Search results for: debinding and sintered parts.

Authors: R. Ibrahim, M. Azmirruddin, M. Jabir, N. Johari, M. Muhamad, A. R. A. Talib

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Inconel718 has been widely used as a super alloy in aerospace application due to the high strength at elevated temperatures, satisfactory oxidation resistance and heat corrosion resistance. In this study, the Inconel718 has been fabricated using high technology of Metal Injection Molding (MIM) process due to the cost effective technique for producing small, complex and precision parts in high volume compared with conventional method through machining. Through MIM, the binder system is one of the most important criteria in order to successfully fabricate the Inconel718. Even though, the binder system is a temporary, but failure in the selection and removal of the binder system will affect on the final properties of the sintered parts. Therefore, the binder system based on palm oil derivative which is palm stearin has been formulated and developed to replace the conventional binder system. The rheological studies of the mixture between the powder and binders system have been determined properly in order to be successful during injection into injection molding machine. After molding, the binder holds the particles in place. The binder system has to be removed completely through debinding step. During debinding step, solvent debinding and thermal pyrolysis has been used to remove completely of the binder system. The debound part is then sintered to give the required physical and mechanical properties. The results show that the properties of the final sintered parts fulfill the Standard Metal Powder Industries Federation (MPIF) 35 for MIM parts.

Keywords: Binder system, rheological study, metal injection molding, debinding and sintered parts.

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Authors: Abdullah Yassin, Takashi Ueda, Syed Tarmizi Syed Shazali

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This paper presents an experimental investigation on the machinability of laser-sintered material using small ball end mill focusing on wear mechanisms. Laser-sintered material was produced by irradiating a laser beam on a layer of loose fine SCM-Ni-Cu powder. Bulk carbon steel JIS S55C was selected as a reference steel. The effects of powder consolidation mechanisms and unsintered powder on the tool life and wear mechanisms were carried out. Results indicated that tool life in cutting laser-sintered material is lower than that in cutting JIS S55C. Adhesion of the work material and chipping were the main wear mechanisms of the ball end mill in cutting laser-sintered material. Cutting with the unsintered powder surrounding the tool and laser-sintered material had caused major fracture on the cutting edge.

Keywords: Laser-sintered material, tool life, wear mechanism.

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Authors: J. K. Khare, Abhay Kumar Sharma, Ajay Tiwari, Amol A. Talankar

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Powder metallurgy (P/M) is the only economic way to produce porous parts/products. P/M can produce near net shape parts hence reduces wastage of raw material and energy, avoids various machining operations. The most vital use of P/M is in production of metallic filters and self lubricating bush bearings and siding surfaces. The porosity of the part can be controlled by varying compaction pressure, sintering temperature and composition of metal powder mix. The present work is aimed for experimental analysis of friction and wear properties of self lubricating copper and tin bush bearing. Experimental results confirm that wear rate of sintered component is lesser for components having 10% tin by weight percentage. Wear rate increases for high tin percentage (experimented for 20% tin and 30% tin) at same sintering temperature. Experimental results also confirms that wear rate of sintered component is also dependent on sintering temperature, soaking period, composition of the preform, compacting pressure, powder particle shape and size. Interfacial friction between die and punch, between inter powder particles, between die face and powder particle depends on compaction pressure, powder particle size and shape, size and shape of component which decides size & shape of die & punch, material of die & punch and material of powder particles.

Keywords: Interfacial friction, porous bronze bearing, sintering temperature, wear rate.

