing alloy steel components, the key technology to ensure laser additive manufacturing production quality and in-service safety and the important technical composition to the production safety guarantee through life cycle. The formation, texture and mechanics properties of alloy steel components made by laser additive manufacturing are different from those made by traditional technologies, so NDT technology faces many challenges. The forming quality characteristics of laser additive manufacturing alloy steel were summarized, including forming flaws and mechanics properties; Based on the development of NDT technologies, the applications of NDT technologies in laser additive manufacturing were reviewed, especially in applications of material mechanics properties and flaws; Based on ultrasonic and micro-magnetic techniques, micro-magnetic sensor design scheme, calibration method and principles of evaluating the material mechanics properties were outlined; Finally, the challenges and prospects of NDT in laser additive manufacturing alloy steel components were discussed.

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Reference (45)

[1]	Zhang Xuejun, Tang Siyi, Zhao Hengyue, et al. Research status and key technologies of 3D printing[J]. Journal of Materials Engineering, 2016, 44(2):122-128. (in Chinese)
[2]	Yang Yongqiang, Liu Yang, Song Changhui. The status and progress of manufacturing of metal parts by 3D printing technology[J]. Mechanical and Electrical Engineering Technology, 2013, 42(4):1-7. (in Chinese)
[3]	Li Huaixue, Sui Fan, Huang Baiying. Development and application of laser additive manufacturing for metal component[J]. Aeronautical Manufacturing Technology, 2012, 416(20):26-31. (in Chinese)
[4]	Lu Bingheng, Li Dichen. Development of the additive manufacturing(3D printing) technology[J]. Machine Building Automation, 2013, 42(4):1-4. (in Chinese)
[5]	Huang Weidong. Laser Solid Forming[M]. Xi'an:Northwestern Polytechnical University Press, 2007. (in Chinese)
[6]	Kumar S. Selective laser sintering/melting[J]. Comprehensive Materials Processing, 2014, 26(3):93-134.
[7]	Zhang Yuanliang, Zhang Hongchao, Zhao Jiaxu, et al. Review of non-destructive testing for remanufacturing of high-end equipment[J]. Journal of Mechanical Engineering, 2013, 49(7):80-90. (in Chinese)
[8]	Xu Binshi, Dong Shiyun. Laser Remanufacturing Technology[M]. Beijing:National Defense Industry Press, 2016. (in Chinese)
[9]	Khairallah S A, Anderson A T, Rubenchik A, et al. Laser powder-bed fusion additive manufacturing:Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones[J]. Acta Materialia, 2016, 108:36-45.
[10]	Murr L E, Gaytan S M, Medina F, et al. Characterization of Ti-6Al-4V open cellular foams fabricated by additive manufacturing using electron beam melting[J]. Materials Science Engineering A, 2010, 527(7-8):1861-1868.
[11]	Yong H, Ming C L, Mazumder J, et al. Additive manufacturing:current state, future potential, gaps and needs, and recommendations[J]. Journal of Manufacturing Science Engineering, 2015, 137(1):014001.
[12]	Brown D W, Bernardin J D, Carpenter J S, et al. Neutron diffraction measurements of residual stress in additively manufactured stainless steel[J]. Materials Science Engineering A, 2016, 678(15):291-298.
[13]	Sander J, Hufenbach J, Giebeler L, et al. Microstructure and properties of FeCrMoVC tool steel produced by selective laser melting[J]. Materials Design, 2016, 89(15):335-341.
[14]	Gu D, Hong C, Jia Q, et al. Combined strengthening of multi-phase and graded interface in laser additive manufactured TiC/Inconel 718 composites[J]. Journal of Physics D Applied Physics, 2014, 47(4):45309-45319.
