Search results for: aluminum alloys

Authors: Daniel Osorio, Andreas Klenk, Stefan Weihe, Andreas Kopp, Frank Rödiger

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Future power plants currently face high design requirements due to worsening climate change and environmental restrictions, which demand high operational flexibility, superior thermal performance, minimal emissions, and higher cyclic capability. The aim of the paper is, therefore, to investigate the creep and thermo-mechanical material behavior of improved materials experimentally and welded joints at component scale under near-to-service operating conditions, which are promising for application in highly efficient and flexible future power plants. These materials promise an increase in flexibility and a reduction in manufacturing costs by providing enhanced creep strength and, therefore, the possibility for wall thickness reduction. At the temperature range between 550°C and 625°C, the investigation focuses on the in-phase thermo-mechanical fatigue behavior of dissimilar welded joints of conventional materials (ferritic and martensitic material T24 and T92) to nickel-based alloys (A617B and HR6W) by means of membrane test panels. The temperature and external load are varied in phase during the test, while the internal pressure remains constant. At the temperature range between 650°C and 750°C, it focuses on the creep behavior under multiaxial stress loading of similar and dissimilar welded joints of high temperature resistant nickel-based alloys (A740H, A617B, and HR6W) by means of a thick-walled-component test. In this case, the temperature, the external axial load, and the internal pressure remain constant during testing. Numerical simulations are used for the estimation of the axial component load in order to induce a meaningful damage evolution without causing a total component failure. Metallographic investigations after testing will provide support for understanding the damage mechanism and the influence of the thermo-mechanical load and multiaxiality on the microstructure change and on the creep and TMF- strength.

Keywords: creep, creep-fatigue, component behaviour, weld joints, high temperature material behaviour, nickel-alloys, high temperature resistant steels

Procedia PDF Downloads 119

Authors: Yaseri Dahlia Apritasari

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Visual comfort is important for the building occupants to need. Visual comfort can be fulfilled through natural lighting (daylighting) and artificial lighting. One strategy to optimize natural lighting can be achieved through the facade second skin design. This strategy can reduce glare, and fulfill visual comfort need. However, the design strategy cannot achieve light intensity for visual comfort. Because the materials, design and opening percentage of the facade of second skin blocked sunlight. This paper discusses aluminum material for the facade second skin design that can fulfill the optimal visual comfort with the case studies Multi Media Tower building. The methodology of the research is combination quantitative and qualitative through field study observed, lighting measurement and visual comfort questionnaire. Then it used too simulation modeling (DIALUX 4.13, 2016) for three facades second skin design model. Through following steps; (1) Measuring visual comfort factor: light intensity indoor and outdoor; (2) Taking visual comfort data from building occupants; (3) Making models with different facade second skin design; (3) Simulating and analyzing the light intensity value for each models that meet occupants visual comfort standard: 350 lux (Indonesia National Standard, 2010). The result shows that optimization of aluminum material for the facade second skin design can meet optimal visual comfort for building occupants. The result can give recommendation aluminum opening percentage of the facade second skin can meet optimal visual comfort for building occupants.

Keywords: aluminium material, Facade, second skin, visual comfort

Procedia PDF Downloads 352

Authors: Li Li, Lei Wang, Chenglin Du, Mengxin Ren, Xinzheng Zhang, Wei Cai, Jingjun Xu

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Strong coupling between excitons of quantum dots and plasmons in nanocavites can be realized at room temperature due to the strong confinement of the plasmon fields, which offers building blocks for quantum information systems or ultralow-power switches and lasers. In this work, by using cathodoluminescence, ultrastrong coupling with Rabi splitting above 1 eV between breathing plasmons in Aluminum metal-insulator-metal (MIM) cavity and excited state of CdZnS/ZnS quantum dots was reported in near-UV spectrum. Analytic analysis and full-wave electromagnetic simulations provide the evidence for the strong coupling and confirm the hybridization of the QDs exciton and LSP breathing mode. This study opens the way for new emerging applications based on strongly coupled light-matter states all over the visible region down to ultra-violet frequencies.

Keywords: breathing mode, plasmonics, quantum dot, strong coupling, ultraviolet

Procedia PDF Downloads 199

Authors: Malik Imran Afzal

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Cadmium supplied nanowires have unique electrical and optical properties and applications. To obtain cadmium supplied nanowires with regular and good aspect ratio, they can be synthesized by template synthesis method. Porous anodized aluminum oxide is the most promising template with regular hexagonal shapes. Their aspect ratio can be controlled by controlling the pores’ depth and diameter which greatly depend on anodization voltage and temperature of the electrolyte. In this research, high purity aluminium was used to prepare nanotemplates at 5-6°C in 1M phosphoric acid and cadmium supplied was deposited electrochemically using a co-solution of thiourea, cadmium acetate and ammonium acetate. pH was maintained at 11 in a heat bath at 75°C with the help of aqueous ammonia solution. Both porous anodized alumina and cadmium supplied nanowires were characterized suing SEM. A good quality Nanowires were obtained in bunches with reasonably high aspect ratio.

