Search results for: cast condition

Authors: Manjinder Bajwa, Mahipal Singh, Manish Nagpal

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This research paper aims to propose a novel approach using ANOVA technique for the strategic investigation of process parameters and their effects on the mechanical properties of Aluminium alloy cast. The two process parameters considered here were permeability of sand and pouring temperature of aluminium alloy. ANOVA has been employed for the first time to determine the effects of these selected parameters on the impact strength of alloy. The experimental results show that this proposed technique has great potential for analyzing sand casting process. Using this approach we have determined the treatment mean square, response mean square and mean square of error as 8.54, 8.255 and 0.435 respectively. The research concluded that at the 5% level of significance, permeability of sand is the more significant parameter influencing the impact strength of cast alloy.

Keywords: aluminium alloy, pouring temperature, permeability of sand, impact strength, ANOVA

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Authors: Ayoola T. Brimmo, Mohamed I. Hassan

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The push to mitigate the aluminum smelting industry’s enormous energy consumption and high emission releases is now even more persistent with the recent climate change happenings. Common approaches to achieve this have been focused on improving energy efficiency in the pot line and cast house sections of the smelter. However, the conventional energy efficiency analyses are based on the first law of thermodynamics, which do not shed proper light on the smelter’s degradation of energy. This just gives a general idea of the furnace’s performance with no reference to locations where improvement is a possibility based on the second law of thermodynamics. In this study, we apply exergy analyses on the pot line and cast house sections of the smelter to identify the locality and causes of energy degradation. The exergy analyses, which are based on a real life smelter conditions, highlight the possible locations for technology improvement in a typical smelter. With this established, methods of minimizing the smelter’s exergy losses are assessed.

Keywords: exergy analysis, electrolytic cell, furnace, heat transfer

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Authors: Khalid Kaddoura, Tarek Zayed

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Sewer networks are constructed to protect the communities and the environment from any contact with the sewer mediums. Pipelines, being laterals or sewer mains, and manholes form the huge underground infrastructure in every urban city. Due to the sewer networks importance, the infrastructure asset management field has extensive advancement in condition assessment and rehabilitation decision models. However, most of the focus was devoted to pipelines giving little attention toward manholes condition assessment. In fact, recent studies started to emerge in this area to preserve manholes from any malfunction. Therefore, the main objective of this study is to propose a condition assessment model for sewer manholes. The model divides the manhole into several components and determines the relative importance weight of each component using the Analytic Network Process (ANP) decision-making method. Later, the condition of the manhole is computed by aggregating the condition of each component with its corresponding weight. Accordingly, the proposed assessment model will enable decision-makers to have a final index suggesting the overall condition of the manhole and a backward analysis to check the condition of each component. Consequently, better decisions are made pertinent to maintenance, rehabilitation, and replacement actions.

Keywords: Analytic Network Process (ANP), condition assessment, decision-making, manholes

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Authors: Linlin Wang, Guangdong Bian, Jifeng Shen, Jingzhu Zeng

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Zinc-aluminum alloys have been applied as alternatives to bronze, aluminum alloys, and cast iron due to their distinguishing features such as high as-cast strength, excellent bearing properties, as well as low energy requirements for melting. In this study, oxide coatings were produced on ZA27 zinc-aluminum alloy by a plasma electrolytic oxidation (PEO) method. Three coatings were deposited by using three various electrolytes, i.e. silicate, aluminate and aluminate/borate composite solutions. The current density is set at 0.1A/cm2, deposition time is 40 mins for all the deposition processes. The surface morphology and phase structure of the three coatings were characterized by scanning electron microscopy （SEM） and X-ray diffraction (XRD). Pin-on-disc sliding wear tests were conducted to test the tribological properties of coatings. The results indicated that the coating produced using the aluminate/borate composite electrolyte had the highest deposition rate and best wear resistance among the three coatings.

Keywords: oxide coating, PEO, tribological properties, ZA27

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Authors: Kyle Saltmarsh

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Acoustic testing possesses many benefits due to its non-destructive nature and practicality. There hence exists many scenarios in which using acoustic testing for condition testing shows powerful feasibility. A wealth of information is contained within the acoustic and vibration characteristics of structures, allowing the development meaningful features for the classification of their respective condition. In this paper, methods, results, and discussions are presented on the use of non-destructive acoustic testing coupled with acoustic feature extraction and machine learning techniques for the condition testing of manufactured circular steel plates subjected to varied levels of damage.

