Search results for: Flux Cored Arc Welding (FCAW)

Authors: Noor Ul Afsar, Wengen Ji, Bin Wu, Muhammad A. Shehzad, Liang Ge, Tongwen Xu

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The synthesis of monovalent cation perm-selective membranes (MCPMs) to efficiently discriminate amongst cations from seawater is of great importance for several industrial applications. However, a technical approach is highly desired to construct MCPMs to obtain a high ionic flux and sustain perm-selectivity simultaneously. In the present work, the thickness of the quaternized poly (2, 6-dimethyl-1, 4-phenylene oxide) (QPPO) layer on the surface of the SPPO-PVA (SPVA) composite membrane was adjusted using a facile procedure to achieve high permselectivity without scarifying the ionic flux. The thickness of the selective layer was precisely controlled using various concentrations of the QPPO solution. By the introduction of the cationic layer on the SPVA membrane, the monovalent cation can be separated from the divalent cation by their difference in charge density. The influence of the selective barrier (thickness) endows MCPMs with high perm-selectivity up to 12.7 for 0.1 mol L⁻¹ Li⁺/Mg²⁺ system, which is very satisfactory for polymeric membranes. The fabricated membranes have low electrical resistance and high limiting current density (iₗᵢₘ). Keeping in view the ED results, the prepared membranes with selective surface layers could be a viable candidate for Li⁺ selective separation from divalent cation Mg²⁺.

Keywords: monovalent cation perm-selective membranes, cation fractionation, perm-selectivity, ionic flux, electrodialysis

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Authors: A.Kouidri, B.Madani

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The present work deals with the study of the heat transfer in a rectangular channel equipped with a metallic foam. The tested metallic foam sample is made from copper with 20 PPI (Pore per Inch Linear) and 93% of porosity and the working fluid used is the n-pentane. In the present work the independent variables are the velocity in the range from 0.02 to 0.06 m/s and a boiling heat flux rate varying between 30 and 70 kW/m2. The heat transfer coefficient is presented versus boiling heat flux, vapor quality and superheat ΔTsat. The thermal results are compared to those found for a plain tube for the same conditions. The comparison with the plain tube shows that the insert of a metallic foam enhances the heat transfer coefficient by a factor between 1.3 and 3.

Keywords: boiling, metallic foam, heat transfer, plate heat exchanger

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Authors: Hanan Mikhael Dawood, Haider Salim, Jafar Al-Wash

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This paper presents Proportional-Integral (PI) controller to improve the system performance which gives better torque and flux response. In addition, it reduces the undesirable torque ripple. The conventional DTC controller approach for induction machines, based on an improved torque and stator flux estimator, is implemented using Xilinx System Generator (XSG) for MATLAB/Simulink environment through Xilinx blocksets. The design was achieved in VHDL which is based on a MATLAB/Simulink simulation model. The hardware in the loop results are obtained considering the implementation of the proposed model on the Xilinx NEXYS2 Spartan 3E1200 FG320 Kit.

Keywords: induction motor, Direct Torque Control (DTC), Xilinx FPGA, motor drive

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Authors: Sireetorn Kuharat, Anwar Beg

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In this study, multi-mode heat transfer characteristics of spacecraft solar collectors are investigated computationally. Two-dimensional steady-state incompressible laminar Newtonian viscous convection-radiative heat transfer in a rectangular solar collector geometry. The ANSYS FLUENT finite volume code (version 17.2) is employed to simulate the thermo-fluid characteristics. Several radiative transfer models are employed which are available in the ANSYS workbench, including the classical Rosseland flux model and the more elegant P1 flux model. Mesh-independence tests are conducted. Validation of the simulations is conducted with a computational Harlow-Welch MAC (Marker and Cell) finite difference method and excellent correlation. The influence of aspect ratio, Prandtl number (Pr), Rayleigh number (Ra) and radiative flux model on temperature, isotherms, velocity, the pressure is evaluated and visualized in color plots. Additionally, the local convective heat flux is computed and solutions are compared with the MAC solver for various buoyancy effects (e.g. Ra = 10,000,000) achieving excellent agreement. The P1 model is shown to better predict the actual influence of solar radiative flux on thermal fluid behavior compared with the limited Rosseland model. With increasing Rayleigh numbers the hot zone emanating from the base of the collector is found to penetrate deeper into the collector and rises symmetrically dividing into two vortex regions with very high buoyancy effect (Ra >100,000). With increasing Prandtl number (three gas cases are examined respectively hydrogen gas mixture, air and ammonia gas) there is also a progressive incursion of the hot zone at the solar collector base higher into the solar collector space and simultaneously a greater asymmetric behavior of the dual isothermal zones. With increasing aspect ratio (wider base relative to the height of the solar collector geometry) there is a greater thermal convection pattern around the whole geometry, higher temperatures and the elimination of the cold upper zone associated with lower aspect ratio.

