Search results for: aluminum

Authors: Daniel Nieto, Ramiro Couceiro

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Microfluidic chips have demonstrated their significant application potentials in microbiological processing and chemical reactions, with the goal of developing monolithic and compact chip-sized multifunctional systems. Heat generation and thermal control are critical in some of the biochemical processes. The paper presents a laser direct-write technique for rapid prototyping and manufacturing of microheater chips and its applicability for perfusion cell culture outside a cell incubator. The aim of the microheater is to take the role of conventional incubators for cell culture for facilitating microscopic observation or other online monitoring activities during cell culture and provides portability of cell culture operation. Microheaters (5 mm × 5 mm) have been successfully fabricated on soda-lime glass substrates covered with aluminum layer of thickness 120 nm. Experimental results show that the microheaters exhibit good performance in temperature rise and decay characteristics, with localized heating at targeted spatial domains. These microheaters were suitable for a maximum long-term operation temperature of 120ºC and validated for long-time operation at 37ºC. for 24 hours. Results demonstrated that the physiology of the cultured SW480 adenocarcinoma of the colon cell line on the developed microheater chip was consistent with that of an incubator.

Keywords: laser microfabrication, microheater, bioengineering, cell culture

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

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

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

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Authors: Leila Momenzadeh, Alexander V. Evteev, Elena V. Levchenko, Tanvir Ahmed, Irina Belova, Graeme Murch

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In this work, the phonon thermal conductivity of f.c.c. Al is investigated in detail in the temperature range 100 – 900 K within the framework of equilibrium molecular dynamics simulations making use of the Green-Kubo formalism and one of the most reliable embedded-atom method potentials. It is found that the heat current auto-correlation function of the f.c.c. Al model demonstrates a two-stage temporal decay similar to the previously observed for f.c.c Cu model. After the first stage of decay, the heat current auto-correlation function of the f.c.c. Al model demonstrates a peak in the temperature range 100-800 K. The intensity of the peak decreases as the temperature increases. At 900 K, it transforms to a shoulder. To describe the observed two-stage decay of the heat current auto-correlation function of the f.c.c. Al model, we employ decomposition model recently developed for phonon-mediated thermal transport in a monoatomic lattice. We found that the electronic contribution to the total thermal conductivity of f.c.c. Al dominates over the whole studied temperature range. However, the phonon contribution to the total thermal conductivity of f.c.c. Al increases as temperature decreases. It is about 1.05% at 900 K and about 12.5% at 100 K.

Keywords: aluminum, gGreen-Kubo formalism, molecular dynamics, phonon thermal conductivity

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Authors: Mustafa Kemal Bilici, Memduh Kurtulmuş, İlyas Kartal, Ahmet İrfan Yükler

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Friction stir welding is a solid-state joining process that has gained acceptable progress in recent years. This method which was first used for welding of aluminum and its alloys is now employed for welding of other materials such as polymers and composites. The aim of the present work is to investigate the mechanical properties of butt joints produced by friction stir welding (FSW) in high density polyethylene sheets of 4 mm thickness. The effects of critical welding parameters and tool design have affected on mechanical properties, weld surface and macrostructure of friction stir welded polyethylene. Experiments were performed at tool rotational speeds of 600, 900, 1200 and 1500 r/min and traverse speeds of 30, 45 and 60 mm/min, tool diameters (d) of 4, 5, 6 mm and tool shoulder diameters (D) 20, 25, 30 mm. A strength value of 80 % of the base material was achieved at the isolated optimum welding condition. According to the tool design, the welding parameters and the mechanical properties changed to a great extent. The highest tensile strength was achieved at low feed rates, high tool rotation speeds and shoulder diameters/pin diameters ratio.

Keywords: friction stir welding, mechanical properties, polyethylene, high density polyethylene, tool design

Procedia PDF Downloads 363

Authors: Hala M. Abdel Mageed, Eman M. Hosny, Adel S. Nada

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Solar radiation test is one of the essential tests performed on electricity meters that is carried out using solar simulators. In this work, the (MKF-240) climatic chamber has been modified to act as a solar simulator at the Egyptian national institute of standard, NIS. Quartz Tungsten Halogen (QTH) lamps and an Aluminum plate are added to the climatic chamber to realize the solar test conditions. Many experimental trials have been performed to reach the optimum number of lamps needed to fulfil the test requirements and to adjust the best uniform test area. The proposed solar simulator design is capable to produce irradiance up to 1066 W/m2. Its output radiation is controlled by changing the number of illuminated lamps as well as changing the distance between lamps and tested electricity meter. The uniformity of radiation within the simulator has been recognized to be 91.5 % at maximum irradiance. Three samples of electricity meters have been tested under different irradiances, temperatures, and electric loads. The electricity meters’ accuracies have been recorded and analyzedfor eachsample. Moreover, measurement uncertainty contribution has been considered in all tests to get precision value. There were noticeable changes in the accuracies of the electricity meters while exposed to solar radiation, although there were no noticeable distortions of their insulationsand outer surfaces.

