Search results for: friction push plug welding

Authors: Agata Tomaszewska, Timothy Kamps, Stephan R. Turnock, Nicola Symonds

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Bob skeleton is a highly competitive sport in which an athlete reaches speeds up to 40 m/s sliding, head first, down an ice track. It is believed that the friction between the runners and ice significantly contributes to the amount of the total energy loss during a bob skeleton descent. There is only limited available experimental data regarding the friction of bob skeleton runners or indeed steel on the ice at high sliding speeds ( > 20 m/s). Testing methods used to investigate the friction of steel on ice in winter sports have been outlined, and their accuracy and repeatability discussed. A system thinking approach was used to investigate the runner-ice interaction during sliding and create concept designs of three ice tribometers. The operational envelope of the bob skeleton system has been defined through mathematical modelling. Designs of a drum, linear and inertia pin-on-disk tribometers were developed specifically for bob skeleton runner testing with the requirement of reaching up to 40 m/s speed and facilitate fresh ice sliding. The design constraints have been outline and the proposed solutions compared based on the ease of operation, accuracy and the development cost.

Keywords: bob skeleton, ice friction, high-speed tribometers, sliding friction

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Authors: Jian Zheng, Li Li, Maxime Daviault

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In several cases, one needs apply lubrication materials in laboratory tests to reduce the friction (shear strength) along the interfaces between a tested soil and the side walls of container. Several types of lubricants are available. Their effectiveness had been tested mostly through direct shear tests. These testing conditions are quite different than those when the tested soil is placed in the container. Thus, the shear strengths measured from direct shear tests may not be totally representative of those of interfaces between the tested soil and the sidewalls of container. In this paper, the effectiveness of different lubricants used to reduce the friction (shear strength) of soil-structure interfaces has been studied. Results show that the selected lubricants do not significantly reduce the sidewall friction (shear strength). Rather, the application of wax, graphite, grease or lubricant oil has effect to increase the sidewall shear strength due probably to the high viscosity of such materials. Subsequently, the application of lubricants between tested soil and sidewall and neglecting the friction (shear strength) along the sidewalls may lead to inaccurate test results.

Keywords: arching, friction, laboratory tests, lubricants

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Authors: Siripen Yiamjanya, Kevin Wongleedee

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This research paper aims to identify travel motivation by push and pull factors that affected decision making of international tourists in selecting Thailand as their destination choice. A total of 200 international tourists who traveled to Thailand during January and February, 2014 were used as the sample in this study. A questionnaire was employed as a tool in collecting the data, conducted in Bangkok. The list consisted of 30 attributes representing both psychological factors as “push- based factors” and destination factors as “pull-based factors”. Mean and standard deviation were used in order to find the top ten travel motives that were important determinants in the respondents’ decision making process to select Thailand as their destination choice. The finding revealed the top ten travel motivations influencing international tourists to select Thailand as their destination choice included [i] getting experience in foreign land; [ii] Thai food; [iii] learning new culture; [iv] relaxing in foreign land; [v] wanting to learn new things; [vi] being interested in Thai culture, and traditional markets; [vii] escaping from same daily life; [viii] enjoying activities; [ix] adventure; and [x] good weather. Classification of push- based and pull- based motives suggested that getting experience in foreign land was the most important push motive for international tourists to travel, while Thai food portrayed its highest significance as pull motive. Discussion and suggestions were also made for tourism industry of Thailand.

Keywords: decision making, destination choice, international tourist, pull factor, push factor, Thailand, travel motivation

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Authors: M. De Maaijer, Wenxuan Shi, , Dolores Pose, Ditmar, F. Barati

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Friction has several detrimental effects on Blind performance, Therefore Ziptak company as the leading company in the blind manufacturing sector, start investigating on how to conquer this problem in next generation of blinds. This problem is more sever in extremely sever condition. Although in these condition Ziptrak suggest not to use the blind, working on blind and its associated parts was the priority of Ziptrak company. The purpose of this article is to measure the effects of lubrication process on reducing friction force between spline and track especially at windy conditions Four different lubricants were implicated to measure their efficiency on reducing friction force.

Keywords: libricant, ziptrak, blind, spline

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Authors: Mikołaj Szyca

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Friction elements of rail vehicle brakes are more and more often made of composite materials that displace cast iron. Materials are tested primarily in terms of their dynamic abilities, but the material structure of brake pads and linings changes during operation. In connection with the above, the changes taking place in the tested rubbing materials were analyzed using X-ray computed tomography in order to obtain data on changes in the structure of the material immediately after production and after a certain number of operating cycles. The implementation of microtomography research for experimental work on new friction materials may result in increasing the potential for the production of new composites by eliminating unfavorable material factors and, consequently, improving the dynamic parameters.