Keywords: thermal convection, radiative heat transfer, solar collector, Rayleigh number

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Authors: Chonlada Choedchun, Ni-on Saelim, Panupong Chuntanalerg, Thanyalak Chaisuwan, Sujitra Wongkasemjit

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Bioethanol is one of the candidates to replace fossil fuels. Membrane technique is one of the attractive processes to produce high purity of ethanol. In this work, polybenzoxazine (PBZ) membrane successfully synthesized from bisphenol-A (BPA), formaldehyde, and two different types of multifunctionalamines: tetraethylenepentamine (tepa), and diethylenetriamine (deta), was evaluated for water-ethanol separation. The membrane thickness was determined by scanning electron microscopy (SEM). Pervaporation technique was carried out to find separation performance. It was found that the optimum PBZ concentration for the preparation of the membranes is 25%. The dipping cycles of PBZ-tepa and PBZ-deta was found to be 4 and 5, giving the total permeation flux of 28.97 and 14.75 g/m2.h, respectively. The separation factor of both membranes was higher than 10,000.

Keywords: polybenzoxazine, pervaporation, permeation flux, separation factor

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Authors: Parul Goel, Jyeshtharaj B. Joshi, Arun K. Nayak

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Nucleate boiling is characterized by the nucleation, growth and departure of the tiny individual vapor bubbles that originate in the cavities or imperfections present in the heating surface. It finds a wide range of applications, e.g. in heat exchangers or steam generators, core cooling in power reactors or rockets, cooling of electronic circuits, owing to its highly efficient transfer of large amount of heat flux over small temperature differences. Hence, it is important to be able to predict the rate of heat transfer and the safety limit heat flux (critical heat flux, heat flux higher than this can lead to damage of the heating surface) applicable for any given system. A large number of experimental and analytical works exist in the literature, and are based on the idea that the knowledge of the bubble dynamics on the microscopic scale can lead to the understanding of the full picture of the boiling heat transfer. However, the existing data in the literature are scattered over various sets of conditions and often in disagreement with each other. The correlations obtained from such data are also limited to the range of conditions they were established for and no single correlation is applicable over a wide range of parameters. More recently, a number of researchers have been trying to remove empiricism in the heat transfer models to arrive at more phenomenological models using extensive numerical simulations; these models require state-of-the-art experimental data for a wide range of conditions, first for input and later, for their validation. With this idea in mind, experiments with sub-cooled and saturated demineralized water have been carried out under atmospheric pressure to study the bubble dynamics- growth rate, departure size and frequencies for nucleate pool boiling. A number of heating elements have been used to study the dependence of vapor bubble dynamics on the heater surface finish and heater geometry along with the experimental conditions like the degree of sub-cooling, super heat and the heat flux. An attempt has been made to compare the data obtained with the existing data and the correlations in the literature to generate an exhaustive database for the pool boiling conditions.

Keywords: experiment, boiling, bubbles, bubble dynamics, pool boiling

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Authors: Hendrik Bernard Van Der Walt, Frik Van Niekerk

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Heterogeneous thorium-based fuels have been proposed as an alternative for conventional reactor fuels and many studies have shown promising results. Fuel cycle characteristics still have to be explored in detail. This study investigates the use of a novel thorium-based fuel design aimed at increasing fuel cycle length of a typical PWR with an explicit focus on thorium- uranium content, neutron spectrum, flux considerations and neutron economy.As nuclear reactions are highly dependent on reactor flux and material matrix, analytical and numerical calculations have been completed to predict the behaviour of the proposed nuclear fuel. The proposed design utilizes various ratios of thorium oxide and uranium oxide pellets within fuel pins, divided into heterogeneous sections of specified length. This design renders multiple regions with unique characteristics. The goal of this study is to determine and optimally utilize these characteristics. Proliferation considerations result in the need for denaturing of heterogeneous regions, which renders more unique characteristics, these aspects were examined in this study. Finally, the use of fertile thorium to emulate a burnable poison for managing excess BOL reactivity has been investigated, as well as an option for flux shaping in a typical PWR.