Keywords: solar radiation, solar simulator, climatic chamber, halogen lamp, electricity meter

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Authors: Young Sik Kim, Tae Kwon Ha

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Russia was one of the world’s leading mineral- producing countries. In 2012, Russia was ranked among the world’s leading producers or was a leading regional producer of such mineral commodities as aluminum, arsenic, asbestos, bauxite, boron, cadmium, cement, coal, cobalt, copper, diamond, fluorspar, gold, iron ore, lime, magnesium compounds and metals, mica (flake, scrap, and sheet), natural gas, nickel, nitrogen, oil shale, palladium, peat, petroleum, phosphate, pig iron, platinum, potash, rhenium, silicon, steel, sulfur, titanium sponge, tungsten, and vanadium. Russia has large reserves of a variety of mineral resources and undoubtedly will continue to be one of the world’s leading mineral producers. Although the country’s economy is expected to grow in 2012, some problems are likely to remain. In 2011, the Russian economy returned to economic growth after the significant decline in 2010. According to some analysts, however, the recovery of 2011 did not appear sufficiently vigorous to carry the country’s strong economic growth into the next decade. Even in the sectors of the economy where the country is among the world leaders (ferrous metals, gas, petroleum), Russian industry has obsolete plants and equipment, a slow rate of innovation, and low labor productivity.

Keywords: Russia, energy resources, economic growth, strategy, oil complex

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Authors: Aoqi Zhang, Changgil Lee Lee, Seunghee Park

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A non-contact nondestructive technique using laser-induced ultrasonic wave generation method was applied to visualize corrosion damage at aluminum alloy plate structures. The ultrasonic waves were generated by a Nd:YAG pulse laser, and a galvanometer-based laser scanner was used to scan specific area at a target structure. At the same time, wave responses were measured at a piezoelectric sensor which was attached on the target structure. The visualization of structural damage was achieved by calculating logarithmic values of root mean square (RMS). Damage-sensitive feature was defined as the scattering characteristics of the waves that encounter corrosion damage. The corroded damage was artificially formed by hydrochloric acid. To observe the effect of the location where the corrosion was formed, the both sides of the plate were scanned with same scanning area. Also, the effect on the depth of the corrosion was considered as well as the effect on the size of the corrosion. The results indicated that the damages were successfully visualized for almost cases, whether the damages were formed at the front or back side. However, the damage could not be clearly detected because the depth of the corrosion was shallow. In the future works, it needs to develop signal processing algorithm to more clearly visualize the damage by improving signal-to-noise ratio.

Keywords: non-destructive testing, corrosion, pulsed laser scanning, ultrasonic waves, plate structure

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Authors: Vishal Kumar Gupta

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Purpose: This study has been undertaken to develop novel pH sensitive interpenetrating network hydrogel beads. Methods: The pH sensitive PAAM-g-Guar gum copolymer was synthesized by free radical polymerization followed by alkaline hydrolysis. Beads of guar gum-grafted-polyacrylamide and sodium Carboxy methyl cellulose (Na CMC) loaded with Pantoprazole sodium were prepared and evaluated for pH sensitivity, swelling properties, drug entrapment efficiency and in vitro drug release characteristics. Seven formulations were prepared for the drug with varying polymer and cross linker concentrations. Results: The grafting and alkaline hydrolysis reactions were confirmed by FT-IR spectroscopy. Differential scanning calorimetry was carried out to know the compatibility of encapsulated drug with the polymers. Scanning electron microscopic study revealed that the IPN beads were spherical. The entrapment efficiency was found to be in the range of 85-92%. Particle size analysis was carried out by optical microscopy. As the pH of the medium was changed from 1.2 to 7.4, a considerable increase in swelling was observed for all beads. Increase in the copolymer concentration showed sustained the drug release up to 12 hrs. Drug release from the beads followed super case II transport mechanism. Conclusion: It was concluded that guar gum-acrylamide beads, cross-linked with aluminum chloride offer an opportunity for controlled drug release of pantoprazole sodium.