Keywords: composite materials, friction pair, X-ray computed microtomography, railway

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Authors: Blanca A. Pichardo, Victor H. Lopez, Melchor Salazar, Rafael Garcia, Alberto Ruiz

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Clad pipes in comparison to plain carbon steel pipes offer the oil and gas industry high corrosion resistance, reduction in economic losses due to pipeline failures and maintenance, lower labor risk, prevent pollution and environmental damage due to hydrocarbons spills caused by deteriorated pipelines. In this context, it is paramount to establish reliable welding procedures to join bimetallic plates or pipes. Thus, the aim of this work is to study the microstructure and mechanical behavior of clad plates welded by the gas metal arc welding (GMAW) process. A clad of 316L stainless steel was deposited onto API 5L X-60 plates by overlay welding with the GMAW process. Welding parameters were, 22.5 V, 271 A, heat input 1,25 kJ/mm, shielding gas 98% Ar + 2% O₂, reverse polarity, torch displacement speed 3.6 mm/s, feed rate 120 mm/s, electrode diameter 1.2 mm and application of an electromagnetic field of 3.5 mT. The overlay welds were subjected to macro-structural and microstructural characterization. After manufacturing the clad plates, a single V groove joint was machined with a 60° bevel and 1 mm root face. GMA welding of the bimetallic plates was performed in four passes with ER316L-Si filler for the root pass and an ER70s-6 electrode for the subsequent welding passes. For joining the clad plates, an electromagnetic field was applied with 2 purposes; to improve the microstructural characteristics and to assist the stability of the electric arc during welding in order to avoid magnetic arc blow. The welds were macro and microstructurally characterized and the mechanical properties were also evaluated. Vickers microhardness (100 g load for 10 s) measurements were made across the welded joints at three levels. The first profile, at the 316L stainless steel cladding, was quite even with a value of approximately 230 HV. The second microhardness profile showed high values in the weld metal, ~400 HV, this was due to the formation of a martensitic microstructure by dilution of the first welding pass with the second. The third profile crossed the third and fourth welding passes and an average value of 240 HV was measured. In the tensile tests, yield strength was between 400 to 450 MPa with a tensile strength of ~512 MPa. In the Charpy impact tests, the results were 86 and 96 J for specimens with the notch in the face and in the root of the weld bead, respectively. The results of the mechanical properties were in the range of the API 5L X-60 base material. The overlap welding process used for cladding is not suitable for large components, however, it guarantees a metallurgical bond, unlike the most commonly used processes such as thermal expansion. For welding bimetallic plates, control of the temperature gradients is key to avoid distortions. Besides, the dissimilar nature of the bimetallic plates gives rise to the formation of a martensitic microstructure during welding.

Keywords: clad pipe, dissimilar welding, gas metal arc welding, magnetic fields

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Authors: Ravindra Raju, Vidhu Kampurath

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For smooth transition of the power from the engine to the transmission system, a clutch is used. In agricultural tractors, friction clutches are widely used in power transmission applications. To transmit the maximum torque in friction clutches, selection of materials is one of the important tasks. The present used material for friction disc is Asbestos, Ceramic etc. In this study, analysis is performed using composites materials. The composite materials are considered due to their high strength to weight ratio. Composite materials like kevlar49, kevlar 29U were used in the study. The paper presents a systematic approach to optimize the structural and thermal characteristics of the clutch friction pad. A single plate clutch is modeled using Creo 2.0 software and analyzed using ANSYS. Thermal analysis considers the reduction of heat generated between the friction surfaces and reducing the temperature rise during the steady state period. Structural analysis is done to minimize the stresses developed as a result of the loading contact between friction surfaces. Also, modal analysis is done to optimize the natural frequency of the friction plate to avoid being in resonance with the engine frequency range. The analysis carried out on ANSYS workbench to get the foremost appropriate friction material for clutch. From the analyzed results stress, strain / total deformation values and natural frequency of the materials were compared for all the composite materials and the best one was taken out. For the study purpose, specifications of the clutch are obtained from the MF1035 (47KW) Tractor model.

Keywords: ANSYS, clutch, composite materials, creo

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Authors: Hyungoo Kang, Jinkoo Kim

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This study investigated the determination of the optimal location and friction force of friction dampers to effectively reduce the seismic response of a reinforced concrete structure designed without considering seismic load. To this end, the genetic algorithm process was applied and the results were compared with those obtained by simplified methods such as distribution of dampers based on the story shear or the inter-story drift ratio. The seismic performance of the model structure with optimally positioned friction dampers was evaluated by nonlinear static and dynamic analyses. The analysis results showed that compared with the system without friction dampers, the maximum roof displacement and the inter-story drift ratio were reduced by about 30% and 40%, respectively. After installation of the dampers about 70% of the earthquake input energy was dissipated by the dampers and the energy dissipated in the structural elements was reduced by about 50%. In comparison with the simplified methods of installation, the genetic algorithm provided more efficient solutions for seismic retrofit of the model structure.