Keywords: nuclear fuel, nuclear characteristics, nuclear fuel cycle, thorium-based fuel, heterogeneous design

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Authors: Md. Rashel Sheikh

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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

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Authors: Eyob Messele Sefene, Atinkut Atinafu Yilma

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The highest strength-to-weight ratio criterion has fascinated increasing curiosity in virtually all areas where weight reduction is indispensable. One of the recent advances in manufacturing to achieve this intention endears friction stir welding (FSW). The process is widely used for joining similar and dissimilar non-ferrous materials. In FSW, the mechanical properties of the weld joints are impelled by property-selected process parameters. This paper presents verdicts of optimum process parameters in attempting to attain enhanced mechanical properties of the weld joint. The experiment was conducted on a 5 mm 6061 aluminum alloy sheet. A butt joint configuration was employed. Process parameters, rotational speed, traverse speed or feed rate, axial force, dwell time, tool material and tool profiles were utilized. Process parameters were also optimized, making use of a mixed L18 orthogonal array and the Grey relation analysis method with larger is better quality characteristics. The mechanical properties of the weld joint are examined through the tensile test, hardness test and liquid penetrant test at ambient temperature. ANOVA was conducted in order to investigate the significant process parameters. This research shows that dwell time, rotational speed, tool shape, and traverse speed have become significant, with a joint efficiency of about 82.58%. Nine confirmatory tests are conducted, and the results indicate that the average values of the grey relational grade fall within the 99% confidence interval. Hence the experiment is proven reliable.

Keywords: friction stir welding, optimization, 6061 AA, Taguchi

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Authors: Aleksandr Kalinenko, Igor Vysotskiy, Sergey Malopheyev, Sergey Mironov, Rustam Kaibyshev

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From a thermo-mechanical standpoint, friction-stir welding (FSW) represents a unique combination of very large strains, high temperature and relatively high strain rate. The material behavior under such extreme deformation conditions is not studied well and thus, the microstructural examinations of the friction-stir welded materials represent an essential academic interest. Moreover, a clear understanding of the microstructural mechanisms operating during FSW should improve our understanding of the microstructure-properties relationship in the FSWed materials and thus enables us to optimize their service characteristics. Despite extensive research in this field, the microstructural behavior of some important structural materials remains not completely clear. In order to contribute to this important work, the present study was undertaken to examine the grain structure evolution during the FSW of 6061-T6 aluminum alloy. To provide an in-depth insight into this process, the electron backscatter diffraction (EBSD) technique was employed for this purpose. Microstructural observations were conducted by using an FEI Quanta 450 Nova field-emission-gun scanning electron microscope equipped with TSL OIMTM software. A suitable surface finish for EBSD was obtained by electro-polishing in a solution of 25% nitric acid in methanol. A 15° criterion was employed to differentiate low-angle boundaries (LABs) from high-angle boundaries (HABs). In the entire range of the studied FSW regimes, the grain structure evolved in the stir zone was found to be dominated by nearly-equiaxed grains with a relatively high fraction of low-angle boundaries and the moderate-strength B/-B {112}<110> simple-shear texture. In all cases, the grain-structure development was found to be dictated by an extensive formation of deformation-induced boundaries, their gradual transformation to the high-angle grain boundaries. Accordingly, the grain subdivision was concluded to the key microstructural mechanism. Remarkably, a gradual suppression of this mechanism has been observed at relatively high welding temperatures. This surprising result has been attributed to the reduction of dislocation density due to the annihilation phenomena.

Keywords: electron backscatter diffraction, friction-stir welding, heat-treatable aluminum alloys, microstructure

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Authors: Maria Neagu

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This paper presents the heat and mass driven natural convection succession in a Darcy thermally stratified porous medium that embeds a vertical semi-infinite impermeable wall of constant heat flux and concentration. The scale analysis of the system determines the two possible maps of the heat and mass driven natural convection sequence along the wall as a function of the process parameters. These results are verified using the finite differences method applied to the conservation equations.

