Search results for: aluminium

Authors: Vasudha Hegde, Narendra Chaulagain, H. M. Ravikumar, Sonu Mishra, Siva Yellampalli

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Acoustic sensors are extensively used in recent days not only for sensing and condition monitoring applications but also for small scale energy harvesting applications to power wireless sensor networks (WSN) due to their inherent advantages. The natural frequency of the structure plays a major role in energy harvesting applications since the sensor key element has to operate at resonant frequency. In this paper, circular diaphragm based MEMS acoustic sensor is modelled by Lumped Element Model (LEM) and the natural frequency is compared with the simulated model using Finite Element Method (FEM) tool COMSOL Multiphysics. The sensor has the circular diaphragm of 3000 µm radius and thickness of 30 µm to withstand the high SPL (Sound Pressure Level) and also to withstand the various fabrication steps. A Piezoelectric ZnO layer of thickness of 1 µm sandwiched between two aluminium electrodes of thickness 0.5 µm and is coated on the diaphragm. Further, a channel with radius 3000 µm radius and length 270 µm is connected at the bottom of the diaphragm. The natural frequency of the structure by LEM method is approximately 16.6 kHz which is closely matching with that of simulated structure with suitable approximations.

Keywords: acoustic sensor, diaphragm based, lumped element modeling (LEM), natural frequency, piezoelectric

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Authors: Harleen Kaur, Richa

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Plants produce a large variety of secondary metabolites. Phenolics are the compounds that contain hydroxyl functional group on an aromatic ring. These are chemically heterogeneous compounds. Some are soluble only in organic solvents, some are water soluble and others are large insoluble polymers. Flavonoids are one of the largest classes of plant phenolics. The carbon skeleton of a flavonoid contains 15 carbons arranged in two aromatic rings connected by a three carbon ridge. Both phenolics and flavonoids are good natural antioxidants. Four Indian aromatic plants were selected for the study i.e, Achillea species, Jasminum primulinum, Leucas cephalotes and Leonotis nepetaefolia. All the plant species were collected from Chail region of Himachal Pradesh, India. The identifying features and anatomical studies were done of the part containing the essential oils. Phenolic cotent was estimated by Folin Ciocalteu’s method and flavonoids content by aluminium chloride method. Antioxidant property was checked by using DPPH method. Maximum antioxidant potential was found in Achillea species, followed by Leonotis nepetaefolia, Jaminum primulinum and Leucas cephalotes. Phenolics and flavonoids are important compounds that serve as defences against herbivores and pathogens. Others function in attracting pollinators and absorbing harmful radiations.

Keywords: antioxidants, DPPH, flavonoids, phenolics

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Authors: B. Chemani, H. Aknouche, A. Zerizer, R. Marchal

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The phenomena occurring during machining are related to the internal friction of the material that deforms and the friction the flake on the rake face of tool. Various researches have been conducted to improve the wear resistance of the tool by thin film deposition. This work aims to present an experimental approach related to wood machining technique to evaluate the wear for the case of ripping Aleppo pine, a species well established in the Mediterranean in general and in Algeria in particular. The study will be done on tungsten carbide cutting tools widely used in woodworking and coated with chrome nitride (CrN) and Chromium Nitride enriched Aluminium (CrAlN) with percentage different of aluminum sputtered through frame magnetron mark Nordiko 3500. The deposition conditions are already optimized by previous studies. The wear tests were performed in the laboratory of ENSAM Cluny (France) on a numerical control ripper of recordi type. This comparative study of the behavior of tools, coated and uncoated, showed that the addition of the aluminum chromium nitride films does not improve the tool ability to resist abrasive wear that is predominant when ripping the Aleppo pine. By against the aluminum addition improves the crystallization of chromium nitride films.

Keywords: Aleppo pine, PVD, coatings, CrAlN, wear

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Authors: Herviyanti, Gusnidar, M. Harianti

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The objective of this research were: a) using low-rank coal (subbituminous) as main humate material sources because this material will not be anthracite, and cannot using to be an energy sources b) to examine residual effects of humic matter from subbituminous which was combined with P fertilizers to adsorp Al and Fe metal, improving soil fertility, and increasing P fertilizing efficiency and Oxisol productivity. Therefore, optimalization crop productivity of upland rice can be achieved. The experiment was designed using a 3 x 4 factorial with 3 replications in randomly groups design. The 1st factor was 3 ways incubating humate material with P-fertilizer, which are: I1 = Incubation of humate material 1 week, then incubation P-fertilizers 1 week; I2 = Incubation of humate materials and P fertilizers directly into the soil for 2 weeks; and I3 = humate material and P fertilizer mixed for 1 week, then incubation to the soil for 1 week. The 2nd factor was residual effects of humate material and P-fertilizer combination which are 4 doses H1 = 400 ppm (0.8 Mg/ha) + 100% R; H2 = 400 ppm + 75% R; H3 = 800 ppm (1.6 Mg/ha) + 100% R,; and H4 = 800 ppm + 75% R. The 2nd year research results showed that the best treatment was founded residue effect of 800 ppm humate material and 100% R P-fertilizer doses in I3 way incubation that is equal to 6.19 t ha-1 upland rice yield. However, this result is almost the same as residual effects of 800 ppm humate material + 75% R P-fertilizer doses and upland rice yield the 1st year. It was concluded that addition of humate material can given the efficiency of P-fertilizer using up to 25% until the 2nd season planted.

