Search results for: plasma welding

Authors: Erfan Ghasemi, Mohammadreza Khani, Hamidreza Mahmoudi, Mohammad Ali Nilforoushzadeh, Babak Shokri, Pouria Akbartehrani

Abstract:

Given the global significance of treating infectious wounds, the goal of this study is to use spark plasma as a new treatment for infectious wounds. To generate spark plasma, a high-voltage (7 kV) and high-frequency (75 kHz) source was used. Infectious wounds in the peritoneum of mice were divided into control and plasma-treated groups at random. The plasma-treated animals received plasma radiation every 4 days for 12 days, for 60 seconds each time. On the 15th day after the first session, the wound in the plasma-treated group had completely healed. The spectra of spark plasma emission and tissue properties were studied. The mechanical resistance of the wound healed in the plasma treatment group was considerably higher than in the control group (p<0.05), according to the findings. Furthermore, histological evidence suggests that wound re-epithelialization is faster in comparison to controls. Angiogenesis and fibrosis (collagen production) were also dramatically boosted in the plasma-treated group, whereas the stage of wound healing inflammation was significantly reduced. Plasma therapy accelerated wound healing by causing considerable wound constriction. The results of this investigation show that spark plasma has an influence on the treatment of infectious wounds.

Keywords: infectious wounds, mice, spark plasma, treatment

Procedia PDF Downloads 295

Authors: Khaled Al-Badani, Andrew Norbury, Essam Elmshawet, Glynn Rotwell, Ian Jenkinson , James Ren

Abstract:

Micro welding procedures are widely used for joining materials, developing duplex components or functional surfaces, through various methods such as Micro Discharge Welding or Spot Welding process, which can be found in the engineering, aerospace, automotive, biochemical, biomedical and numerous other industries. The relationship between the material properties, structure and processing is very important to improve the structural integrity and the final performance of the welded joints. This includes controlling the shape and the size of the welding nugget, state of the heat affected zone, residual stress, etc. Nowadays, modern high volume productions require the welding of much versatile shapes/sizes and material systems that are suitable for various applications. Hence, an improved understanding of the micro welding process and the digital tools, which are based on computational numerical modelling linking key welding parameters, dimensional attributes and functional performance of the weldment, would directly benefit the industry in developing products that meet current and future market demands. This paper will introduce recent work on developing an integrated experimental and numerical modelling code for micro welding techniques. This includes similar and dissimilar materials for both ferrous and non-ferrous metals, at different scales. The paper will also produce a comparative study, concerning the differences between the micro discharge welding process and the spot welding technique, in regards to the size effect of the welding zone and the changes in the material structure. Numerical modelling method for the micro welding processes and its effects on the material properties, during melting and cooling progression at different scales, will also be presented. Finally, the applications of the integrated numerical modelling and the material development for the digital manufacturing of welding, is discussed with references to typical application cases such as sensors (thermocouples), energy (heat exchanger) and automotive structures (duplex steel structures).

Keywords: computer modelling, droplet formation, material distortion, materials forming, welding

Procedia PDF Downloads 255

Authors: Ahmad K. Jassim, Raheem Kh. Al-Subar

Abstract:

Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.

Keywords: friction, spot, stir, environmental, sustainable, AA1100 aluminum alloy

Procedia PDF Downloads 195

Authors: Waqas A. Toor, Anis U. Baig, Nuaman Shafqat, Raafia Irfan, Muhammad Ashraf

Abstract:

A 2.45GHz microwave plasma system and its few applications have been developed. Argon and helium plasma is produced by metallic nozzle and also in a quartz tube at atmospheric pressure, using WR-340 waveguide and its tapered version. The waveguide applicator is also simulated in HFSS and field patterns are analyzed for maximum power absorption in the load. The system is tuned to operate at less than 10% reflected power. Various experimental techniques are used to initiate and sustain the plasma at atmospheric pressure. Plasma of atmospheric air is also produced without using any other shielding gas. The plasma flame is also characterized by its spectrum. Spectral analyses of plasma flame can be used for online analysis of combustion gases produced in industry. The applications of the system include glass and quartz processing, vitrification, emission spectroscopy, plasma coating. Low pressure plasma applications of the system include intense UV light for water purification and ozone generation.