Keywords: finite difference method, natural convection, porous medium, scale analysis, thermal stratification

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Authors: D. Miroud, H. Mokaddem, M. Tata, N. Foucha

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The body of PDC (polycrystalline diamond compact) drill bit can be manufactured from two different materials, steel and tungsten carbide matrix. Commonly the steel body is produced by machining, thermal spraying a bonding layer and hardfacing of Ni-based matrix reinforced with fused eutectic tungsten carbide (WC/W2C). The matrix body bit is manufactured by infiltrating tungsten carbide particles, with a Copper binary or ternary alloy. By erosion-corrosion mechanisms, the PDC drill bits matrix undergoes severe damage, occurring particularly around the PDC inserts and near injection nozzles. In this study, we investigated the possibility to repair the damaged matrix regions by hardfacing technic. Ni-based hardfacing alloy reinforced with fused eutectic tungsten carbide is deposited on infiltrated WC-W-Ni substrate by oxyacetylene welding (OAW). The microstructure at the hardfacing / matrix interface is characterized by SEM- EDS, XRD and micro hardness Hv0.1. The hardfacing conditions greatly affect the dilution phenomenon and the distribution of carbides at the interface, without formation of transition zone. During OAW welding deposition, interdiffusion of atoms occurs: Cu and Sn diffuse from infiltrated matrix substrate into hardfacing and simultaneously Cr and Si alloy elements from hardfacing diffuse towards the substrate. The dilution zone consists of a nickel-rich phase with a heterogeneous distribution of eutectic spherical (Ni-based hardfacing alloy) and irregular (matrix) WC/W2C carbides and a secondary phase rich in Cr-W-Si. Hardfacing conditions cause the dissolution of banding around both spherical and irregular carbides. The micro-hardness of interface is significantly improved by the presence of secondary phase in the inter-dendritic structure.

Keywords: dilution, dissolution, hardfacing, infiltrated matrix, PDC drill bits

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Authors: Peng Lu, Branimir Radisavljevic, Martin Seeger, Daniel Over, Torsten Votteler, Bernardo Galletti

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CO₂-based gas mixtures exhibit huge potential as the interruption medium for replacing SF₆ in high voltage switchgears. In this paper, the recovery characteristics of dielectric strength of CO₂-O₂ mixture in the post arc phase after the current zero are presented. As representative examples, the dielectric recovery curves under conditions of different gas filling pressures and short-circuit current amplitudes are presented. A series of dielectric recovery measurements suggests that the dielectric recovery rate is proportional to the mass flux of the blowing gas, and the dielectric strength recovers faster in the case of lower short circuit currents.

Keywords: CO₂ mixture, high voltage circuit breakers, dielectric recovery rate, short-circuit current, mass flux

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Authors: Yang-Gyun Kim, Eun-Taek Woo, Myeong-Gon Lee, Yun-Hyun Cho, Seung-Ho Han

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For the sustainable development of wind energy, energy industries have invested in the development of highly efficient wind turbines such as an axial flux permanent magnet (AFPM) generator. The AFPM generator, however, has a history of overheating on the surface of the stator, so that power production decreases significantly. A proper cooling system, therefore, is needed. Although a convective-type cooling system has been developed, the size of the air blower must be increased when the generator’s capacity exceeds 2.5 MW. In this paper, we proposed a newly developed conductive-type cooling system using a heat pipe wound to the stator of a 2.5 MW AFPM generator installed on an offshore wind turbine. The numerical results showed that the temperatures on the stator surface using convective-type cooling system and the proposed conductive-type cooling system at thermal saturation were 60 and 76°C, respectively, which met the requirements for power production. The temperatures of the permanent magnet cased by the radiant heating from the stator surface were 53°C and 66°C, respectively, in each case. As a result, the permanent magnet did not reach the malfunction temperature. Although the cooling temperatures in the case of the conductive-type cooling system were higher than that of the convective-type cooling system, the relatively small size of the water pump and radiators make a light-weight design of the AFPM generator possible.

Keywords: wind turbine, axial flux permanent magnet (AFPM) generator, conductive-type cooling system

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Authors: G. Rosaz, V. Semblanet, S. Calatroni, A. Sublet, M. Taborelli

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We report in this paper the design and qualification of a cylindrical unbalanced magnetron source. The dedicated magnetic assemblies were simulated using a finite element model. A hall-effect magnetic probe was then used to characterize those assemblies and compared to the theoretical magnetic profiles. These show a good agreement between the expected and actual values. The qualification of the different magnetic assemblies was then performed by measuring the ion flux density reaching the surface of the sample to be coated using a commercial retarding field energy analyzer. The strongest unbalanced configuration shows an increase from 0.016 A.cm^-2 to 0.074 A.cm^-2 of the ion flux density reaching the sample surface compared to the standard balanced configuration for a pressure 5.10^-3 mbar and a plasma source power of 300 W.