Keywords: IPN, hydrogels, DSC, SEM

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Authors: Sung-Chul Hwang, Di Ren, Sang-Moon Yoon, Jong-Chun Park, Abbas Khayyer, Hitoshi Gotoh

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The slamming impact problem has a very important engineering background. For seaplane landing, recycling for the satellite re-entry capsule, and the impact load of the bow in the adverse sea conditions, the slamming problem always plays the important role. Due to its strong nonlinear effect, however, it seems to be not easy to obtain the accurate simulation results. Combined with the strong interaction between the fluid field and the elastic structure, the difficulty for the simulation leads to a new level for challenging. This paper presents a fully Lagrangian coupled solver for simulations of fluid-structure interactions, which is based on the Moving Particle Semi-implicit (MPS) method to solve the governing equations corresponding to incompressible flows as well as elastic structures. The developed solver is verified by reproducing the high velocity impact loads of deformable thin wedges with two different materials such as aluminum and steel on water entry. The present simulation results are compared with analytical solution derived using the hydrodynamic Wagner model and linear theory by Wan.

Keywords: fluid-structure interaction, moving particle semi-implicit (MPS) method, elastic structure, incompressible flow, wedge slamming impact

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Authors: Zhaozhi Liu, Feng Xu, Junhua Xu, Xiaolong Tang, Ying Liu, Dunwen Zuo

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Chemical vapor deposition (CVD) diamond coated cutting tool has excellent cutting performance, it is the most ideal tool for the processing of nonferrous metals and alloys, composites, nonmetallic materials and other difficult-to-machine materials efficiently and accurately. Depositing CVD diamond coating on the cemented carbide with high cobalt content can improve its toughness and strength, therefore, it is very important to research on the preparation technology and cutting properties of CVD diamond coated cemented carbide cutting tool with high cobalt content. The preparation technology of boron-doped diamond (BDD) coating has been studied and the coated drills were prepared. BDD coating were deposited on the drills by using the optimized parameters and the SEM results show that there are no cracks or collapses in the coating. Cutting tests with the prepared drills against the silumin and aluminum base printed circuit board (PCB) have been studied. The results show that the wear amount of the coated drill is small and the machined surface has a better precision. The coating does not come off during the test, which shows good adhesion and cutting performance of the drill.

Keywords: cemented carbide with high cobalt content, CVD boron-doped diamond, cutting test, drill

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Authors: Suresh Vidyasagar Chevuri, D. B. Karunakar Chevuri

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The main advantages of 'Metal Matrix Nano Composites (MMNCs)' include excellent mechanical performance, good wear resistance, low creep rate, etc. The method of fabrication of MMNCs is quite a challenge, which includes processing techniques like Spark Plasma Sintering (SPS), etc. The objective of the present work is to fabricate aluminum based MMNCs with the addition of small amounts of yttrium using Spark Plasma Sintering and to evaluate their mechanical and microstructure properties. Samples of 2024 AA with yttrium ranging from 0.1% to 0.5 wt% keeping 1 wt% TiB2 constant are fabricated by Spark Plasma Sintering (SPS). The mechanical property like hardness is determined using Vickers hardness testing machine. The metallurgical characterization of the samples is evaluated by Optical Microscopy (OM), Field Emission Scanning Electron Microscopy (FE-SEM) and X-Ray Diffraction (XRD). Unreinforced 2024 AA sample is also fabricated as a benchmark to compare its properties with that of the composite developed. It is found that the yttrium addition increases the above-mentioned properties to some extent and then decreases gradually when yttrium wt% increases beyond a point between 0.3 and 0.4 wt%. High density is achieved in the samples fabricated by spark plasma sintering when compared to any other fabrication route, and uniform distribution of yttrium is observed.

Keywords: spark plasma sintering, 2024 AA, yttrium addition, microstructure characterization, mechanical properties

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Authors: Hyun KI Kang, Hi Won Jeong

