Search results for: aluminium clad PCB

Authors: P. C. Chiu, Jehnming Lin

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In this study, a 50-W CO₂ laser was used for the clad of 304L powders on the stainless steel substrate with a temperature sensor and image monitoring system. The laser power and cladding speed and focal position were modified to achieve the requirement of the workpiece flatness and mechanical properties. The numerical calculation is based on ANSYS to analyze the temperature change of the moving heat source at different surface positions when coating the workpiece, and the effect of the process parameters on the bath size was discussed. The temperature of stainless steel powder in the nozzle outlet reacting with the laser was simulated as a process parameter. In the experiment, the difference of the thermal conductivity in three-dimensional space is compared with single-layer cladding and multi-layer cladding. The heat dissipation pattern of the single-layer cladding is the steel plate and the multi-layer coating is the workpiece itself. The relationship between the multi-clad temperature and the profile was analyzed by the temperature signal from an IR pyrometer.

Keywords: laser cladding, temperature, profile, microstructure

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Authors: Kartikaningsih Danis, Yao-Hui Huang

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Various techniques including conventional and advanced have been employed for the boron treatment from water and wastewater. The electrocoagulation involves an electrolytic reactor for coagulation/flotation with aluminium as anode and cathode. There is aluminium as coagulant to be used for removal which may induce secondary pollution in chemical coagulation. The purpose of this study is to investigate and compare the performance between electrocoagulation and chemical coagulation on boron removal from synthetic wastewater. The effect of different parameters, such as pH reaction, coagulant dosage, and initial boron concentration were examined. The results show that the boron removal using chemical coagulation was lower. At the optimum condition (e.g. pH 8 and 0.8 mol coagulant dosage), boron removal efficiencies for chemical coagulation and electrocoagulation were 61% and 91%, respectively. In addition, the electrocoagulation needs no chemical reagents and makes the boron treatment easy for application.

Keywords: boron removal, chemical coagulation, aluminum, electro-coagulation

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Authors: M. A. Islam, P. J. Hazell, J. P. Escobedo, M. Saadatfar

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Quasistatic compression and micro structural characterization of closed cell aluminium foams of different pore size and cell distributions has been carried out. Metallic foams have good potential for lightweight structures for impact and blast mitigation and therefore it is important to find out the optimized foam structure (i.e. cell size, shape, relative density, and distribution) to maximize energy absorption. In this paper, we present results for two different aluminium metal foams of density 0.5 g/cc and 0.7 g/cc respectively that have been tested in quasi-static compression. The influence of cell geometry and cell topology on quasistatic compression behavior has been investigated using computed tomography (micro-CT) analysis. The compression behavior and micro structural characterization will be presented.

Keywords: metal foams, micro-CT, cell topology, quasistatic compression

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Authors: Kevin Mark Banks, Dannis Rorisang Nkarapa Maubane, Carel Coetzee

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The influence of aluminium content, reheating temperature, and sizing (final) strain on the as-rolled microstructure was systematically investigated in vanadium-microalloyed and C-Mn plate steels. Reheating, followed by hot rolling and air cooling simulations were performed on steels containing a range of aluminium and nitrogen contents. Natural air cooling profiles, corresponding to 6 and 20mm thick plates, were applied. The austenite and ferrite/pearlite microstructures were examined using light optical microscopy. Precipitate species and volume fraction were determined on selected specimens. No influence of aluminium content was found below 0.08% on the as-rolled grain size in all steels studied. A low Al-V-steel produced the coarsest initial austenite grain size due to AlN dissolution at low temperatures leading to abnormal grain growth. An Al-free V-N steel had the finest initial microstructure. Although the as-rolled grain size for 20mm plate was similar in all steels tested, the grain distribution was relatively mixed. The final grain size in 6mm plate was similar for most compositions; the exception was an as-cast V low N steel, where the size of the second phase was inversely proportional to the sizing strain. This was attributed to both segregation and a low VN volume fraction available for effective pinning of austenite grain boundaries during cooling. Increasing the sizing strain refined the microstructure significantly in all steels.

Keywords: aluminium, grain size, nitrogen, reheating, sizing strain, steel, vanadium

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Authors: S. Singh, P. Patel, D. Kachhadiya, Swapnil Dharaskar