Keywords: bunches, electrodeposition, hexagonal, thiourea

Procedia PDF Downloads 328

Authors: Yebeen Ji, Jimin Yun, Kwonhoo Kim

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Magnesium alloys were limited for industrial applications due to having a limited slip system and high plastic anisotropy. It has been known that specific textures were formed during processing (rolling, etc.), and These textures cause poor formability. To solve these problems, many researchers have studied controlling texture by adding rare-earth elements. However, the high cost limits their use; therefore, alternatives are needed to replace them. Although Pb addition doesn’t directly improve magnesium properties, it has been known to suppress the diffusion of other alloying elements and reduce grain boundary energy. These characteristics are similar to the additions of rare-earth elements, and a similar texture behavior is expected as well. However, there is insufficient research on this. Therefore, this study investigates the behavior of texture and microstructure development after adding Pb to magnesium. This study compared and analyzed AZ61 alloy and Mg-15wt%Pb alloy to determine the effect of adding solute elements. The alloy was hot rolled and annealed to form a single phase and initial texture. Afterward, the specimen was set to contraction and elongate parallel to the rolling surface and the rolling direction and then subjected to high-temperature plane strain compression under the conditions of 723K and 0.05/s. Microstructural analysis and texture measurements were performed by SEM-EBSD. The peak stress in the true strain-stress curve after compression was higher in AZ61, but the shape of the flow curve was similar for both alloys. For both alloys, continuous dynamic recrystallization was confirmed to occur during the compression process. The basal texture developed parallel to the compressed surface, and the pole density was lower in the Mg-15wt%Pb alloy. It is confirmed that this change in behavior is because the orientation distribution of recrystallized grains has a more random orientation compared to the parent grains when Pb is added.

Keywords: Mg, texture, Pb, DRX

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Authors: Emilia Olivos, R. Arroyave, A. Vargas-Calderon, J. E. Dominguez-Herrera

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More efficient cooling systems are needed to reduce building energy consumption and environmental impact. At present researchers focus mainly on environmentally-friendly magnetic materials and the potential application in cooling devices. The magnetic materials presented in this project belong to a group known as Heusler alloys. These compounds are characterized by a strong coupling between their structure and magnetic properties. Usually, a change in one of them can alter the other, which implies changes in other electronic or structural properties, such as, shape magnetic memory response or the magnetocaloric effect. Those properties and its dependence with external fields make these materials interesting, both from a fundamental point of view, as well as on their different possible applications. In this work, first principles and Monte Carlo simulations have been used to calculate exchange couplings and magnetic properties as a function of an applied magnetic field on Heusler alloys. As a result, we found a large dependence of the magnetic susceptibility, entropy and heat capacity, indicating that the magnetic field can be used in experiments to trigger particular magnetic properties in materials, which are necessary to develop solid-state refrigeration devices.

Keywords: ferromagnetic materials, magnetocaloric effect, materials design, solid state refrigeration

Procedia PDF Downloads 215

Authors: F. Ghasim-akbari, A. M. Hadian, A. M. Aminazad

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Fluid transmission pipes made of aluminum are widely use in petrochemical industries. For many applications they have to be brazed to each other. The brazed joints, in many cases, are encountered with corrosive medias. This paper reports a part of a work to investigate the corrosion behavior of brazed Al6061 using Al4047 as filler metal with and without the use of flux to discover the effect of different brazing atmospheres. The samples brazed under air, vacuum, argon, and hydrogen atmospheres. The interfacial area of the joints was examined to ensure being free of any defects. The sides of each test piece were covered with insulator and the surface of the joint was encountered to polarization test. The results revealed a significant difference of corrosion resistance. The samples that brazed under argon and hydrogen atmospheres had better corrosion resistance than other samples. Microstructure of the corroded joints revealed that the amount of the filler metal is a critical parameter on corrosion resistance of the joints.

Keywords: brazing, corrosion behavior, Al6061, polarization

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Authors: Dunwen Zuo, Yongfang Deng, Bo Song

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An attempt is made here to measure the forces of three directions, under conditions of different feed speeds, different tilt angles of tool and without or with the pin on the tool, by using octagonal ring dynamometer in the AA2024 aluminum FSJ (Friction Stir Joining) process, and investigate how four main factors influence forces in the FSJ process. It is found that, high feed speed lead to small feed force and small lateral force, but high feed speed leads to large feed force in the stable joining stage of process. As the rotational speed increasing, the time of axial force drop from the maximum to the minimum required increased in the push-up process. In the stable joining stage, the rotational speed has little effect on the feed force; large rotational speed leads to small lateral force and axial force. The maximum axial force increases as the tilt angle of tool increases at the downward movement stage. At the moment of start feeding, as tilt angle of tool increases, the amplitudes of the axial force increasing become large. In the stable joining stage, with the increase of tilt angle of tool, the axial force is increased, the lateral force is decreased, and the feed force almost unchanged. The tool with pin will decrease axial force in the downward movement stage. The feed force and lateral force will increase, but the axial force will reduced in the stable joining stage by using the tool with pin compare to by using the tool without pin.