Keywords: humate materials, P-fertilizer, subbituminous, upland rice

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Authors: M. V. Rane, Tareke Tekia

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Fresh Air Dehumidifier having a capacity of 1 TR has been developed by Heat Pump Laboratory at IITB. This fresh air dehumidifier is based on potassium formate liquid desiccant. The regeneration of the liquid desiccant can be done in two stages. The first stage of liquid desiccant regeneration involves the boiling of liquid desiccant inside the evacuated glass type solar thermal collectors. Further regeneration of liquid desiccant can be achieved using Low Temperature Regenerator, LTR. The coefficient of performance of the fresh air dehumidifier greatly depends on the performance of the major components such as high temperature regenerator, low temperature regenerator, fresh air dehumidifier, and solution heat exchangers. High effectiveness solution heat exchanger has been developed and tested. The solution heat exchanger is based on a patented aluminium extrusion with special passage geometry to enhance the heat transfer rate. Effectiveness up to 90% was achieved. Before final testing of the dehumidifier, major components have been tested individually. Testing of the solar thermal collector as hot water and steam generator reveals that efficiency up to 55% can be achieved. In this paper, the development of 1 TR fresh air dehumidifier with special focus on solution heat exchangers and solar thermal collector performance is presented.

Keywords: solar, liquid desiccant, dehumidification, air conditioning, regeneration, coefficient of performance

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Authors: Anastasia Stamatiou, Markus Odermatt, Dominic Leemann, Ludger J. Fischer, Joerg Worlitschek

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The successful integration of thermal energy storage in industrial processes is expected to play an important role in the energy turnaround. Latent heat storage technologies can offer more compact thermal storage at a constant temperature level, in comparison to conventional, sensible thermal storage technologies. The focus of this study is the development of latent heat storage solutions based on the Phase Change Slurry (PCS) concept. Such systems promise higher energy densities both as refrigerants and as storage media while presenting better heat transfer characteristics than conventional latent heat storage technologies. This technology is expected to deliver high thermal power and high-temperature stability which makes it ideal for storage of process heat. An evaluation of important batch processes in industrial applications set the focus on materials with a melting point in the range of 55 - 90 °C. Aluminium ammonium sulfate dodecahydrate (NH₄Al(SO₄)₂·12H₂O) was chosen as the first interesting PCM for the next steps of this study. The ability of this material to produce slurries at the relevant temperatures was demonstrated in a continuous mode in a laboratory test-rig. Critical operational and design parameters were identified.

Keywords: esters, latent heat storage, phase change materials, thermal properties

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Authors: S. Palaniyappan, P. K. Chennam, M. Trautmann, H. Ahmad, T. Mehner, T. Lampke, G. Wagner

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In structural-health monitoring of fiber reinforced plastics (FRPs), every single inorganic fiber sensor that are integrated into the bulk material requires an electrical insulation around itself, when the surrounding reinforcing fibers are electrically conductive. This results in a more accurate data acquisition only from the sensor fiber without any electrical interventions. For this purpose, thin nano-films of aluminium oxide (Al₂O₃)-based electrical-insulation coatings have been fabricated around the Silicon Carbide (SiC) single fiber sensors through reactive DC magnetron sputtering technique. The sputtered coatings were amorphous in nature and the thickness of the coatings increased with an increase in the sputter time. Microstructural characterization of the coated fibers performed using scanning electron microscopy (SEM) confirmed a homogeneous circumferential coating with no detectable defects or cracks on the surface. X-ray diffraction (XRD) analyses of the as-sputtered and 2 hours annealed coatings (825 & 1125 ˚C) revealed the amorphous and crystalline phases of Al₂O₃ respectively. Raman spectroscopic analyses produced no characteristic bands of Al₂O₃, as the thickness of the films was in the nanometer (nm) range, which is too small to overcome the actual penetration depth of the laser used. In addition, the influence of the insulation coatings on the mechanical properties of the SiC sensor fibers has been analyzed.

Keywords: Al₂O₃ thin film, electrical insulation coating, PVD process, SiC fibre, single fibre tensile test

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Authors: H. Selcuk Halkacı, Mevlüt Türköz, Ekrem Öztürk, Murat Dilmec

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Various attempts concerning the low formability issue for lightweight materials like aluminium and magnesium alloys are being investigated in many studies. Advanced forming processes such as hydroforming is one of these attempts. In last decades sheet hydroforming process has an increasing interest, particularly in the automotive and aerospace industries. This process has many advantages such as enhanced formability, the capability to form complex parts, higher dimensional accuracy and surface quality, reduction of tool costs and reduced die wear compared to the conventional sheet metal forming processes. There are two types of sheet hydroforming. One of them is hydromechanical deep drawing (HDD) that is a special drawing process in which pressurized fluid medium is used instead of one of the die half compared to the conventional deep drawing (CDD) process. Another one is sheet hydroforming with die (SHF-D) in which blank is formed with the act of fluid pressure and it takes the shape of die half. In this study, transition of cup height according to cup diameter between the processes was determined by performing simulation of the processes in Finite Element Analysis. Firstly SHF-D process was simulated for 40 mm cup diameter at different cup heights chancing from 10 mm to 30 mm and the cup height to diameter ratio value in which it is not possible to obtain a successful forming was determined. Then the same ratio was checked for a different cup diameter of 60 mm. Then thickness distributions of the cups formed by SHF-D and HDD processes were compared for the cup heights. Consequently, it was found that the thickness distribution in HDD process in the analyses was more uniform.

