Search results for: welding of ceramic to aluminum

Authors: B. Varaprasad, C. Srinivasa Rao

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Hard turning has been explored as an alternative to the conventional one used for manufacture of Parts using tool steels. In the present study, the effects of cutting speed, feed rate and Depth of Cut (DOC) on cutting forces, specific cutting force, power and surface roughness in the hard turning are experimentally investigated. Experiments are carried out using mixed ceramic(Al2O3+TiC) cutting tool of corner radius 0.8mm, in turning operations on AISI H13 tool steel, heat treated to a hardness of 62 HRC. Based on Design of Experiments (DOE), a total of 20 tests are carried out. The range of each one of the three parameters is set at three different levels, viz, low, medium and high. The validity of the model is checked by Analysis of variance (ANOVA). Predicted models are derived from regression analysis. Comparison of experimental and predicted values of specific cutting force, power and surface roughness shows that good agreement has been achieved between them. Therefore, the developed model may be recommended to be used for predicting specific cutting force, power and surface roughness in hard turning of tool steel that is AISI H13 steel.

Keywords: hard turning, specific cutting force, power, surface roughness, AISI H13, mixed ceramic

Procedia PDF Downloads 700

Authors: Samkeliso S. Ndzimandze, Welldone Moyo, Oranso T. Mahlangu, Adolph A. Muleja, Alex T. Kuvarega, Thabo T. I. Nkambule

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The high cost of precursor materials has hindered the commercialization of ceramic membrane technology in water treatment. In this work, a ceramic membrane disc (approximately 50 mm in diameter and 4 mm thick) was prepared from low-cost starting materials, kaolin, and fly ash by pressing at 200 bar and calcining at 900 °C. The fabricated membrane was characterized for various physicochemical properties, natural organic matter (NOM) removal as well as fouling propensity using several techniques. Further, the ceramic membrane was tested on samples collected from four drinking water treatment plants in KwaZulu-Natal, South Africa (named plants 1-4). The membrane achieved 48.6%, 54.6%, 57.4%, and 76.4% bulk UV254 reduction for raw water at plants 1, 2, 3, and 4, respectively. These removal rates were comparable to UV254 reduction achieved by coagulation/flocculation steps at the respective plants. Further, the membrane outperformed sand filtration steps in plants 1-4 in removing disinfection by-product precursors (8%-32%) through size exclusion. Fluorescence excitation-emission matrices (FEEM) studies showed the removal of fluorescent NOM fractions present in the water samples by the membrane. The membrane was fabricated using an up-scalable facile method, and it has the potential for application as a polishing step to complement conventional processes in water treatment for drinking purposes.

Keywords: crossflow filtration, drinking water treatment plants, fluorescence excitation-emission matrices, ultraviolet 254 (UV₂₅₄)

Procedia PDF Downloads 43

Authors: P. Meethum, C. Suvanjumrat

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Many aluminum motorcycle parts produced by a high pressure die casting. Some parts such as fuel caps were a thin and complex shape. This part risked for porosities and blisters on surface if it only depended on an experience of mold makers for mold design. This research attempted to use CAST-DESIGNER software simulated the high pressure die casting process with the same process parameters of a motorcycle fuel cap production. The simulated results were compared with fuel cap products and expressed the same porosity and blister locations on cap surface. An average of absolute difference of simulated results was obtained 0.094 mm when compared the simulated porosity and blister defect sizes on the fuel cap surfaces with the experimental micro photography. This comparison confirmed an accuracy of software and will use the setting parameters to improve fuel cap molds in the further work.

Keywords: aluminum, die casting, fuel cap, motorcycle

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Authors: Zita Šereš, Ljubica Dokić, Nikola Maravić, Dragana Šoronja Simović, Cecilia Hodur, Ivana Nikolić, Biljana Pajin

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New environmental regulations and the increasing market preference for companies that respect the ecosystem had encouraged the industry to look after new treatments for its effluents. The sugar industry, one of the largest emitter of environmental pollutants, follows this tendency. Membrane technology is convenient for separation of suspended solids, colloids and high molecular weight materials that are present in a wastewater from the sugar industry. The idea is to microfilter the wastewater, where the permeate passes through the membrane and becomes available for recycle and re-use in the sugar manufacturing process. For microfiltration of this effluent a tubular ceramic membrane was used with a pore size of 200 nm at transmembrane pressure in range of 1 – 3 bars and in range of flow rate of 50 – 150 l/h. Kenics static mixer was used for permeate flux enhancement. Turbidity and suspended solids were removed and the permeate flux was continuously monitored during the microfiltration process. The flux achieved after 90 minutes of microfiltration was in a range of 50-70 L/m2h. The obtained turbidity decrease was in the range of 50-99% and the total amount of suspended solids was removed.