Keywords: FSJ, force factor, AA2024 aluminum, friction stir joining

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Authors: Nidal Dwaikat

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This work presents the development of alpha spectroscopy method with Solid-state nuclear track detectors using aluminum thin films. The resolution of this method is high, and it is able to discriminate between alpha particles at different incident energy. It can measure the exact number of alpha particles at specific energy without needing a calibration of alpha track diameter versus alpha energy. This method was tested by using Cf-252 alpha standard source at energies 5.11 Mev, 3.86 MeV and 2.7 MeV, which produced by the variation of detector -standard source distance. On front side, two detectors were covered with two Aluminum thin films and the third detector was kept uncovered. The thickness of Aluminum thin films was selected carefully (using SRIM 2013) such that one of the films will block the lower two alpha particles (3.86 MeV and 2.7 MeV) and the alpha particles at higher energy (5.11 Mev) can penetrate the film and reach the detector’s surface. The second thin film will block alpha particles at lower energy of 2.7 MeV and allow alpha particles at higher two energies (5.11 Mev and 3.86 MeV) to penetrate and produce tracks. For uncovered detector, alpha particles at three different energies can produce tracks on it. For quality assurance and accuracy, the detectors were mounted on thick enough copper substrates to block exposure from the backside. The tracks on the first detector are due to alpha particles at energy of 5.11 MeV. The difference between the tracks number on the first detector and the tracks number on the second detector is due to alpha particles at energy of 3.8 MeV. Finally, by subtracting the tracks number on the second detector from the tracks number on the third detector (uncovered), we can find the tracks number due to alpha particles at energy 2.7 MeV. After knowing the efficiency calibration factor, we can exactly calculate the activity of standard source.

Keywords: aluminium thin film, alpha particles, copper substrate, CR-39 detector

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Authors: Jeong-Hyun Yoo, Hanjung Kwon, Sung-Wook Cho

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Fused salt electrolysis was studied to make the high purity rare-earth metals using domestic rare-earth ore. The target metals of the fused salt electrolysis were Mm (Misch metal), La, Ce, Nd, etc. Fused salt electrolysis was performed with the supporting salt such as chloride and fluoride at the various temperatures and ampere. The metals made by fused salt electrolysis were analyzed to identify the phase and composition using the methods of XRD and ICP. As a result, the acquired rare-earth metals were the high purity ones which had more than 99% purity. Also, VIM (vacuum induction melting) was studied to make the kg level rare-earth alloy for the use of secondary battery and hydrogen storage. In order to indentify the physicochemical properties such as phase, impurity gas, alloy composition and hydrogen storage, the alloys were investigated. The battery characteristics were also analyzed through the various tests in the real production line of a battery company.

Keywords: domestic rare-earth ore, fused salt electrolysis, rare-earth materials, hydrogen storage alloy, secondary battery

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Authors: G. K. S. Prakash, Rao K. Srinivasa

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MEMS plays an important role in wide range of applications like biological, automobiles, military and communication engineering. This paper mainly investigates on capacitive shunt RF MEMS switch with low actuation voltage and low insertion losses. To trim the pull-in voltage, a step structure has introduced to trim air gap between the beam and the dielectric layer with that pull in voltage is trim to 2.9 V. The switching time of the proposed switch is 39.1μs, and capacitance ratio is 67. To get more isolation, we have used aluminum nitride as dielectric material instead of silicon nitride (Si₃N₄) and silicon dioxide (SiO₂) because aluminum nitride has high dielectric constant (εᵣ = 9.5) increases the OFF capacitance and eventually increases the isolation of the switch. The results show that the switch is ON state involves return loss (S₁₁) less than -25 dB up to 40 GHz and insertion loss (S₂₁) is more than -1 dB up to 35 GHz. In OFF state switch shows maximum isolation (S₂₁) of -38 dB occurs at a frequency of 25-27 GHz for K band applications.