Keywords: finite element analysis, HDD, hydroforming sheet metal forming, SHF-D

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Authors: Ajay Sidana, Kulbir Singh Sandhu, Balwinder Singh Sidhu

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Joining of dissimilar non-ferrous alloys like aluminium and magnesium alloys becomes important in various automobile and aerospace applications due to their low density and good corrosion resistance. Friction Stir Welding (FSW), a solid state joining process, successfully welds difficult to weld similar and dissimilar aluminum and magnesium alloys. Two tool rotation speeds were selected by keeping the transverse speed constant to weld similar and dissimilar alloys. Similar(Al to Al) and Dissimilar(Al to Mg) weld joints were obtained by FSW. SEM scans revealed that higher tool rotation fragments the coarse grains of base material into fine grains in the weld zone. Also, there are less welding defects in weld joints obtained with higher tool rotation speed. The material of dissimilar alloys was mixed with each other forming recrystallised new intermetallics. There was decrease in hardness of similar weld joint however there is significant increase in hardness of weld zone in case of dissimilar weld joints due to stirring action of tool and formation of inter metallics. Tensile tests revealed that there was decrease in percentage elongation in both similar and dissimilar weld joints.

Keywords: aluminum alloys, magnesium alloys, friction stir welding, microstructure, mechanical properties

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Authors: Pujan Sarkar

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

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

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Authors: Shadatul Hanom Rashid, Xiaorong Zhou

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Hybrid sol-gel coatings are the blend of both advantages of inorganic and organic networks have been reported as environmentally friendly anti-corrosion surface pre-treatment for several metals, including aluminum alloys. In this current study, Si-Zr hybrid sol-gel coatings were synthesized from (3-glycidoxypropyl)trimethoxysilane (GPTMS), tetraethyl orthosilicate (TEOS) and zirconium(IV) propoxide (TPOZ) precursors and applied on AA6111 aluminum alloy by dip coating technique. The hybrid sol-gel coatings doped with different concentrations of cerium nitrate (Ce(NO3)3) as a corrosion inhibitor were also prepared and the effect of Ce(NO3)3 concentrations on the morphology and corrosion resistance of the coatings were examined. The surface chemistry and morphology of the hybrid sol-gel coatings were analyzed by Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM). The corrosion behavior of the coated aluminum alloy samples was evaluated by electrochemical impedance spectroscopy (EIS). Results revealed that good corrosion resistance of hybrid sol-gel coatings were prepared from hydrolysis and condensation reactions of GPTMS, TEOS and TPOZ precursors deposited on AA6111 aluminum alloy. When the coating doped with cerium nitrate, the properties were improved significantly. The hybrid sol-gel coatings containing lower concentration of cerium nitrate offer the best inhibition performance. A proper doping concentration of Ce(NO3)3 can effectively improve the corrosion resistance of the alloy, while an excessive concentration of Ce(NO3)3 would reduce the corrosion protection properties, which is associated with defective morphology and instability of the sol-gel coatings.

Keywords: AA6111, Ce(NO3)3, corrosion, hybrid sol-gel coatings

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Authors: K. Almi, S.Lakel, A. Benchabane, A. Kriker

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The fiber–matrix compatibility can be improved if suitable enforcements are chosen. Whenever the reinforcements have more thermal stability, they can resist to the main processes for wood–thermoplastic composites. This paper is an investigation of effect of different treatment process on the mechanical proprieties and on the thermal stability of date palm leaflets fibers with a view to improve the date palm fiber proprieties used as reinforcement of thermoplastic materials which main processes require extrusion, hot press. To compare the effect of alkali and acid treatment on the date palm leaflets fiber properties, different treatment were used such as Sodium hydroxide NaOH solution, aluminium chloride AlCl3 and acid treatment with HCL solution. All treatments were performed at 70°C for 4h and 48 h. The mechanical performance (tensile strength and elongation) is affected by immersion time in alkaline and acid solutions. The reduction of the tensile strength and elongation of fibers at 48h was higher in acid treatment than in alkali treatment at high concentration. No significant differences were observed in mechanical and thermal proprieties of raw fibers and fibers submerged in AlCl3 at low concentration 1% for 48h. Fibers treated by NaOH at 6% for 4h showed significant increase in the mechanical proprieties and thermal stability of date palm leaflets fibers. Hence, soda treatment is necessary to improve the fibers proprieties and consequently optimize the composite performance.