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Authors: Yukinori Taniguchi, Kazuyoshi Kurita, Kohei Mizuta, Keigo Nishitani, Ryuichi Fukuda

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Tungsten carbide is widely used as a tool material in metal manufacturing process. Since tungsten is typical rare metal, establishment of recycle process of tungsten carbide tools and restore into cemented carbide material bring great impact to metal manufacturing industry. Recently, recycle process of tungsten carbide has been developed and established gradually. However, the demands for quality of cemented carbide tool are quite severe because hardness, toughness, anti-wear ability, heat resistance, fatigue strength and so on should be guaranteed for precision machining and tool life. Currently, it is hard to restore the recycled tungsten carbide powder entirely as raw material for new processed cemented carbide tool. In this study, to suggest positive use of recycled tungsten carbide powder, we have tried to fabricate a carbon based sintered steel which shows reinforced mechanical properties with recycled tungsten carbide powder. We have made set of newly designed sintered steels. Compression test of sintered specimen in density ratio of 0.85 (which means 15% porosity inside) has been conducted. As results, at least 1.7 times higher in nominal strength in the amount of 7.0 wt.% was shown in recycled WC powder. The strength reached to over 600 MPa for the Fe-WC-Co-Cu sintered alloy. Wear test has been conducted by using ball-on-disk type friction tester using 5 mm diameter ball with normal force of 2 N in the dry conditions. Wear amount after 1,000 m running distance shows that about 1.5 times longer life was shown in designed sintered alloy. Since results of tensile test showed that same tendency in previous testing, it is concluded that designed sintered alloy can be used for several mechanical parts with special strength and anti-wear ability in relatively low cost due to recycled tungsten carbide powder.

Keywords: Tungsten carbide, recycle process, compression test, powder metallurgy, anti-wear ability.

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Authors: Anurag Gaur, Neha Sharma

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In this work, we have synthesized BaTiO₃ via sol gel method by sintering at different temperatures (600, 700, 800, 900, 1000⁰C) and studied their structural, optical and ferroelectric properties through X-ray diffraction (XRD), UV-Vis spectrophotometer and PE Loop Tracer. X-ray diffraction patterns of barium titanate samples show that the peaks of the diffractogram are successfully indexed with the tetragonal and cubic structure of BaTiO₃. The Optical band gap calculated through UV Visible spectrophotometer varies from 4.37 to 3.80 eV for the samples sintered at 600 to 1000⁰C, respectively. The particle size calculated through transmission electron microscopy varies from 20 to 40 nm for the samples sintered at 600 to 1000⁰C, respectively. Moreover, it has been observed that the ferroelectricity increases as we increase the sintering temperature.

Keywords: Nanostructures, Ferroelectricity, Sol-gel method.

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Authors: N. Z. Baderisham, H. A. Hamid, N. Osman

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The powders of Ba(Ce_1-xZr_x)_0.90Y_0.1O_3-δ (BCZY) with 0.2 ≤ x ≤ 0.6 have been prepared by a modified sol-gel method. Triethylenetetramine (TETA) was employed as chelating agent. Phase formation of calcined powders at 1100^oC and sintered pellets at 1400^oC of BCZY were examined by an X-ray diffractrometer (XRD). XRD results showed the calcined powder and sintered pellet formed a single perovskite phase over the entire range of x values. As the amount of zirconium substitution (x values) increase, the main peaks are shifted to the higher 2theta values which suggest a complete substitution of zirconium into cerium sites. All the obtained calcined powders and sintered pellets possess cubic structure (Pm-3m) at all x values.

Keywords: Structure, phase formation, modified sol-gel, cerate-zirconate electrolye, XRD.

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Authors: Tadahiro Wada, Hiroyuki Hanyu

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In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: Cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, sintered steel.

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Authors: Nandy Putra, Atrialdipa Duanovsah, Kristofer Haliansyah

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The aim of this research is to design a LHP with low thermal resistance and low condenser temperature. A Self-designed cascade LHP was tested by using biomaterial, sintered copper powder, and aluminum screen mesh as the wick. Using pure water as the working fluid for the first level of the LHP and 96% alcohol as the working fluid for the second level of LHP, the experiments were run with 10W, 20W, and 30W heat input. Experimental result shows that the usage of biomaterial as wick could reduce more temperature at evaporator than by using sintered copper powder and screen mesh up to 22.63% and 37.41% respectively. The lowest thermal resistance occurred during the usage of biomaterial as wick of heat pipe, which is 2.06 ^oC/W. The usage of cascade system could be applied to LHP to reduce the temperature at condenser and reduced thermal resistance up to 17.6%.