Keywords: RF MEMS, actuation voltage, isolation loss, switches

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Authors: Jing Ning, Kunyuan Gao

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The microstructure and phase structure of Al-Er alloys with Er content of 10, 20, 30wt% at cooling rate of 60, 40 and 5℃/h were analyzed using scanning electron microscope (SEM) and X-ray diffraction (XRD). Experimental results showed that for solidification of the hypereutectic Al-Er alloys at different conditions, a halo of α-Al appeared around the primary Al₃Er phase. Analysis of the solidification process indicated that after the primary Al₃Er phase formed, the composition of supercooled liquid phase located outside the coupled zone of eutectic growth below the eutectic line, which leaded to the formation of Al halo. With the increase of Er content, the blocky primary Al₃Er phase expanded from 200μm to 1mm in size. With the decrease of cooling rate, the morphology and phase structure of alloy were different. At the cooling rate of 60℃/h, it was obtained the primary Al3Er phase with L1₂ structure, whose profile was straight. Meanwhile, the eutectic structure was flocculent. At the quite slow cooling rate of 5℃/h, it was obtained the primary Al₃Er phase with hR20 structure with irregular jagged profile, and the eutectic structure was approximately strip-shaped. These characteristics were closely related to the cooling rate of solidification. The XRD analysis showed that for Al₃Er phase, the lattice constant a of L1₂ structure was 4.2158Å, and a, c of hR20 structure were 6.0321Å and 35.6290Å, respectively.

Keywords: Al-Er alloy, composition, cooling rate, microstructure

Procedia PDF Downloads 108

Authors: A. B. Chehreh, M. Grätzel, M. Klein, J. P. Bergmann, F. Walther

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Friction stir welding (FSW) is an advantageous method in the thermal joining processes, featuring the welding of various dissimilar and similar material combinations, joining temperatures below the melting point which prevents irregularities such as pores and hot cracks as well as high strengths mechanical joints near the base material. The FSW process consists of a rotating tool which is made of a shoulder and a probe. The welding process is based on a rotating tool which plunges in the workpiece under axial pressure. As a result, the material is plasticized by frictional heat which leads to a decrease in the flow stress. During the welding procedure, the material is continuously displaced by the tool, creating a firmly bonded weld seam behind the tool. However, the mechanical properties of the weld seam are affected by the design and geometry of the tool. These include in particular microstructural and surface properties which can favor crack initiation. Following investigation compares the dynamic properties of FSW weld seams with conventional and stationary shoulder geometry based on load increase test (LIT). Compared to classical Woehler tests, it is possible to determine the fatigue strength of the specimens after a short amount of time. The investigations were carried out on a robotized welding setup on 2 mm thick EN AW 5754 aluminum alloy sheets. It was shown that an increased tensile and fatigue strength can be achieved by using the stationary shoulder concept. Furthermore, it could be demonstrated that the LIT is a valid method to describe the fatigue behavior of FSW weld seams.

Keywords: aluminum alloy, fatigue performance, fracture, friction stir welding

Procedia PDF Downloads 153

Authors: Emre Kara, Ahmet Fatih Geylan, Kadir Koç, Şura Karakuzu, Metehan Demir, Halil Aykul

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The structures obtained with the use of sandwich technologies combine low weight with high energy absorbing capacity and load carrying capacity. Hence, there is a growing and markedly interest in the use of sandwiches with aluminium foam core because of very good properties such as flexural rigidity and energy absorption capability. The static (bending and penetration) and dynamic (dynamic bending and low velocity impact) tests were already performed on the aluminum foam cored sandwiches with different types of outer skins by some of the authors. In the current investigation, the static three-point bending tests were carried out on the sandwiches with aluminum foam core and glass fiber reinforced polymer (GFRP) skins at different values of support span distances (L= 55, 70, 80, 125 mm) aiming the analyses of their flexural performance. The influence of the core thickness and the GFRP skin type was reported in terms of peak load, energy absorption capacity and energy efficiency. For this purpose, the skins with two different types of fabrics ([0°/90°] cross ply E-Glass Woven and [0°/90°] cross ply S-Glass Woven which have same thickness value of 1.5 mm) and the aluminum foam core with two different thicknesses (h=10 and 15 mm) were bonded with a commercial polyurethane based flexible adhesive in order to combine the composite sandwich panels. The GFRP skins fabricated via Vacuum Assisted Resin Transfer Molding (VARTM) technique used in the study can be easily bonded to the aluminum foam core and it is possible to configure the base materials (skin, adhesive and core), fiber angle orientation and number of layers for a specific application. The main results of the bending tests are: force-displacement curves, peak force values, absorbed energy, energy efficiency, collapse mechanisms and the effect of the support span length and core thickness. The results of the experimental study showed that the sandwich with the skins made of S-Glass Woven fabrics and with the thicker foam core presented higher mechanical values such as load carrying and energy absorption capacities. The increment of the support span distance generated the decrease of the mechanical values for each type of panels, as expected, because of the inverse proportion between the force and span length. The most common failure types of the sandwiches are debonding of the upper or lower skin and the core shear. The obtained results have particular importance for applications that require lightweight structures with a high capacity of energy dissipation, such as the transport industry (automotive, aerospace, shipbuilding and marine industry), where the problems of collision and crash have increased in the last years.