Keywords: date palm fibers, surface treatments, thermoplastic composites, thermal analysis

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Authors: H. Solomon, A. Abdul-Latif, R. Baleh, I. Deiab, K. Khanafer

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Aluminum foams were developed and tested due to their high energy absorption abilities for multifunctional applications. The aim of this research work was to investigate experimentally the effect of quasi-static biaxial loading complexity (combined compression-torsion) on the energy absorption capacity of highly uniform architecture open-cell aluminum foam manufactured by kelvin cell model. The two generated aluminum foams have 80% and 85% porosities, spherical-shaped pores having 11mm in diameter. These foams were tested by means of several square-section specimens. A patented rig called ACTP (Absorption par Compression-Torsion Plastique), was used to investigate the foam response under quasi-static complex loading paths having different torsional components (i.e., 0°, 37° and 53°). The main mechanical responses of the aluminum foams were studied under simple, intermediate and severe loading conditions. In fact, the key responses to be examined were stress plateau and energy absorption capacity of the two foams with respect to loading complexity. It was concluded that the higher the loading complexity and the higher the relative density, the greater the energy absorption capacity of the foam. The highest energy absorption was thus recorded under the most complicated loading path (i.e., biaxial-53°) for the denser foam (i.e., 80% porosity).

Keywords: open-cell aluminum foams, biaxial loading complexity, foams porosity, energy absorption capacity, characterization

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Authors: H. I. Beloufa, M. Tarfaoui

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For many applications, adhesively bonded assemblies have gained an increasing interest in the industry due to several advantages over welding, riveting and bolting, such as reduction of stress concentrations, lightness, low cost and easy manufacturing. This work is largely concerned to show the effects of the loading rate of the adhesively bonded joints under different speed rates. The tensile tests were conducted at four different rates; static (5mm/min, 50mm/min) and dynamic tests (1m/s, and 10m/s). An attempt was made to determine the damage kinetic and a comparison between the use of aluminium and composite laminate substrates is introduced. Aluminum T6082 and glass/vinylester laminated composite Substrates were used to construct aluminum/aluminum and laminate/laminate specimens. The adhesive used in this study was Araldite 2015. The results showed the effects of the loading rate évolution on the double joint strength. The comparison of the results of static and dynamic tests showed a raise of the strength of the specimens while the load velocity is elevated. In the case of composite substrates double joint lap, the stiffness increased by more than 60% between static and dynamic tests. However, in the case of aluminum substrates, the rigidity improved about 28% from static to moderately high velocity loading. For both aluminum and composite double joint lap, the strength increased by approximately 25% when the tensile velocity is increased from 5 mm/min to 50 mm/min (static tests). Nevertheless, the tensile velocity is extended to 1m/s the strength increased by 13% and 25% respectively for composite and aluminum substrates.

Keywords: adhesive, double lap joints, static and dynamic behavior, tensile tests

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Authors: Khalid S. Hashim, Andy Shaw, Rafid Alkhaddar, David Phipps, Ortoneda Pedrola

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Temperature is an essential parameter in the electrocoagulation process (EC) as it governs the solubility of electrodes and the precipitates and the collision rate of particles in water being treated. Although it has been about 100 years since the EC technology was invented and applied in water and wastewater treatment, the effects of temperature on the its performance were insufficiently investigated. Thus, the present project aims to fill this gap by an innovative use of perforated flow columns in the designing of a new EC reactor (ECR1). The new reactor (ECR1) consisted of a Perspex made cylinder container supplied with a flow column consisted of perorated discoid electrodes that made from aluminium. The flow column has been installed vertically, half submerged in the water being treated, inside a plastic cylinder. The unsubmerged part of the flow column works as a radiator for the water being treated. In order to investigate the performance of ECR1; water samples with different initial temperatures (15, 20, 25, 30, and 35 °C) to the ECR1 for 20 min. Temperature of effluent water samples were measured using Hanna meter (Model: HI 98130). The obtained results demonstrated that the ECR1 reduced water temperature from 35, 30, and 25 °C to 24.6, 23.8, and 21.8 °C respectively. While low water temperature, 15 °C, increased slowly to reach 19.1 °C after 15 minutes and kept the same level till the end of the treatment period. At the same time, water sample with initial temperature of 20 °C showed almost a steady level of temperature along the treatment process, where the temperature increased negligibly from 20 to 20.1 °C after 20 minutes of treatment. In conclusion, ECR1 is able to control the temperature of water being treated around the room temperature even when the initial temperature was high (35 °C) or low (15 °C).

Keywords: electrocoagulation, flow column, treatment, water temperature

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Authors: R. Vetrimurugan, Terry Lim, M. J. Goodson, R. Nagarajan

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This study investigates the cleaning performance of high intensity 360 kHz frequency on the removal of nano-dimensional and sub-micron particles from various surfaces, uniformity of the cleaning tank and run to run variation of cleaning process. The uniformity of the cleaning tank was measured by two different methods i.e 1. ppbTM meter and 2. Liquid Particle Counting (LPC) technique. In the second method, aluminium metal spacer components was placed at various locations of the cleaning tank (such as centre, top left corner, bottom left corner, top right corner, bottom right corner) and the resultant particles removed by 360 kHz frequency was measured. The result indicates that the energy was distributed more uniformly throughout the entire cleaning vessel even at the corners and edges of the tank when megasonic sweeping technology is applied. The result also shows that rinsing the parts with 360 kHz frequency at final rinse gives lower particle counts, hence higher cleaning efficiency as compared to other frequencies. When megasonic sweeping technology is applied each piezoelectric transducers will operate at their optimum resonant frequency and generates stronger acoustic cavitational force and higher acoustic streaming velocity. These combined forces are helping to enhance the particle removal and at the same time improve the overall cleaning performance. The multiple extractions study was also carried out for various frequencies to measure the cleaning potential and asymptote value.