Keywords: Biomaterial, cascade loop heat pipe, screen mesh, sintered Cu.

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Authors: J. D. Marinaccio, I. Mabbett, C. Glover, D. Worsley

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Through use of novel modern/rapid processing techniques such as screen printing and Near-Infrared (NIR) radiative curing, process time for the sintering of sintered nickel plaques, applicable to alkaline nickel battery chemistries, has been drastically reduced from in excess of 200 minutes with conventional convection methods to below 2 minutes using NIR curing methods. Steps have also been taken to remove the need for forming gas as a reducing agent by implementing carbon as an in-situ reducing agent, within the ink formulation.

Keywords: Batteries, energy, iron, nickel, storage.

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Authors: Loai Ben Naji, Osama M. Ibrahim, Khaled J. Al-Fadhalah

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The objective of this paper is to investigate the formation and adhesion of a protective aluminum-oxide (Al₂O₃, alumina) layer on the surface of Iron-Chromium-Aluminum Alloy (Fe-Cr-Al) sintered-metal-fibers. The oxide-scale layer was developed via multi-stage thermal oxidation at 930 ^oC for 1 hour, followed by 1 hour at 960 ^oC, and finally at 990 ^oC for 2 hours. Scanning Electron Microscope (SEM) images show that the multi-stage thermal oxidation resulted in the formation of predominantly Al₂O₃ platelets-like and whiskers. SEM images also reveal non-uniform oxide-scale growth on the surface of the fibers. Furthermore, peeling/spalling of the alumina protective layer occurred after minimum handling, which indicates weak adhesion forces between the protective layer and the base metal alloy.  Energy Dispersive Spectroscopy (EDS) analysis of the heat-treated Fe-Cr-Al sintered-metal-fibers confirmed the high aluminum content on the surface of the protective layer, and the low aluminum content on the exposed base metal alloy surface. In conclusion, the failure of the oxide-scale protective layer exposes the base metal alloy to further oxidation, and the fragile non-uniform oxide-scale is not suitable as a support for catalysts.

Keywords: High-temperature oxidation, alumina protective layer, iron-chromium-aluminum alloy, sintered-metal-fibers.

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Authors: O. Altuntaş, A. Güral

Abstract:

The hardness-microstructure relationships of spherical cementite in bainitic matrix obtained by a different heat treatment cycles carried out to high carbon powder metallurgy (P/M) steel were investigated. For this purpose, 1.5 wt.% natural graphite powder admixed in atomized iron powders and the mixed powders were compacted under 700 MPa at room temperature and then sintered at 1150 °C under a protective argon gas atmosphere. The densities of the green and sintered samples were measured via the Archimedes method. A density of 7.4 g/cm³ was obtained after sintering and a density of 94% was achieved. The sintered specimens having primary cementite plus lamellar pearlitic structures were fully quenched from 950 ^°C temperature and then over-tempered at 705 °C temperature for 60 minutes to produce spherical-fine cementite particles in the ferritic matrix. After by this treatment, these samples annealed at 735 °C temperature for 3 minutes were austempered at 300 °C salt bath for a period of 1 to 5 hours. As a result of this process, it could be able to produced spherical cementite particle in the bainitic matrix. This microstructure was designed to improve wear and toughness of P/M steels. The microstructures were characterized and analyzed by SEM and micro and macro hardness.

Keywords: Powder metallurgy steel, heat treatment, bainite, spherical cementite.

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Authors: A. Yönetken, A. Erol, M. Cakmakkaya

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Intermetallic materials are among advanced technology materials that have outstanding mechanical and physical properties for high temperature applications. Especially creep resistance, low density and high hardness properties stand out in such intermetallics. The microstructure, mechanical properties of %88Ni- %10Cr and %2Mn powders were investigated using specimens produced by tube furnace sintering at 900-1300°C temperature. A composite consisting of ternary additions, a metallic phase, Fe, Cr and Mn have been prepared under Ar shroud and then tube furnace sintered. XRD, SEM (Scanning Electron Microscope), were investigated to characterize the properties of the specimens. Experimental results carried out for composition %88Ni-%10Cr and %2Mn at 1300°C suggest that the best properties as 138,80HV and 6,269/cm3 density were obtained at 1300°C.