Keywords: HFSS high frequency structure simulator, Microwave plasma, UV ultraviolet, WR rectangular waveguide

Procedia PDF Downloads 271

Authors: Ajay Biswas, Swapan Bhaumik, Abhijit Bhowmik

Abstract:

Present experiment has been carried out to study the microstructure of weldment obtained by submerged arc welding on mild steel plate at zero degree Celsius. To study this, bead on plate welding is done by submerged arc welding on the sample plate of heavy duty mild steel of designation IS 2062 grade B, fitted on the special fixture ensuring the plate temperature at zero degree Celsius. Sixteen numbers of such samples are welded by varying the most influencing parameters viz. travel speed, voltage, wire feed rate and electrode stick-out at four different levels. Taguchi’s design of experiment is applied by selecting Taguchi's L16 orthogonal array to restrict the number of experimental runs. Cross sectioned samples are polished and etched to view the weldment. Finally, different zone of the weldment is observed by optical microscope. From the type of microstructure of weldment it is concluded that submerged arc welding is feasible at zero degree Celsius on mild steel plate.

Keywords: Submerged Arc Welding, zero degree Celsius, Taguchi’s design of experiment, microstructure of weldment

Procedia PDF Downloads 440

Authors: Guoqing Wang, Yanhua Zhao, Lina Zhang, Jingbin Bai, Ruican Zhu

Abstract:

Friction stir welding with bobbin tool is a simple technique compared to conventional FSW since the backing fixture is no longer needed and assembling labor is reduced. It gets adopted more and more in the aerospace industry as a result. However, a post-weld problem, the left keyhole, has to be fixed by forced repair welding. To close the keyhole, the conventional fusion repair could be an option if the joint properties are not deteriorated; friction push plug welding, a forced repair, could be another except that a rigid support unit is demanded at the back of the weldment. Therefore, neither of the above ways is satisfaction in welding a large enclosed structure, like rocket propellant tank. Although friction pulls plug welding does not need a backing plate, the wide applications are still held back because of the disadvantages in respects of unappropriated tensile stress, (i.e. excessive stress causing neck shrinkage of plug that will bring about back defects while insufficient stress causing lack of heat input that will bring about face defects), complicated welding parameters (including rotation speed, transverse speed, friction force, welding pressure and upset)，short welding time (approx. 0.5 sec.), narrow windows and poor stability of process. In this research, an updated technique called inertia friction pull plug welding, and its equipment was developed. The influencing rules of technological parameters on joint properties of inertia friction pull plug welding were observed. The microstructure characteristics were analyzed. Based on the elementary performance data acquired, the conclusion is made that the uniform energy provided by an inertia flywheel will be a guarantee to a stable welding process. Meanwhile, due to the abandon of backing plate, the inertia friction pull plug welding is considered as a promising technique in repairing keyhole of bobbin tool FSW and point type defects of aluminium base material.

Keywords: defect repairing, equipment, inertia friction pull plug welding, technological parameters

Procedia PDF Downloads 313

Authors: Muna Khethier Abbass, Khairia Salman Hussan, Huda Mohummed AbdudAlaziz

Abstract:

This work aims to study the effect of shot peening on the mechanical properties of welded joints which performed by two different welding processes: Tungsten inert gas (TIG) welding and friction stir welding (FSW) processes of aluminum alloy 6061 T6. Arc welding process (TIG) was carried out on the sheet with dimensions of (100x50x6 mm) to obtain many welded joints with using electrode type ER4043 (AlSi5) as a filler metal and argon as shielding gas. While the friction stir welding process was carried out using CNC milling machine with a tool of rotational speed (1000 rpm) and welding speed of (20 mm/min) to obtain the same butt welded joints. The welded pieces were tested by X-ray radiography to detect the internal defects and faulty welded pieces were excluded. Tensile test specimens were prepared from welded joints and base alloy in the dimensions according to ASTM17500 and then subjected to shot peening process using steel ball of diameter 0.9 mm and for 15 min. All specimens were subjected to Vickers hardness test and micro structure examination to study the effect of welding process (TIG and FSW) on the micro structure of the weld zones. Results showed that a general decay of mechanical properties of TIG and FSW welded joints comparing with base alloy while the FSW welded joint gives better mechanical properties than that of TIG welded joint. This is due to the micro structure changes during the welding process. It has been found that the surface hardening by shot peening improved the mechanical properties of both welded joints, this is due to the compressive residual stress generation in the weld zones which was measured using X-Ray diffraction (XRD) inspection.