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The research objective is to integrate nanoparticles into fuels- i.e. diesel, biodiesel, biodiesel blended with diesel, plastic derived fuels, etc. to increase the fuel efficiency. The metal oxide nanoparticles will reduce the carbon monoxide emissions by donating oxygen atoms from their lattices to catalyze the combustion reactions and to aid complete combustion; due to this, there will be an increase in the calorific value of the blend (fuel + metal nanoparticles). Aluminium oxide and cobalt oxide nanoparticles have been synthesized by sol-gel method. The characterization was done by Fourier Transform Infrared Spectroscopy (FTIR), X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). The size of the particles was determined by XRD to be 28.6 nm and 28.06 nm for aluminium oxide and cobalt oxide nanoparticles respectively. Different concentration blends- 50, 100, 150 ppm were prepared by adding the required weight of metal oxides in 1 liter of diesel and sonicating for 30 minutes at 500W. The blend properties- calorific value, viscosity, and flash point were determined by bomb calorimeter, Brookfield viscometer and pensky-martin apparatus. For the aluminum oxide blended diesel, there was a maximum increase of 5.544% in the calorific value, but at the same time, there was an increase in the flash point from 43°C to 58.5°C and an increase in the viscosity from 2.45 cP to 3.25 cP. On the other hand, for the cobalt oxide blended diesel there was a maximum increase of 2.012% in the calorific value while the flash point increased from 43°C to 51.5°C and the viscosity increased from 2.45 cP to 2.94 cP. There was a linear increase in the calorific value, viscosity and flash point when the concentration of the metal oxide nanoparticles in the blend was increased. For the 50 ppm Al₂O₃ and 50 ppm Co₃O₄ blend the increasing the calorific value was 1.228 %, and the viscosity changed from 2.45 cP to 2.64 cP and the flash point increased from 43°C to 50.5°C. Clearly the aluminium oxide nanoparticles increase the calorific value but at the cost of flash point and viscosity, thus it is better to use the 50 ppm aluminium oxide, and 50 ppm cobalt oxide blended diesel.

Keywords: aluminium oxide nanoparticles, cobalt oxide nanoparticles, fuel additives, fuel characteristics

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Authors: A. M. Khourshid, A. M. El-Kassas, I. Sabry

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The objective of this work was to investigate the mechanical properties in order to demonstrate the feasibility of friction stir welding for joining Al 6061 aluminium alloys. Welding was performed on pipe with different thickness (2, 3 and 4 mm), five rotational speeds (485, 710, 910, 1120 and 1400 rpm) and a traverse speed of 4mm/min. This work focuses on two methods which are artificial neural networks using software and Response Surface Methodology (RSM) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminium alloy. An Artificial Neural Network (ANN) model was developed for the analysis of the friction stir welding parameters of 6061 pipe. Tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters tool rotation speed, material thickness and axial force as a function. A comparison was made between measured and predicted data. Response Surface Methodology (RSM) was also developed and the values obtained for the response tensile strength, the percentage of elongation and hardness are compared with measured values. The effect of FSW process parameters on mechanical properties of 6061 aluminium alloy has been analysed in detail.

Keywords: friction stir welding, aluminium alloy, response surface methodology, artificial neural network

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Authors: Bastien Sanglard, Lou Magnat, Ligia Barna, Julian Carrey, Sébastien Lachaize

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Cooking is a primary need for humans, several techniques being used around the globe based on different sources of energy: electricity, solid fuel (wood, coal...), fuel or liquefied petroleum gas. However, all of them leads to direct or indirect greenhouse gas emissions and sometimes health damage in household. Therefore, the solar concentrated power represent a great option to lower the damages because of a cleaner using phase. Nevertheless, the construction phase of the solar cooker still requires primary energy and materials, which leads to environmental impacts. The aims of this work is to analyse the ecological impacts of a commercialaluminium parabola and to compare it with other means of cooking, taking the boiling of 2 litres of water three times a day during 40 years as the functional unit. Life cycle assessment was performed using the software Umberto and the EcoInvent database. Calculations were realized over more than 13 criteria using two methods: the international panel on climate change method and the ReCiPe method. For the reflector itself, different aluminium provenances were compared, as well as the use of recycled aluminium. For the structure, aluminium was compared to iron (primary and recycled) and wood. Results show that climate impacts of the studied parabola was 0.0353 kgCO2eq/kWh when built with Chinese aluminium and can be reduced by 4 using aluminium from Canada. Assessment also showed that using 32% of recycled aluminium would reduce the impact by 1.33 and 1.43 compared to the use of primary Canadian aluminium and primary Chinese aluminium, respectively. The exclusive use of recycled aluminium lower the impact by 17. Besides, the use of iron (recycled or primary) or wood for the structure supporting the reflector significantly lowers the impact. The impact categories of the ReCiPe method show that the parabola made from Chinese aluminium has the heaviest impact - except for metal resource depletion - compared to aluminium from Canada, recycled aluminium or iron. Impact of solar cooking was then compared to gas stove and induction. The gas stove model was a cast iron tripod that supports the cooking pot, and the induction plate was as well a single spot plate. Results show the parabolic solar cooker has the lowest ecological impact over the 13 criteria of the ReCiPe method and over the global warming potential compared to the two other technologies. The climate impact of gas cooking is 0.628kgCO2/kWh when used with natural gas and 0.723 kgCO2/kWh when used with a bottle of gas. In each case, the main part of emissions came from gas burning. Induction cooking has a global warming potential of 0.12 kgCO2eq/kWh with the electricity mix of France, 96.3% of the impact being due to electricity production. Therefore, the electricity mix is a key factor for this impact: for instance, with the electricity mix of Germany and Poland, impacts are 0.81kgCO2eq/kWh and 1.39 kgCO2eq/kWh, respectively. Therefore, the parabolic solar cooker has a real ecological advantages compared to both gas stove and induction plate.

Keywords: life cycle assessement, solar concentration, cooking, sustainability

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Authors: Gurcan A. B., Baker T. N.