Keywords: friction dampers, genetic algorithm, optimal design, RC buildings

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Authors: Lia Gventsadze, Elguja Kutelia, David Gventsadze

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The purpose of the article is to show the possibility for the development of a new generation, eco-friendly (asbestos free) nano-porous friction materials on the basis of Georgian raw materials, along with the determination of technological parameters for their production, as well as the optimization of tribological properties and the investigation of structural aspects of wear peculiarities of elaborated materials using the scanning electron microscopy (SEM) and Auger electron spectroscopy (AES) methods. The study investigated the tribological properties of the polymer friction materials on the basis of the phenol-formaldehyde resin using the porous diatomite filler modified by silane with the aim to improve the thermal stability, while the composition was modified by iron phosphate, technical carbon and basalt fibre. As a result of testing the stable values of friction factor (0.3-0,45) were reached, both in dry and wet friction conditions, the friction working parameters (friction factor and wear stability) remained stable up to 500 OC temperatures, the wear stability of gray cast-iron disk increased 3-4 times, the soundless operation of materials without squeaking were achieved. Herewith it was proved that small amount of ingredients (5-6) are enough to compose the nano-porous friction materials. The study explains the mechanism of the action of nano-porous composition base brake lining materials and its tribological efficiency on the basis of the triple phase model of the tribo-pair.

Keywords: brake lining, friction coefficient, wear, nanoporous composite, phenolic resin

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Authors: Ruben Dario Tovar-Valencia, Eshan Ganju, Fei Han, Monica Prezzi, Rodrigo Salgado

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Particle breakage occurs even in strong silica sand particles. There is compelling evidence that suggests that particle breakage causes changes in several properties such as permeability, peak strength, dilatancy and critical state friction angle. Current pile design methods that are based on soil properties do not account for particle breakage that occurs during driving or jacking of displacement piles. This may lead to significant overestimation of pile capacity in sands dominated by particles susceptible to breakage, such as carbonate sands. The objective of this paper is to study the influence of shear displacement on particle breakage and friction angle of carbonate sands, and to furthermore quantify the change in friction angle observed with different levels of particle breakage. To study the phenomenon of particle breakage, multiple ring shear tests have been performed at different levels of vertical confinement on a thoroughly characterized carbonate sand to find i) the shear displacement necessary to reach stable friction angles and ii) the effect of particle breakage on the mobilized friction angle of the tested sand. The findings of this study can potentially be used to update the current pile design methods by developing a friction angle which is a function of shear displacement and breakage characteristics of the sand instead of being a constant value.

Keywords: breakage, carbonate sand, friction angle, pile design, ring shear test

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Authors: Ashraf Mohammed M. Eid, Hossam El Badry

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The bored pile friction resistance may be affected by many factors such as the method of construction, pile length and diameter, the soil properties, as well as the depth below ground level. These factors can be represented analytically to study the influence of diameter on the unit skin friction. In this research, the Egyptian Code of soil mechanics is used to assess the skin friction capacity for either the ordinary pile diameter as well as for the large pile diameter. The later is presented in the code and through the work of some researchers based on the results of investigations adopted for a sufficient number of field tests. The comparative results of these researchers with respect to the Egyptian Code are used to check the adequacy of both methods. Based on the results of this study, the traditional static formula adopted for piles of diameter less than 60 cm may be continually used for larger piles by correlating the analyzed formulae. Accordingly, the corresponding modified angle of internal friction is concluded demonstrating a reduction of shear strength due to soil disturbance along the pile shaft. Based on this research the difference between driven piles and bored piles constructed in same soil can be assessed and a better understanding can be evaluated for the effect of different factors on pile skin friction capacity.

Keywords: large piles, static formula, friction piles, sandy soils

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Authors: H. Mohammadi Majd, M. Jalali Azizpour, V. Tavaf, A. Jaderi

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In upsetting processes contact friction significantly influence metal flow, stress-strain state and process parameters. Furthermore, tribological conditions influence workpiece deformation and its dimensional precision. A viscoplastic constitutive law, the Anand model, was applied to represent the inelastic deformation behavior in upsetting process. This paper presents research results of the influence of contact friction coefficient on a workpiece deformation in upsetting process.finite element parameters. This technique was tested for three different specimens simulations of the upsetting and the corresponding material and can be successfully employed to predict the deformation of the upsetting process.