Keywords: friction stir welding, TIG welding, mechanical properties, shot peening

Procedia PDF Downloads 339

Authors: Meisam Akbari, Seyed Hossein Elahi, Mohammad Mashadgarmeh

Abstract:

In this study, the effect of nickel-electrode as a stainless steel buffer layer is considered. Then, the effect of dilution of the last layer of welding on two samples of steel plate A516 Gr70 (C-Mn-Si) with SMAW welding process was investigated. Then, in a sample, the ENI-cl nickel electrode was welded as the buffer layer and the E316L-16 electrode as the last layer of welding and another sample with an E316L-16 electrode in two layers. The chemical composition of the latter layer was determined by spectrophotometry method. The results indicate that the chemical composition of the latter layer is different and the lowest dilution rate is obtained using the nickel electrode.

Keywords: degree of dilution, C-Mn-Si, spectrometry, nickel electrode, stainless steel

Procedia PDF Downloads 220

Authors: Fatemeh Mirakhorli

Abstract:

Porosity is the main issue during welding of aluminum alloys, and surface cleaning has a critical influence to reduce the porosity level by removing the oxidized surface layer before fusion welding. Developing an optimum and economical surface cleaning method has an enormous benefit for aluminum welding industries to reduce costs related to repairing and repeating welds as well as increasing the mechanical properties of the joints. In this study, several mechanical and chemical surface cleaning methods were examined for butt joint welding of 2 mm thick AA6xxx alloys using ER5556 filler metal. The effects of each method on porosity formation and tensile properties are evaluated. It has been found that, compared to the conventional mechanical cleaning method, the use of chemical cleaning leads to an important reduction in porosity level even after a significant delay between cleaning and welding. The effect of the higher porosity level in the fusion zone to reduce the tensile strength of the welds is shown.

Keywords: gas metal arc welding (GMAW), aluminum alloy, surface cleaning, porosity formation, mechanical property

Procedia PDF Downloads 139

Authors: A. Mousavi, S. Sadegzadeh

Abstract:

In this research, the effect of non-thermal micro plasma with non-Maxwellian distribution function on the one dimensional plasma photonic crystals containing alternate plasma-dielectric layers, has been studied. By using Kronig Penny model, the dispersion relation of electromagnetic modes for such a periodic structure is obtained. In this study we take two plasma photonic crystals with different dielectric layers: the first one with Silicon monoxide named PPCI, and the second one with Tellurium dioxide named PPCII. The effects of the plasma layer thickness and the material of the dielectric layer on the plasma photonic crystal band gaps have been illustrated in the dispersion relation and the group velocity figures. Results revealed that in such a system, the non-thermal plasma exerts stronger limit on the wave’s propagation. In another word, for the non-thermal plasma photonic crystals (NPPC), there are two distinct regions in the dispersion plot. The upper region consists of alternate band gaps in such a way that both width and length of the bands decrease gradually as the band gaps order increases. Whereas in the lower region where v_ph > 20 c (for PPCI), waves will not be allowed to propagate.