Keywords: ion energy distribution function, magnetron sputtering, niobium, unbalanced, SRF cavities, thin film

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

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Membrane technology is convenient for separation of suspended solids, colloids and high molecular weight materials that are present. The idea is that the waste stream from edible oil industry, after the separation of oil by using skimmers is subjected to microfiltration and the obtained permeate can be used again in the production process. The wastewater from edible oil industry was used for the microfiltration. For the microfiltration of this effluent a tubular membrane was used with a pore size of 200 nm at transmembrane pressure in range up to 3 bar and in range of flow rate up to 300 L/h. Box–Behnken design was selected for the experimental work and the responses considered were permeate flux and chemical oxygen demand (COD) reduction. The reduction of the permeate COD was in the range 40-60% according to the feed. The highest permeate flux achieved during the process of microfiltration was 160 L/m²h.

Keywords: ceramic membrane, edible oil, microfiltration, wastewater

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

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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

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Authors: J. H. Park, S. K. Lee, Y. W. Kim, D. C. Ko

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A large variety of pipe flange is required in marine and construction industry.Pipe flanges are usually welded or screwed to the pipe end and are connected with bolts.This approach is very simple and widely used for a long time, however, it results in high development cost and low productivity, and the productions made by this approach usually have safety problem at the welding area.In this research, a new approach of forming pipe flange based on cold forging and floating die concept is presented.This innovative approach increases the effectiveness of the material usage and save the time cost compared with conventional welding method. To ensure the dimensional accuracy of the final product, the finite element analysis (FEA) was carried out to simulate the process of cold forging, and the orthogonal experiment methods were used to investigate the influence of four manufacturing factors (pin die angle, pipe flange angle, rpm, pin die distance from clamp jig) and predicted the best combination of them. The manufacturing factors were obtained by numerical and experimental studies and it shows that the approach is very useful and effective for the forming of pipe flange, and can be widely used later.

Keywords: cold forging, FEA (finite element analysis), forge-3D, rotating forming, tubes

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Authors: Shu-Yu Chung, Ying-Fang Wang, Shih-Min Wang

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To conduct long-term exposure assessments are important for workers exposed to chemicals with chronic effects. However, it usually encounters with several constrains, including cost, workers' willingness, and interference to work practice, etc., leading to inadequate long-term exposure data in the real world. In this study, an integrated approach was developed for conducting long-term exposure assessment for welding workers in a shipbuilding factory. A laboratory study was conducted to yield the fume generation rates under various operating conditions. The results and the measured environmental conditions were applied to the near field/far field (NF/FF) model for predicting long term fume exposures via the Monte Carlo simulation. Then, the predicted long-term concentrations were used to determine the prior distribution in Bayesian decision analysis (BDA). Finally, the resultant posterior distributions were used to assess the long-term exposure and serve as basis for initiating control strategies for shipbuilding workers. Results show that the NF/FF model was a suitable for predicting the exposures of metal contents containing in welding fume. The resultant posterior distributions could effectively assess the long-term exposures of shipbuilding welders. Welders' long-term Fe, Mn and Pb exposures were found with high possibilities to exceed the action level indicating preventive measures should be taken for reducing welders' exposures immediately. Though the resultant posterior distribution can only be regarded as the best solution based on the currently available predicting and monitoring data, the proposed integrated approach can be regarded as a possible solution for conducting long term exposure assessment in the field.

Keywords: Bayesian decision analysis, exposure assessment, near field and far field model, shipbuilding industry, welding fume

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Authors: A. Sharma, S. S. Sandhu, A. Shahi, A. Kumar

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The aim of present investigation was to carry out Finite element modeling of distortion in the case of butt weld. 12mm thick AISI 304L plates were butt welded using three different combinations of groove design namely Double U, Double V and Composite. A full simulation of shielded metal arc welding (SMAW) of nonlinear heat transfer is carried out. Aspects like, temperature-dependent thermal properties of AISI stainless steel above liquid phase, the effect of thermal boundary conditions, were included in the model. Since welding heat dissipation characteristics changed due to variable groove design significant changes in the microhardness tensile strength and impact toughness of the joints were observed. The cumulative distortion was found to be least in double V joint followed by the Composite and Double U-joints. All the joints have joint efficiency more than 100%. CVN value of the Double V-groove weld metal was highest. The experimental results and the FEM results were compared and reveal a very good correlation for distortion and weld groove design for a multipass joint with a standard analogy of 83%.