Keywords: power distribution, megasonic sweeping, cavitation intensity, particle removal, laser particle counting, nano, submicron

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Authors: P. S. Jain, K. D. Bobade, S. J. Surana

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A simple, selective, precise and Stability-indicating High-performance thin-layer chromatographic method for analysis of Naftopidil both in a bulk and in pharmaceutical formulation has been developed and validated. The method employed, HPTLC aluminium plates precoated with silica gel as the stationary phase. The solvent system consisted of hexane: ethyl acetate: glacial acetic acid (4:4:2 v/v). The system was found to give compact spot for Naftopidil (Rf value of 0.43±0.02). Densitometric analysis of Naftopidil was carried out in the absorbance mode at 253 nm. The linear regression analysis data for the calibration plots showed good linear relationship with r2=0.999±0.0001 with respect to peak area in the concentration range 200-1200 ng per spot. The method was validated for precision, recovery and robustness. The limits of detection and quantification were 20.35 and 61.68 ng per spot, respectively. Naftopidil was subjected to acid and alkali hydrolysis, oxidation and thermal degradation. The drug undergoes degradation under acidic, basic, oxidation and thermal conditions. This indicates that the drug is susceptible to acid, base, oxidation and thermal conditions. The degraded product was well resolved from the pure drug with significantly different Rf value. Statistical analysis proves that the method is repeatable, selective and accurate for the estimation of investigated drug. The proposed developed HPTLC method can be applied for identification and quantitative determination of Naftopidil in bulk drug and pharmaceutical formulation.

Keywords: naftopidil, HPTLC, validation, stability, degradation

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Authors: Kolela J Nyembwe, Darlington C. Ashiegbu, Herman J. Potgieter

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Over the past few decades, the demand for metals has increased significantly. This has led to a decrease and decline of high-grade ore over time and an increase in mineral complexity and matrix heterogeneity. In addition to that, there are rising concerns about greener processes and a sustainable environment. Due to these challenges, the mining and metal industry has been forced to develop new technologies that are able to economically process and recover metallic values from low-grade ores, materials having a metal content locked up in industrially processed residues (tailings and slag), and complex matrix mineral deposits. Several methods to address these issues have been developed, among which are ionic liquids (IL), heap leaching, and bioleaching. Recently, the gas phase extraction technique has been gaining interest because it eliminates many of the problems encountered in conventional mineral processing methods. The technique relies on the formation of volatile metal complexes, which can be removed from the residual solids by a carrier gas. The complexes can then be reduced using the appropriate method to obtain the metal and regenerate-recover the organic extractant. Laboratory work on the gas phase have been conducted for the extraction and recovery of aluminium (Al), iron (Fe), copper (Cu), chrome (Cr), nickel (Ni), lead (Pb), and vanadium V. In all cases the extraction revealed to depend of temperature and mineral surface area. The process technology appears very promising, offers the feasibility of recirculation, organic reagent regeneration, and has the potential to deliver on all promises of a “greener” process.

Keywords: gas-phase extraction, hydrometallurgy, low-grade ore, sustainable environment

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Authors: Md Omar Faruq Howlader, Tariq Pervez Sattar, Sandra Dudley

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This paper describes the design process of a 200 MHz Ground Penetrating Radar (GPR) and a battery powered concrete vertical concrete surface climbing mobile robot. The key design feature is a miniaturized 200 MHz dipole antenna using additional radiating arms and procedure records a reduction of 40% in length compared to a conventional antenna. The antenna set is mounted in front of the robot using a servo mechanism for folding and unfolding purposes. The robot’s adhesion mechanism to climb the reinforced concrete wall is based on neodymium permanent magnets arranged in a unique combination to concentrate and maximize the magnetic flux to provide sufficient adhesion force for GPR installation. The experiments demonstrated the robot’s capability of climbing reinforced concrete wall carrying the attached prototype GPR system and perform floor-to-wall transition and vice versa. The developed GPR’s performance is validated by its capability of detecting and localizing an aluminium sheet and a reinforcement bar (rebar) of 12 mm diameter buried under a test rig built of wood to mimic the concrete structure environment. The present robotic GPR system proves the concept of feasibility of undertaking inspection procedure on large concrete structures in hazardous environments that may not be accessible to human inspectors.