Keywords: band gap, dispersion relation, non-thermal plasma, plasma photonic crystal

Procedia PDF Downloads 539

Authors: Bilge Demir, Ahmet Durgutlu, Mustafa Acarer

Abstract:

In this study, the butt welding of the commercial AZ31 magnesium alloy sheets have been carried out by using Tungsten Inert Gas (TIG) welding process with alternative and pulsed current. Welded samples were examined with regards to hardness and microstructure. Despite some recent developments in welding of magnesium alloys, they have some problems such as porosity, hot cracking, oxide formation and so on. Samples of the welded parts have undergone metallographic and mechanical examination. Porosities and homogeneous micron grain oxides were rarely observed. Orientations of the weld microstructure in terms of heat transfer also were rarely observed and equiaxed grain morphology was dominant grain structure as in the base metal. As results, fusion zone and few locations of the HAZ of the welded samples have shown twin’s grains. Hot cracking was not observed for any samples. Weld bead geometry of the welded samples were evaluated as normal according to welding parameters. In the results, conditions of alternative and pulsed current and the samples were compared to each other with regards to microstructure and hardness.

Keywords: AZ31 magnesium alloy, microstructures, micro hardness TIG welding

Procedia PDF Downloads 390

Authors: Abdulmagid A. Khattabi, Abdul Fatah M. Emhamed

Abstract:

The steel alloy Introduced after becoming carbon-steel does not meet the requirements of engineering industry; and it cannot be obtained tensile strength from carbon-steel higher than (700MPa), the low alloy steel enters in a lot of heavy engineering equipment parts, molds, agricultural equipment and other industry. In addition, that may be exposed to in-service failure, which may require returned to work, to do the repairs or maintenance by one of the welding methods available. The ability of steel weld determined through palpation of the cracks, which can reduce by many ways. These ways are often expensive and difficult to implement, perhaps the control to choose the type of electrode welding user is one of the easiest and least expensive applications. It has been welding the steel low alloys high resistance by manual metal arc (MMA), and by using a set of welding electrodes which varying in chemical composition and in their prices as well and test their effect on tensile strength. Results showed that using the poles of welding, which have a high proportion of iron powder and low hydrogen. The Tensile resistance is (484MPa) and the weld joint efficiency was (56.9%), but when (OK 47.04) electrode was used the tensile strength increased to (720MPa) and the weld joint efficiency to (84.7%). Using the cheapest electrode (OK 45.00) the weld joint efficiency did not exceed (24.2%), but when using the most expensive electrode (OK 91.28) the weld joint efficiency is (38.1%).

Keywords: steel low alloys high resistance, electrodes welding, tensile test

Procedia PDF Downloads 319

Authors: Zahra Ghasemi, Fatemeh Babaei

Abstract:

Plasma-derived medicinal products are vital categories of biological therapies. These products are used to treat rare, chronic, severe, and life-threatening conditions, such as bleeding disorders (Hemophilia A and B), hemolytic disease of the fetus and newborn, severe infections, burns and liver diseases, and other diseases caused by the absence or malfunction of certain proteins. In addition, they improve the patient’s quality of life. The process of producing plasma-derived medicinal products begins with the collection of human plasma from healthy donors. This initial stage is complex and is monitored with high precision and sensitivity by global authorities to maintain the quality and safety of the final products as well as the health of the donors. The amount of manufactured plasma-derived medicinal products depends on the availability of its raw material, human plasma, so collecting enough plasma for fractionation is essential. Therefore, adopting a suitable national policy regarding plasma donation, establishing collection centers, and increasing public awareness of the importance of plasma donation will improve any country’s conditions regarding the timely and sufficient supply of these medicines. In this study, we tried to briefly examine the importance of sustainability of the plasma industry and its situation in our beloved country of Iran.

Keywords: plasma, source plasma, plasma-derived medicinal products, fractionation

Procedia PDF Downloads 120

Authors: Okba Belahssen, Said Benramache

Abstract:

This paper presents wear behavior of the plasma-nitrided 20MnCr5 steel. Untreated and plasma nitrided samples were tested. The morphology was observed by scanning electron microscopy (SEM). The plasma nitriding behaviors of 20MnCr5 steel have been assessed by evaluating tribological properties and surface hardness by using a pin-on-disk wear machine and microhardness tester. Experimental results showed that the nitrides ε-Fe2−3N and γ′-Fe4N present in the white layer improve the wear resistance.