Keywords: plates, deformation, acoustic features, machine learning

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Authors: Navneet Dabra, Baljinder Kaur, Lakhbir Singh, V. Annapu Reddy, R. Nath, Dae-Yong Jeong, Jasbir S. Hundal

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Nano-composite films of sodium nitrite (NaNO2): Starch with different proportions of NaNO2 and Starch have been prepared by drop cast technique. The ferroelectric hysteresis loops (P-V) have been traced using modified Sawyar-Tower circuit. The films containing equal proportions of NaNO2 and Starch exhibit optimized ferroelectric properties. The stability of the remanent polarization, Pr in the optimized nano-composite films exhibit improved stability over the pure NaNO2 films. The Atomic Force Microscopy (AFM) has been employed to investigate the surface morphology. AFM images clearly reveal the nano sized particles of NaNO2 dispersed in starch with small value of surface roughness.

Keywords: ferroelectricity, nano-composite films, Atomic Force Microscopy (AFM), nano composite film

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Authors: Seok Hong Min, Tae Kwon Ha

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High strength Fe-36Ni-base Invar alloys containing Al contents up to 0.3 weight percent were cast into ingots and thermodynamic equilibrium during solidification has been investigated in this study. From the thermodynamic simulation using Thermo-Calc®, it has been revealed that equilibrium phases which can be formed are two kinds of MC-type precipitates, MoC, and M2C carbides. The mu phase was also expected to form by addition of aluminum. Microstructure observation revealed the coarse precipitates in the as-cast ingots, which was non-equilibrium phase and could be resolved by the successive heat treatment. With increasing Al contents up to 0.3 wt.%, tensile strength of Invar alloy increased as 1400MPa after cold rolling and thermal expansion coefficient increased significantly. Cold rolling appeared to dramatically decrease thermal expansion coefficient.

Keywords: invar alloy, aluminum, phase equilibrium, thermal expansion coefficient, microstructure, tensile properties

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Authors: John Q. Todd

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Given that modern equipment can provide comprehensive health, status, and error condition data via built-in sensors, maintenance organizations have a new and valuable source of insight to take advantage of. This presentation will expose what these data payloads might look like and how they can be filtered, visualized, calculated into metrics, used for machine learning, and generate alerts for further action.

Keywords: condition based maintenance, equipment data, metrics, alerts

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Authors: Williams S. Ebhota, Freddie L. Inambao

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This study investigates the use of centrifugal casting method to fabricate functionally graded aluminium A356 Alloy and A356-10%SiCp composite for hydro turbine bucket application. The study includes the design and fabrication of a permanent mould. The mould was put into use and the buckets of A356 Alloy and A356-10%SiCp composite were cast, cut and machined into specimens. Some specimens were given T6 heat treatment and the specimens were prepared for different examinations accordingly. The SiCp particles were found to be more at inner periphery of the bucket. The maximum hardness of As-Cast A356 and A356-10%SiCp composite was recorded at the inner periphery to be 60 BRN and 95BRN, respectively. And these values were appreciated to 98BRN and 122BRN for A356 alloy and A356-10%SiCp composite, respectively. It was observed that the ultimate tensile stress and yield tensile stress prediction curves show the same trend.

Keywords: A356 alloy, A356-10%SiCp composite, centrifugal casting, Pelton bucket, turbine blade

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Authors: Rikke Lybæk, Tyge Kjær