Keywords: ceramic membrane, microfiltration, permeate flux, sugar industry, wastewater

Procedia PDF Downloads 523

Authors: Amir Mahmoudi

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In this investigation, AISI321 steel after welding by Shilded Metal Arc Welding (SMAW) was solution heat treated in various temperatures and times, and then was sensitizied. Results indicated, increasing of temperature in solution heat treatment raises the sensitization and creates the cavity structure in grain boundaries. Besides, in order to examine the effect of time on solution heat treatment, all samples were solution heat treated at different times and fixed temperature (1050°C). By increasing the time, more chrome carbides were created due to dissolution of delta ferrite phase and reproduce titanium carbides. Additionally, the best process for solution heat treatment for this steel was suggested.

Keywords: stainless steel, solution heat treatment, intergranular corrosion, DLEPR

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Authors: Anup Kumar Keshri, Arvind Agarwal

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Carbon nanotube (CNT) reinforced aluminum oxide (Al2O3) composite coating was synthesized on the steel substrate using plasma spraying technique. Three different compositions of coating such as Al2O3, Al2O¬3-4 wt. % CNT and Al2O3-8 wt. % CNT were synthesized and the fracture strength was determined using the four point bend test. Uniform dispersion of CNTs over Al2O3 powder particle was successfully achieved. With increasing CNT content, porosity in the coating showed decreasing trend and hence contributed towards enhanced mechanical properties such as hardness (~12% increased) and elastic modulus (~34 % increased). Fracture strength of the coating was found to be increasing with the CNT additions. By reinforcement of 8 wt. % of CNT, fracture strength increased by ~2.5 times. The improvement in fracture strength of Al2O3-CNT coating was attributed to three competitive phenomena viz. (i) lower porosity (ii) higher hardness and elastic modulus (iii) CNT bridging between splats.

Keywords: aluminum oxide, carbon nanotube, fracture strength, plasma spraying

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Authors: Maria V. Morozova, Zoya A. Mikhaylovskaya, Elena S. Buyanova, Sofia A. Petrova, Ksenia V. Arishina, Robert G. Zaharov

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The present work is devoted to the investigation of two series of doped bismuth molybdates: Bi₂₆-₂ₓMn₂ₓMo₁₀O₆₉-d and Bi₂₆Mo₁₀-₂yMn₂yO₆₉-d. Complex oxides were synthesized by conventional solid state technology and by co-precipitation method. The products were identified by powder diffraction. The powders and ceramic samples were examined by means of densitometry, laser diffraction, and electron microscopic methods. Porosity of the ceramic materials was estimated using the hydrostatic method. The electrical conductivity measurements were carried out using impedance spectroscopy method.

Keywords: bismuth molybdate, columnar structures, impedance spectroscopy, oxygen ionic conductors

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Authors: Aptullah Karakas, Murat Baydogan

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The hot dip aluminizing (HDA) process involves immersing a metallic substrate into a molten aluminum bath for several minutes, and removed from the bath and cooled down to room temperature. After the HDA process, various aluminide layers are formed as a result of interdiffusion between the substrate and the molten aluminum and between the aluminide layers. In order to form a uniform aluminide layer, the specimen must be covered and wet well by the molten aluminum. Surface roughness plays an important role in wettability, and thus, surface preparation is an important stage in determining the final surface roughness. In this study, different roughness values were achieved by grinding the surface with emery papers as 180, 320 and 600 grids. After the surface preparation, the HDA process was performed in a molten Al-Si bath at 700 ᴼC for 10 minutes. After the HDA process, a microstructural examination of the coating was carried out to evaluate the uniformity of the coating and adhesion between the substrate and the coating. According to the results, the best adhesion at the interface was observed on the specimen, which was prepared by 320 grid emery paper having a mean surface roughness (Ra) of 0.097 µm.

Keywords: hot-dip aluminizing, microstructure, surface roughness, coating

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Authors: Onan Kilicaslan, Anil Kabaklarli, Levent Subasi, Erdem Bektas, Rifat Yilmaz

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The Aluminum-Copper casting alloys are well known for their high mechanical strength, especially when compared to more commonly used Aluminum-Silicon alloys. A201 is one of the best in terms of strength vs. weight ratio among other aluminum alloys, which makes it suitable for premium quality casting applications in aerospace and automotive industries. It is reported that A201 has low castability, but it is easy to machine. However, there is a need to specifically determine the process window for feasible machining. This research investigates the machinability of A201 alloy after T7 heat treatment in terms of chip/burr formation, surface roughness, hardness, and microstructure. The samples are cast with low-pressure sand casting method and milling experiments are performed with uncoated carbide tools using different cutting speeds and feeds. Statistical analysis is used to correlate the machining parameters to surface integrity. It is found that there is a strong dependence of the cutting conditions on machinability and a process window is determined.