Keywords: plasma-nitriding, alloy 20mncr5, steel, friction, wear

Procedia PDF Downloads 557

Authors: I. M. B. Omiogbemi, D. S. Yawas, I. M. Dagwa, F. G. Okibe

Abstract:

This work present the effects of some gas metal arc welding parameters on the corrosion behavior of austenitic stainless steel, exposed to 0.5M sodium hydroxide at ambient temperatures (298K) using conventional weight loss determination, together with surface morphology evaluation by scanning electron microscopy and the application of factorial design of experiment to determine welding conditions which enhance the integrity of the welded stainless steel. The welding variables evaluated include speed, voltage and current. Different samples of the welded stainless steels were immersed in the corrosion environment for 8, 16, 24, 32 and 40 days and weight loss determined. From the results, it was found that increase in welding current and speed at constant voltage gave the optimum performance of the austenitic stainless steel in the environment. At a of speed 40cm/min, 110Amp current and voltage of 230 volt the welded stainless steel showed only a 0.0015mg loss in weight after 40 days. Pit-like openings were observed on the surface of the metals indicating corrosion but were minimal at the optimum conditions. It was concluded from the research that relatively high welding speed and current at a constant voltage gives a good welded austenitic stainless steel with better integrity.

Keywords: welding, current, speed, austenitic stainless steel, sodium hydroxide

Procedia PDF Downloads 318

Authors: H. Lee, Jr., L. Bo-ot, R. Tumlos, H. Ramos

Abstract:

The objective of the study is to be able to calculate excitation and vibrational temperatures of a 2.45 GHz microwave-induced atmospheric pressure plasma jet. The plasma jet utilizes Argon gas as a primary working gas, while Nitrogen is utilized as a shroud gas for protecting the quartz tube from the plasma discharge. Through Optical Emission Spectroscopy (OES), various emission spectra were acquired from the plasma discharge. Selected lines from Ar I and N2 I emissions were used for the Boltzmann plot technique. The Boltzmann plots yielded values for the excitation and vibrational temperatures. The various values for the temperatures were plotted against varying parameters such as the gas flow rates.

Keywords: plasma jet, OES, Boltzmann plots, vibrational temperatures

Procedia PDF Downloads 713

Authors: Yong Ho Jeon, Youn Mi Lee, Yong Yoon Lee

Abstract:

Effects of cold plasma treatment on various plant seed germination were studied. The seeds of hot pepper, cucumber, tomato and arabidopsis were exposed to plasma and the plasma was generated in various devices. The germination speed was evaluated compared to an unexposed control. A positive effect on germination speed was observed in all tested seeds but the effects strongly depended on the type of the used plasma device (Argon-DBD, surface-DBD or MARX generator), time of exposure (6s~10min or 1~10shots) and kind of seeds. The SEM images showed that arrays of gold particles along the cell wall were observed on the surface of cucumber seeds showed a germination-accelerating effect by plasma treatment, which was the same as untreated. However, when treated with the high dose plasma, gold particles were not arrayed at the seed surface, it seems that due to the surface etching. This may suggest that the germination is not promoted by etching or damage of surface caused by the plasma treatment. Seedling growth improvement was also observed by indirect plasma treatment. These lead to an important conclusion that the effect of charged particles on plasma play the essential role in plant germination and indirect plasma treatment offers new perspectives for large scale application.

Keywords: cold plasma, cucumber, germination, SEM

Procedia PDF Downloads 315

Authors: Ezzeddin Anawa, Abdol-Ghane Olabi

Abstract:

The dissimilar joint between aluminum /titanium alloys (Al 6082 and Ti G2) alloys were successfully achieved by CO2 laser welding with a single pass and without filler material using the overlap joint design. Laser welding parameters ranges combinations were experimentally determined using Taguchi approach with the objective of producing welded joint with acceptable welding profile and high quality of mechanical properties. In this study a joining of dissimilar Al 6082 / Ti G2 was result in three distinct regions fusion area (FA), heat-affected zone (HAZ), and the unaffected base metal (BM) in the weldment. These regions are studied in terms of its microstructural characteristics and microhardness which are directly affecting the welding quality. The weld metal was mainly composed of martensite alpha prime. In two different metals in the two different sides of joint HAZ, grain growth was detected. The microhardness of the joint distribution also has shown microhardness increasing in the HAZ of two base metals and a varying microhardness in fusion zone.