Keywords: friction, upsetting, barreling, Anand model

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Authors: Joon-Suk Kim, Hae-Woo Lee

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This study discusses the effect of welding heat input on intergranular corrosion of the weld metal of Inconel 625 alloy. A specimen of Inconel 625 with a weld metal that controlled welding heat input was manufactured, and aging heat treatment was conducted to investigate sensitization by chromium carbides. The electrochemical SL and DL EPR experiments, together with the chemical ferric sulfate-sulfuric acid and nitric acid tests, were conducted to determine intergranular corrosion susceptibility between the specimens. In the SL and DL EPR experiments, specimens were stabilized in the weld metal, and therefore intergranular corrosion susceptibility could not be determined. However, in the ferric sulfate-sulfuric acid and nitric acid tests, the corrosion speed increased as heat input increased. This was because the amount of diluted Fe increased as the welding heat input increased, leading to microsegregation between the dendrites, which had a negative effect on the corrosion resistance.

Keywords: Inconel 625, weling, overlay, heat input, intergranular corrosion

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Authors: M. R. Daneshgar, S. E. Habibi, E. Daneshgar, A. Daneshgar

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In this paper, a two-dimensional method is developed to simulate the fillet welds in a stiffened cylindrical shell, using finite element method. The stiffener material is aluminum 2519. The thermo-elasto-plastic analysis is used to analyze the thermo-mechanical behavior. Due to the high heat flux rate of the welding process, two uncouple thermal and mechanical analysis are carried out instead of performing a single couple thermo-mechanical simulation. In order to investigate the effects of the welding procedures, two different welding techniques are examined. The resulted residual stresses and distortions due to different welding procedures are obtained. Furthermore, this study employed the technique of element birth and death to simulate the weld filler variation with time in fillet welds. The obtained results are in good agreement with the published experimental and three-dimensional numerical simulation results. Therefore, the proposed 2D modeling technique can effectively give the corresponding results of 3D models. Furthermore, by inspection of the obtained residual hoop and transverse stresses and angular distortions, proper welding procedure is suggested.

Keywords: stiffened cylindrical shell, fillet welds, residual stress, angular distortion, finite element method

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Authors: Abdullah Kaymakci, Daniel M. Madyira, Ntokozo Nkwanyana

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The effect of metal transfer modes on mechanical properties of welded 3CR12 stainless steel were investigated. This was achieved by butt welding 10 mm thick plates of 3CR12 in different positions while varying the welding positions for different metal transfer modes. The ASME IX: 2010 (Welding and Brazing Qualifications) code was used as a basis for welding variables. The material and the thickness of the base metal were kept constant together with the filler metal, shielding gas and joint types. The effect of the metal transfer modes on the microstructure and the mechanical properties of the 3CR12 steel was then investigated as it was hypothesized that the change in welding positions will affect the transfer modes partly due to the effect of gravity. The microscopic examination revealed that the substrate was characterized by dual phase microstructure, that is, alpha phase and beta phase grain structures. Using the spectroscopic examination results and the ferritic factor calculation had shown that the microstructure was expected to be ferritic-martensitic during air cooling process. The tested tensile strength and Charpy impact energy were measured to be 498 MPa and 102 J which were in line with mechanical properties given in the material certificate. The heat input in the material was observed to be greater than 1 kJ/mm which is the limiting factor for grain growth during the welding process. Grain growths were observed in the heat affected zone of the welded materials. Ferritic-martensitic microstructure was observed in the microstructure during the microscopic examination. The grain growth altered the mechanical properties of the test material. Globular down hand had higher mechanical properties than spray down hand. Globular vertical up had better mechanical properties than globular vertical down.

Keywords: welding, metal transfer modes, stainless steel, microstructure, hardness, tensile strength

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Authors: Pujan Sarkar

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Frictional behavior of glass epoxy and Al particulate glass-epoxy composites sliding against mild steel are investigated experimentally at normal atmospheric condition. Glass epoxy (0 wt% Al) and 5, 10 and 15 wt% Al particulate filled glass-epoxy composites are fabricated in conventional hand lay-up technique followed by light compression moulding process. A pin on disc type friction apparatus is used under dry sliding conditions. Experiments are carried out at a normal load of 5-50 N, and sliding speeds of 0.5-5.0 m/s for a fixed duration. Variations of friction coefficient with sliding time at different loads and speeds for all the samples are considered. Results show that the friction coefficient is influenced by sliding time, normal loads, sliding speeds, and wt% of Al content. In general, with respect to time, friction coefficient increases initially with a lot of fluctuations for a certain duration. After that, it becomes stable for the rest of the experimental time. With the increase of normal load, friction coefficient decreases at all speed levels and for all the samples whereas, friction coefficient increases with the increase of sliding speed at all normal loads for glass epoxy and 5 wt% Al content glass-epoxy composites. But for 10 and 15 wt%, Al content composites at all loads, reverse trend of friction coefficient has been recorded. Under different tribological conditions, the suitability of composites in respect of wt% of Al content is noted, and 5 wt% Al content glass-epoxy composite reports as the lowest frictional material at all loads compared to other samples.