Keywords: A201-T7, machinability, milling, surface integrity

Procedia PDF Downloads 196

Authors: B. V. Feujofack Kemda, N. Barka, M. Jahazi, D. Osmani

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Automobile manufacturers are constantly seeking means to reduce the weight of car bodies. The usage of several steel grades in auto body assembling has been found to be a good technique to enlighten vehicles weight. This few years, the usage of dual phase (DP) steels, transformation induced plasticity (TRIP) steels and boron steels in some parts of the auto body have become a necessity because of their lightweight. However, these steels are martensitic, when they undergo a fast heat treatment, the resultant microstructure is essential, made of martensite. Resistance spot welding (RSW), one of the most used techniques in assembling auto bodies, becomes problematic in the case of these steels. RSW being indeed a process were steel is heated and cooled in a very short period of time, the resulting weld nugget is mostly fully martensitic, especially in the case of DP, TRIP and boron steels but that also holds for plain carbon steels as AISI 1010 grade which is extensively used in auto body inner parts. Martensite in its turn must be avoided as most as possible when welding steel because it is the principal source of brittleness and it weakens weld nugget. Thus, this work aims to find a mean to reduce martensite fraction in weld nugget when using RSW for assembling. The prediction of phase transformation kinetics during RSW has been done. That phase transformation kinetics prediction has been made possible through the modelling of the whole welding process, and a technique called post weld heat treatment (PWHT) have been applied in order to reduce martensite fraction in the weld nugget. Simulation has been performed for AISI 1010 grade, and results show that the application of PWHT leads to the formation of not only martensite but also ferrite, bainite and pearlite during the cooling of weld nugget. Welding experiments have been done in parallel and micrographic analyses show the presence of several phases in the weld nugget. Experimental weld geometry and phase proportions are in good agreement with simulation results, showing here the validity of the model.

Keywords: resistance spot welding, AISI 1010, modeling, post weld heat treatment, phase transformation, kinetics

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Authors: Nikki A. Barla, P. K. Ghosh, Sourav Das

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Two different groove sizes 13.6 mm (narrow groove) and 7.5 mm (ultra-narrow groove) of 304 LN austenitic stainless steel (ASS) plate was welded using pulse gas metal arc welding (P-GMAW). These grooves were welded using multi-pass single seam per layer (MSPPL) deposition technique with full assurance of groove wall fusion. During bead on plate deposition process, the thermal cycle was recorded using strain buster (temperature measuring device). Both the groove has heat affected Zone (HAZ) width of 1-2 mm. After welding, the microstructure studies was done which revealed that there was higher sensitization (Chromium carbide formation in grain boundary) in the HAZ of 13.6 mm groove weldment as compared to the HAZ of 7.5 mm weldment. Electrochemical potentiokinetic reactivation test (EPR) was done in 0.5 N H₂SO₄ + 1 M KSCN solution to study the degree of sensitization (DOS) and it was observed that 7.5 mm groove HAZ has lower DOS. Mass deposition in the 13.6 mm weld is higher than 7.5mm groove weld, which naturally induces higher residual stress in 13.6 mm weld. Comparison between microstructural studies and corrosion test summarized that the residual stress affects the sensitization property of welded ASS.

Keywords: austenitic stainless steel (ASS), electrochemical potentiokinetic reactivation test (EPR), microstructure, pulse gas metal arc welding (P-GMAW), sensitization

Procedia PDF Downloads 163

Authors: B. Khatri, K. Lappe, M. Habedank, T. Müller, C. Megnin, T. Hanemann

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We present a process flow for the development of ceramic-filled polymer composite filaments compatible with the fused deposition modeling (FDM) 3D printing process. Thermoplastic-ceramic composites were developed using acrylonitrile butadiene styrene (ABS) and 10- and 20 vol.% barium titanate (BaTiO3) powder (corresponding to 39.47- and 58.23 wt.% respectively) and characterized for their flow properties. To make them compatible with the existing FDM process, the composites were extruded into filaments. These composite filaments were subsequently structured into tensile stress specimens using a commercially available FDM 3D printer and characterized for their mechanical properties. Rheometric characterization of the material composites revealed non-Newtonian behavior with the viscosity logarithmically decreasing over increasing shear rates, as well as higher viscosities for samples with higher BaTiO3 filler content for a given shear rate (with the ABS+20vol.% BaTiO3 composite being over 50% more viscous compared to pure ABS at a shear rate of 1x〖10〗^3 s^(-1)). Mechanical characterization of the tensile stress specimens exhibited increasingly brittle behavior as well as a linearly decreasing ultimate tensile strength of the material composites with increasing volumetric ratio of BaTiO3 (from σ_max=32.4MPa for pure ABS to σ_max=21.3MPa for ABS+20vol.% BaTiO3). Further studies being undertaken include the development of composites with higher filler concentrations, sintering of the printed composites to yield pure dielectric structures and the determination of the dielectric characteristics of the composites.