Keywords: microharness , microstructure, laser welding and dissimilar jointed materials.

Procedia PDF Downloads 374

Authors: Sylwia Wiewiorowska, Zbigniew Muskalski

Abstract:

The article presents part of research on the development of nickel plated welding wire production technology, whose application will enable the elimination of the flaws of currently manufactured welding wires. The nickel plated welding wire will be distinguished by high quality, because the Ni layer which is deposited electrochemically onto it from acid baths is characterized by very good adhesion to the steel wire surface, while the ductile nickel well deforms plastically in the drawing process and the adhesion of the Ni layer increases in the drawing process due to the occurring process of diffusion between the Ni and the steel. The Ni layer obtained in the proposed technology, despite a smaller thickness than when the wire is coated with copper, is continuous and tight, thus ensuring high corrosion resistance, as well as unsusceptible to scaling, which should provide a product that meets requirements imposed by the market. The product will also reduce, to some extent, the amount of copper brought in to steel through recycling, while the wire coating nickel introduced to the weld in the welding process is expected, to a degree, to favorably influence its mechanical properties. The paper describes the tests of the process of nickel plating of f1.96 mm-diameter wires using various nickel plating baths with different process parameters.

Keywords: steel wire, properties, welding process, Ni layer

Procedia PDF Downloads 147

Authors: Rachid Fermous, Rima Mebrek

Abstract:

Plasma expansion is an important physical process that takes place in laser interactions with solid targets. Within a self-similar model for the hydrodynamic multi-fluid equations, we investigated the expansion of dense plasma. The weakly relativistic electrons are produced by ultra-intense laser pulses, while ions are supposed to be in a non-relativistic regime. It is shown that dense plasma expansion is found to be governed mainly by quantum contributions in the fluid equations that originate from the degenerate pressure in addition to the nonlinear contributions from exchange and correlation potentials. The quantum degeneracy parameter profile provides clues to set the limit between under-dense and dense relativistic plasma expansions at a given density and temperature.

Keywords: plasma expansion, quantum degeneracy, weakly relativistic, under-dense plasma

Procedia PDF Downloads 87

Authors: Fares Khalfallah, Zakaria Boumerzoug, Selvarajan Rajakumar, Elhadj Raouache

Abstract:

The ceramic-aluminum bond is strongly present in industrial tools, due to the need to combine the properties of metals, such as ductility, thermal and electrical conductivity, with ceramic properties like high hardness, corrosion and wear resistance. In recent years, some joining techniques have been developed to achieve a good bonding between these materials such as brazing, diffusion bonding, ultrasonic joining and friction welding. In this work, AA1100 aluminum alloy rods were welded with Alumina 99.9 wt% ceramic rods, by friction welding. The effect of friction pressure on mechanical and structural properties of welded joints was studied. The welding was performed by direct friction welding machine. The welding samples were rotated at a constant rotational speed of 900 rpm, friction time of 4 sec, forging strength of 18 MPa, and forging time of 3 sec. Three different friction pressures were applied to 20, 34 and 45 MPa. The three-point bending test and Vickers microhardness measurements were used to evaluate the strength of the joints and investigate the mechanical properties of the welding area. The microstructure of joints was examined by optical microscopy (OM), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results show that bending strength increased, and then decreased after reaching a maximum value, with increasing friction pressure. The SEM observation shows that the increase in friction pressure led to the appearance of cracks in the microstructure of the interface area, which is decreasing the bending strength of joints.