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The Baltic Sea is suffering from nitrogen and phosphorus pollution, which causes eutrophication of the maritime environment and hence threatens the biodiversity of the Baltic Sea area. The intensified quantity of nutrients in the water has created challenges with the growth of seaweed being discarded on beaches around the sea. The cast seaweed has led to odor problems hampering the use of beach areas around the Bay of Køge in Denmark. This is the case in, e.g., Solrød Municipality, where recreational activities have been disrupted when cast seaweed pile up on the beach. Initiatives have, however, been introduced within the municipality to remove the cast seaweed from the beach and utilize it for renewable energy production at the nearby Solrød Biogas Plant, thus being co-digested with animal manure for power and heat production. This paper investigates which type of technology application’s have been applied in the effort to optimize the collection of cast seaweed, and will further reveal, how the seaweed has been pre-treated at the biogas plant to be utilized for energy production the most efficient, hereunder the challenges connected with the content of sand. Heavy metal contents in the seaweed and how it is managed will also be addressed, which is vital as the digestate is utilized as soil fertilizer on nearby farms. Finally, the paper will outline the energy production scheme connected to the use of seaweed as feedstock for biogas production, as well as the amount of nitrogen-rich fertilizer produced. The theoretical approach adopted in the paper relies on the thinking of Circular Bio-Economy, where biological materials are cascaded and re-circulated etc., to increase and extend their value and usability. The data for this research is collected as part of the EU Interreg project “Cluster On Anaerobic digestion, environmental Services, and nuTrients removAL” (COASTAL Biogas), 2014-2020. Data gathering consists of, e.g., interviews with relevant stakeholders connected to seaweed collection and operation of the biogas plant in Solrød Municipality. It further entails studies of progress and evaluation reports from the municipality, analysis of seaweed digestion results from scholars connected to the research, as well as studies of scientific literature to supplement the above. Besides this, observations and photo documentation have been applied in the field. This paper concludes, among others, that the seaweed harvester technology currently adopted is functional in the maritime environment close to the beachfront but inadequate in collecting seaweed directly on the beach. New technology hence needs to be developed to increase the efficiency of seaweed collection. It is further concluded that the amount of sand transported to Solrød Biogas Plant with the seaweed continues to pose challenges. The seaweed is pre-treated for sand in a receiving tank with a strong stirrer, washing off the sand, which ends at the bottom of the tank where collected. The seaweed is then chopped by a macerator and mixed with the other feedstock. The wear down of the receiving tank stirrer and the chopper are, however, significant, and new methods should be adopted.

Keywords: biogas, circular bio-economy, Denmark, maritime technology, cast seaweed, solrød municipality

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Authors: Jae-Jeong Kim, Ki-Ro Kim, Hyoung-Kyu Song

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In this paper, we propose an efficient signal detector that switches M parameter of QRD-M detection scheme is proposed for MIMO-OFDM system. The proposed detection scheme calculates the threshold by 1-norm condition number and then switches M parameter of QRD-M detection scheme according to channel information. If channel condition is bad, the parameter M is set to high value to increase the accuracy of detection. If channel condition is good, the parameter M is set to low value to reduce complexity of detection. Therefore, the proposed detection scheme has better trade off between BER performance and complexity than the conventional detection scheme. The simulation result shows that the complexity of proposed detection scheme is lower than QRD-M detection scheme with similar BER performance.

Keywords: MIMO-OFDM, QRD-M, channel condition, BER

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Authors: Emine Tuğba Akyüz

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In this study, the analysis of Hadamard matrices, which is a special type of matrix, was made under three headings: norms, singular values, condition number. Six norm types was applied to Hadamard matrices and the relationship between the results and the size of the matrix has been studied. As a result of the investigation when 2-norm was used on the problem Hx =f, the equation ‖x‖_2= ‖f‖_2/√n was shown (H is n-dimensional Hadamard matrix). Related with this, the relationship between the the singular value of H and 2-norm and eigenvalues was shown. Then, the evaluation of condition number for Hx =f was made.

Keywords: condition number, Hadamard matrix, norm, singular value

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Authors: S. Ghorbani, N. I. Polushin

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Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: cutting condition, vibration, natural frequency, decision tree, CART algorithm

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Authors: Sun Fan, Wu Xiaoguang, Fang Miaomiao, Wei Chi

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The degree of damage to the support is simulated by finite element software, and its influence on the static and dynamic effects of the bridge structure is analyzed. Four working conditions are selected for the study of bearing damage impact: the bearing is intact (condition 1), the bearing damage coefficient is 0.8 (condition 2), the bearing damage coefficient is 0.6 (condition 3), and the bearing damage coefficient is 0.4 (Working Condition 4). The effect value of the bridge structure under each working condition is calculated, and the simple-supported girder bridge and continuous girder bridge with typical spans are taken as examples to analyze the overall change of the bridge structure after the bearing completely fails.

Keywords: bridge bearing damage, dynamic response, finite element analysis, load conditions

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Authors: A. P .I. Popoola, V. S. Aigbodion, O. S. I. Fayomi

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The experimental study of the microstructure and properties of Al-Cu-Mg alloy/bean pod ash (BPA) nanoparticles was investigated. The aluminium matrix composites (AMCs) were produced by varying the BPA nanoparticles from 1-4wt%. The microstructure and phases of the composites produced were examined by SEM/EDS and XRD. Properties such as: hardness, tensile strength, impact energy, fatigue and wear were evaluated. The results showed that tensile strength and hardness values increased by 35 and 44.1% at 4wt% BPA nanoparticles with appreciable impact energy. The fatigue limit of 167MPa, 135 MPa and 75Mpa were obtained for the nano-particle (55nm), micro-particle (100µm) BPA composites and unreinforced alloy respectively. The wear properties of the as-cast Al–3.7%Cu-1.4%Mg/BPA nanoparticle have been improved significantly even with a low weight percent of BPA nanoparticle. The properties of the as-cast aluminium nanoparticles (MMNCs) have been improved significantly even with a low weight percent of nano-sized BPAp.