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Due to economic and environmental requirements, it is becoming increasingly important to reduce vehicle weight. The first approach consisted in using light materials with high thermal conductivity, such as aluminium alloys. This choice allowed significant mass reduction and lower temperature but required recourse to ventilated discs. Among aluminium alloys, Al 6xxx series alloys enjoy the highest strength-to-weight ratio and, therefore, have found wide applications in the automobile and aerospace industries. However, these alloys lose their high strength rapidly when they are exposed to elevated temperatures. This rapid decline in the strength is directly related to the coarsening of very fine precipitates which are then not as effective in obstructing the dislocations. The incorporation of micro-scale and nano-scale particulates in aluminium systems can greatly enhance their mechanical characteristics.

Keywords: mechanical and tribological behaviour, scanning electron microscope, optical test, mechanical properties test, experimental test

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Authors: Manjinder Bajwa, Mahipal Singh, Manish Nagpal

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

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

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Authors: A. Anbu Raj, V. Mugendiren

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Sheet metal forming is a vital manufacturing process used in automobile, aerospace, agricultural industries, etc. Incremental forming is a promising process providing a short and inexpensive way of forming complex three-dimensional parts without using die. The aim of this research is to study the forming behaviour of AA 5052, Aluminium Alloy, using incremental forming and also to study the FLD of cone shape AA 5052 Aluminium Alloy at room temperature and various annealing temperature. Initially the surface roughness and wall thickness through incremental forming on AA 5052 Aluminium Alloy sheet at room temperature is optimized by controlling the effects of forming parameters. The central composite design (CCD) was utilized to plan the experiment. The step depth, feed rate, and spindle speed were considered as input parameters in this study. The surface roughness and wall thickness were used as output response. The process performances such as average thickness and surface roughness were evaluated. The optimized results are taken for minimum surface roughness and maximum wall thickness. The optimal results are determined based on response surface methodology and the analysis of variance. Formability Limit Diagram is constructed on AA 5052 Aluminium Alloy at room temperature and various annealing temperature by using optimized process parameters from the response surface methodology. The cone has higher formability than the square pyramid and higher wall thickness distribution. Finally the FLD on cone shape and square pyramid shape at room temperature and the various annealing temperature is compared experimentally and simulated with Abaqus software.

Keywords: incremental forming, response surface methodology, optimization, wall thickness, surface roughness

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Authors: Rio Hirakawa, Christian Gundlach, Sven Hartwig

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In recent years, the use of aluminium has further expanded and is expected to replace steel in the future as vehicles become lighter and more recyclable in order to reduce greenhouse gas (GHG) emissions and improve fuel economy. In line with this, structures and components are becoming increasingly multi-material, with different materials, including aluminium, being used in combination to improve mechanical utility and performance. A common method of assembling dissimilar materials is mechanical fastening, but it has several drawbacks, such as increased manufacturing processes and the influence of substrate-specific mechanical properties. Adhesive bonding and fusion bonding are methods that overcome the above disadvantages. In these two joining methods, surface pre-treatment of the substrate is always necessary to ensure the strength and durability of the joint. Previous studies have shown that laser surface treatment improves the strength and durability of the joint. Yan et al. showed that laser surface treatment of aluminium alloys changes α-Al2O3 in the oxide layer to γ-Al2O3. As γ-Al2O3 has a large specific surface area, is very porous and chemically active, laser-treated aluminium surfaces are expected to undergo physico-chemical changes over time and adsorb moisture and organic substances from the air or storage atmosphere. The impurities accumulated on the laser-treated surface may be released at the adhesive and bonding interface by the heat input to the bonding system during the joining phase, affecting the strength and durability of the joint. However, only a few studies have discussed the effect of such storage periods on laser-treated surfaces. This paper, therefore, investigates the ageing of laser-treated aluminium alloy surfaces through thermal analysis, electrochemical analysis and microstructural observations.AlMg3 of 0.5 mm and 1.5 mm thickness was cut using a water-jet cutting machine, cleaned and degreased with isopropanol and surface pre-treated with a pulsed fibre laser at 1060 nm wavelength, 70 W maximum power and 55 kHz repetition frequency. The aluminium surface was then analysed using SEM, thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR) and cyclic voltammetry (CV) after storage in air for various periods ranging from one day to several months TGA and FTIR analysed impurities adsorbed on the aluminium surface, while CV revealed changes in the true electrochemically active surface area. SEM also revealed visual changes on the treated surface. In summary, the changes in the laser-treated aluminium surface with storage time were investigated, and the final results were used to determine the appropriate storage period.

Keywords: laser surface treatment, pre-treatment, adhesion, bonding, corrosion, durability, dissimilar material interface, automotive, aluminium alloys

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Authors: L. Bazzi, E. Azzouyahar, A. Lamiri, M. Essahli

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Effect of addition of linseed oil (LSO) on the corrosion of aluminium in 0.1 M Na2CO3 has been studied by weight loss measurements, potentiodynamic polarization and Electrochemical Impedance Spectroscopy (EIS) measurements. The inhibition efficiency was found to increase with inhibitor content to attain 70% for LSO at 4g/L. Inhibition efficiency E (%) obtained from the various methods is in good agreement. The temperature effect on the corrosion behavior of aluminium was studied by potentiodynamic technique in the range from 298 to 308 K.