Keywords: welding of ceramic to aluminum, friction welding, alumina, AA1100 aluminum alloy

Procedia PDF Downloads 129

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

Abstract:

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

Procedia PDF Downloads 534

Authors: T. A. Faria, C. C. Toniolo, L. F. Ribeiro

Abstract:

In order to satisfy the costumer’s needs, many sectors of industry and services has been spending major effort to make its processes more efficient. Facing a situation, when its production cannot cover the demand, the traditional way to achieve the production required involves, mostly, adding shifts, workforce, or even more machines. This paper narrates how lean manufacturing supported a dramatic increase of productivity at a rail welding plant in Brazil in order to meet the demand for the next years.

Keywords: productivity, lean manufacturing, rail welding, value stream mapping

Procedia PDF Downloads 364

Authors: Mohd Afif Md Nasir, Faizal Amin Nur Yunus, Jamaluddin Hashim, Abd Samad Hassan Basari, A. Halim Sahelan

Abstract:

The aim of this study is to identify the suitability of Virtual Learning Environment (VLE) in welding simulator application towards Computer-Based Training (CBT) in developing skills upon new students at the Advanced Technology Training Center (ADTEC), Batu Pahat, Johor, Malaysia and GIATMARA, Batu Pahat, Johor, Malaysia. The purpose of the study is to create a computer-based skills development approach in welding technology among new students in ADTEC and GIATMARA, as well as cultivating the elements of general skills among them. This study is also important in elevating the number of individual knowledge workers (K-workers) working in manufacturing industry in order to achieve a national vision which is to be an industrial nation in the year of 2020. The design of the study is a survey type of research which uses questionnaires as the instruments and 136 students from ADTEC and GIATMARA were interviewed. Descriptive analysis is used to identify the frequency and mean values. The findings of the study shows that the welding technology skills have developed in the students as a result of the application of VLE simulator at a high level and the respondents agreed that the skills could be embedded through the application of the VLE simulator. In summary, the VLE simulator is suitable in welding skills development training in terms of exposing new students with the relevant characteristics of welding skills and at the same time spurring the students’ interest towards learning more about the skills.

Keywords: computer-based training (CBT), knowledge workers (K-workers), virtual learning environment, welding simulator, welding technology

Procedia PDF Downloads 348

Authors: Lloyd G. Allred

Abstract:

The distribution of velocities of particles in plasma is a well understood discipline of plasma physics. Boltzmann’s law and the Maxwell-Boltzmann distribution describe the distribution of velocity of a particle in plasma as a function of mass and temperature. Particles with the same mass tend to have the same velocity. By expressing the same law in terms of energy alone, the author obtains a distribution independent of mass. In summary, for particles in plasma, the energies tend to equalize, independent of the masses of the individual particles. For high-energy plasma, the original law predicts velocities greater than the speed of light. If one uses Einstein’s formula for energy (E=mc²), then a relativistic correction is not required.

Keywords: cosmology, EMP, plasma physics, relativity

Procedia PDF Downloads 219

Authors: Nemes Alexandra

Abstract:

The aim of the research is to develop an optimum microstructure of steel coatings on aluminum surfaces for application on the crankcase cylinder bores. For the proper design of the microstructure of the coat, it is important to control the plasma gun unit properly. The maximum operating time was determined while the plasma gun could optimally work before its destruction. Objectives: The aim of the research is to determine the optimal operating time of the plasma gun between renovations (the renovation shall involve the replacement of the test components of the plasma gun: electrode, nozzle plate, powder injector. Methodology: Plasma jet and particle flux analysis with PFI (PFI is a diagnostic tool for all kinds of thermal spraying processes), CT reconstruction and analysis on the new and the used plasma guns, failure analysis of electrodes, nozzle plates, and powder injectors, microscopic examination of the microstructure of the coating. Contributions: As the result of the failure analysis detailed above, the use of the plasma gun was maximized at 100 operating hours in order to get optimal microstructure for the coat.