Keywords: aluminum foam, composite panel, flexure, transport application

Procedia PDF Downloads 338

Authors: Li Qian, Jinchao Tong, Daohua Zhang, Weijun Fan, Fei Suo

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Photonic applications based on group IV semiconductors have always been an interest but also a challenge for the research community. We report manufacturing group IV Ge₁₋ₓSnₓ alloys with tuneable energy band gap on (100) GaAs substrate by a modified radio frequency magnetron co-sputtering. Images were taken by atomic force microscope, and scanning electron microscope clearly demonstrates a smooth surface profile, and Ge₁₋ₓSnₓ nano clusters are with the size of several tens of nanometers. Transmittance spectra were measured by Fourier Transform Infrared Spectroscopy that showed changing energy gaps with the variation in elementary composition. Calculation results by 8-band k.p method are consistent with measured gaps. Our deposition system realized direct growth of Ge₁₋ₓSnₓ thin film on GaAs (100) substrate by sputtering. This simple deposition method was modified to be able to grow high-quality photonic materials with tuneable energy gaps. This work provides an alternative and successful method for fabricating Group IV photonic semiconductor materials.

Keywords: GeSn, crystal growth, sputtering, photonic

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Authors: Y. Benallou, K. Amara, O. Arbouche

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In this paper, we report a density functional study of the structural, electronic and elastic properties of the ordered phases of SrxPb1-xS ternary semiconductor alloys namely rocksalt compounds: PbS and SrS and the rocksalt-based compounds: SrPb3S4, SrPbS2, and Sr3PbS4. These First-principles calculations have been performed using the full potential linearized augmented plane wave method (FP-LAPW) within the Generalized Gradient Approximation developed by Perdew–Burke–Ernzerhor for solids (PBEsol). The calculated structural parameters like the lattice parameters, the bulk modulus B and their pressure derivative B' are in reasonable agreement with the available experimental and theoretical data. In addition, the elastic properties such as elastic constants (C11, C12, and C44), the shear modulus G, the Young modulus E, the Poisson’s ratio ν and the B/G ratio are also given. For the electronic properties calculations, the exchange and correlation effects were treated by the Tran-Blaha modified Becke-Johnson (TB-mBJ) potential to prevent the shortcoming of the underestimation of the energy gaps in both LDA and GGA approximations. The obtained results are compared to available experimental data and to other theoretical calculations.

Keywords: SrxPb1-xS, GGA-PBEsol+TB-MBJ, density functional, Perdew–Burke–Ernzerhor, FP-LAPW

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Authors: M. R. Aziz, W. Kuntjoro, N. V. David

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This paper presents the ballistic terminal study of the non-filled and water-filled aluminum tank. The objective was to determine the failure stages for both cases. The tank was impacted by fragment simulating projectile (FSP) with 260 m/s for non-filled and 972 m/s for water-filled. The aluminum tank was 3 mm thick, 150 mm wide and 750 mm long. The ends of the tank were closed with two polymethyl methacrylate (PMMA) windows. The test was conducted at the Science and Technology Research Institute for Defense (STRIDE) Batu Arang, Selangor, Malaysia. The results showed four main stages for non-filled tank, which were first contact between FSP and the tank, partially perforated, fully perforated with FSP and plug still intact and lastly fully perforated with FSP and plug separated. Meanwhile, for the water-filled tank, there were seven main stages, which were first contact between FSP and the tank, partial perforation, full perforation, drag phase, cavity phase, bounce wave event and the collapse of the cavity.

Keywords: fragment simulating projectile, high speed camera, tensile test, terminal ballistic

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Authors: Lingaraju Dumpala, Laxmi Mohan Kumar Chintada, Devadas Deepu, Pravin Kumar Yadav

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Friction stir welding is the new-fangled and cutting-edge technique in welding applications; it is widely used in the fields of transportation, aerospace, defense, etc. For thriving significant welding joints and properties of friction stir welded components, it is essential to carry out this advanced process in a prescribed systematic procedure. At this moment, Underwater Friction Stir Welding (UFSW) Process is the field of interest to do research work. In the continuous assessment, the study of UFSW process is to comprehend problems occurred in the past and the structure through which the mechanical properties of the welded joints can be value-added and contributes to conclude results an acceptable and resourceful joint. A meticulous criticism is given on how to modify the experimental setup from NFSW to UFSW. It can discern the influence of tool materials, feeds, spindle angle, load, rotational speeds and mechanical properties. By expending the DEFORM-3D simulation software, the achieved outcomes are validated.