Keywords: ceramic composites, fused deposition modeling, material characterization, rapid prototyping

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Authors: Jose Gois

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The paper presents the development of a porous porcelain frappe with thermochromic visualization for port wines, having as a partner the Institute of Vinhos do Douro and Porto. This ceramic frappe is intended to promote the cooling and maintenance of the temperature of port wines through porous ceramic materials, consisting of a porcelain composite with sawdust addition, so as to contain, on the one hand, the similar cooling properties of the terracotta and, on the other, the resistance of materials such as porcelain. The application of the thermochromic element makes it possible to see if the wine is at optimal service temperatures, allowing users to drink the wine in the ideal conditions and contributing to more efficient maintenance of the service.

Keywords: design, frappe, porcelain, porous, thermochromic

Procedia PDF Downloads 135

Authors: Adnan I. O. Zaid, Safwan M. A. Alqawabah

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Review of the available literature on grain refinement of aluminum and its alloys reveals that little work is published on the effect of refiners on mechanical characteristics and wear resistance. In this paper, the effect of addition of Zr to Al grain refined by Ti+B on its metallurgical, mechanical characteristics and wear resistance both in the as cast and after extrusion condition are presented and discussed. It was found that Addition of Zr to Al resulted in deterioration of its mechanical strength and hardness, whereas it resulted in improvement of both of them when added to Al grain refined by Ti+B. Furthermore it was found that the direct extrusion process resulted in further increase of the mechanical strength and hardness of Al and its micro-alloys. Also it resulted in increase of their work hardening index, n, i.e. improved their formability, hence it reduces the number of stages required for forming at large strains in excess of the plastic instability before Zr addition.

Keywords: aluminum, grain refinement, titanium + boron, zirconium, mechanical characteristics, wear resistance, direct extrusion

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Authors: Anuj Suhag, Rahul Dayal

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Aluminum matrix composites (AMCs) refer to the class of metal matrix composites that are lightweight but high performance aluminum centric material systems. The reinforcement in AMCs could be in the form of continuous/discontinuous fibers, whisker or particulates, in volume fractions. Properties of AMCs can be altered to the requirements of different industrial applications by suitable combinations of matrix, reinforcement and processing route. This work focuses on the fabrication of aluminum alloy (Al6061) matrix composites (AMCs) reinforced with 5 and 3 wt% Al2O3 particulates of 45µm using stir casting route. The aim of the present work is to investigate the effects of process parameters, determined by design of experiments, on microhardness, microstructure, Charpy impact strength, surface roughness and tensile properties of the AMC.

Keywords: aluminium matrix composite, Charpy impact strength test, composite materials, matrix, metal matrix composite, surface roughness, reinforcement

Procedia PDF Downloads 656

Authors: Abdelghani May

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This paper reports on experimental investigations concerning the underlying reasons for the anisotropic behavior observed during the cyclic loading of AA2017 aluminum alloy. Initially, we quantified the evolution of fatigue damage resulting from controlled proportional cyclic loadings along the axial and shear directions. Our primary objective at this stage was to verify the anisotropic mechanical behavior recently observed. To accomplish this, we utilized various models of fatigue damage quantification and conducted a comparative study of the obtained results. Our analysis confirmed the anisotropic nature of the material under investigation. In the subsequent step, we performed microstructural investigations aimed at understanding the origins of the anisotropic mechanical behavior. To this end, we utilized scanning electron microscopy to examine the phases and precipitates in both the transversal and longitudinal sections. Our findings indicate that the structure and morphology of these entities are responsible for the anisotropic behavior observed in the aluminum alloy. Furthermore, results obtained from Kikuchi diagrams, pole figures, and inverse pole figures have corroborated these conclusions. These findings demonstrate significant differences in the crystallographic texture of the material.