Keywords: climbing robot, dipole antenna, ground penetrating radar (GPR), mobile robots, robotic GPR

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Authors: S. Ghanaraja, Subrata Ray, S. K. Nath

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Particle reinforced Metal Matrix Composite (MMC) succeeds in synergizing the metallic matrix with ceramic particle reinforcements to result in improved strength, particularly at elevated temperatures, but adversely it affects the ductility of the matrix because of agglomeration and porosity. The present study investigates the outcome of tensile properties in a cast and hot forged composite reinforced simultaneously with coarse and fine particles. Nano-sized alumina particles have been generated by milling mixture of aluminum and manganese dioxide powders. Milled particles after drying are added to molten metal and the resulting slurry is cast. The microstructure of the composites shows good distribution of both the size categories of particles without significant clustering. The presence of nanoparticles along with coarser particles in a composite improves both strength and ductility considerably. Delay in debonding of coarser particles to higher stress is due to reduced mismatch in extension caused by increased strain hardening in presence of the nanoparticles. However, higher addition of powder mix beyond a limit results in deterioration of mechanical properties, possibly due to clustering of nanoparticles. The porosity in cast composite generally increases with the increasing addition of powder mix as observed during process and on forging it has got reduced. The base alloy and nanocomposites show improvement in flow stress which could be attributed to lowering of porosity and grain refinement as a consequence of forging.

Keywords: aluminium, alumina, nano-particle reinforced composites, porosity

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Authors: Julius Denafas, Irina Kliopova, Gintaras Denafas

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Three opportunities for implementation of industrial ecology principles in the real industrial production of c-Si solar cells and modules are presented in this study. It includes: material flow dematerialisation, product modification and industrial symbiosis. Firstly, it is shown how the collaboration between R&D institutes and industry helps to achieve significant reduction of material consumption by a) refuse from phosphor silicate glass cleaning process and b) shortening of silicon nitride coating production step. Secondly, it was shown how the modification of solar module design can reduce the CO2 footprint for this product and enhance waste prevention. It was achieved by implementing a frameless glass/glass solar module design instead of glass/backsheet with aluminium frame. Such a design change is possible without purchasing new equipment and without loss of main product properties like efficiency, rigidity and longevity. Thirdly, industrial symbiosis in the solar cell production is possible in such case when manufacturing waste (silicon wafer and solar cell breakage) also used solar modules are collected, sorted and supplied as raw-materials to other companies involved in the production chain of c-Si solar cells. The obtained results showed that solar cells produced from recycled silicon can have a comparable electrical parameters like produced from standard, commercial silicon wafers. The above mentioned work was performed at solar cell producer Soli Tek R&D in the frame of H2020 projects CABRISS and Eco-Solar.

Keywords: manufacturing, process optimisation, recycling, solar cells, solar modules, waste prevention

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Authors: Sanaz Mosadeghsedghi, Mathew Hudder, Mohammad Ali Baghbanzadeh, Charbel Atallah, Seyedeh Laleh Dashtban Kenari, Konstantin Volchek

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Lithium has recently been extensively used in lithium-ion batteries (LIBs) for electric vehicles and portable electronic devices. The conventional evaporative approach to recover and concentrate lithium is extremely slow and may take 10-24 months to concentrate lithium from dilute sources, such as geothermal brines. To response to the increasing industrial lithium demand, alternative extraction and concentration technologies should be developed to recover lithium from brines with low concentrations. In this study, a combination of electrocoagulation (EC) and electrodialysis (ED) was evaluated for the recovery of lithium from geothermal brines. The brine samples in this study, collected in Western Canada, had lithium concentrations of 50-75 mg/L on a background of much higher (over 10,000 times) concentrations of sodium. This very high sodium-to-lithium ratio poses challenges to the conventional direct-lithium extraction processes which employ lithium-selective adsorbents. EC was used to co-precipitate lithium using a sacrificial aluminium electrode. The precipitate was then dissolved, and the leachate was treated using ED to separate and concentrate lithium from other ions. The focus of this paper is on the study of ED, including a two-step ED process that included a mono-valent selective stage to separate lithium from multi-valent cations followed by a bipolar ED stage to convert lithium chloride (LiCl) to LiOH product. Eventually, the ED cell was reconfigured using mono-valent cation exchange with the bipolar membranes to combine the two ED steps in one. Using this process at optimum conditions, over 95% of the co-existing cations were removed and the purity of lithium increased to over 90% in the final product.

Keywords: electrochemical separation, electrocoagulation, electrodialysis, lithium extraction

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Authors: Julius Denafas, Irina Kliopova, Gintaras Denafas

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Three opportunities for implementation of industrial ecology principles in the real industrial production of c-Si solar cells and modules are presented in this study. It includes: material flow dematerialisation, product modification and industrial symbiosis. Firstly, it is shown how the collaboration between R&D institutes and industry helps to achieve significant reduction of material consumption by a) refuse from phosphor silicate glass cleaning process and b) shortening of SiNx coating production step. This work was performed in the frame of Eco-Solar project, where Soli Tek R&D is collaborating together with the partners from ISC-Konstanz institute. Secondly, it was shown how the modification of solar module design can reduce the CO2 footprint for this product and enhance waste prevention. It was achieved by implementing a frameless glass/glass solar module design instead of glass/backsheet with aluminium frame. Such a design change is possible without purchasing new equipment and without loss of main product properties like efficiency, rigidity and longevity. Thirdly, industrial symbiosis in the solar cell production is possible in such case when manufacturing waste (silicon wafer and solar cell breakage) are collected, sorted and supplied as raw-materials to other companies involved in the production chain of c-Si solar cells. The obtained results showed that solar cells produced from recycled silicon can have a comparable electrical parameters like produced from standard, commercial silicon wafers. The above mentioned work was performed at solar cell producer Soli Tek R&D in the frame of H2020 projects CABRISS and Eco-Solar.