Keywords: Al powder, composite, epoxy, friction, glass fiber

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Authors: Michal Urzynicok, Krzysztof Kwiecinski

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The development of materials used in the power generation industry for the production of boilers and their parts is characterized by high steam parameters, which present new challenges. Implementation of new combinations of alloying elements that lead to the best possible mechanical properties, including creep resistance, greatly affects new steels' weldability. All new grades have to undergo many different examinations, in regards to bending and welding, in order to enable the development of fabrication technologies, ensuring failure-free production and assembly of boiler components. 12% Cr martensitic steels like THOR™ 115 or VM-12 SHC are characterized by high oxidation resistance in high-temperature environments. At the moment, VM-12 SHC can be found in many boilers where both headers and superheater coils were produced. As this material is very difficult to obtain, a search for a proper replacement has begun. A new creep strength-enhanced ferritic steel for service in supercritical and ultra-supercritical boiler applications was developed by Tenaris in Italy and it is designated as Thor™115 (Tenaris High Oxidation Resistance). As high demand in power plants occurred to replace some parts of existing installations fabricated from VM12-SHC with other alternatives, a new development of welding procedures has begun to prepare fabricators for the challenges of joining old components with new THOR™ 115 material. This paper covers the first research of welding of dissimilar joints made out of VM12-SHC and THOR™ 115.

Keywords: thor, vm12, dissimilar welding, weldability

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Authors: Apetsi K. Ampiah, Zhao Xin

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Earthquakes over the years have been known to cause devastating damage on buildings and induced huge loss on human life and properties. It is for this reason that engineers have devised means of protecting buildings and thus protecting human life. Since the invention of devices such as the viscous and friction dampers, scientists/researchers have been able to incorporate these devices into buildings and other engineering structures. The viscous damper is a hydraulic device which dissipates the seismic forces by pushing fluid through an orifice, producing a damping pressure which creates a force. In the friction damper, the force is mainly resisted by converting the kinetic energy into heat by friction. Devices such as viscous and friction dampers are able to absorb almost all the earthquake energy, allowing the structure to remain undamaged (or with some amount of damage) and ready for immediate reuse (with some repair works). Comparing these two devices presents the engineer with adequate information on the merits and demerits of these devices and in which circumstances their use would be highly favorable. This paper examines the performance of both viscous and friction dampers under different ground motions. A two-storey frame installed with both devices under investigation are modeled in commercial computer software and analyzed under different ground motions. The results of the performance of the structure are then tabulated and compared. Also included in this study is the ease of installation and maintenance of these devices.

Keywords: friction damper, seismic, slip load, viscous damper

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Authors: Maz Muradvich

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The Federal Highway Administration's Everyday Counts (EDC) initiative is designed to identify and deploy innovations, enhancing the safety of our roadways. According to and as referenced in FHWA everyday counts (2) website, High friction surface treatment (HFST) is an emerging surface application that has been proven to reduce crashes. High Friction Surface Treatment involves the application of Calcined Bauxite, very high-quality aggregate to the pavement using a polymer binder to restore and maintain pavement friction at existing or potentially high crash areas. Bauxite is a byproduct of manufacturing aluminum resulting in very hard aggregate and is abrasion and polish resistant. HFST is an approach that has been recognized nationally and internationally and has provided considerable increases in friction for curves and intersections spot applications. Maricopa County qualified and received HSIP (Highway Safety Improvement Program) funding that was applied towards HFST application on 2 locations in Maricopa County. The project was successfully completed in December 2019. Four years later MCDOT continues to conduct wet and dry ABS and Non-ABS friction coefficient testing in pursuit of after studies evaluation of HFST application.

Keywords: roadway departure, sever crashes, coefficient of friction, break meter technology

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Authors: F. Villaret, I. Jacot, Y. Shen, Z. Kong, T. XU, Y. Wang, D. Lu

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Wire Arc Additive Manufacturing (WAAM) allows the rapid production of large, homogeneous parts with complex geometry. However, in the nuclear field, parts can reach dimensions of ten to a hundred tons. In this case, the usual WAAM TIG or CMT processes do not have sufficient deposition rates to consider the manufacture of parts of such dimensions within a reasonable time. The submerged arc welding process (SAW, Submerged Arc Welding) allows much higher deposition rates. Although there are very few references to this process for additive manufacturing in the literature, it has been used for a long time for the welding and coating of nuclear power plant vessels, so this process is well-known and mastered as a welding process. This study proposes to evaluate the SAW process as an additive manufacturing technique by taking as an example a low-alloy steel of type 16MND5. In the first step, a parametric study allowed the evaluation of the effect of the different parameters and the deposition rate on the geometry of the beads and their microstructure. Larger parts were also fabricated and characterized by metallography and mechanical tests (tensile, impact, toughness). The effect of different heat treatments on the microstructure is also studied.