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The gas turbine operates for a long period of time under harsh, cyclic conditions of high temperature and pressure, where high turbine inlet temperature (TIT) can range from 1273 to 1873K. Therefore, Ni-base superalloys such as IN738, IN939, Rene 45, Rene 71, Rene 80, Mar M 247, CM 247, and CMSX-4 with excellent mechanical properties and resistance to creep, corrosion and oxidation at high temperatures are indeed used. Among the alloying additions for these alloys, aluminum (Al) and titanium (Ti) form gamma prime and enhance the high-temperature properties. However, when crack-damaged high-temperature turbine components such as blade and vane are repaired by fusion welding, they cause cracks. For example, when arc welding is applied to certain superalloys that contain Al and Ti with more than 3 wt.% and T3.5 wt%, respectively, such as IN738, IN939, Rene 80, Mar M 247, and CM 247, aging cracks occur. Therefore, repair technologies using diffusion brazing, which has less heat input into the base material, are being developed. Analysis of microstructural evolution of the brazed joints with a base metal of IN 939 Ni-base superalloy using brazing different filler metals was also carried out using X-ray diffraction, OEM, SEM-EDS, and EPMA. Stress rupture and high-temperature tensile strength properties were also measured to analyze the effects of different brazing heat cycles. The boron amount in the diffusion-affected zone (DAZ) was decreased towards the base metal and the formation of borides at grain boundaries was detected through EPMA.

Keywords: gas turbine, diffusion brazing, superalloy, gas turbine repair

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Authors: Gurinder Singh Brar, Sarbjeet Singh, Harry Garg

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Wire Electric Discharge Machining (WEDM) is thermal machining process capable of machining very hard electrically conductive material irrespective of their hardness. WEDM is being widely used to machine micro-scale parts with the high dimensional accuracy and surface finish. The objective of this paper is to optimize the process parameters of wire EDM to fabricate the microchannels and to calculate the surface finish and material removal rate of microchannels fabricated using wire EDM. The material used is aluminum 6061 alloy. The experiments were performed using CNC wire cut electric discharge machine. The effect of various parameters of WEDM like pulse on time (TON) with the levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35, 45) and current (IP) with the levels (105, 110, 115) were investigated to study the effect on output parameter i.e. Surface Roughness and Material Removal Rate (MRR). Each experiment was conducted under different conditions of a pulse on time, pulse off time and peak current. For material removal rate, TON and Ip were the most significant process parameter. MRR increases with the increase in TON and Ip and decreases with the increase in TOFF. For surface roughness, TON and Ip have the maximum effect and TOFF was found out to be less effective.

Keywords: microchannels, Wire Electric Discharge Machining (WEDM), Metal Removal Rate (MRR), surface finish

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Authors: Tejeet Singh, Virat Khanna

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Composite materials have drawn considerable attention of engineers due to their light weight and application at high thermo-mechanical loads. With regard to the prediction of the life of high temperature structural components like rotating cylinders and the evaluation of their deterioration with time, it is essential to have a full knowledge of creep characteristics of these materials. Therefore, in the present study the secondary stage creep stresses and strain rates are estimated in thick-walled composite cylinders subjected to rotary inertia at different angular speeds. The composite cylinder is composed of aluminum matrix (Al) and reinforced with silicon carbide (SiC) particles which are uniformly mixed. The creep response of the material of the cylinder is described by threshold stress based creep law. The study indicates that with the increase in angular speed, the radial, tangential, axial and effective stress increases to a significant value. However, the radial stress remains zero at inner radius and outer radius due to imposed boundary conditions of zero pressure. Further, the stresses are tensile in nature throughout the entire radius of composite cylinder. The strain rates are also influenced in the same manner as that of creep stresses. The creep rates will increase significantly with the increase of centrifugal force on account of rotation.

Keywords: composite, creep, rotating cylinder, angular speed

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Authors: Aminu Yakubu Umar

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X-ray is the major contributor to the effective dose of both the patient and the personnel. Because of the radiological risks involved, it is usually recommended that dose to patient from X-ray be kept as low as reasonably achievable (ALARA) with adequate image quality. The implementation of quality assurance in diagnostic radiology can help greatly in achieving that, as it is a technique designed to reduce X-ray doses to patients undergoing radiological examination. In this study, quality control was carried out in six hospitals, which involved KVp test, evaluation of total filtration, test for constancy of radiation output, and check for mA linearity. Equipment used include KVp meter, Rad-check meter, aluminum sheets (0.1–1.0 mm) etc. The results of this study indicate that, the age of the X-ray machines in the hospitals ranges from 3-13 years, GHI and GH2 being the oldest and FMC being the newest. In the evaluation of total filtration, the HVL of the X-ray machines in the hospitals varied, ranging from 2.3-5.2 mm. The HVL was found to be highest in AHC (5.2 mm), while it was lowest in GH3 (2.3 mm). All HVL measurements were done at 80 KVp. The variation in voltage accuracy in the hospitals ranges from 0.3%-127.5%. It was only in GH1 that the % variation was below the allowed limit. The test for constancy of radiation output showed that, the coefficient of variation ranges from 0.005–0.550. In GH3, FMC and AHC, the coefficient of linearity were less than the allowed limit, while in GH1, GH2 and GH4 the coefficient of linearity had exceeded the allowed limit. As regard to mA linearity, FMC and AHC had their coefficients of linearity as 0.12 and 0.10 respectively, which were within the accepted limit, while GH1, GH3 and GH4 had their coefficients as 0.16, 0.69 and 0.98 respectively, which exceeded the allowed limit.