Keywords: Underwater Friction Stir Welding(UFSW), Al alloys, mechanical properties, Normal Friction Stir Welding(NFSW)

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Authors: B. J. Babalola, M. B. Shongwe

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Spark Plasma Sintering technique is a novel processing method that produces limited grain growth and highly dense variety of materials; alloys, superalloys, and carbides just to mention a few. However, initial particle size and spark plasma sintering parameters are factors which influence the grain growth and mechanical properties of sintered materials. Ni-Cr alloys are regarded as the most promising alloys for aerospace turbine blades, owing to the fact that they meet the basic requirements of desirable mechanical strength at high temperatures and good resistance to oxidation. The conventional method of producing this alloy often results in excessive grain growth and porosity levels that are detrimental to its mechanical properties. The effect of sintering temperature was evaluated on the microstructure and mechanical properties of the nanostructured Ni-17Cr alloy. Nickel and chromium powder were milled using high energy ball milling independently for 30 hours, milling speed of 400 revs/min and ball to powder ratio (BPR) of 10:1. The milled powders were mixed in the composition of Nickel having 83 wt % and chromium, 17 wt %. This was sintered at varied temperatures from 800°C, 900°C, 1000°C, 1100°C and 1200°C. The structural characteristics such as porosity, grain size, fracture surface and hardness were analyzed by scan electron microscopy and X-ray diffraction, Archimedes densitometry, micro-hardness tester. The corresponding results indicated an increase in the densification and hardness property of the alloy as the temperature increases. The residual porosity of the alloy reduces with respect to the sintering temperature and in contrast, the grain size was enhanced. The study of the mechanical properties, including hardness, densification shows that optimum properties were obtained for the sintering temperature of 1100°C. The advantages of high sinterability of Ni-17Cr alloy using milled powders and microstructural details were discussed.

Keywords: densification, grain growth, milling, nanostructured materials, sintering temperature

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Authors: Armansyah, I. P. Almanar, M. Saiful Bahari Shaari, M. Shamil Jaffarullah

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Finite element approach have been used via three-dimensional models by using Altair Hyper Work, a commercially available software, to describe heat gradients along the welding zones (axially and coronaly) in Friction Stir Welding (FSW). Transient thermal finite element analyses are performed in AA 6061-T6 Aluminum Alloy to obtain temperature distribution in the welded aluminum plates during welding operation. Heat input from tool shoulder and tool pin are considered in the model. A moving heat source with a heat distribution simulating the heat generated by frictions between tool shoulder and work piece is used in the analysis. The developed model was then used to show the effect of various input parameters such as total rate of welding speed and rotational speed on temperature distribution in the work piece.

Keywords: Frictions Stir Welding (FSW), temperature distribution, Finite Element Method (FEM), altair hyperwork

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Authors: Mohammed A. Tashkandi, Jawdat A. Al-Jarrah, Masoud Ibrahim

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This paper investigates the shear strength of the joints produced by friction stir spot welding process (FSSW). FSSW parameters such as tool rotational speed, plunge depth, shoulder diameter of the welding tool and dwell time play the major role in determining the shear strength of the joints. The effect of these four parameters on FSSW process as well as the shear strength of the welded joints was studied via five levels of each parameter. Taguchi method was used to minimize the number of experiments required to determine the fracture load of the friction stir spot-welded joints by incorporating independently controllable FSSW parameters. Taguchi analysis was applied to optimize the FSSW parameters to attain the maximum shear strength of the spot weld for this type of aluminum alloy.

Keywords: Friction Stir Spot Welding, Al6061 alloy, Shear Strength, FSSW process parameters

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Authors: Muhammad Talal Asghar

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The lift-off technique of the photoresist for metal patterning in integrated circuit (IC) packaging has been widely utilized in the field of microelectromechanical systems and semiconductor component manufacturing. The main advantage lies in cost-saving, reduction in complexity, and maturity of the process. The selection of photoresist depends upon many factors such as cost, the thickness of the resist, comfortable and valuable parameters extraction. In the present study, an extremely cheap dry film photoresist E8015 of thickness 38-micrometer is processed for the first time for edge profiling, according to the author's best knowledge. Successful extraction of the helpful parameter range for resist processing is performed. An undercut angle of 66 to 73 degrees is realized by parameter variation like exposure energy and development time. Finally, 10-micrometer thick metallic multilayer aluminum nickel is lifted off on the plain silicon wafer. Possible applications lie in controlled self-propagating reactions within structured metallic multilayer that may be utilized for IC packaging in the future.