Keywords: microstructural investigation, fatigue damage quantification, anisotropic behavior, AA2017 aluminum alloy, cyclic loading, crystallographic texture, scanning electron microscopy

Procedia PDF Downloads 76

Authors: T. Kuchukhidze, N. Jalagonia, Z. Phachulia, R. Chedia

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Ceramic obtained on the base of aluminum oxide has wide application range, because it has unique properties, for example, wear-resistance, dielectric characteristics, exploitation ability at high temperatures and in corrosive atmosphere. Low temperature synthesis of α-Al2O3 is energo-economical process and it is actual for developing technologies of corundum ceramics fabrication. In the present work possibilities of low temperature transformation of oxyhydroxides in α-Al2O3, during a presence of small amount of rare–earth elements compounds (also Th, Re), have been discussed. Aluminium unstable oxyhydroxides have been obtained by hydrolysis of aluminium isopropoxide, nitrates, sulphate, chloride in alkaline environment at 80-90ºC tempertures. β-Al(OH)3 has been received from aluminium powder by ultrasonic development. Drying of oxyhydroxide sol has been conducted with presence of various types seeds, which amount reaches 0,1-0,2% (mas). Neodymium, holmium, thorium, lanthanum, cerium, gadolinium, disprosium nitrates and rhenium carbonyls have been used as seeds and they have been added to the sol specimens in amount of 0.1-0.2% (mas) calculated on metals. Annealing of obtained gels is carried out at 70 – 1100ºC for 2 hrs. The same specimen transforms in α-Al2O3 at 1100ºC. At this temperature in case of presence of lanthanum and gadolinium transformation takes place by 70-85%. In case of presence of thorium stabilization of γ-and θ-phases takes place. It is established, that thorium causes inhibition of α-phase generation at 1100ºC, at the time in all other doped specimens α-phase is generated at lower temperatures (1000-1050ºC). During the work the following devices have been used: X-ray difractometer DRON-3M (Cu-Kα, Ni filter, 2º/min), High temperature vacuum furnace OXY-GON, electronic scanning microscopes Nikon ECLIPSE LV 150, NMM-800TRF, planetary mill Pulverisette 7 premium line, SHIMADZU Dynamic Ultra Micro Hardness Tester, DUH-211S, Analysette 12 Dyna sizer.

Keywords: α-Alumina, combustion, phase transformation, seeding

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Authors: Abhijit Pattnayak, Abhijith N.V, Deepak Kumar, Jayant Jain, Vijay Chaudhry

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Hard and dense ceramic coatings deposited on the surface provide the ideal solution to the poor tribological properties exhibited by some popular stainless steels like EN-36, 17-4PH, etc. These steels are widely used in nuclear, fertilizer, food processing, and marine industries under extreme environmental conditions. The present study focuses on the development of Al₂O₃-CeO₂-rGO-based coatings on the surface of 17-4PH steel using High-Velocity Oxygen Flame (HVOF) thermal spray process. The coating is developed using an oxyacetylene flame. Further, we report the physical (Density, Surface roughness, Surface energetics), Metallurgical (Scanning electron microscopy, X-ray diffraction, Raman), Mechanical (Hardness(Vickers and Nano Hard-ness)), Tribological (Wear, Scratch hardness) and Chemical (corrosion) characterization of both As-sprayed coating and the Substrate (17-4 PH steel). The comparison of the properties will help us to understand the microstructure-property relationship of the coating and reveal the necessity and challenges of such coatings.

Keywords: thermal spray process, HVOF, ceramic coating, hardness, wear, corrosion

Procedia PDF Downloads 94

Authors: L. Bazzi, E. Azzouyahar, A. Lamiri, M. Essahli

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Effect of addition of linseed oil (LSO) on the corrosion of aluminium in 0.1 M Na2CO3 has been studied by weight loss measurements, potentiodynamic polarization and Electrochemical Impedance Spectroscopy (EIS) measurements. The inhibition efficiency was found to increase with inhibitor content to attain 70% for LSO at 4g/L. Inhibition efficiency E (%) obtained from the various methods is in good agreement. The temperature effect on the corrosion behavior of aluminium was studied by potentiodynamic technique in the range from 298 to 308 K.

Keywords: aluminum, corrosion, green inhibitors, carbonate, linseed oil

Procedia PDF Downloads 360

Authors: Sheng-Che Chen, Keng-Ren Lin, Che-Hsin Lin, Hao-Yuan Tseng, Chih-Han Chang

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Teeth play an important role in providing the essential nutrients. The force loading of chewing on the crow is important condition to evaluate long-term success of many dental treatments. However, the quantification of the force regarding forces are distributed over the dental crow is still not well recognized. This study presents an industrial-grade piezoelectric-based multilayer ceramic capacitors (MLCCs) force sensor for measuring the distribution of the force distribute over the first molar. The developed sensor array is based on a flexible polyimide electrode and barium titanate-based MLCCs. MLCCs are commonly used in the electronic industry and it is a typical electric component composed of BaTiO₃, which is used as a capacitive material. The most important is that it also can be used as a force-sensing component by its piezoelectric property. In this study, to increase the sensitivity as well as to reduce the variation of different MLCCs, a treatment process is utilized. The MLCC force sensors are able to measure large forces (above 500 N), making them suitable for measuring the bite forces on the tooth crown. Moreover, the sensors also show good force response and good repeatability.