Keywords: aluminum, corrosion, green inhibitors, carbonate, linseed oil

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Authors: Chhaya Sharma, Dushyant Kumar

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The present work deals with the treatment of wastewater generated by paper industry by using aluminium as anode material. The quantitative and qualitative analyses of chloropenolics have been carried out by using primary clarifier effluent with the help of gas chromatography mass spectrometry. Sixteen chlorophenolics compounds have been identified and estimated. Results indicated that among 16 identified compounds, 7 are 100% removed and overall 66% reduction in chorophenolics compounds have been detected. Moreover, during the treatment, the biodegradability index of wastewater significantly increases, along with 70 % reduction in chemical oxygen demand and 99 % in color.

Keywords: aluminium anode, chlorophenolics, electrocoagulation, pollution load, wastewater

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Authors: Wilson Handoko, Farshid Pahlevani, Isha Singla, Himanish Kumar, Veena Sahajwalla

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Aluminium bronze alloys are well known for their superior abrasion, tensile strength and non-magnetic properties, due to the co-presence of iron (Fe) and aluminium (Al) as alloying elements and have been commonly used in many industrial applications. However, continuous exposure to the marine environment will accelerate the risk of a tendency to Al bronze alloys parts failures. Although a higher level of corrosion resistance properties can be achieved by modifying its elemental composition, it will come at a price through the complex manufacturing process and increases the risk of reducing the ductility of Al bronze alloy. In this research, the use of ironmaking slag and waste plastic as the input source for surface modification of Al bronze alloy was implemented. Microstructural analysis conducted using polarised light microscopy and scanning electron microscopy (SEM) that is equipped with energy dispersive spectroscopy (EDS). An electrochemical corrosion test was carried out through Tafel polarisation method and calculation of protection efficiency against the base-material was determined. Results have indicated that uniform modified surface which is as the result of selective diffusion process, has enhanced corrosion resistance properties up to 12.67%. This approach has opened a new opportunity to access various industrial utilisations in commercial scale through minimising the dependency on natural resources by transforming waste sources into the protective coating in environmentally friendly and cost-effective ways.

Keywords: aluminium bronze, waste-based surface modification, tafel polarisation, corrosion resistance

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Authors: J. Kazior, A. Szewczyk-Nykiel, T. Pieczonka, M. Laska

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Aluminium alloys are an important class of engineering materials for structural applications. This is due to the fact that these alloys have many interesting properties, namely, low density, high ratio of strength to density, good thermal and electrical conductivity, good corrosion resistance as well as extensive capabilities for shaping processes. In case of classical PM technology a particular attention should be paid to the selection of appropriate parameters of compacting and sintering processes and to keeping them. The latter need arises from the high sensitivity of aluminium based alloy powders on any fluctuation of technological parameters, in particular those related to the temperature-time profile and gas flow. Only then the desired sintered compacts with residual porosity may be produced. Except high mechanical properties, the other profitable properties of almost fully dense sintered components could be expected. Among them is corrosion resistance, rarely investigated on PM aluminium alloys. Thus, in the current study the Alumix 431/D commercial, press-ready grade powder was used for this purpose. Sintered compacts made of it in different conditions (isothermal sintering temperature, gas flow rate) were subjected to corrosion experiments in 0,1 M and 0,5 M NaCl solutions. The potentiodynamic curves were used to establish parameters characterising the corrosion resistance of sintered Alumix 431/D powder, namely, the corrosion potential, the corrosion current density, the polarization resistance, the breakdown potential. The highest value of polarization resistance, the lowest value of corrosion current density and the most positive corrosion potential was obtained for Alumix431/D powder sintered at 600°C and for highest protective gas flow rate.

Keywords: aluminium alloys, sintering, corrosion resistance, industry

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Authors: Pakorn Uttayopas, Chawalit Kittichaikarn

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This paper presents an experimental investigation for the characteristics of an energy harvesting device exploiting flow-induced vibration in a wind tunnel. A stationary bluff body is connected with a downstream tip body via an aluminium cantilever beam. Various lengths of aluminium cantilever beam and different shapes of downstream tip body are considered. The results show that the characteristics of the energy harvester’s vibration depend on both the length of the aluminium cantilever beam and the shape of the downstream tip body. The highest ratio between vibration amplitude and bluff body diameter was found to be 1.39 for an energy harvester with a symmetrical triangular tip body and L/D₁ = 5 at 9.8 m/s of flow speed (Re = 20077). Using this configuration, the electrical energy was extracted with a polyvinylidene fluoride (PVDF) piezoelectric beam with different load resistances, of which the optimal value could be found on each Reynolds number. The highest power output was found to be 3.19 µW, at 9.8 m/s of flow speed (Re = 20077) and 27 MΩ of load resistance.