Keywords: WAAM, low alloy steel, submerged arc, caracterization

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Authors: Lucas Wilman Crispim, Patrícia Hallack, Maikel Ballester

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This work aims at modeling electric discharges in gas mixtures. The mathematical model mimics the ignition process in a commercial spark-plug when a high voltage is applied to the plug terminals. A longitudinal unidimensional Cartesian domain is chosen for the simulation region. Energy and mass transfer are considered for a macroscopic fluid representation, while energy transfer in molecular collisions and chemical reactions are contemplated at microscopic level. The macroscopic model is represented by a set of uncoupled partial differential equations. Microscopic effects are studied within a discrete model for electronic and molecular collisions in the frame of ZDPlasKin, a plasma modeling numerical tool. The BOLSIG+ solver is employed in solving the electronic Boltzmann equation. An operator splitting technique is used to separate microscopic and macroscopic models. The simulation gas is a mixture of atomic Argon neutral, excited and ionized. Spatial and temporal evolution of such species and temperature are presented and discussed.

Keywords: CFD, electronic discharge, ignition, spark plug

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Authors: Ian Jones, Jonathan Griffiths

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Laser welding offers the potential for making very precise joints in plastics products, both in terms of the joint location and the amount of heating applied. These methods have allowed the production of complex products such as microfluidic devices where channels and structure resolution below 100 µm is regularly used. However, to date, the dimension of welds made using lasers has been limited by the focus spot size that is achievable from the laser source. Theoretically, the minimum spot size possible from a laser is comparable to the wavelength of the radiation emitted. Practically, with reasonable focal length optics the spot size achievable is a few factors larger than this, and the melt zone in a plastics weld is larger again than this. The narrowest welds feasible to date have therefore been 10-20 µm wide using a near-infrared laser source. The aim of this work was to prepare laser absorber tracks and channels less than 10 µm wide in PMMA thermoplastic using EB lithography followed by sealing of channels using laser welding to carry out welds with widths of the order of 1 µm, below the resolution limit of the near-infrared laser used. Welded joints with a width of 1 µm have been achieved as well as channels with a width of 5 µm. The procedure was based on the principle of transmission laser welding using a thin coating of infrared absorbent material at the joint interface. The coating was patterned using electron-beam lithography to obtain the required resolution in a reproducible manner and that resolution was retained after the transmission laser welding process. The joint strength was ratified using larger scale samples. The results demonstrate that plastics products could be made with a high density of structure with resolution below 1 um, and that welding can be applied without excessively heating regions beyond the weld lines. This may be applied to smaller scale sensor and analysis chips, micro-bio and chemical reactors and to microelectronic packaging.

Keywords: microchannels, polymer, EB lithography, laser welding

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Authors: Antônio P. de Araújo Neto, Ruy D. A. da Silva Neto, Juliana R. de Souza, Salete K. P. de Medeiros, João T. N. de Medeiros

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The tribological test with Pin-On-Disc configuration measures friction and wear properties in dry or lubricated sliding surfaces of a variety of materials and coatings. Polymeric matrix composites loaded with mineral filler were used, 1%, 3%, 10%, 30%, and 50% mass percentage of filler, to reduce the material cost by using mineral tailings. Using a pin-on-disc tribometer to quantify coefficient of friction and wear resistance of the specimens. The parameters known to performing the test were 300 rpm rotation, normal load of 16N and duration of 33.5 minutes. The composite with 10% mineral filler performed better, considering that the wear resistance was good when compared to the other compositions and an average low coefficient of friction, in the order of μ ≤ 0.15.