Keywords: Composite, Intermetallic, High temperature, Sintering.

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Authors: Bing-Jing Li, Sih-Yin Wang, Tse-Chun Yeh, Yuan-Bin Chen

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Microwave dielectric ceramic materials of (Mg1-xNix)2(Ti0.95Sn0.05)O4 for x = 0.01, 0.03, 0.05, 0.07 and 0.09 were prepared and sintered at 1250–1400 ºC. The microstructure and microwave dielectric properties of the ceramic materials were examined and measured. The observations shows that the content of Ni2+ ions has little effect on the crystal structure, dielectric constant, temperature coefficient of resonant frequency (τf) and sintering temperatures of the ceramics. However, the quality values (Q×f) are greatly improved due to the addition of Ni2+ ions. The present study showed that the ceramic material prepared for x = 0.05 and sintered at 1325ºC had the best Q×f value of 392,000 GHz, about 23% improvement compared with that of Mg2(Ti0.95Sn0.05)O4.

Keywords: (Mg1-xNix)2(Ti0.95Sn0.05)O4, microwave dielectric ceramics, high quality factor, high frequency wireless communication.

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Authors: Ridvan Yamanoglu, Erdinc Efendi, Ismail Daoud

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In this study, Ti-5Al-2.5Fe alloy was prepared by powder metallurgy. The elemental titanium, aluminum, and iron powders were mechanically alloyed for 10 h in a vacuum atmosphere. A stainless steel jar and stainless steel balls were used for mechanical alloying. The alloyed powders were then sintered by vacuum hot pressing at 950 °C for a soaking time of 30 minutes. Pure titanium was also sintered at the same conditions for comparison of mechanical properties and microstructural behavior. The samples were investigated by scanning electron microscopy, XRD analysis, and optical microscopy. Results showed that, after mechanical alloying, a homogeneous distribution of the elements was obtained, and desired a-b structure was determined. Ti-5Al-2.5Fe alloy was successfully produced, and the alloy showed enhanced mechanical properties compared to the commercial pure titanium.

Keywords: Ti5Al2.5Fe, mechanical alloying, hot pressing, sintering.

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Authors: M. B. Shuai, S. Xiao, Q. S. Li, M. F. Chu, X. F. Yang

Abstract:

Ambient hydrolysis products in moist air and hydrolysis kinetics in argon with humidity of RH1.5% for polycrystalline LiH powders and sintered bulks were investigated by X-ray diffraction, Raman spectroscopy and gravimetry. The results showed that the hydrolysis products made up a layered structure of LiOH•H2O/LiOH/Li2O from surface of the sample to inside. In low humid argon atmosphere, the primary hydrolysis product was Li2O rather than LiOH. The hydrolysis kinetic curves of LiH bulks present a paralinear shape, which could be explained by the “Layer Diffusion Control" model. While a three-stage hydrolysis kinetic profile was observed for LiH powders under the same experimental conditions. The first two sections were similar to that of the bulk samples, and the third section also presents a linear reaction kinetics but with a smaller reaction rate compared to the second section because of a larger exothermic effect for the hydrolysis reaction of LiH powder.

Keywords: Hydrolysis, lithium compound, polycrystallinelithium hydride

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Authors: Seema Kapoor, Uma Batra

Abstract:

In this study, hydroxyapatite (HA) composites are prepared on addition of 30%CaO-30%P2O5-40%Na2 O based glass to pure HA, in proportion of 2, 5, and 10 wt %. Each composition was sintered over a range of temperatures. The quantitative phase analysis was carried out using XRD and the microstructures were studied using SEM. The density, microhardness, and compressive strength have shown increase with the increasing amount of glass addition. The resulting composites have chemical compositions that are similar to the inorganic constituent of the mineral part of bone, and constitutes trace elements like Na. X-ray diffraction showed no decomposition of HA to secondary phases, however, the glass reinforced-HA composites contained a HA phase and variable amounts of tricalcium phosphate phase, depending on the amount of bioglass added. The HA-composite material exhibited higher compressive strength compared to sintered HA. The HA composite reinforced with 10 wt % bioglass showed highest bioactivity level.