Keywords: downstream structures, energy harvesting, flow-induced vibration, piezoelectric material, wind tunnel

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Authors: Minoo Tavakoli, Mojtaba Zebarjad, Golestanipour

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Metallic sandwich structures with aluminum foam core are good energy absorbers. In this paper, perforation test were carried out on different samples to study energy absorption. In the experiments, effect of several parameters, i.e. skin thickness and thickness of foam core, on the energy absorption, delamination zone of back faces and deformation strain(φ) are discussed. Results show that increasing plates thickness will results in more absorbed energy and delamination. Moreover, thickening foam core has the same effect.

Keywords: sandwich panel, aluminium foam, perforation, energy absorption

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Authors: Misuk Kim, Seokho Kang, Jehyuk Lee, Hyunchang Cho, Sungzoon Cho

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In semiconductor manufacturing, virtual metrology (VM) refers to methods to predict properties of a wafer based on machine parameters and sensor data of the production equipment, without performing the (costly) physical measurement of the wafer properties (Wikipedia). Additional benefits include avoidance of human bias and identification of important factors affecting the quality of the process which allow improving the process quality in the future. It is however rare to find VM applied to other areas of manufacturing. In this work, we propose to use VM to copper clad laminate (CCL) manufacturing. CCL is a core element of a printed circuit board (PCB) which is used in smartphones, tablets, digital cameras, and laptop computers. The manufacturing of CCL consists of three processes: Treating, lay-up, and pressing. Treating, the most important process among the three, puts resin on glass cloth, heat up in a drying oven, then produces prepreg for lay-up process. In this process, three important quality factors are inspected: Treated weight (T/W), Minimum Viscosity (M/V), and Gel Time (G/T). They are manually inspected, incurring heavy cost in terms of time and money, which makes it a good candidate for VM application. We developed prediction models of the three quality factors T/W, M/V, and G/T, respectively, with process variables, raw material, and environment variables. The actual process data was obtained from a CCL manufacturer. A variety of variable selection methods and learning algorithms were employed to find the best prediction model. We obtained prediction models of M/V and G/T with a high enough accuracy. They also provided us with information on “important” predictor variables, some of which the process engineers had been already aware and the rest of which they had not. They were quite excited to find new insights that the model revealed and set out to do further analysis on them to gain process control implications. T/W did not turn out to be possible to predict with a reasonable accuracy with given factors. The very fact indicates that the factors currently monitored may not affect T/W, thus an effort has to be made to find other factors which are not currently monitored in order to understand the process better and improve the quality of it. In conclusion, VM application to CCL’s treating process was quite successful. The newly built quality prediction model allowed one to reduce the cost associated with actual metrology as well as reveal some insights on the factors affecting the important quality factors and on the level of our less than perfect understanding of the treating process.

Keywords: copper clad laminate, predictive modeling, quality control, virtual metrology

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Authors: Md. Salim Kaiser

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In the present work, the effect of load and sliding distance on the performance tribology of commercially used aluminium-silicon engine block and piston was evaluated at ambient conditions with humidity of 80% under dry sliding conditions using a pin-on-disc with two different loads of 5N and 20N yielding applied pressure of 0.30MPa and 1.4MPa, respectively, at sliding velocity of 0.29ms-1 and with varying sliding distance ranging from 260m-4200m. Factors and conditions that had significant effect were identified. The results showed that the load and the sliding distance affect the wear rate of the alloys and the wear rate increased with increasing load for both the alloys. Wear rate also increases almost linearly at low loads and increase to a maximum then attain a plateau with increasing sliding distance. For both applied loads, the piston alloy showed the better performance due to higher Ni and Mg content. The worn surface and wear debris was characterized by optical microscope, SEM and EDX analyzer. The worn surface was characterized by surface with shallow grooves at loads while the groove width and depth increased as the loads increases. Oxidative wear was found to be the predominant mechanisms in the dry sliding of Al-Si alloys at low loads

Keywords: wear, friction, gravimetric analysis, aluminium-silicon alloys, SEM, EDX

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Authors: Maizatulnisa Othman, Mohamad Bukhari, Zahurin Halim, Souad A. Muhammad, Khalisani Khalid

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Sandwich structure composites produced by epoxy core and aluminium skin were developed as potential building materials. Interface bonding between core and skin was controlled by varying kenaf content. Five different weight percentage of kenaf loading ranging from 10 wt% to 50 wt% were employed in the core manufacturing in order to study the mechanical properties of the sandwich composite. Properties of skin aluminium with epoxy were found to be affected by drying time of the adhesive. Mechanical behavior of manufactured sandwich composites in relation with properties of constituent materials was studied. It was found that 30 wt% of kenaf loading contributed to increase the flexural strength and flexural modulus up to 102 MPa and 32 Gpa, respectively. Analysis were done on the flatwise and edgewise compression test. For flatwise test, it was found that 30 wt% of fiber loading could withstand maximum force until 250 kN, with compressive strength results at 96.94 MPa. However, at edgewise compression test, the sandwich composite with same fiber loading only can withstand 31 kN of the maximum load with 62 MPa of compressive strength results.