Keywords: bean pod ash nanoparticles, al-cu-mg alloy, mechanical properties, wear, microstructures

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Authors: Kleiner Marques Marra, Tércio Pedrosa

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This paper reports the production of uranium-molybdenum alloys, which have been considered promising fuel for test and research nuclear reactors. U-Mo alloys were produced in three molybdenum contents: 5 wt.%, 7 wt.%, and 10 wt.%, using an electric vacuum induction furnace. A boron nitride-coated graphite crucible was employed in the production of the alloys and, after melting, the material was immediately poured into a boron nitride-coated graphite mold. The incorporation of carbon was observed, but it happened in a lower intensity than in the case of the non-coated crucible/mold. It is observed that the carbon incorporation increased and alloys density decreased with Mo addition. It was also noticed that the increase in the carbon or molybdenum content did not seem to change the as-cast structure in terms of granulation. The three alloys presented body-centered cubic crystal structure (g phase), after solidification, besides a seeming negative microsegregation of molybdenum, from the center to the periphery of the grains. There were signs of macrosegregation, from the base to the top of the ingots.

Keywords: uranium-molybdenum alloys, incorporation of carbon, solidification, macrosegregation and microsegregation

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Authors: Tim Dunne, Jiaxiang Ren, Lei Zhao, Peng Cheng, Yi Song, Yu Liu, Wenhan Yue, Xiongwen Yang

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Two decades of the Shale Revolution has transforming transformed the global energy market, in part by the adaption of multi-stage dissolvable frac plugs. Magnesium has been favored for the bulk of plugs, requiring development of materials to suit specific field requirements. Herein, the mechanical and dissolution results from equal channel angular pressing (ECAP) of two cast dissolvable magnesium alloy are described. ECAP was selected as a route to increase the mechanical properties of two formulations of dissolvable magnesium, as solutionizing failed. In this study, 1” square cross section samples cast Mg alloys formulations containing rare earth were processed at temperatures ranging from 200 to 350 °C, at a rate of 0.005”/s, with a backpressure from 0 to 70 MPa, in a brass, or brass + graphite sheet. Generally, the yield and ultimate tensile strength (UTS) doubled for all. For formulation DM-2, the yield increased from 100 MPa to 250 MPa; UTS from 175 MPa to 325 MPa, but the strain fell from 2 to 1%. Formulation DM-3 yield increased from 75 MPa to 200 MPa, UTS from 150 MPa to 275 MPa, with strain increasing from 1 to 3%. Meanwhile, ECAP has also been found to reduce the dissolution rate significantly. A microstructural analysis showed grain refinement of the alloy and the movement of secondary phases away from the grain boundary. It is believed that reconfiguration of the grain boundary phases increased the mechanical properties and decreased the dissolution rate. ECAP processing of dissolvable high rare earth content magnesium is possible despite the brittleness of the material. ECAP is a possible processing route to increase mechanical properties for dissolvable aluminum alloys that do not extrude.

Keywords: equal channel angular processing, dissolvable magnesium, frac plug, mechanical properties

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Authors: Manthan Patel, Vinit Ahlawat, Anshh Singh Claire, Pijush Samui

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This paper focuses on the analysis of quicksand condition for a dam foundation. The quicksand condition occurs in cohesion less soil when effective stress of soil becomes zero. In a dam, the saturated sediment may appear quite solid until a sudden change in pressure or shock initiates liquefaction. This causes the sand to form a suspension and lose strength hence resulting in failure of dam. A soil profile shows different properties at different points and the values obtained are uncertain thus reliability analysis is performed. The reliability is defined as probability of safety of a system in a given environment and loading condition and it is assessed as Reliability Index. The reliability analysis of dams under quicksand condition is carried by Gaussian Process Regression (GPR). Reliability index and factor of safety relating to liquefaction of soil is analysed using GPR. The results of reliability analysis by GPR is compared to that of conventional method and it is demonstrated that on applying GPR the probabilistic analysis reduces the computational time and efforts.