Keywords: lift-off, IC packaging, photoresist, multilayer

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Authors: Yu-Ting Wang, Yun-Hsiang Cheng, Chien-Cheng Lin, Kun-Lin Lin

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Using a transient liquid phase method, Al was successfully bonded with Al₂O₃, which deposited Ni, Cu, Ge, and Si at the surface of the Al₂O₃ substrate after annealing at the relatively low melting point of Al. No reaction interlayer existed at the interface of any Al/Al₂O₃ specimens. Al−Fe intermetallic compounds, such as Al₉Fe₂ and Al₃Fe, formed in the Al substrate because of the precipitation of Fe, which was an impurity of the Al foil, and the reaction with Al at the grain boundaries of Al during annealing processing. According to the evaluation results of mechanical and thermal properties, the Al/Al₂O₃ specimen deposited on the Ni film possessed the highest shear strength, thermal conductivity, and bonding area percentage, followed by the Cu, Ge, and Si films. The properties of the Al/Al₂O₃ specimens deposited with Ge and Si were relatively unsatisfactory, which could be because the deposited amorphous layers easily formed oxide, resulting in inferior adhesion between Al and Al₂O₃. Therefore, the optimal choice for use in high-power devices is Al/Al₂O₃, with the deposition of Ni film.

Keywords: direct-bonded aluminum, transient liquid phase, thermal conductivity, microstructures, shear strength

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Authors: Ploysai Ohama, Nattida Tumpat

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Natural dye extracted from Caesalpinia sappan Linn. was applied to a cotton fabric and silk yarn by dyeing process. The dyestuff component of Caesalpinia sappan Linn. was extracted using water and ethanol. Analytical studies such as UV–VIS spectrophotometry and gravimetric analysis were performed on the extracts. Brazilein, the major dyestuff component of Caesalpinia sappan Linn. was confirmed in both aqueous and ethanolic extracts by UV–VIS spectrum. The color of each dyed material was investigated in terms of the CIELAB (L*, a* and b*) and K/S values. Cotton fabric dyed without mordant had a shade of reddish-brown, while those post-mordanted with aluminum potassium sulfate, ferrous sulfate and copper sulfate produced a variety of wine red to dark purple color shades. Cotton fabric and silk yarn dyeing was studied using aluminum potassium sulfate as a mordant. The observed color strength was enhanced with increase in mordant concentration.

Keywords: natural dyes, plant materials, dyeing, mordant

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Authors: K. S. Ghosh, Sagnik Bose, Kapil Tripati

Abstract:

Potentiodynamic polarization studies carried out on AA2024 and AA2014 Al-Cu-Mg alloys of various tempers in 3.5 wt. % NaCl and in 3.5 wt. % NaCl + 1.0 % H2O2 solution characteristic E-i curves. Corrosion potential (Ecorr) value has shifted towards more negative potential with the increase of artificial aging time. The Ecorr value for the alloy tempers has also shifted anodically in presence of H2O2 in 3.5 % NaCl solution. Further, passivity phenomenon has been observed in all the alloy tempers when tested in 3.5 wt. % NaCl solution at pH 12. Stress corrosion cracking (SCC) behaviour of friction stir weld (FSW) joint of AA2014 alloy has been studied bu slow strain rate test (SSRT) in 3.5 wt. % NaCl solution. Optical micrographs of the corroded surfaces of polarised samples showed general corrosion, extensive pitting and intergranular corrosion as well. Further, potentiodynamic cyclic polarization curves displayed wide hysteresis loop indicating that the alloy tempers are susceptible to pit growth damage. Attempts have been made to explain the variation of observed electrochemical and SCC behaviour of the alloy tempers and the electrolyte conditions with the help of microstructural features.

Keywords: AA 2014 and AA 2024 Al-C-Mg alloy, artificial ageing, potentiodynamic polarization, TEM micrographs, stress corrosion cracking (SCC)

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Authors: Chien Chon Chen, Chun Mei Chu, Chuan Ju Wang, Chih Yuan Chen, Ker Jer Huang

Abstract:

Cesiumiodide with Na doping (CsI(Na)) solution or melt is easily forming three- dimension dendrites on the free surface. The defects or bobbles form inside the CsI(Na) during the solution or melt solidification. The defects or bobbles can further effect the x-ray path in the CsI(Na) crystal and decrease the scintillation characteristics of CsI(Na). In order to enhance the CsI(Na) scintillated property we made single crystal of CsI(Na) column in the anodic aluminum oxide (AAO) template by hydraulic pressure injection method. It is interesting that when CsI(Na) melt is confined in the small AAO channels, the column grow as stable single column without any dendrites. The high aspect ratio (100~10000) of AAO and nano to sub-micron channel structure which is a suitable template for single of crystal CsI(Na) formation. In this work, a new low-cost approach to fabricate scintillator crystals using anodic aluminum oxide (AAO) rather than Si is reported, which can produce scintillator crystals with a wide range of controllable size to optimize their performance in X-ray detection.