Keywords: sandwich structure composite, epoxy, aluminium, kenaf fiber

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Authors: S. Wisutmethangoon, S. Pannaray, T. Plookphol, J. Wannasin

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2024 Aluminium alloy was squeezed cast by the Gas Induced Semi Solid (GISS) process. Effect of artificial aging on microstructure and mechanical properties of this alloy was studied in the present work. The solutionized specimens were aged hardened at temperatures of 175°C, 200°C, and 225°C under various time durations. The highest hardness of about 77.7 HRE was attained from specimen aged at the temperature of 175 °C for 36 h. Upon investigation the microstructure by using Transmission Electron Microscopy (TEM), the phase was mainly attributed to the strengthening effect in the aged alloy. The apparent activation energy for precipitation hardening of the alloy was calculated as 133,805 J/mol.

Keywords: 2024 aluminium alloy, gas induced semi solid, T6 heat treatment, aged hardening, transmission electron microscopy

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Authors: E. Ewemoje Oluseyi, T. A. Ewemoje, A. A. Adedeji

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Biodegradable solid waste disposal and management has been a major problem in Nigeria and indiscriminate dumping of this waste either into watercourses or drains has led to environmental hazards affecting public health. The study investigated the nutrients level of pit composting and vermicomposting. Wooden bins 60 cm × 30 cm × 30 cm³ in size were constructed and bedding materials (sawdust, egg shell, paper and grasses) and red worms (Eisenia fetida) introduced to facilitate the free movement and protection of the worms against harsh weather. A pit of 100 cm × 100 cm × 100 cm³ was dug and worms were introduced into the pit, which was turned every two weeks. Food waste was fed to the red worms in the bin and pit, respectively. The composts were harvested after 100 days and analysed. The analyses gave: nitrogen has average value 0.87 % and 1.29 %; phosphorus 0.66 % and 1.78 %; potassium 4.35 % and 6.27 % for the pit and vermicomposting, respectively. Higher nutrient status of vermicomposting over pit composting may be attributed to the secretions in the intestinal tracts of worms which are more readily available for plant growth. However, iron and aluminium were more in the pit compost than the vermin compost and this may be attributed to the iron and aluminium already present in the soil before the composting took place. Other nutrients in ppm concentrations were aluminium 4,999.50 and 3,989.33; iron 2,131.83 and 633.40 for the pit and vermicomposting, respectively. These nutrients are only needed by plants in small quantities. Hence, vermicomposting has the higher concentration of essential nutrients necessary for healthy plant growth.

Keywords: food wastes, pit composting, plant nutrient status, tropical environment, vermicomposting

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Authors: Sai Harshini Irigineni, Suresh Kumar Reddy Narala

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The industrial applicability of aluminium metal matrix composites (AMMCs) has been rapidly growing due to their exceptional materials traits such as low weight, high strength, excellent thermal performance, and corrosion resistance. The increasing demand for AMMCs in automobile, aviation, aerospace and defence ventures has opened up windows of opportunity for the development of processing methods that facilitate low-cost production of AMMCs with superior properties. In the present work, owing to its economy, efficiency, and suitability, powder metallurgy (P/M) technique was employed to develop AMMCs with pure aluminium as matrix material and titanium diboride (TiB₂) as reinforcement. AMMC samples with different weight compositions (Al-0.1%TiB₂, Al-5%TiB₂, Al-10%TiB₂, and Al-15% TiB₂) were prepared through hot press compacting followed by traditional sintering. The developed AMMC was subjected to metallographic studies and mechanical characterization. Experimental evidences show significant improvement in mechanical properties such as tensile strength, hardness with increasing reinforcement content. The current study demonstrates the superiority of AMMCs over conventional metals and alloys and the results obtained may be of immense in material selection for different structural applications.

Keywords: AMMCs, mechanical characterization, powder metallurgy, TiB₂

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Authors: Laura Dembovska, Ina Pundiene, Diana Bajare

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Alkali-activated aluminium-silicate composites (AASC) can be used in the production of innovative materials with a wide range of properties and applications. AASC are associated with low CO₂ emissions; in the production process, it is possible to use industrial by-products and waste, thereby minimizing the use of a non-renewable natural resource. This study deals with the preparation of heat-resistant porous AASC based on chamotte for high-temperature applications up to 1200°C. Different fillers, aluminium scrap recycling waste as pores forming agent and alkali activation with 6M sodium hydroxide (NaOH) and potassium hydroxide (KOH) solution were used. Sodium hydroxide (NaOH) is widely used for the synthesis of AASC compared to potassium hydroxide (KOH), but comparison of using different activator for geopolymer synthesis is not well established. Changes in chemical composition of AASC during heating were identified and quantitatively analyzed by using DTA, dimension changes during the heating process were determined by using HTOM, pore microstructure was examined by SEM, and mineralogical composition of AASC was determined by XRD. Lightweight porous AASC activated with NaOH have been obtained with density in range from 600 to 880 kg/m³ and compressive strength from 0.8 to 2.7 MPa, but for AAM activated with KOH density was in range from 750 to 850 kg/m³ and compressive strength from 0.7 to 2.1 MPa.