Keywords: factor of safety, GPR, reliability index, quicksand

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Authors: S. Ghorbani, N. I. Polushin

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In this study, an approach to identify factors affecting on surface roughness in a machining process is presented. This study is based on 81 data about surface roughness over a wide range of cutting tools (conventional, cutting tool with holes, cutting tool with composite material), workpiece materials (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). A single decision tree (SDT) analysis was done to identify factors for predicting a model of surface roughness, and the CART algorithm was employed for building and evaluating regression tree. Results show that a single decision tree is better than traditional regression models with higher rate and forecast accuracy and strong value.

Keywords: cutting condition, surface roughness, decision tree, CART algorithm

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Authors: Sahil Kumar, Surinder Pal, Rahul Kapoor

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This paper is focused on to define the basic difference between hot and cold chamber high pressure die casting process which is not fully defined in a research before paper which we have studied. The pressure die casting is basically defined into two types (1) Hot chamber Die Casting (2) Cold chamber Die Casting. Cold chamber die casting is used for casting alloys that require high pressure and have a high melting temperature, such as brass, aluminum, magnesium, copper based alloys and other high melting point nonferrous alloys. Hot chamber die casting is suitable for casting zinc, tin, lead, and low melting point alloys. In hot chamber die casting machine, the molten metal is an integral pan of the machine. It mainly consists of hot chamber and gooseneck type metal container made of cast iron. This machine is mainly used for low melting alloys and alloys of metals like zinc, lead etc. Metals and alloys having a high melting point and those which are having an affinity for iron cannot be cast by this machine, which could otherwise attack the shot sleeve and damage the machine.

Keywords: hot chamber die casting, cold chamber die casting, metals and alloys, casting technology

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Authors: Kitti Leangkrua

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This paper presents a risk-based maintenance strategy of a power transformer in order to optimize operating and maintenance costs. The methodology involves the study and preparation of a database for the collection the technical data and test data of a power transformer. An evaluation of the overall condition of each transformer is performed by a program developed as a result of the measured results; in addition, the calculation of the main equipment separation to the overall condition of the transformer (% HI) and the criteria for evaluating the importance (% ImI) of each location where the transformer is installed. The condition assessment is performed by analysis test data such as electrical test, insulating oil test and visual inspection. The condition of the power transformer will be classified from very poor to very good condition. The importance is evaluated from load criticality, importance of load and failure consequence. The risk matrix is developed for evaluating the risk of each power transformer. The high risk power transformer will be focused firstly. The computerized program is developed for practical use, and the maintenance strategy of a power transformer can be effectively managed.

Keywords: asset management, risk-based maintenance, power transformer, health index

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Authors: Supaporn Yamuangmorn, Chanakan Prom-U-Thai

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Wetland and upland purple rice are the two major types classified by its original ecotypes in Northern Thailand. Wetland rice is grown under flooded condition from transplanting until the mutuality, while upland rice is naturally grown under well-drained soil known as aerobic cultivations. Both ecotypes can be grown and adapted to the reverse systems but little is known on its responses of grain yield and qualities between the 2 ecotypes. This study evaluated responses of grain yield as well as anthocyanin and antioxidant capacity between the wetland and upland purple rice genotypes grown in the submerged and aerobic conditions. A factorial arrangement in a randomized complete block design (RCBD) with two factors of rice genotype and water condition were carried out in three replications. The two wetland genotypes (Kum Doi Saket: KDK and Kum Phayao: KPY) and two upland genotypes (Kum Hom CMU: KHCMU and Pieisu1: PES1) were used in this study by growing under submerged and aerobic conditions. Grain yield was affected by the interaction between water condition and rice genotype. The wetland genotypes, KDK and KPY grown in the submerged condition produced about 2.7 and 0.8 times higher yield than in the aerobic condition, respectively. The 0.4 times higher grain yield of upland genotype (PES1) was found in the submerged condition than in the aerobic condition, but no significant differences in KHCMU. In the submerged condition, all genotypes produced higher yield components of tiller number, panicle number and percent filled grain than in the aerobic condition by 24% and 32% and 11%, respectively. The thousand grain weight and spikelet number were affected by water condition differently among genotypes. The wetland genotypes, KDK and KPY, and upland genotype, PES1, grown in the submerged condition produced about 19-22% higher grain weight than in the aerobic condition. The similar effect was found in spikelet number which the submerged condition of wetland genotypes, KDK and KPY, and the upland genotype, KHCMU, had about 28-30% higher than the aerobic condition. In contrast, the anthocyanin concentration and antioxidant capacity were affected by both the water condition and genotype. Rice grain grown in the aerobic condition had about 0.9 and 2.6 times higher anthocyanin concentration than in the submerged condition was found in the wetland rice, KDK and upland rice, KHCMU, respectively. Similarly, the antioxidant capacity of wetland rice, KDK and upland rice, KHCMU were 0.5 and 0.6 times higher in aerobic condition than in the submerged condition. There was a negative correlation between grain yield and anthocyanin concentration in wetland genotype KDK and upland genotype KHCMU, but it was not found in the other genotypes. This study indicating that some rice genotype can be adapted in the reverse ecosystem in both grain yield and quality, especially in the wetland genotype KPY and upland genotype PES1. To maximize grain yield and quality of purple rice, proper water management condition is require with a key consideration on difference responses among genotypes. Increasing number of rice genotypes in both ecotypes is needed to confirm their responses on water management.