Keywords: radiation, X-ray output, quality control, half-value layer, mA linearity, KVp variation

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Authors: Nattawit Thiapairat

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Multiple diseases have been linked to excessive levels of free radicals, which cause tissue or cell damage as a result of oxidative stress. Many plants are sources of high antioxidant activity. Derris scandens has a high amount of phenolic and flavonoid contents which demonstrated good biological activities. This study focused on the antioxidant activity of polyphenols extracted from D. scandens. This study performs total flavonoids content and various antioxidant assays, which were 2,2-diphenyl-1-picryl-hydrazyl-hydrate (DPPH) and 2,2'-azino-bis(3-ethylbenzothiazoline-6-sulfonic acid) (ABTS) radical scavenging capacity assays. The total flavonoid content of D. scandens extract was determined and expressed as quercetin equivalents (QE)/g measured by the aluminum chloride colorimetric method. The antioxidant activity of D. scandens extract was also determined by DPPH and ABTS assays. In the DPPH assay, vitamin C was used as a positive control, whereas Trolox was used as a positive control in the ABTS assay. The half-maximal inhibitory concentration (IC50) values for D. scandens extract from DPPH and ABTS assays were 41.79 μg/mL ± 0.783 and 29.42 μg/mL ± 0.890, respectively, in the DPPH assay. To conclude, D. scandens extract consists of a high amount of total phenolic content, which exhibits a significant antioxidant activity. However, further investigation regarding antioxidant activity such as SOD, ROS, and RNS scavenging assays and in vivo experiments should be performed.

Keywords: ABTS assay, antioxidant activity, Derris scandens, DPPH assays, total flavonoid content

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Authors: B. Pavan Kumar Reddy, P. Michael Preetam Raj, Souri Banerjee, Souvik Kundu

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In this work, the fabrication and characterization of copper-doped zinc oxide (Cu:ZnO) based memristor devices with aluminum (Al) and indium tin oxide (ITO) metal electrodes are reported. The thin films of Cu:ZnO was synthesized using low-cost and low-temperature chemical process. The Cu:ZnO was then deposited onto ITO bottom electrodes using spin-coater technique, whereas the top electrode Al was deposited utilizing physical vapor evaporation technique. Ellipsometer was employed in order to measure the Cu:ZnO thickness and it was found to be 50 nm. Several surface and materials characterization techniques were used to study the thin-film properties of Cu:ZnO. To ascertain the efficacy of Cu:ZnO for memristor applications, electrical characterizations such as current-voltage (I-V), data retention and endurance were obtained, all being the critical parameters for next-generation memory. The I-V characteristic exhibits switching behavior with asymmetrical hysteresis loops. This work imputes the resistance switching to the positional drift of oxygen vacancies associated with respect to the Al/Cu:ZnO junction. Further, a non-linear curve fitting regression techniques were utilized to determine the equivalent circuit for the fabricated Cu:ZnO memristors. Efforts were also devoted in order to establish its potentiality for different electronic applications.

Keywords: copper doped, metal-oxides, oxygen vacancies, resistive switching

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Authors: Ha-Guk Jeong, Jong-Beom Lee

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Cladding process is very typical technology for manufacturing composite materials by the hydrostatic extrusion. Because there is no friction between the metal and the container, it can be easily obtained in uniform flow during the deformation. The general manufacturing process for a metal-matrix composite in the solid state, mixing metal powders and ceramic powders with a suited volume ratio, prior to be compressed or extruded at the cold or hot condition in a can. Since through a plurality of unit processing steps of dispersing the materials having a large difference in their characteristics and physical mixing, the process is complicated and leads to non-uniform dispersion of ceramics. It is difficult and hard to reach a uniform ideal property in the coherence problems at the interface between the metal and the ceramic reinforcements. Metal hybrid composites, which presented in this report, are manufactured through the traditional plastic deformation processes like hydrostatic extrusion, caliber-rolling, and drawing. By the previous process, the realization of uniform macro and microstructure is surely possible. In this study, as a constituent material, aluminum, copper, and titanium have been used, according to the component ratio, excellent characteristics of each material were possible to produce a metal hybrid composite that appears to maximize. MgB₂ superconductor wire also fabricated via the same process. It will be introduced to their unique artistic and thermal characteristics.