Keywords: force sensor array, multilayer ceramic capacitors, occlusal force, piezoelectric

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Authors: H. Erbiyik, A. Bal, M. Sirakaya, Ö. Yesildal, E. Yolcu

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The emergence of many environmental issues began with the Industrial Revolution. The depletion of natural resources and emerging environmental challenges over time requires enterprises and managers to take into consideration environmental factors while managing business. If we take notice of these causes; the design and implementation of environmentally friendly green purchasing, production and waste management systems become very important at green logistics systems. Companies can adopt green supply chain with the awareness of these facts. The concept of green supply chain constitutes from green purchasing, green production, green logistics, waste management and reverse logistics. In this study, we wanted to identify the concept of green supply chain and why green supply chain should be applied. In the practice part of the study an analytic hierarchy process (AHP) study is conducted on an aluminum production company to evaluate suppliers.

Keywords: aluminum sector, analytic hierarchy process, decision making, green logistics

Procedia PDF Downloads 354

Authors: Arnold S. Freitas Neto, Rodrigo E. Coelho, Erick S. Mendonça

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The study aims to assess if high-purity iron powder in iron-aluminum alloys can be replaced by SAE 1020 steel chips with an atomicity proportion of 50% for each element. Chips of SAE 1020 are rejected in industrial processes. Thus, the use of SAE 1020 as a replaceable composite for iron increase the sustainability of ferrous alloys by recycling industrial waste. The alloys were processed by high energy milling, of which the main advantage is the minimal loss of raw material. The raw material for three of the six samples were high purity iron powder and recyclable aluminum cans. For the other three samples, the high purity iron powder has been replaced with chips of SAE 1020 steel. The process started with the separate milling of chips of aluminum and SAE 1020 steel to obtain the powder. Subsequently, the raw material was mixed in the pre-defined proportions, milled together for five hours and then underwent a closed-die hot compaction at the temperature of 500 °C. Thereafter, the compacted samples underwent heat treatments known as sintering and solubilization. All samples were sintered one hour, and 4 samples were solubilized for either 4 or 10 hours under well-controlled atmosphere conditions. Lastly, the composition and the mechanical properties of their hardness were analyzed. The samples were analyzed by optical microscopy, scanning electron microscopy and hardness testing. The results of the analysis showed a similar chemical composition and interesting hardness levels with low standard deviations. This verified that the use of SAE 1020 steel chips can be a low-cost alternative for high-purity iron powder and could possibly replace high-purity Iron in industrial applications.

Keywords: Fe-Al alloys, high energy milling, iron-aluminum alloys, metallography characterization, powder metallurgy, recycling ferrous alloy, SAE 1020 steel recycling

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Authors: Benchalak Muangmeesri

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The purpose of this paper is to discuss how to test the best control performance of a ceramics. Hydraulic press machine (HPM) is the most common shaping of advanced ceramic with products, dimensions, and ceramic products mainly from synthetic powders. A microcontroller can be achieved to control process and has set high standards in the shaping of raw materials in powder form. HPM was proposed to develop a position control system that linked to the embedded controller PIC16F877 via Proportional and Derivative (PD) controller. The model is performed using MATLAB/SIMULINK and the best control performance of an HPM. Finally, PD controller results, showing the best performance as it had the smallest overshoot and highest quality using a microcontroller control.

Keywords: ceramics, hydraulic press, microcontroller, PD controller

Procedia PDF Downloads 356

Authors: Ankit Khurana

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The sufficient heat storage capacity or ability to dissipate heat is the most decisive parameter to have an effective and efficient functioning of Friction-based Brake Disc systems. The primary aim of the research was to analyse the effect of multiple coatings on lightweight disk rotors surface which not only alleviates the mass of vehicle & also, augments heat transfer. This research is projected to aid the automobile fraternity with an enunciated view over the thermal aspects in a braking system. The results of the project indicate that with the advent of modern coating technologies a brake system’s thermal curtailments can be removed and together with forced convection, heat transfer processes can see a drastic improvement leading to increased lifetime of the brake rotor. Other advantages of modifying the surface of a lightweight rotor substrate will be to reduce the overall weight of the vehicle, decrease the risk of thermal brake failure (brake fade and fluid vaporization), longer component life, as well as lower noise and vibration characteristics. A mathematical model was constructed in MATLAB which encompassing the various thermal characteristics of the proposed coatings and substrate materials required to approximate the heat flux values in a free and forced convection environment; resembling to a real-time braking phenomenon which could easily be modelled into a full cum scaled version of the alloy brake rotor part in ABAQUS. The finite element of a brake rotor was modelled in a constrained environment such that the nodal temperature between the contact surfaces of the coatings and substrate (Wrought Aluminum alloy) resemble an amalgamated solid brake rotor element. The initial results obtained were for a Plasma Electrolytic Oxidized (PEO) substrate wherein the Aluminum alloy gets a hard ceramic oxide layer grown on its transitional phase. The rotor was modelled and then evaluated in real-time for a constant ‘g’ braking event (based upon the mathematical heat flux input and convective surroundings), which reflected the necessity to deposit a conducting coat (sacrificial) above the PEO layer in order to inhibit thermal degradation of the barrier coating prematurely. Taguchi study was then used to bring out certain critical factors which may influence the maximum operating temperature of a multi-coated brake disc by simulating brake tests: a) an Alpine descent lasting 50 seconds; b) an Autobahn stop lasting 3.53 seconds; c) a Six–high speed repeated stop in accordance to FMVSS 135 lasting 46.25 seconds. Thermal Barrier coating thickness and Vane heat transfer coefficient were the two most influential factors and owing to their design and manufacturing constraints a final optimized model was obtained which survived the 6-high speed stop test as per the FMVSS -135 specifications. The simulation data highlighted the merits for preferring Wrought Aluminum alloy 7068 over Grey Cast Iron and Aluminum Metal Matrix Composite in coherence with the multiple coating depositions.