Keywords: purple rice, water condition, anthocyanin, grain yield

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Authors: Veeresham Mokali

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Recrystallization microstructure and grain growth studies of Ta₀.₅Nb₀.₅Hf₀.₅ZrTi₁.₅ refractory high entropy alloy have been explored in the present work. The as-cast Ta₀.₅Nb₀.₅Hf₀.₅ZrTi₁.₅ alloy was cold-rolled to 90% in several passes at room temperature and further subjected to annealing treatment for recrystallization at 800°C, 1000°C, 1250°C, and 1400°C temperatures for one hour. However, the characterization of heavily cold-rolled and annealed condition specimens was done using scanning electron microscopy (SEM-EBSD). The cold-rolled specimens showed the development of an inhomogeneous microstructure. Upon annealing, recrystallized microstructures were achieved; in addition to that, the coarsening of microstructure with raising annealing temperature noticed in the range of 800°C – 1400°C annealed temperatures.

Keywords: refractory high entropy alloys, cold-rolling, recrystallization, microstructure

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Authors: Pooja Verma, Rajnesh Tyagi, Sunil Mohan

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Al-Si alloys are widely used in various components such as liner-less engine blocks, piston, compressor bodies and pumps for automobile sector and aerospace industries due to their excellent combination of properties like low thermal expansion coefficient, low density, excellent wear resistance, high corrosion resistance, excellent cast ability, and high hardness. The low density and high hardness of primary Si phase results in significant reduction in density and improvement in wear resistance of hypereutectic Al-Si alloys. Keeping in view of the industrial importance of the alloys, hypereutectic Al-Si alloys containing 14, 16, 18 and 20 wt. % of Si were prepared in a resistance furnace using adequate amount of deoxidizer and degasser and their erosion behavior was evaluated by conducting tests at impingement angles of 30°, 60°, and 90° with an erodent discharge rate of 7.5 Hz, pressure 1 bar using erosion test rig. Microstructures of the cast alloys were examined using Optical microscopy (OM) and scanning electron microscopy (SEM) and the presence of Si particles was confirmed by x-ray diffractometer (XRD). The mechanical properties and hardness were measured using uniaxial tension tests at a strain rate of 10-3/s and Vickers hardness tester. Microstructures of the alloys and X-ray examination revealed the presence of primary and eutectic Si particles in the shape of cuboids or polyhedral and finer needles. Yield strength (YS), ultimate tensile strength (UTS), and uniform elongation of the hypereutectic Al-Si alloys were observed to increase with increasing content of Si. The optimal strength and ductility was observed for Al-20 wt. % Si alloy which is significantly higher than the Al-14 wt. % Si alloy. The increased hardness and the strength of the alloys with increasing amount of Si has been attributed presence of Si in the solid solution which creates strain, and this strain interacts with dislocations resulting in solid-solution strengthening. The interactions between distributed primary Si particles and dislocations also provide Orowan strengthening leading to increased strength. The steady state erosion rate was found to decrease with increasing angle of impact as well as Si content for all the alloys except at 900 where it was observed to increase with the increase in the Si content. The minimum erosion rate is observed in Al-20 wt. % Si alloy at 300 and 600 impingement angles because of its higher hardness in comparison to other alloys. However, at 90° impingement angle the wear rate for Al-20 wt. % Si alloy is found to be the minimum due to deformation, subsequent cracking and chipping off material.