Keywords: cladding process, metal-hybrid composites, hydrostatic extrusion, electronic/thermal characteristics

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

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

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

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Authors: Abdallah M. Abdelkawy, Tarek M. El Hossainya, I. El Mahallawib

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Recently, significant achievements have been made in development and manufacturing of nano-dispersed metal matrix nanocomposites (MMNCs). They gain their importance due to their high strength to weight ratio. The machining problems of these new materials are less widely investigated, thus this work focuses on machining of them. Aluminum-Silicon (A356)/ MMNC dispersed with alumina (Al2O3) is important in many applications include engine blocks. The final finish process of this application depends heavily on machining. The most important machining parameter studied includes: cutting force and surface roughness. Experimental trails are performed on the number of special samples of MMNC (with different Al2O3%) where the relation between Al2O3% and cutting speed, feed rate and cutting depth with cutting force and surface roughness were studied. The data obtained were statistically analyzed using Analysis of variance (ANOVA) to define the significant factors on both cutting force and surface roughness and their level of confident. Response Surface Methodology (RSM) is used to build a model relating cutting conditions and Al2O3% to the cutting force and surface roughness. The results have shown that feed and depth of cut have the major contribution on the cutting force and the surface roughness followed by cutting speed and nano-percent in MMNCs.

Keywords: machinability, cutting force, surface roughness, Ra, RSM, ANOVA, MMNCs

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Authors: Wu Wei-Ting, Liu Po-Yen, Chang Chin-Tzu, Cheng Wei-Chun

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Three types of low-temperature phase transformations in an Fe-12.5 Mn-6.53 Al-1.28 C (wt %) alloy have been studied. The steel underwent solution heat treatment at 1100℃ and isothermal holding at low temperatures. γ’ phase appears in the austenite matrix in the air-cooled steel. Coherent ultra-fine particles of γ’ phase precipitated uniformly in the austenite matrix after the air-cooling process. These ultra-fine particles were very small and only could be detected by TEM through dark-field images. After short periods of isothermal holding at low temperatures these particles of γ’ phase grew and could be easily detected by TEM. A pro-eutectoid reaction happened after isothermal holding at temperatures below 875 ℃. Proeutectoid κ-carbide and ferrite appear in the austenite matrix as grain boundary precipitates and cellular precipitates. The cellular precipitates are composed of lamellar κ-carbide and austenite. The lamellar κ-carbide grains are always accompanied by layers of austenite twins. The presence of twin layers adhering to the κ-carbide plates might be attributed to the lower activation energy for the precipitation of κ-carbide plates in the austenite. The final form of phase transformation is the eutectoid reaction for the decomposition of supersaturated austenite into stable κ-carbide and ferrite phases at temperatures below 700℃. The ferrite and κ-carbide are in the form of pearlite lamellae.

Keywords: austenite, austenite twin layers, κ-carbide, twins

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Authors: Alaa Al Hawari, Mohammad Khader, Wael El Hasan, Mahmoud Alijla, Ammar Manawi, Abdelbaki Benamour

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The production of aluminium alloys and ingots -starting from the processing of alumina to aluminium, and the final cast product- was studied using a Life Cycle Assessment (LCA) approach. The studied aluminium supply chain consisted of a carbon plant, a reduction plant, a casting plant, and a power plant. In the LCA model, the environmental loads of the different plants for the production of 1 ton of aluminium metal were investigated. The impact of the aluminium production was assessed in eight impact categories. The results showed that for all of the impact categories the power plant had the highest impact only in the cases of Human Toxicity Potential (HTP) the reduction plant had the highest impact and in the Marine Aquatic Eco-Toxicity Potential (MAETP) the carbon plant had the highest impact. Furthermore, the impact of the carbon plant and the reduction plant combined was almost the same as the impact of the power plant in the case of the Acidification Potential (AP). The carbon plant had a positive impact on the environment when it comes to the Eutrophication Potential (EP) due to the production of clean water in the process. The natural gas based power plant used in the case study had 8.4 times less negative impact on the environment when compared to the heavy fuel based power plant and 10.7 times less negative impact when compared to the hard coal based power plant.