Keywords: microcomposites, microparticles tailings of scheelite, PTFE, tribology

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Authors: S. Talebnezhad, S. Pourmahdian, D. Soudbar, M. Khosravani, J. Merasi

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Adding toughened polypropylene and plastomer in FFS 3 layered blown film formulation resulted in superior dart impact and MD tear resistance along with acceptable tensile properties in TD and MD. The optimum loading of toughened polypropylene and plastomer in each layer depends on miscibility of polypropylene in polyethylene medium, mechanical properties, welding characteristics in bags top and bottoms and friction coefficient of film surfaces. Film property tests and efficiency of FFS machinery during processing in industrial scale showed that about 4% loading of plastomer and 16% of toughened polypropylene (reactor grade) in middle layer and loading of 0-1% plastomer and 5-19% of toughened polypropylene in other layers results optimum characteristics in the formulation based on 1-butene LLDPE grade with MFR of 0.9 and LDPE grade with MFI of 0.3. Both the plastomer and toughened polypropylene had the MFI of blow 1 and the TiO2 and processing aid masterbatches loading was 2%. The friction coefficient test results also represented the anti-block masterbatch could be omitted from formulation with adding toughened polypropylene due to partial miscibility of PP in PE which makes the surface of films somewhat bristly.

Keywords: FFS 3 layered blown film, toughened polypropylene, plastomer, dart impact, tear resistance

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Authors: Mostafa Makrahy, Nouby Ghazaly, Ahmad Moaaz

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Brakes are one of the most important safety and performance components in automobiles and airplanes. Development of brakes has mainly focused on increasing braking power and stability. Nowadays, brake noise, vibration and harshness (NVH) together with brake dust emission and pad life are very important to vehicle drivers. The main objective of this research is to define the relationship between compressibility of friction materials and their tendency to generate vibration. An experimental study of the friction-induced vibration obtained by the disc brake system of a passenger car is conducted. Three commercial brake pad materials from different manufacturers are tested and evaluated under various brake conditions against cast iron disc brake. First of all, compressibility test for the brake friction material are measured for each pad. Then, brake dynamometer is used to simulate and reproduce actual vehicle braking conditions. Finally, a comparison between the three pad specimens is conducted. The results showed that compressibility have a very significant effect on reduction the vibration occurrence.

Keywords: automotive brake, friction material, brake dynamometer, compressibility test

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Authors: T. Teruzzi, S. Antonietti, C. Mosca, C. Paglia

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This paper discusses the causes of the structural failure in a tower crane. The structural collapse occurred at the upper joints of the extension element used to increase the height of the crane. The extension element consists of a steel lattice structure made with angular profiles and plates joined to the tower element by arc welding. Macroscopic inspection of the sections showed that the break was always observed on the angular profiles at the weld bead edge. The case study shows how, using mechanical characterization, chemical analysis of the steel and macroscopic and microscopic metallographic examinations, it was possible to obtain significant evidence that identified the mechanism causing the breakage. The analyses identified the causes of the structural failure as the use of materials that were not suitable for welding and poor performance in the welding joints.

Keywords: failure, metals, weld, microstructure

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Authors: Carolina Payares-Asprino

Abstract:

Dual-phase duplex stainless steel comprised of ferrite and austenite has shown high strength and corrosion resistance in many aggressive environments. Joining duplex alloys is challenging due to several embrittling precipitates and metallurgical changes during the welding process. The welding parameters strongly influence the quality of a weld joint. Therefore, it is necessary to quantify the weld bead’s integral properties as a function of welding parameters, especially when part of the weld bead is removed through a machining process due to aesthetic reasons or to couple the elements in the in-service structure. The present study uses the existing stress-strain model to predict the stress-strain curves for duplex stainless-steel welds under different welding conditions. Having mathematical expressions that predict the shape of the stress-strain curve is advantageous since it reduces the experimental work in obtaining the tensile test. In analysis and design, such stress-strain modeling simplifies the time of operations by being integrated into calculation tools, such as the finite element program codes. The elastic zone and the plastic zone of the curve can be defined by specific parameters, generating expressions that simulate the curve with great precision. There are empirical equations that describe the stress-strain curves. However, they only refer to the stress-strain curve for the stainless steel, but not when the material is under the welding process. It is a significant contribution to the applications of duplex stainless steel welds. For this study, a 3x3 matrix with a low, medium, and high level for each of the welding parameters were applied, giving a total of 27 weld bead plates. Two tensile specimens were manufactured from each welded plate, resulting in 54 tensile specimens for testing. When evaluating the four models used to predict the stress-strain curve in the welded specimens, only one model (Rasmussen) presented a good correlation in predicting the strain stress curve.