Keywords: alkali activation, alkali activated materials, elevated temperature application, heat resistance

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Authors: Taposh Roy, Anna Paradowska, Ralph Abrahams, Quan Lai, Michael Law, Peter Mutton, Mehdi Soodi, Wenyi Yan

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In this investigation, a laser cladding process with a powder feeding was used to deposit stainless steel 410L (high strength, excellent resistance to abrasion and corrosion, and great laser compatibility) onto railhead (higher strength, heat treated hypereutectoid rail grade manufactured in accordance with the requirements of European standard EN 13674 Part 1 for R400HT grade), to investigate the development and controllability of process-induced residual stress in the cladding, heat-affected zone (HAZ) and substrate and to analyse their correlation with hardness profile during two different laser cladding directions (across and along the track). Residual stresses were analysed by neutron diffraction at OPAL reactor, ANSTO. Neutron diffraction was carried out on the samples in longitudinal (parallel to the rail), transverse (perpendicular to the rail) and normal (through thickness) directions with high spatial resolution through the thickness. Due to the thick rail and thin cladding, 4 mm thick reference samples were prepared from every specimen by Electric Discharge Machining (EDM). Metallography across the laser claded sample revealed four distinct zones: The clad zone, the dilution zone, HAZ and the substrate. Compressive residual stresses were found in the clad zone and tensile residual stress in the dilution zone and HAZ. Laser cladding in longitudinally cladding induced higher tensile stress in the HAZ, whereas transversely cladding rail showed lower tensile behavior.

Keywords: laser cladding, residual stress, neutron diffraction, HAZ

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Authors: Vidula Shevade, B. J. Nagare, Sajeev Chacko

Abstract:

First principles simulation, meaning density functional theory (DFT) calculations with plane waves and pseudopotential, has become a prized technique in condensed matter theory. Nanoparticles (NP) have been known to possess good catalytic activities, especially for molecules such as CO, O₂, etc. Among the metal NPs, Aluminium based NPs are also widely known for their catalytic properties. Aluminium metal is a lightweight, excellent electrical, and thermal abundant chemical element in the earth’s crust. Aluminium NPs, when added to solid rocket fuel, help improve the combustion speed and considerably increase combustion heat and combustion stability. Adding aluminium NPs into normal Al/Al₂O₃ powder improves the sintering processes of the ceramics, with high heat transfer performance, increased density, and enhanced thermal conductivity of the sinter. We used VASP and Gaussian 0₃ package to compute the geometries, electronic structure, and bonding properties of Al₁₂Ni as well as its interaction with O₂ and CO molecules. Several MD simulations were carried out using VASP at various temperatures from which hundreds of structures were optimized, leading to 24 unique structures. These structures were then further optimized through a Gaussian package. The lowest energy structure of Al₁₂Ni has been reported to be a singlet. However, through our extensive search, we found a triplet state to be lower in energy. In our structure, the Ni atom is found to be on the surface, which gives the non-zero magnetic moment. Incidentally, O2 and CO molecules are also triplet in nature, due to which the Al₁₂-Ni cluster is likely to facilitate the oxidation process of the CO molecule. Our results show that the most favourable site for the CO molecule is the Ni atom and that for the O₂ molecule is the Al atom that is nearest to the Ni atom. Al₁₂Ni-O₂ and Al₁₂-Ni-CO structures we extracted using VMD. Al₁₂Ni nanocluster, due to in triplet electronic structure configuration, indicates it to be a potential candidate as a catalyst for oxidation of CO molecules.

Keywords: catalyst, gaussian, nanoparticles, oxidation

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Authors: Uzaira Rafique, Kousar Parveen

Abstract:

The discharge volume and composition of Textile effluents gains scientific concern due to its hazards and biotoxcity of azo dyes. Azo dyes are non-biodegradable due to its complex molecular structure and recalcitrant nature. Serious attempts have been made to synthesize and develop new materials to combat the environmental problems. The present study is designed for removal of a range of azo dyes (Methyl orange, Congo red and Basic fuchsine) from synthetic aqueous solutions and real textile effluents. For this purpose, Metal (cobalt) doped alumina hybrids are synthesized and applied as adsorbents in the batch experiment. Two different aluminium precursor (aluminium nitrate and spent aluminium foil) and glucose are mixed following sol gel method to get hybrids. The synthesized materials are characterized for surface and bulk properties using FTIR, SEM-EDX and XRD techniques. The characterization of materials under FTIR revealed that –OH (3487-3504 cm-1), C-H (2935-2985 cm-1), Al-O (~ 800 cm-1), Al-O-C (~1380 cm-1), Al-O-Al (659-669 cm-1) groups participates in the binding of dyes onto the surface of hybrids. Amorphous shaped particles and elemental composition of carbon (23%-44%), aluminium (29%-395%), and oxygen (11%-20%) is demonstrated in SEM-EDX micrograph. Time-dependent batch-experiments under identical experimental parameters showed 74% congo red, 68% methyl orange and 85% maximum removal of basic fuchsine onto the surface of cobalt doped alumina hybrids probably through the ion-exchange mechanism. The experimental data when treated with adsorption models is found to have good agreement with pseudo second order kinetic and freundlich isotherm for adsorption process. The present study concludes the successful synthesis of novel and efficient cobalt doped alumina hybrids providing environmental friendly and economical alternative to the commercial adsorbents for the treatment of industrial effluents.