Keywords: life cycle assessment, aluminium production, supply chain, ecological impacts

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Authors: Shuo Tian, Xuepiao Bai, Jianqin Shang, Pengtao Gai, Yuansong Zeng

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Shot peen forming is an essential forming process for aircraft metal wing panel. With the development of computer simulation technology, scholars have proposed a numerical simulation method of shot peen forming based on stress field. Three shot peen forming indexes of crater diameter, shot speed and surface coverage are required as simulation parameters in the stress field method. It is necessary to establish the relationship between simulation and experimental process parameters in order to simulate the deformation under different shot peen forming parameters. The shot peen forming tests of the 2024-T351 aluminum alloy workpieces were carried out using uniform test design method, and three factors of air pressure, feed rate and shot flow were selected. The second-order response surface model between simulation parameters and uniform test factors was established by stepwise regression method using MATLAB software according to the results. The response surface model was combined with the stress field method to simulate the shot peen forming deformation of the workpiece. Compared with the experimental results, the simulated values were smaller than the corresponding test values, the maximum and average errors were 14.8% and 9%, respectively.

Keywords: shot peen forming, process parameter, response surface model, numerical simulation

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Authors: M. A. Moghaddas, M. Short, N. Wiley, A. Y. Yi, K. F. Graff

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The application of ultrasonic vibrations to machining processes has a long history, ranging from slurry-based systems able to drill brittle materials, to more recent developments involving low power ultrasonics for high precision machining, with many of these at the research and laboratory stages. The focus of this development is the application of high levels of ultrasonic power (1,000’s of watts) to standard, heavy duty machine tools – drilling being the immediate focus, with developments in milling in progress – with the objective of dramatically increasing system productivity through faster feed rates, this benefit arising from the thrust force reductions obtained by power ultrasonic vibrations. The presentation will describe development of an advanced drilling system based on a special, acoustically designed, rugged drill module capable of functioning under heavy duty production conditions, and making use of standard tool holder means, and able to obtain thrust force reductions while maintaining or improving surface finish and drilling accuracy. The characterization of the system performance will be described, and results obtained in drilling several materials (Aluminum, Stainless steel, Titanium) presented.

Keywords: dimensional accuracy, machine tool, productivity, surface roughness, thrust force, ultrasonic vibrations, ultrasonic-assisted drilling

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Authors: Sky Chou, Joseph C. Chen

Abstract:

This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index C_p and C_pk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L₉ orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: CNC machining, six sigma, surface roughness, Taguchi methodology

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Authors: Parameshwaran Nair

Abstract:

Filling and packaging lines for bottling of beverages into glass, PET or aluminum containers require specialized expertise and a different configuration of equipment like – Filler, Warmer, Labeller, Crater/Recrater, Shrink Packer, Carton Erector, Carton Sealer, Date Coder, Palletizer, etc. Over the period of time, the packaging industry has evolved from manually operated single station machines to highly automized high-speed lines. Human factor and ergonomics have gained significant consideration in this course of transformation. A pre-requisite for such bottling lines, irrespective of the container type and size, is to be suitable for multi-format applications. It should also be able to handle format changeovers with minimal adjustment. It should have variable capacity and speeds, for providing great flexibility of use in managing accumulation times as a function of production characteristics. In terms of layout as well, it should demonstrate flexibility for operator movement and access to machine areas for maintenance. Packaging technology during the past few decades has risen to these challenges by a series of major breakthroughs interspersed with periods of refinement and improvement. The milestones are many and varied and are described briefly in this paper. In order to have a brief understanding of the human factor and ergonomics in the modern packaging lines, this paper, highlights the various technologies, design considerations and statutory requirements in packaging equipment for different types of containers used in India.

Keywords: human-factor, ergonomics, bottling lines, automized high-speed lines

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Authors: Rym Sassi, Franck Fayon, Mohend Chaouche, Emmanuel Veron, Valerie Montouillout

Abstract:

The chemical phenomena occurring during cement hydration are complex and interdependent, and even after almost two centuries of studies, they are still difficult to solve for complex mixtures combining different hydraulic binders. Powder-XRD has been widely used for characterizing the crystalline phases in both anhydrous and hydrated cement, but only limited information is obtained in the case of strongly disordered and amorphous phases. In contrast, local spectroscopies like solid-state NMR can provide a quantitative description of noncrystalline phases. In this work, the structural modifications occurring during hydration of a fast-setting ternary binder based on white Portland cement, white calcium aluminate cement, and calcium sulfate were investigated using advanced solid-state NMR methods. We particularly focused on the early stage of the hydration up to 28 days, working with samples whose hydration was controlled and stopped. ²⁷Al MQ-MAS as well as {¹H}-²⁷Al and {¹H}-²⁹Si Cross- Polarization MAS NMR techniques were combined to distinguish all of the aluminum and silicon species formed during the hydration. The NMR quantification of the different phases was conducted in parallel with the XRD analyses. The consumption of initial products, as well as the precipitation of hydraulic phases (ettringite, monosulfate, strätlingite, CSH, and CASH), were unambiguously quantified. Finally, the drawing of the consumption and formation of phases was correlated with mechanical strength measurements.