[15]	Cox S C, Jamshidi P, Eisenstein N M, et al. Adding functionality with additive manufacturing:Fabrication of titanium-based antibiotic eluting implants[J]. Materials Science Engineering C, 2016, 533(64):407-415.
[16]	Kim T B, Yue S, Zhang Z, et al. Additive manufactured porous titanium structures:through-process quantification of pore and strut networks[J]. Journal of Materials Processing Technology, 2014, 214(11):2706-2715.
[17]	Ibrahim K A, Wu B, Brandon N P. Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering[J]. Materials Design, 2016, 106(15):51-59.
[18]	Benedetti M, Cazzolli M, Fontanari V, et al. Fatigue limit of Ti6Al4V alloy produced by selective laser sintering[J]. Procedia Structural Integrity, 2016(2):3158-3167.
[19]	Cerniglia D, Scafidi M, Pantano A, et al. Inspection of additive-manufactured layered components[J]. Ultrasonics, 2015, 62(7):292-298.
[20]	Mengucci P, Barucca G, Gatto A, et al. Effects of thermal treatments on microstructure and mechanical properties of a Co-Cr-Mo-W biomedical alloy produced by laser sintering[J]. Journal of the Mechanical Behavior of Biomedical Materials, 2016, 60(March):106-117.
[21]	Li P. Constitutive and failure behaviour in selective laser melted stainless steel for microlattice structures[J]. Materials Science Engineering A, 2015, 622(12):114-120.
[22]	Sun Z, Tan X, Shu B T, et al. Selective laser melting of stainless steel 316L with low porosity and high build rates[J]. Materials Design, 2016, 104(15):197-204.
[23]	Baek S W, Song E J, Kim J H, et al. Hydrogen embrittlement of 3-D printing manufactured austenitic stainless steel part for hydrogen service[J]. Scripta Materialia, 2017, 130(15):87-90.
[24]	Liu Bin. Ultrasonic and metal magnetic memory testing method for quality nondestructive evaluation of remanufacturing coating[D]. Harbin:Harbin Institute of Technology, 2013. (in Chinese)
[25]	American Society for Nondestructive Testing. American NDT Manual[M]. Beijing:World Book Publishing Company, 1999. (in Chinese)
[26]	Hu Mulin, Xie Changsheng, Huang Kaijin. Measurement of residual stress in multi-track laser-clad coating[J]. Laser Technology, 2006, 30(3):262-264. (in Chinese)
[27]	Dong Shiyun, Yan Xiaoling, Xu Binshi. Influence of microstructure and residual stress on surface stress measurement of laser cladding layer by Rayleigh wave[J]. Journal of Mechanical Engineering, 2015, 51(24):50-56. (in Chinese)
[28]	Liu Bin, Dong Shiyun. Stress measurement of laser cladding coating with critically refracted longitudinal wave method[J]. Transactions of the China Welding Institution, 2014, 35(9):53-56. (in Chinese)
[29]	Liu B, Dong S. Stress evaluation of laser cladding coating with critically refracted longitudinal wave based on cross correlation function[J]. Applied Acoustics, 2016, 101(1):98-103.
[30]	Haat G, Calmon P, Lasserre F. Application of ultrasonic modeling to the positioning of defects in a cladded component[C]//American Institute of Physics Conference Proceeding, 2004(2):1.1711612.
[31]	Fang Yan, Chen Xichen. Research on key techniques of defect detection for laser remanufacturing[J]. Chinese Journal of Lasers, 2012, 39(4):54-59. (in Chinese)
[32]	Yan Xiaoling. Numerical simulation and experimental study on ultrasonic testing for laser cladding[D]. Beijing:Beijing Institute of Technology, 2015. (in Chinese)
[33]	Liu Bin, Gong Kai, Qiao Yanxin, et al. Evaluation of influence of preset crack burial depth on stress of laser cladding coating with metal magnetic memory[J]. Acta Metallurgica Sinica, 2016, 52(2):241-248. (in Chinese)
[34]	Dong Shiyun, Yan Shixing, Xu Binshi, et al. Laser cladding remanufacturing technology of cast iron cylinder head and its quality evaluation[J]. Journal of Academy of Armored Forces Engineering, 2013, 27(1):90-93. (in Chinese)