Keywords: lightweight brakes, surface modification, simulated braking, PEO, aluminum

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Authors: Siming Wang, Qing Ni, Yu Wu, Ruihai Xu, Hong Ye

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Porous electric heaters, compared to conventional electric heaters, exhibit excellent heating performance due to their large specific surface area. Porous electric heaters employ porous metallic materials or conductive porous ceramics as the heating element. The former attains a low heating power with a fixed current due to the low electrical resistivity of metal. Although the latter can bypass the inherent challenges of porous metallic materials, the fabrication process of the conductive porous ceramics is complicated and high cost. This work proposed a porous ceramic electric heater with dielectric honeycomb ceramic as a substrate and surface conductive coating as a heating element. The conductive coating was prepared by the sol-gel method using silica sol and methyl trimethoxysilane as raw materials and graphite powder as conductive fillers. The conductive mechanism and degradation reason of the conductive coating was studied by electrical resistivity and thermal stability analysis. The heating performance of the proposed heater was experimentally investigated by heating air and deionized water. The results indicate that the electron transfer is achieved by forming the conductive network through the contact of the graphite flakes. With 30 wt% of graphite, the electrical resistivity of the conductive coating can be as low as 0.88 Ω∙cm. The conductive coating exhibits good electrical stability up to 500°C but degrades beyond 600°C due to the formation of many cracks in the coating caused by the weight loss and thermal expansion. The results also show that the working medium has a great influence on the volume power density of the heater. With air under natural convection as the working medium, the volume power density attains 640.85 kW/m3, which can be increased by 5 times when using deionized water as the working medium. The proposed honeycomb ceramic electric heater has the advantages of the simple fabrication method, low cost, and high volume power density, demonstrating great potential in the fluid heating field.

Keywords: conductive coating, honeycomb ceramic electric heater, high specific surface area, high volume power density

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Authors: Bentata Samir, Bendahma Fatima

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We have numerically studied the random trimer barrier AlxGa1-xAs superlattices (RTBSL). Such systems consist of two different structures randomly distributed along the growth direction, with the additional constraint that the barriers of one kind appear in triply. An explicit formula is given for evaluating the transmission coefficient of superlattices (SL's) in intentional correlated disorder. We have specially investigated the effect of aluminum concentration on the laser wavelength. We discuss the impact of the aluminum concentration associated with the structure profile on the laser wavelengths.

Keywords: superlattices, transfer matrix method, transmission coefficient, quantum laser

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Authors: F. Pedron, M. Grifoni, G. Petruzzelli, M. Barbafieri, I. Rosellini, B. Pezzarossa

Abstract:

Lead contamination of agricultural land mainly vegetated with perennial ryegrass (Lolium perenne) has been investigated. The metal derived from the discharge of sludge from a ceramic industry in the past had used lead paints. The results showed very high values of lead concentration in many soil samples. In order to assess the lead soil contamination, a sequential extraction with H₂O, KNO₃, EDTA was performed, and the chemical forms of lead in the soil were evaluated. More than 70% of lead was in a potentially bioavailable form. Analysis of Lolium perenne showed elevated lead concentration. A Freundlich-like model was used to describe the transferability of the metal from the soil to the plant.