Keywords: cement, hydration, hydrates structure, mechanical strength, NMR

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Authors: Fadi Al-Badour, Nesar Merah, Abdelrahman Shuaib, Abdelaziz Bazoune

Abstract:

In the current work, a Coupled Eulerian Lagrangian (CEL) model is developed to simulate the friction stir welding (FSW) process of dissimilar Aluminum alloys (Al 6061-T6 with Al 5083-O). The model predicts volumetric defects, material flow, developed temperatures, and stresses in addition to tool reaction loads. Simulation of welding phase is performed by employing a control volume approach, whereas the welding speed is defined as inflow and outflow over Eulerian domain boundaries. Only material softening due to inelastic heat generation is considered and material behavior is assumed to obey Johnson-Cook’s Model. The model was validated using published experimentally measured temperatures, at similar welding conditions, and by qualitative comparison of dissimilar weld microstructure. The FE results showed that most of developed temperatures were below melting and that the bulk of the deformed material in solid state. The temperature gradient on AL6061-T6 side was found to be less than that of Al 5083-O. Changing the position Al 6061-T6 from retreating (Ret.) side to advancing (Adv.) side led to a decrease in maximum process temperature and strain rate. This could be due to the higher resistance of Al 6061-T6 to flow as compared to Al 5083-O.

Keywords: friction stir welding, dissimilar metals, finite element modeling, coupled Eulerian Lagrangian Analysis

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Authors: Mai M. Farid, Ximeng Yang, Tomoharu Kuboyama, Yuna Inada, Chihiro Tohda

Abstract:

Intro: Trigonella foenum-graecum (Fenugreek), from Fabaceae family is a well-known plant traditionally used as food and medicine. Many pharmacological effects of Trigonella foenum- graecum seeds extract (TF extract) were evaluated such as anti-diabetic, anti-tumor and anti-dementia effects using in vivo models. Regarding the anti-dementia effects of TF extract, diabetic rats, aluminum chloride-induced amnesia rats and scopolamine-injected mice were used previously for evaluation, which are not well established as Alzheimer’s disease models. In addition, those previous studies, active constituents in TF extract for memory function were not identified. Method: This study aimed to clarify the effect of TF extract on Alzheimer’s disease model, 5XFAD mouse that overexpresses mutated APP and PS1 genes and determine the major active constituent in the brain after oral intake of TF extract. Results: Trigonelline was detected in the cerebral cortex of 5XFAD mice after 24 hours of oral administration of TF extract by LC-MS/MS. Oral administration of TF extract for 17 days improved object location memory in 5XFAD mice. Conclusion: These results suggest that TF extract and its active constituents could be an expected therapeutic candidate for Alzheimer’s disease.

Keywords: Alzheimer's disease, LC-MS/MS, memory recovery, Trigonella foenum-graecum Seeds, 5XFAD mice

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Authors: Tania Bose, Minto Rattan, Neeraj Chamoli

Abstract:

In this paper, an attempt has been made to study the effect of thermal gradation on the steady-state creep behavior of rotating isotropic disc made of functionally graded material using threshold stress based Sherby’s creep law. The composite discs made of aluminum matrix reinforced with silicon carbide particulate have been taken for analysis. The stress and strain rate distributions have been calculated for the discs rotating at elevated temperatures having thermal gradation. The material parameters of creep vary radially and have been estimated by regression fit of the available experimental data. Investigations for discs made up of linearly increasing particle content operating under linearly decreasing temperature from inner to outer radii have been done using von Mises’ yield criterion. The results are displayed and compared graphically in designer friendly format for the above said disc profile with the disc made of particle reinforced composite operating under uniform temperature profile. It is observed that radial and tangential stresses show minor variation and the strain rates vary significantly in the presence of thermal gradation as compared to disc having uniform temperature.

Keywords: creep, isotropic, steady-state, thermal gradation

Procedia PDF Downloads 214