Keywords: AISI 304 L, Butt joint, distortion, FEM, groove design, SMAW

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Authors: Lingaraju Dumpala, Narasa Raju Gosangi

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Friction Stir Welding (FSW) is relatively new, environmentally friendly, versatile, and widely used joining technique for soft materials such as aluminum. FSW has got a lot of attention as a solid-state joining method which avoids many common problems of fusion welding and provides an improved way of producing aluminum joints in a faster way. FSW can be used for various aerospace, defense, automotive and transportation applications. It is necessary to understand the friction stir welded joints and its characteristics to use this new joining technique in critical applications. This study investigated the mechanical properties of friction stir welded aluminum 6063 alloys. FSW is carried out based on the design of experiments using L16 mixed level array by considering tool rotational speeds, tool feed rate and tool tilt angles as process parameters. The optimization of process parameters is carried by Taguchi based regression analysis and the significance of process parameters is analyzed using ANOVA. It is observed that the considered process parameters are high influences the mechanical properties of Al6063.

Keywords: FSW, aluminum alloy, mechanical properties, optimization, Taguchi, ANOVA

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Authors: Michel Han, Christophe Besson, Alain Savary, Yvan Becher

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The variable flux permanent magnet synchronous motor (VF-PMSM), also called "Memory Motor", is a new generation of motor capable of modifying the magnetization state with short pulses of current during operation or standstill. The impact of such operation is the expansion of the operating range in the torque-speed characteristic and an improvement in energy efficiency at high-speed in comparison to conventional permanent magnet synchronous machines (PMSMs). This paper reviews the operating principle and the unique features of the proposed memory motor. The benefits of this concept are highlighted by comparing the performance of the rotor of the VF-PMSM to that of two PM rotors that are typically found in the industry. The investigation emphasizes the properties of the variable magnetization and presents the comparison of the torque-speed characteristic with the capability of loss reduction in a VF-PMSM by means of experimental results, especially when tests are conducted under identical conditions for each rotor (same stator, same inverter and same experimental setup). The experimental results demonstrated that the VF-PMSM gives an additional degree of freedom to optimize the efficiency over a wide speed range. Thus, with a design easy to manufacture and with the possibility of controlling the magnetization and the demagnetization of the magnets during operations, the VF-PMSM can be interesting for various applications.

Keywords: efficiency, magnetization state, memory motors, performances, permanent-magnet, synchronous machine, variable-flux, variable magnetization, wide speed application

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Authors: Piyakajornkul T., Noppiboon S., Hochareon L., Kitsubun P.

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Nowadays, DNA vaccines become an interesting subject in the third vaccine generation. The platform of DNA vaccines production has been developed and its downstream process becomes challenging due to the quality of the products in terms of purity and percentage of supercoiled DNA. To overcome these challenges, tangential flow filtration (TFF), which is involved in the purification process, could be used since it provides effective separation of impurity prior to performing further purification steps. However, operating conditions of TFF is varied based on several factors such as sizes of target particle and impurities, a concentration of solution as well as a concentration polarization on the membrane surface. In this study, pVAX1/lacZ was used as a model of TFF optimization in order to prevent a concentration polarization that can lead to the membrane fouling and also minimize a diafiltration volume while maintaining the maximum permeate flux resulting in proper operating times and buffer volume. By using trans membrane pressure (TMP) excursion method, feed flow rates and TMP were varied. The results showed a correlation of permeate flux with TMP where the maximum volume concentration factor reached 2.5 times of the initial volume when feed flow rate and TMP were 7 liters/m²/min and 1 bar, respectively. It was optimal operating conditions before TFF system undergone pressure independent regime. In addition, the diafiltration volume was 14 times of the concentrated volume prior to performing a further anion chromatography process.