Keywords: alumina hybrid, adsorption, dopant, isotherm, kinetic

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Authors: Maryam Ehsanpour, Maryam Malekpour, Rastin Afkhami

Abstract:

Today, industry is one of the indices of growth and development of countries and is a suitable applicable criterion to compare the countries. Bandar Abbas has a high industrial centralization in term of geographical redundancy of industries in comparison with other rural and urban places of Hormozgan province. Most important and major industries of the province are located in Bandar abbas eighth refinery, power plant, zinc melting company, Almahdi Aluminium, Hormozgan steel, south steel, which are the most important of these industries. So, it is necessary to study pollution from these industries and their destructive effects on environment of region. In respect of these things, general purpose of this research is codling and presenting managing solution of Almahdi Aluminium factory in them of measuring of air (atmosphere) parameters. For gaining this purpose it is necessary to determine measure of heavy metals suspension in the air (atmosphere) in the neighborhood of industries and also in residential regions close to them as partial purposes. So, for achieving the purposes above, operation of sampling from the air in two hot and cold seasons of the year (2010-2011) was performed, after field reviews to recognize the sources of effluence and to choose place of sampling stations. Sampling and preparation way to read was based on EPA and NIOSH. Also, decreasing process was included Fe>Al>Cd>Pb>Ni respectively, in term of results gaining from sampling of ingredients existing in the air (atmosphere). Also Ni and Fe elements in samples of air were higher than permissive measure in both of cold and hot season. Average of these two metals was 34% and 33% in cold season and 44% and 34% micrograms/m3 in hot season. Finally, suitable managing solutions to improve existing situation is presented in term for all results.

Keywords: Almahdi aluminium factory, Bandar Abbas, scarce metals, atmosphere

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Authors: Al Ameen H., Rakesh P.

Abstract:

To improve the combustion efficiency of fuels and to reduce the emissions of pollutants as well as to improve heat transfer characteristics of fuels, both non-metallic and metallic nanoparticles can be added into it. By varying the concentration and size of nano particles added into the fuels, behaviour of droplet combustion and hence heat generated can be altered. In case of solid or liquid fuels, surface area of the fuel in contact with oxidizer(gaseous) is small because of higher density compared to gases. If the surface area of fuel exposed to the oxidizer is very small, then the combustion will not occur, because the combustion rate is proportional to the surface area of fuel droplet. To avoid such instance there is a way to increase the exposed surface area. To increase the specific surface area available for reaction, the particle size can be reduced. If the additives are solid then by reducing the particles size the specific surface area of liquid fuel can be increased. For the liquid fuels the exposed surface area available for combustion can be increased by suspending nanoparticles. Addition of non-metallic and metallic nanoparticles in fuels improves its combustion efficiency by enhancing the thermo-physical properties. The burn rate constants and temperatures of Kerosene-Oxygen combustion for fuel droplet sizes of 50μm, 75μm, 100μm and 125μm under varying concentrations of 25%, 50%, 75% and 100% are studied numerically and its characteristic velocities are determined. Later the burn rate constants of fuel with concentrations of 0.5%, 1.0% and 2.0% by weight of aluminium nanoparticles are added. The spray combustion characteristics of such nano-fuel has improved the combustion temperature by the addition of aluminium nanoparticles. Thus, aluminium nanoparticles have improved burn rate and characteristic velocity of Kerosene-Oxygen combustion. An increase of 40% in characteristic velocity is observed.

Keywords: burn rate, characteristic velocity, combustion, thermo-physical properties

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Authors: H. Mohit

Abstract:

In automotive air conditioning system, two heat exchangers are used as evaporator and condenser which are placed inside the bonnet of a car in a compact manner. The dust particles from outside and moisture content produced during the process leads to formation of impure particles on the surface of evaporator coil. But in condenser coil, the impure particles are settling down due to dust from atmosphere. The major problem of the heat exchanger used in automotive air conditioning is leakage of refrigerant due to corrosion. This effect of corrosion will lead to damage on the surface of heat exchanger and leakage of refrigerant from the system. To protect from corrosion, coatings are applied on its surfaces. Nowadays, to improve the corrosion resistance of these heat exchangers, hydrophilic coatings are used, which is very expensive. Cryogenic treatment is one method which involves the treatment of materials below -150 °C using the cryogenic fluid such as liquid nitrogen. In this project work, a study of improvement in corrosion resistance of materials of aluminium alloys of various grades as AA 1100, AA 6061, AA 6063 and AA 2024 that are mainly used for fin and tube heat exchangers in automotive air conditioning system is made. In total, five different processes are selected for these grades of aluminium alloy and various parameters like corrosion rate, dimensional stability, hardness and microstructure are measured. The improvements were observed in these parameters while comparing it with conventional heat treatment process.

Keywords: cryogenic treatment, corrosion resistance, dimensional stability, materials science

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