Keywords: Al-Si alloy, erosion wear, cast alloys, dislocation, strengthening

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Authors: Ilja Käch, Abdul R. Jandali, Nadja Zechmann-Müller

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Introduction: We discuss the treatment of two young male patients suffering from scaphoid non-union after a traumatic scaphoid fracture. The currently propagated techniques for treating a scaphoid non-union in children are either the operative reconstruction of the scaphoid or the conservative treatment with splinting in a scaphoid cast. Cases: In the first case, we operated on a 13 years old male patient with a posttraumatic scaphoid non-union in the middle third with a humpback deformity. We resected the middle third of the scaphoid and grafted the defect with an iliac crest bone, and the DISI-Deformity was reduced. Fixation was performed with K-Wires and immobilisation in a scaphoid cast. In the second case a 13 years old male patient also with a posttraumatic scaphoid non-union in the middle third and humpback deformity, DISI-deformity, was treated conservatively. Immobilisation in a scaphoid cast for four months was performed. Results: Operative: One year postoperatively the patient achieved a painless free arc of motion. Flexion/Extension 70/0/60°, Radial-/Ulnarduction 30/0/30° and Pro-/Supination 90/0/90°. The computer tomogram showed complete consolidation and bony fusion of the iliac crest bone. Conservative: Six to eight months after conservative treatment the patient demonstrated painless motion and AROM Flexion/Extension 80/0/80°, Radial-/Ulnarduction and Pro-/Supination in maximum range. Complete consolidation in the computer tomogram with persistent humpback- and DISI deformity. Conclusion: In the literature, both techniques are described, either the operative scaphoid reconstruction or the conservative treatment with splinting. In our cases, both the operative and conservative treatments showed comparable good results. However, the humpback- and DISI deformity can only be addressed with a surgical approach.

Keywords: scaphoid, non-union, trauma, operative vs. non operative

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Authors: Rezwana Rahman

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Various simulations have been conducted to understand the particle's macroscopic behavior in the solid-gas multiphase flow in rotating drums in the past. In these studies, the particle-wall no-slip boundary condition was usually adopted. However, the non-slip boundary condition is rarely encountered in real systems. A little effort has been made to investigate the particle behavior at slip boundary conditions. The paper represents a study of the gas-solid flow in a horizontal rotating drum at a slip boundary wall condition. Two different sizes of particles with the same density have been considered. The Eulerian–Eulerian multiphase model with the kinetic theory of granular flow was used in the simulations. The granular pressure at the rolling flow regime with specularity coefficient 1 was examined and compared with that obtained based on the no-slip boundary condition. The results reveal that the profiles of granular pressure distribution on the transverse plane of the drum are similar for both boundary conditions. But, overall, compared with those for the no-slip boundary condition, the values of granular pressure for specularity coefficient 1 are larger for the larger particle and smaller for the smaller particle.

Keywords: boundary condition, eulerian–eulerian, multiphase, specularity coefficient, transverse plane

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Authors: Byung Il You, Ryun Oh, Gyo Woo Lee

Abstract:

Manhole refers to facilities that are accessible to the people cleaning and inspection of sewer, and its covering is called manhole lid. Manhole lid is typically made of a cast iron material. Due to the heavy weight of the cast iron manhole lids their installation and maintenance are not easy, and an electrical shock and corrosion aging of them can cause critical problems. The manhole body and the lid manufacturing using the fiber-reinforced composite material can reduce the weight considerably compared to the cast iron manhole. But only the fiber reinforcing is hard to maintain the heavy load, and the method of the iron frame with double injection molding of the composite material has been proposed widely. In this study reflecting the situation of this market, the structural design of the iron frame for the composite manhole lid was carried out. Structural analysis with the computer simulation for the effectively distributed load on the iron frame was conducted. In addition, we want to assess manufacturing costs through the comparing of weights and number of welding spots of the frames. Despite the cross-sectional area is up to 38% compared with the basic solid form the maximum von Mises stress is increased at least about 7 times locally near the rim and the maximum strain in the central part of the lid is about 5.5 times. The number of welding points related to the manufacturing cost was increased gradually with the more complicated shape. Also, the higher the height of the arch in the center of the lid the better result might be obtained. But considering the economic aspect of the composite fabrication we determined the same thickness as the frame for the height of the arch at the center of the lid. Additionally in consideration of the number of the welding points we selected the hexagonal as the optimal shape. Acknowledgment: These are results of a study on the 'Leaders Industry-university Cooperation' Project, supported by the Ministry of Education (MOE).