Keywords: concentration polarization, DNA vaccines, optimization, permeate flux, pressure dependent, tangential flow filtration (TFF), trans membrane pressure (TMP)

Procedia PDF Downloads 122

Authors: A. Sharma, S. S. Sandhu, A.Shahi, A. Kumar

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In this study, the effects of geometric configurations of butt joints i.e. double V groove, double U groove and UV groove of AISI 304L of thickness 12 mm by using Gas Tungsten Arc Welding (GTAW) are investigated. The magnitude of transverse shrinkage stress and distortion generated during welding under the unrestrained conditions of butt joints is the main objective of the study. The effect of groove design on impact strength and metallurgical properties are also studied. The Finite element analysis for the groove design is done and compared the actual experimentation. The experimental results and the FEM results were compared and reveal a very good correlation for distortion and weld groove design for multipass joint with a standard analogy of 80%. In the case of VV groove design it was found that the transverse stress and cumulative deflection have the lowest value. It was found that the UV groove design had the maximum ultimate and yield tensile strength, VV groove had the highest impact strength. Vicker’s hardness value of all the groove design was measured. Micro structural studies were carried out using conventional microscopic tools which revealed a lot of useful information for correlating the microstructure with mechanical properties.

Keywords: weld groove design, distortion, AISI 304 L, butt joint, FEM, GTAW

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Authors: Aashutosh A. Tadse, Kush Mehta, Hardik Vyas

Abstract:

Friction Stir Welding is a process in which an FSW tool produces friction heat and thus penetrates through the junction and upon rotation carries out the weld by exchange of material within the 2 metals being welded. It involves holding the workpieces stiff enough to bear the force of the tool moving across the junction to carry out a successful weld. The weld that has flat plates as workpieces, has a quite simpler geometry in terms of fixture holding them. In the case of FSW of pipes, the pipes need to be held firm with the chucks and jaws according to the diameter of the pipes being welded; the FSW tool is then revolved around the pipes to carry out the weld. Machine requires a larger area and it becomes more costly because of such a setup. To carry out the weld on the Milling machine, the newly designed fixture must be set-up on the table of milling machine and must facilitate rotation of pipes by the motor being shafted to one end of the fixture, and the other end automatically rotated because of the rotating jaws held tight enough with the pipes. The set-up has tapered cones as the jaws that would go in the pipes thus holding it with the help of its knurled surface providing the required grip. The process has rotation of pipes with the stationary rotating tool penetrating into the junction. The FSW on pipes in this process requires a very low RPM of pipes to carry out a fine weld and the speed shall change with every combination of material and diameter of pipes, so a variable speed setting motor shall serve the purpose. To withstand the force of the tool, an attachment to the shaft is provided which will be diameter specific that will resist flow of material towards the center during the weld. The welded joint thus carried out will be proper to required standards and specifications. Current industrial requirements state the need of space efficient, cost-friendly and more generalized form of fixtures and set-ups of machines to be put up. The proposed design considers every mentioned factor and thus proves to be positive in the same.

Keywords: force of tool, friction stir welding, milling machine, rotation of pipes, tapered cones

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Authors: Vishnu Asokan, Zaid M. Paloba

Abstract:

Flow over cavities is an important area of research due to the significant change in flow physics caused by cavity aspect ratio, free stream Mach number and the nature of upstream boundary layer approaching the cavity leading edge. Cavity flow finds application in aircraft wheel well, weapons bay, combustion chamber of scramjet engines, etc. These flows are highly unsteady, compressible and turbulent and it involves mass entrainment coupled with acoustics phenomenon. Variation of flow dynamics in an angled cavity with a heated and cooled pylon upstream to the cavity with spatial combinations of heat flux addition and removal to the wall studied numerically. The goal of study is to investigate the effect of energy addition, removal to the cavity walls and pylon cavity flow dynamics. Preliminary steady state numerical simulations on inclined cavities with heat addition have shown that wall pressure profiles, as well as the recirculation, are influenced by heat transfer to the compressible fluid medium. Such a hybrid control of cavity flow dynamics in the form of heat transfer and pylon geometry can open out greater opportunities in enhancement of mixing and flame holding requirements of supersonic combustors. Addition of pylon upstream to the cavity reduces the acoustic oscillations emanating from the geometry. A numerical unsteady analysis of supersonic flow past cavities exposed to cavity wall heating and cooling with heated and cooled pylon helps to get a clear idea about the oscillation suppression in the cavity. A Cavity of L/D 4 and aft wall angle 22 degree with an upstream pylon of h/D=1.5 mm with a wall angle 29 degree exposed to supersonic flow of Mach number 2 and heat flux of 40 W/cm² and -40 W/cm² modeled for the above study. In the preliminary study, the domain is modeled and validated numerically with a turbulence model of SST k-ω using an HLLC implicit scheme. Both qualitative and quantitative flow data extracted and analyzed using advanced CFD tools. Flow visualization is done using numerical Schlieren method as the fluid medium gives the density variation. The heat flux addition to the wall increases the secondary vortex size of the cavity and removal of energy leads to the reduction in vortex size. The flow field turbulence seems to be increasing at higher heat flux. The shear layer thickness increases as heat flux increases. The steady state analysis of wall pressure shows that there is variation on wall pressure as heat flux increases. Shift in frequency of unsteady wall pressure analysis is an interesting observation for the above study. The time averaged skin friction seems to be reducing at higher heat flux due to the variation in viscosity of fluid inside the cavity.