Keywords: solar cells and solar modules, manufacturing, waste prevention, recycling

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Authors: S. S. Sravanthi, Swati Ghosh Acharyya

Abstract:

Automotive light weighting is of major prominence in the current times due to its contribution in improved fuel economy and reduced environmental pollution. Various arc welding technologies are being employed in the production of automobile components with reduced weight. The present study is of practical importance since it involves preferential substitution of Zinc coated mild steel with a light weight alloy such as 6061 Aluminium by means of Gas Metal Arc Welding (GMAW) – Brazing technique at different processing parameters. However, the fabricated joints have shown the generation of Al – Fe layer at the interfacial regions which was confirmed by the Scanning Electron Microscope and Energy Dispersion Spectroscopy. These Al-Fe compounds not only affect the mechanical strength, but also predominantly deteriorate the corrosion resistance of the joints. Hence, it is essential to understand the phases formed in this layer and their crystal structure. Micro area X - ray diffraction technique has been exclusively used for this study. Moreover, the crevice corrosion analysis at the joint interfaces was done by exposing the joints to 5 wt.% FeCl₃ solution at regular time intervals as per ASTM G 48-03. The joints have shown a decreased crevice corrosion resistance with increased heat intensity. Inner surfaces of welds have shown severe oxide cracking and a remarkable weight loss when exposed to concentrated FeCl₃. The weight loss was enhanced with decreased filler wire feed rate and increased heat intensity. 

Keywords: automobiles, welding, corrosion, lap joints, Micro XRD

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

Abstract:

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

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

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Authors: A.Farrag Farrag, A. M. El-Aziz Abdel Aziz, W. Khlifa Khlifa

Abstract:

Ultrasonic treatment is a promising process nowadays in the engineering field due to its high efficiency and it is a low-cost process. It enhances mechanical properties, corrosion resistance, and homogeneity of the microstructure. In this study, the effect of ultrasonic treatment and several casting conditions on microstructure, hardness and corrosion behavior of AC4C aluminum alloy was examined. Various ultrasonic treatments of the AC4C alloys were carried out to prepare billets for thixocasting process. Treatment temperatures varied from about 630oC and cooled down to under ultrasonic field. Treatment time was about 90s. A 600-watts ultrasonic system with 19.5 kHz and intensity of 170 W/cm2 was used. Billets were reheated to semisolid state and held for 5 minutes at 582 oC and temperatures (soaking) using high-frequency induction system, then thixocasted using a die casting machine. Microstructures of the thixocast parts were studied using optical and SEM microscopes. On the other hand, two samples were conventionally cast and poured at 634 oC and 750 oC. The microstructure showed a globular none dendritic grains for AC4C with the application of UST at 630-582 oC, Less dendritic grains when the sample was conventionally cast without the application of UST and poured at 624 oC and a fully dendritic microstructure When the sample was cast and poured at 750 oC without UST .The ultrasonic treatment during solidification proved that it has a positive influence on the microstructure as it produced the finest and globular grains thus it is expected to increase the mechanical properties of the alloy. Higher values of corrosion resistance and hardness were recorded for the ultrasound-treated sample in comparison to cast one.

Keywords: ultrasonic treatment, aluminum alloys, corrosion behaviour, mechanical behaviour, microstructure

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Authors: Reza Soleimanpour, Ching Tai Ng

Abstract:

Fibre-composites are widely used in various structures due to their attractive properties such as higher stiffness to mass ratio and better corrosion resistance compared to metallic materials. However, one serious weakness of this composite material is delamination, which is a subsurface separation of laminae. A low level of this barely visible damage can cause a significant reduction in residual compressive strength. In the last decade, the application of guided waves for damage detection has been a topic of significant interest for many researches. Among all guided wave techniques, nonlinear guided wave has shown outstanding sensitivity and capability for detecting different types of damages, e.g. cracks and delaminations. So far, most of researches on applications of nonlinear guided wave have been dedicated to isotropic material, such as aluminium and steel, while only a few works have been done on applications of nonlinear characteristics of guided waves in anisotropic materials. This study investigates the nonlinear interactions of the fundamental antisymmetric lamb wave (A0) with delamination in composite laminates using three-dimensional (3D) explicit finite element (FE) simulations. The nonlinearity considered in this study arises from interactions of two interfaces of sub-laminates at the delamination region, which generates contact acoustic nonlinearity (CAN). The aim of this research is to investigate the phenomena of CAN in composite laminated beams by a series of numerical case studies. In this study interaction of fundamental antisymmetric lamb wave with delamination of different sizes are studied in detail. The results show that the A0 lamb wave interacts with the delaminations generating CAN in the form of higher harmonics, which is a good indicator for determining the existence of delaminations in composite laminates.