Keywords: manhole lid, iron frame, structural design, computer simulation

Procedia PDF Downloads 252

Authors: Pooja Kherudkar, Namdeo Hedaoo

Abstract:

There are various causes for asphalt pavement distresses which can develop prematurely or with aging in services. These causes are not limited to aging of bitumen binder but include poor quality materials and construction, inadequate mix design, inadequate pavement structure design considering the traffic and lack of preventive maintenance. There is physical evidence available for each type of pavement distress. Distress in asphalt pavements can be categorized in different distress modes like fracture (cracking and spalling), distortion (permanent deformation and slippage), and disintegration (raveling and potholes). This study shows the importance of severity determination of distresses for the selection of appropriate preventive maintenance treatment. Distress analysis of the deteriorated roads was carried out. Four roads of urban flexible pavements from Pune city was selected as a case study. The roads were surveyed to detect the types, to measure the severity and extent of the distresses. Causes of distresses were investigated. The pavement condition rating values of the roads were calculated. These ranges of ratings were as follows; 1 for poor condition road, 1.1 to 2 for fair condition road and 2.1 to 3 for good condition road. Out of the four roads, two roads were found to be in fair condition and the other two were found in good condition. From the various preventive maintenance treatments like crack seal, fog seal, slurry seal, microsurfacing, surface dressing and thin hot mix/cold mix bituminous overlays, the effective maintenance treatments with respect to the surface condition and severity levels of the existing pavement were recommended.

Keywords: distress analysis, pavement condition rating, preventive maintenance treatments, surface distress measurement

Procedia PDF Downloads 159

Authors: Amrit Pal Singh Arora

Abstract:

The paper reports the results of a study undertaken to study the effects of addition of steel fibres of different aspect ratios on the permeability and strength characteristics of steel fiber reinforced fly ash concrete (SFRC). Corrugated steel fibres having a diameter of 0.6 mm and lengths of 12.5 mm, 30 mm and 50 mm were used in this study. Cube samples of 100 mm x 100 mm x 100 mm were cast from mixes replacing 0%, 10%, 20% and 30% cement content by fly ash with and without fibres and tested for the determination of coefficient of water permeability, compressive and split tensile strengths after 7 and 28 days of curing. Plain concrete samples were also cast and tested for reference purposes. Permeability was observed to decrease significantly for all concrete mixes with the addition of steel fibers as compared to plain concrete. The replacement of cement content by fly ash results in an increase in the coefficient of water permeability. With the addition of fly ash to the plain mix the7 day compressive and split tensile strengths decreased, however both the compressive and split tensile strengths increased with increase in curing age.

Keywords: curing age, fiber shape, fly ash, Darcy’s law, Ppermeability

Procedia PDF Downloads 285

Authors: Ricardo Paiva, Rui Soares, Felix Harnau, Bruno Fragoso

Abstract:

Nickel-based alloys are materials well suited for service in extreme environments subjected to pressure and heat. Some industrial applications for Nickel-based alloys are aerospace and jet engines, oil and gas extraction, pollution control and waste processing, automotive and marine industry. It is generally recognized that grain refinement is an effective methodology to improve the quality of casted parts. Conventional grain refinement techniques involve the addition of inoculation substances, the control of solidification conditions, or thermomechanical treatment with recrystallization. However, such methods often lead to non-uniform grain size distribution and the formation of hard phases, which are detrimental to both wear performance and biocompatibility. Stirring of the melt by electromagnetic fields has been widely used in continuous castings with success for grain refinement, solute redistribution, and surface quality improvement. Despite the advantages, much attention has not been paid yet to the use of this approach on functional castings such as investment casting. Furthermore, the effect of electromagnetic stirring (EMS) fields on Nickel-based alloys is not known. In line with the gaps/needs of the state-of-art, the present research work targets to promote new advances in controlling grain size and morphology of investment cast Nickel based alloys. For such a purpose, a set of experimental tests was conducted. A high-frequency induction furnace with vacuum and controlled atmosphere was used to cast the Inconel 718 alloy in ceramic shells. A coil surrounded the casting chamber in order to induce electromagnetic stirring during solidification. Aiming to assess the effect of the electromagnetic stirring on Ni alloys, the samples were subjected to microstructural analysis and mechanical tests. The results show that electromagnetic stirring can be an effective methodology to modify the grain size and mechanical properties of investment-cast parts.

Keywords: investment casting, grain refinement, electromagnetic stirring, nickel alloys

Procedia PDF Downloads 110