Keywords: energy addition, frequency shift, Numerical Schlieren, shear layer, vortex evolution

Procedia PDF Downloads 112

Authors: Tunahan Sapmaz, Harun Etçi, İbrahim Şenol, Yasemin Öner

Abstract:

Rotor bar dimensions have a great influence on the air-gap magnetic flux density. Therefore, poor selection of this parameter during the machine design phase causes the air-gap magnetic flux density to be distorted. Thus, it causes noise, torque fluctuation, and losses in the induction motor. On the other hand, the change in rotor bar dimensions will change the resistance of the conductor, so the current will be affected. Therefore, the increase and decrease of rotor bar current affect operation, starting torque, and efficiency. The aim of this study is to examine the effect of rotor bar dimensions on the electromagnetic performance criteria of the induction motor. Modeling of the induction motor is done by the finite element method (FEM), which is a very powerful tool. In FEM, the results generally focus on performance criteria such as torque, torque fluctuation, efficiency, and current.

Keywords: induction motor, finite element method, optimization, rotor bar

Procedia PDF Downloads 95

Authors: C. S. Paglia

Abstract:

The deformation and the crystallization in a 7075-T651 friction stir weld, in particular for regions directly in contact with the mechanical action of the rotating probe, have been investigated by means of optical microscopy. The investigation enabled to identify regions of the weld differently affected by the deformation caused by the welding process. The highly deformed grains in the horizontal direction close to the plate margin were indicative of shear movements along the horizontal plane, while highly deformed grains along the plate margin in the vertical direction were indicative of vertical shear movements of opposite directions, which superimposed the shear movement along the horizontal plane. The vertical shear movements were not homogeneous through the plate thickness. The microstructure indicated that after the probe passes, the grain growth may take place under static conditions. The small grains microstructure of the nugget region, formed after the main dynamic recrystallization process, develops to an equiaxed microstructure. A material transport influenced by the rotating shoulder was also observed from the trailing to the advancing side of the weld.

Keywords: AA7075-T651, friction stir welding, deformation, crystallization

Procedia PDF Downloads 94

Authors: V. Nikkhah Rashidabad, M. Manteghian, M. Masoumi, S. Mousavian, D. Ashouri

Abstract:

In this research, the capability of neural networks in modeling and learning complicated and nonlinear relations has been used to develop a model for the prediction of changes in the diameter of bubbles in pool boiling distilled water. The input parameters used in the development of this network include element temperature, heat flux, and retention time of bubbles. The test data obtained from the experiment of the pool boiling of distilled water, and the measurement of the bubbles form on the cylindrical element. The model was developed based on training algorithm, which is typologically of back-propagation type. Considering the correlation coefficient obtained from this model is 0.9633. This shows that this model can be trusted for the simulation and modeling of the size of bubble and thermal transfer of boiling.

Keywords: bubble diameter, heat flux, neural network, training algorithm

Procedia PDF Downloads 419

Authors: Tugrul Tulunay, Iyas Devran Celik

Abstract:

When the materials used in structural steel industry are evaluated, box beam profiles are considerably preferred. As a result of the cross-sectional properties that these profiles possess, the connection of these profiles to each other and to profiles having different types of cross sections is becoming viable by means of additional measures. An important point to note in such combinations is continuous transfer of internal forces from element to element. At the beginning to ensure this continuity, header plate is needed to use. The connection of the plates to the elements works mainly through welds. In this study, it is aimed to determine the ideal welding thickness in box beam under bending effect and the joints exposed to local buckles that will form in the column. The connection with box column and box beam designed in this context was made by means of corner and circular filler welds. Corner welds of different thickness and analysis by types with different lengths depending on plate dimensions in numerical models were made with the help of ANSYS Workbench program and examined behaviours.

Keywords: welding thickness, box beam-column joints, design of steel structures, calculation and construction principles 2016, welded joints under local buckling

Procedia PDF Downloads 131