Keywords: cesiumiodide, AAO, scintillator, crystal, X-ray

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Authors: A. Yazdanmehr, H. Jahed

Abstract:

Being made with the lightest commercially available industrial metal, Magnesium (Mg) alloys are of interest for light-weighting. Expanding their application to different material processing methods requires Mg properties at large strains. Several room-temperature processes such as shot and laser peening and hole cold expansion need compressive large strain data. Two methods have been proposed in the literature to obtain the stress-strain curve at high strains: 1) anti-buckling guides and 2) small cubic samples. In this paper, an anti-buckling fixture is used with the help of digital image correlation (DIC) to obtain the compression-tension (C-T) of AZ31B-H24 rolled sheet at large strain values of up to 10.5%. The effect of the anti-bucking fixture on stress-strain curves is evaluated experimentally by comparing the results with those of the compression tests of cubic samples. For testing cubic samples, a new fixture has been designed to increase the accuracy of testing cubic samples with DIC strain measurements. Results show a negligible effect of anti-buckling on stress-strain curves, specifically at high strain values.

Keywords: large strain, compression-tension, loading-unloading, Mg alloys

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Authors: Nauman A. Siddiqui

Abstract:

High performance requirement of aircrafts and marines industry demands to cater major industrial problems like wetting, high-speed efficiency, and corrosion resistance. These problems can be resolved by producing the hydrophobic surfaces on the metal substrate. By anodization process, the surface of AA 7075 has been modified and achieved a rough surface with a porous aluminum oxide (Al2O3) structure at nano-level. This surface modification process reduces the surface contact energy and increases the liquid contact angle which ultimately enhances the anti-icing properties. Later the Silane and Polyurethane (PU) coatings on the anodized surface have produced a contact angle of 130°. The results showed a good water repellency and self-cleaning properties. Using SEM analysis, micrographs revealed the round nano-porous oxide structure on the substrate. Therefore this technique can help in increasing the speed efficiency by reducing the friction with the outer interaction and can also be declared as a green technique since it is user-friendly.

Keywords: AA 7075, hydrophobicity, silanes, polyurethane, anodization

Procedia PDF Downloads 277

Authors: B. Käfer, V. K. Bheemineni, H. Lammer, M. Kotnik, F. O. Riemelmoser

Abstract:

Axial compression tests are performed on circular tubes made of Aluminum EN AW 6060 (AlMgSi0.5 alloy) in T66 state. All the received tubes have the uniform outer diameter of 40mm and thickness of 1.5mm. Two different lengths 100mm and 200mm are used in the analysis. After performing compression tests on the uniform tube, important crashworthy parameters like peak force, average force, crush efficiency and energy absorption are measured. The present paper has given importance to increase the percentage of crush efficiency without decreasing the value energy absorption of a tube, so a circumferential notch was introduced on the top section of the tube. The effects of position and cut-out lengths of a circumferential notch on the crush efficiency are well explained with relative deformation modes and force-displacement curves. The numerical simulations were carried on the software tool ANSYS/LS-DYNA. It is seen that the numerical results are reasonably good in agreement with the experimental results. 

Keywords: crash box, Notch triggering, energy absorption, FEM simulation

Procedia PDF Downloads 459

Authors: M. Insiat Islam Rabby, M. Mahbubur Rahman, Eshanul Islam, A. K. M. Sadrul Islam

Abstract:

The numerical and simulative analysis of laminar heat exchange convection of aluminum oxide (Al₂O₃) - water nanofluid for the developed region through two parallel plates is presented in this present work. The second order single phase energy equation, mass and momentum equation are solved by using finite volume method with the ANSYS FLUENT 16 software. The distance between two parallel plates is 4 mm and length is 600 mm. Aluminum oxide (Al₂O₃) is used as nanoparticle and water is used as the base/working fluid for the investigation. At the time of simulation 1% to 5% volume concentrations of the Al₂O₃ nanoparticles are used for mixing with water to produce nanofluid and a wide range of interval of Reynolds number from 500 to 1100 at constant heat flux 500 W/m² at the channel wall has also been introduced. The result reveals that for increasing the Reynolds number the Nusselt number and heat transfer coefficient are increased linearly and friction factor decreased linearly in the developed region for both water and Al₂O₃-H₂O nanofluid. By increasing the volume fraction of Al₂O₃-H₂O nanofluid from 1% to 5% the value of Nusselt number increased rapidly from 0.7 to 7.32%, heat transfer coefficient increased 7.14% to 31.5% and friction factor increased very little from 0.1% to 4% for constant Reynolds number compared to pure water. At constant heat transfer coefficient 700 W/m2-K the pumping power advantages have been achieved 20% for 1% volume concentration and 62% for 3% volume concentration of nanofluid compared to pure water.

Keywords: convective heat transfer, pumping power, constant heat flux, nanofluid, nanoparticles, volume concentration, thermal conductivity

Procedia PDF Downloads 159