Keywords: APS, air plasma spray, failure analysis, electrode, nozzle plate, powder injector

Procedia PDF Downloads 119

Authors: Chukwuemeka Daniel Ezeliora, Chukwuebuka Lawrence Ezeliora

Abstract:

The research focused on the appraisal of impact strength on mild steel cladding weld metal geometry. Over the years, poor welding has resulted in failures in engineering components, poor material quality, the collapse of welded materials, and failures in material strength. This is as a result of poor selection and combination of welding input process parameters. The application of the Tungsten Inert Gas (TIG) welding method with weld specimen of length 60; width 40, and thickness of 10 was used for the experiment. A butt joint method was prepared for the welding, and tungsten inert gas welding process was used to perform the twenty (20) experimental runs. A response surface methodology was used to model and to analyze the system. For an adequate polynomial approximation, the experimental design was used to collect the data. The key parameters considered in this work are welding current, gas flow rate, welding speed, and voltage. The range of the input process parameters was selected from the literature and the design. The steps followed to achieve the experimental design and results is the use of response surface method (RSM) implemented in central composite design (CCD) to generate the design matrix, to obtain quadratic model, and evaluate the interactions in the factors as well as optimizing the factors and the response. The result expresses that the best impact strength of the mild steel cladding weld metal geometry is 115.419 Joules. However, it was observed that the result of the input factors is; current 180.4 amp, voltage 23.99 volt, welding speed 142.7 mm.s and gas flow rate 10.8 lit/min as the optimum of the input process parameters. The optimal solution gives a guide for optimal impact strength of the weldment when welding with tungsten inert gas (TIG) under study.

Keywords: mild steel, impact strength, response surface, bead geometry, welding

Procedia PDF Downloads 119

Authors: Meihua Fang, Yipan Guo, Tao Fei, Pengyu Tian

Abstract:

Space plasma caused spacecraft surface charging is the major space environment hazard. Particle in cell (PIC) method can be used to simulate the interaction between space plasma and spacecraft. It was proved that surface charging level of spacecraft in Jupiter’s orbits was high for its’ electron-heavy plasma environment. In this paper, Jovian plasma environment is modeled and surface charging analysis is carried out by PIC based software Spacecraft Plasma Interaction System (SPIS). The results show that the spacecraft charging potentials exceed 1000V at 2Rj, 15Rj and 25Rj polar orbits in the dark side at worst case plasma model. Furthermore, the simulation results indicate that the large Jovian magnetic field increases the surface charging level for secondary electron gyration.

Keywords: Jupiter, PIC, space plasma, surface charging

Procedia PDF Downloads 151

Authors: Gurmeet Singh Cheema, Gurjinder Singh, Amardeep Singh Kang

Abstract:

Aluminium alloy 6061 is a medium to high strength heat-treatable alloy which has very good corrosion resistance and very good weldability. Friction Stir Welding was developed and this technique has attracted considerable interest from the aerospace and automotive industries since it is able to produce defect free joints particularly for light metals i.e aluminum alloy and magnesium alloy. In the friction stir welding process, welding parameters such as tool rotational speed, welding speed and tool shoulder diameter play a major role in deciding the weld quality. In this research work, an attempt has been made to understand the effect of tool rotational speed, welding speed and tool shoulder diameter on friction stir welded AA6061 aluminium alloy joints. Statistical tool such as central composite design is used to develop the mathematical relationships. The mathematical model was developed to predict mechanical properties of friction stir welded aluminium alloy joints at the 95% confidence level.

Keywords: aluminium alloy, friction stir welding, central composite design, mathematical relationship

Procedia PDF Downloads 502

Authors: Armansyah, I. P. Almanar, M. Saiful Bahari Shaari, M. Shamil Jaffarullah, Nur’amirah Busu, M. Arif Fadzleen Zainal Abidin, M. Amlie A. Kasim

Abstract:

Temperature distribution in Friction Stir Welding (FSW) of 6061-T6 Aluminum Alloy is modeled using the Finite Element Method (FEM). In order to obtain temperature distribution in the welded aluminum plates during welding operation, transient thermal finite element analyses are performed. 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 workpiece is used in the analysis. Three-dimensional model for simulated process is carried out by using Altair HyperWork, a commercially available software. Transient thermal finite element analyses are performed in order to obtain the temperature distribution in the welded Aluminum plates during welding operation. 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 workpiece.

Keywords: frictions stir welding, temperature distribution, finite element method, altair hyperwork

Procedia PDF Downloads 543