Keywords: duplex stainless steels, modeling, stress-stress curve, tensile test, welding

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Authors: Md. Rashel Sheikh

Abstract:

The shipbuilding industry in Bangladesh had become a fast-growing industry in recent years when it began to export newly built ships. The various activities of shipbuilding industries in their limited, confined spaces added occupational worker exposures to chemicals, dusts, and metal fumes. The aim of this literature search is to identify the potential sources of occupational health hazards in shipyards and to promote the regulation of appropriate personal protective equipment (PPE) for the workers. In shipyards, occupational workers are involved in various activities, such as the manufacture, repair, maintenance, dismantling of boats and ships, building small ocean-going vessels and ferries. The occupational workers in the shipbuilding industry suffer from a number of hazardous issues, such as asthma, dermatitis, hearing deficits, and musculoskeletal disorders. The use of modern technologies, such as underwater plasma welding, electron beam welding, and friction stir welding and laser cutting and welding, and appropriate PPE (i.e., long-sleeved shirt and long pants, shoes plus socks, safety masks, chemical resistant gloves, eyewear, face shield, and respirators) can help reduce the occupational exposure to environmental hazards created by different activities in the shipyards. However, most shipyards in Bangladesh use traditional methods, e.g., flame cutting and arc, that add hazardous waste and pollutants to the environment in and around the shipyard. The safety and security of occupational workers in the shipyard workplace are very important. It is the primary responsibility of employers to ensure the safety and security of occupational workers in the shipyards. Employers must use advanced technologies and supply adequate and appropriate PPE for the workers. There are a number of accidents and illnesses that happen daily in the shipyard industries in Bangladesh due to the negligence and lack of adequate technologies and appropriate PPE. In addition, there are no specific regulations and implementations available to use the PPE. It is essential to have PPE regulations and strict enforcement for the adoption of PPE in the shipbuilding industries in Bangladesh. Along with the adoption of PPE with regular health examinations, health education to the workers regarding occupational hazards and lifestyle diseases are also important and require reinforcement. Monitoring health and safety hazards in shipyards are essential to enhance worker protection, and ensure worker safety, and mitigate workplace injuries and illnesses.

Keywords: shipbuilding Industries, health education, occupational health hazards, personal protective equipment, shipyard workers, occupational workers, shipyards

Procedia PDF Downloads 142

Authors: Haibin Zhou, Pingping Yao, Kunyang Fan

Abstract:

Copper-based sintered friction materials are widely used in the brake system of different applications such as engineering machinery or high-speed train, due to the excellent mechanical, thermal and tribological performance. Considering the diversity of the working conditions of brake system, it is necessary to identify well and understand the tribological performance and wear mechanisms of friction materials for different conditions. Fe has been a preferred reinforcement for copper-based friction materials, due to its ability to improve the wear resistance and mechanical properties of material. Wear map is well accepted as a useful research method for evaluation of wear performances and wear mechanisms over a wider range of working conditions. Therefore, it is significantly important to construct a wear map which can give out the effects of work condition and Fe reinforcement on tribological performance of Cu-based friction materials. In this study, the copper-based sintered friction materials with the different addition of Fe reinforcement (0-20 vol. %) were studied. The tribological tests were performed against stainless steel in a ring-on-ring braking tester with varying braking energy density (0-5000 J/cm2). The linear wear and friction coefficient were measured. The worn surface, cross section and debris were analyzed to determine the dominant wear mechanisms for different testing conditions. On the basis of experimental results, the wear map and wear mechanism map were established, in terms of braking energy density and the addition of Fe. It was found that with low contents of Fe and low braking energy density, adhesive wear was the dominant wear mechanism of friction materials. Oxidative wear and abrasive wear mainly occurred under moderate braking energy density. In the condition of high braking energy density, with both high and low addition of Fe, delamination appeared as the main wear mechanism.

Keywords: Cu-based friction materials, Fe reinforcement, wear map, wear mechanism

Procedia PDF Downloads 249

Authors: Ajay Biswas, Swapan Bhaumik, Saurav Datta, Abhijit Bhowmik

Abstract:

A series of experiments has been carried out to study the feasibility of submerged arc welding (SAW) on mild steel plate of designation IS 2062 grade B. Specimen temperature of which is reduced to zero degree Celsius whereas the ambient temperature is about 25-27 degree Celsius. To observe this, bead on plate submerged arc welding is formed on the specimen plate of heavy duty mild steel of designation IS 2062 grade B, fitted on the special fixture ensuring zero degree Celsius temperature to the specimen plate. Sixteen numbers of cold samples is welded by varying the most influencing parameters viz. voltage, wire feed rate, travel speed, and electrode stick-out at four different levels. Another sixteen numbers of specimens are at normal room temperature are welded by applying same combination of parameters. Those sixteen numbers of specimens are selected based on the design of experiment of Taguchi‘s L16 orthogonal array with the intension of reducing the number of experimental runs. Different attributes of bead geometry of the entire sample for both the situations are measured and compared. It is established that submerged arc welding is feasible at zero degree Celsius on mild steel plate of designation IS 2062 grade B and optimization of the process parameters can also be drawn as a clear response of parameters are obtained.

Keywords: submerged arc welding, zero degree celsius, Taguchi’s design of experiment, geometry of weldment

Procedia PDF Downloads 428