[35]	Shi Changliang. Metal magnetic memory and ultrasonic complex method for damage degree evaluation of used ferromagnetic component before remanufacturing[D]. Harbin:Harbin Institute of Technology, 2011. (in Chinese)
[36]	Chinese Society for Nondestructive Testing. 2016 China NDT annual report[R]. Shanghai:Nondestructive Testing Editorial Department, 2016. (in Chinese)
[37]	Deng Ziyun, Ma Bing, Yi Yinghui, et al. Microstructure and properties of nickel-based super alloys valve by laser cladding remanufacturing[J]. Ordnance Material Science and Engineering, 2013, 36(3):101-104. (in Chinese)
[38]	Wang Xiao, Shi Yiwei, Liang Jing, et al. The method for nondestructive testing additive manufacturing parts on line by laser ultrasonic:China, CN106018288A[P]. 2016-10-12. (in Chinese)
[39]	Men Ping, Dong Shiyun, Kang Xueliang, et al. Material early damage diagnosis with nonlinear ultrasound[J]. Chinese Journal of Scientific Instrument, 2017, 38(5):1101-1118. (in Chinese)
[40]	Chen Yunpeng, Li Mangmang, Tang Chenglong. Progression of online detection technologies of mechanical property of cold-rolled strip steels[J]. Physical Testing and Chemical Analysis Part A:Physical Testing, 2017, 53(12):859-865. (in Chinese)
[41]	Ukomski T, Stepinski T. Steel hardness evaluation based on ultrasound velocity measurements[J]. Insight-Non-Destructive Testing and Condition Monitoring, 2010, 52(11):592-596.
[42]	Freitas V L D A, Albuquerque V H C D, Silva E D M, et al. Nondestructive characterization of microstructures and determination of elastic properties in plain carbon steel using ultrasonic measurements[J]. Materials Science Engineering A, 2010, 527(16):4431-4437.
[43]	Rayes M M E, El-Danaf E A, Almajid A A. Ultrasonic characterization of heat-treatment effects on SAE-1040 and -4340 steels[J]. Journal of Materials Processing Tech, 2015, 216(2):188-198.
[44]	Wiskel J B, Kennedy J, Ivey D G, et al. Ultrasonic velocity and attenuation measurements in l80 steel and their correlation with tensile properties[C]//19th World Conference on Non-Destructive Testing, 2016(7):1-9.
[45]	Murthy G V S, Ghosh S, Das M, et al. Correlation between ultrasonic velocity and indentation-based mechanical properties with microstructure in Nimonic 263[J]. Materials Science Engineering A, 2008, 488(1-2):398-405.

Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

doi: 10.3788/IRLA201847.0401001

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通讯作者: 陈斌, bchen63@163.com

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Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

doi: 10.3788/IRLA201847.0401001

1. National Key Laboratory for Remanufacturing,Academy of Army Armored Forces,Beijing 100072,China;

2. The 92601 Troops of People's Liberation Army Navy,Zhanjiang 524009,China

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Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

doi: 10.3788/IRLA201847.0401001

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通讯作者: 陈斌, bchen63@163.com

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Related

Proportional views

Quality characteristics and nondestructive test and evaluation technology for laser additive manufacturing alloy steel components (invited)

doi: 10.3788/IRLA201847.0401001

1. National Key Laboratory for Remanufacturing,Academy of Army Armored Forces,Beijing 100072,China; 2. The 92601 Troops of People's Liberation Army Navy,Zhanjiang 524009,China

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1. National Key Laboratory for Remanufacturing,Academy of Army Armored Forces,Beijing 100072,China;

2. The 92601 Troops of People's Liberation Army Navy,Zhanjiang 524009,China