Keywords: contact acoustic nonlinearity, delamination, fibre reinforced composite beam, finite element, nonlinear guided waves

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Authors: Shaher Bano, Samia Fida, Asif Israr

Abstract:

The continuous development and exploitation of materials and designs have diverted the attention of the world towards the use of robust composite materials known as fiber-metal laminates in many high-performance applications. The hybrid structure of fiber metal laminates makes them a material of choice for various applications such as aircraft skin panels, fuselage floorings, door panels and other load bearing applications. The synergistic effect of properties of metals and fibers reinforced laminates are responsible for their high damage tolerance as the metal element provides better fatigue and impact properties, while high stiffness and better corrosion properties are inherited from the fiber reinforced matrix systems. They are mostly used as a layered structure in different joint configurations such as lap and but joints. The FML layers are usually bonded with each other using either mechanical fasteners or adhesive bonds. This research work is also focused on modification of an adhesive bonded joint as a single lap joint of carbon fibers based CARALL FML has been modified to increase interlaminar shear strength and avoid delamination. For this purpose different joint modification techniques such as the introduction of spews and shoulder to modify the bond shape and use of nanofillers such as carbon nano-tubes as a reinforcement in the adhesive materials, have been utilized to improve shear strength of lap joint of the adhesively bonded FML layers. Both the simulation and experimental results showed that lap joint with spews and shoulders configuration have better properties due to stress distribution over a large area at the corner of the joint. The introduction of carbon nanotubes has also shown a positive effect on shear stress and joint strength as they act as reinforcement in the adhesive bond material.

Keywords: adhesive joint, Carbon Reinforced Aluminium Laminate (CARALL), fiber metal laminates, spews

Procedia PDF Downloads 263

Authors: Karthik K. R, Viswanath V, Asraff A. K

Abstract:

The first stage of a new-generation launch vehicle of ISRO makes use of large pressure vessels made of Aluminium alloy AA2219 to store fuel and oxidizer. These vessels have many weld joints that may contain cracks or crack-like defects during their fabrication. These defects may propagate across the vessel during pressure testing or while in service under the influence of tensile stresses leading to catastrophe. Though ductile materials exhibit significant stable crack growth prior to failure, it is not generally acceptable for an aerospace component. There is a need to predict the initiation of stable crack growth. The structural integrity of the vessel from fracture considerations can be studied by constructing the Failure Assessment Diagram (FAD) that accounts for both brittle fracture and plastic collapse. Critical crack sizes of the pressure vessel may be highly conservative if it is predicted from FAD alone. If the J-R curve for material under consideration is available apriori, the critical crack sizes can be predicted to a certain degree of accuracy. In this paper, a novel approach is proposed to predict the integrity of a weld in a pressure vessel made of AA2219 material. Fracture parameter ‘J-integral’ at the crack front, evaluated through finite element analyses, is used in the new procedure. Based on the simulation of tension tests carried out on SCT specimens by NASA, a cut-off value of J-integral value (J?ᵤₜ_ₒ??) is finalised. For the pressure vessel, J-integral at the crack front is evaluated through FE simulations incorporating different surface cracks at long seam weld in a cylinder and in dome petal welds. The obtained J-integral, at vessel level, is compared with a value of J?ᵤₜ_ₒ??, and the integrity of vessel weld in the presence of the surface crack is firmed up. The advantage of this methodology is that if SCT test data of any metal is available, the critical crack size in hardware fabricated using that material can be predicted to a better level of accuracy.

Keywords: FAD, j-integral, fracture, surface crack

Procedia PDF Downloads 156

Authors: Alireza Vahid, Santu Rana, Sunil Gupta, Pratibha Vellanki, Svetha Venkatesh, Thomas Dorin

Abstract:

Aluminum is the preferred material for lightweight applications and its alloys are constantly improving. The high strength 7xxx alloys have been extensively used for structural components in aerospace and automobile industries for the past 50 years. In the next decade, a great number of airplanes will be retired, providing an obvious source of valuable used metals and great demand for cost-effective methods to re-use these alloys. The design of proper aerospace alloys is primarily based on optimizing strength and ductility, both of which can be improved by controlling the additional alloying elements as well as heat treatment conditions. In this project, we explore the design of high-performance alloys with 7xxx as a base material. These designed alloys have to be optimized and improved to compare with modern 7xxx-series alloys and to remain competitive for aircraft manufacturing. Aerospace alloys are extremely complex with multiple alloying elements and numerous processing steps making optimization often intensive and costly. In the present study, we used Bayesian optimization algorithm, a well-known adaptive design strategy, to optimize this multi-variable system. An Al alloy was proposed and the relevant heat treatment schedules were optimized, using the tensile yield strength as the output to maximize. The designed alloy has a maximum yield strength and ultimate tensile strength of more than 730 and 760 MPa, respectively, and is thus comparable to the modern high strength 7xxx-series alloys. The microstructure of this alloy is characterized by electron microscopy, indicating that the increased strength of the alloy is due to the presence of a high number density of refined precipitates.

Keywords: aluminum alloys, Bayesian optimization, heat treatment, tensile properties

Procedia PDF Downloads 91