Keywords: bioavailability, Freundlich-like equation, sequential extraction, soil lead contamination

Procedia PDF Downloads 310

Authors: Shadatul Hanom Rashid, Xiaorong Zhou

Abstract:

Hybrid sol-gel coatings are the blend of both advantages of inorganic and organic networks have been reported as environmentally friendly anti-corrosion surface pre-treatment for several metals, including aluminum alloys. In this current study, Si-Zr hybrid sol-gel coatings were synthesized from (3-glycidoxypropyl)trimethoxysilane (GPTMS), tetraethyl orthosilicate (TEOS) and zirconium(IV) propoxide (TPOZ) precursors and applied on AA6111 aluminum alloy by dip coating technique. The hybrid sol-gel coatings doped with different concentrations of cerium nitrate (Ce(NO3)3) as a corrosion inhibitor were also prepared and the effect of Ce(NO3)3 concentrations on the morphology and corrosion resistance of the coatings were examined. The surface chemistry and morphology of the hybrid sol-gel coatings were analyzed by Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM). The corrosion behavior of the coated aluminum alloy samples was evaluated by electrochemical impedance spectroscopy (EIS). Results revealed that good corrosion resistance of hybrid sol-gel coatings were prepared from hydrolysis and condensation reactions of GPTMS, TEOS and TPOZ precursors deposited on AA6111 aluminum alloy. When the coating doped with cerium nitrate, the properties were improved significantly. The hybrid sol-gel coatings containing lower concentration of cerium nitrate offer the best inhibition performance. A proper doping concentration of Ce(NO3)3 can effectively improve the corrosion resistance of the alloy, while an excessive concentration of Ce(NO3)3 would reduce the corrosion protection properties, which is associated with defective morphology and instability of the sol-gel coatings.

Keywords: AA6111, Ce(NO3)3, corrosion, hybrid sol-gel coatings

Procedia PDF Downloads 158

Authors: A. Yönetken, A. Erol, A. Yakar, G. Peşmen

Abstract:

The microstructure, mechanical properties and metalgraphic characteristics of Ni plated AlN-Astaloy Cr-M powders were investigated using specimens produced by tube furnace sintering at 1000-1400 °C temperature. A uniform nickel layer on AlN powders was deposited prior to sintering using electroless plating technique. A composite consisting of ternary additions, metallic phase, Ni and ceramic phase AlN within a matrix of Astaloy Cr-M had been prepared under Ar shroud and then tube furnace sintered. The experimental results carried out by using XRD (X-Ray Diffraction) and SEM (Scanning Electron Microscope) for composition (10% AlN-Astaloy Cr-M) 10% Ni at 1400 °C suggest that the best properties as 132.45HB and permittivity were obtained at 1400 °C.

Keywords: composite, electroless nickel plating, powder metallurgy, sintering

Procedia PDF Downloads 277

Authors: S. M. Mabandla, P. Loveday, C. Gomes, D. T. Maiga, T. T. Phadi

Abstract:

Lead zirconate titanate (PZT) piezoelectric ceramics are widely used in ultrasonic applications due to their ability to effectively convert electrical energy into mechanical vibrations and vice versa. This paper presents a study on the behaviour of various combinations of pairs of PZT piezoelectric ceramic materials positioned adjacent to each other with an intermediate gap submerged in water, where one piezoelectric ceramic material is excited by a cyclic electric field with constant frequency and amplitude displacement. The transmitted ultrasonic sound propagates through the medium and is received by the PZT ceramic at the other end, the ultrasonic sound signal amplitude displacement experiences attenuation during propagation due to acoustic impedance. The investigation focuses on understanding the causes of extremely high amplitude displacement attenuation that have been observed in various combinations of piezoelectric ceramic pairs that are submerged in water arranged in a manner stipulated earlier. by examining various combinations of pairs of these piezoelectric ceramics, their physical, electrical, and acoustic properties, and behaviour and attributing them to the observed significant signal attenuation. The experimental setup involves exciting one piezoelectric ceramic material at one end with a burst square cyclic electric field signal of constant frequency, which generates a burst of ultrasonic sound that propagates through the water medium to the adjacent piezoelectric ceramic at the other end. Mechanical vibrations of a PZT piezoelectric ceramic are measured using a double-beam laser Doppler vibrometer to mimic the incident ultrasonic waves generated and received ultrasonic waves on the other end due to mechanical vibrations of a PZT. The measured ultrasonic sound wave signals are continuously compared to the applied cyclic electric field at both ends. The impedance matching networks are continuously tuned at both ends to eliminate electromechanical impedance mismatch to improve ultrasonic transmission and reception. The study delves into various physical, electrical, and acoustic properties of the PZT piezoelectric ceramics, such as the electromechanical coupling factor, acoustic coupling, and elasticity, among others. These properties are analyzed to identify potential factors contributing to the unusually high acoustic impedance in the water medium between the ceramics. Additionally, impedance-matching networks are investigated at both ends to offset the high signal attenuation and improve overall system performance. The findings will be reported in this paper.

Keywords: acoustic impedance, impedance mismatch, piezoelectric ceramics, ultrasonic sound

Procedia PDF Downloads 78