Keywords: Bioactivity, Bioglass, Compressive strength, Hydroxyapatite.

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Authors: Adewale O. Adegbenjo, Elsie Nsiah-Baafi, Mxolisi B. Shongwe, Mercy Ramakokovhu, Peter A. Olubambi

Abstract:

The sintering step in powder metallurgy (P/M) processes is very sensitive as it determines to a large extent the properties of the final component produced. Spark plasma sintering over the past decade has been extensively used in consolidating a wide range of materials including metallic alloy powders. This novel, non-conventional sintering method has proven to be advantageous offering full densification of materials, high heating rates, low sintering temperatures, and short sintering cycles over conventional sintering methods. Ti6Al4V has been adjudged the most widely used α+β alloy due to its impressive mechanical performance in service environments, especially in the aerospace and automobile industries being a light metal alloy with the capacity for fuel efficiency needed in these industries. The P/M route has been a promising method for the fabrication of parts made from Ti6Al4V alloy due to its cost and material loss reductions and the ability to produce near net and intricate shapes. However, the use of this alloy has been largely limited owing to its relatively poor hardness and wear properties. The effect of sintering temperature on the densification, hardness, and wear behaviors of spark plasma sintered Ti6Al4V powders was investigated in this present study. Sintering of the alloy powders was performed in the 650–850°C temperature range at a constant heating rate, applied pressure and holding time of 100°C/min, 50 MPa and 5 min, respectively. Density measurements were carried out according to Archimedes’ principle and microhardness tests were performed on sectioned as-polished surfaces at a load of 100gf and dwell time of 15 s. Dry sliding wear tests were performed at varied sliding loads of 5, 15, 25 and 35 N using the ball-on-disc tribometer configuration with WC as the counterface material. Microstructural characterization of the sintered samples and wear tracks were carried out using SEM and EDX techniques. The density and hardness characteristics of sintered samples increased with increasing sintering temperature. Near full densification (99.6% of the theoretical density) and Vickers’ micro-indentation hardness of 360 HV were attained at 850°C. The coefficient of friction (COF) and wear depth improved significantly with increased sintering temperature under all the loading conditions examined, except at 25 N indicating better mechanical properties at high sintering temperatures. Worn surface analyses showed the wear mechanism was a synergy of adhesive and abrasive wears, although the former was prevalent.

Keywords: Hardness, powder metallurgy, Spark plasma sintering, wear.

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Authors: Bruno Henriques, Rafaela Santos, Mihaela Buciumeanu, Júlio Matias de Souza, Filipe Silva, Rubens Nascimento, Márcio Fredel

Abstract:

Dental porcelain composites reinforced and toughened by 20 wt.% tetragonal zirconia (3Y-TZP) were processed by hot pressing at 1000°C. Two types of particles were tested: yttriastabilized zirconia (ZrO2–3%Y2O3) agglomerates and pre-sintered yttria-stabilized zirconia (ZrO2–3%Y2O3) particles. The composites as well as the reinforcing particles were analyzed by the means of optical and Scanning Electron Microscopy (SEM), Energy Dispersion Spectroscopy (EDS) and X-Ray Diffraction (XRD). The mechanical properties were obtained by the transverse rupture strength test. Wear tests were also performed on the composites and monolithic porcelain. The best mechanical results were displayed by the porcelain reinforced with the pre-sintered ZrO2–3%Y2O3 agglomerates.

Keywords: Composite, dental restoration, porcelain, strengthening, toughening, wear, zirconia.

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Authors: M. Heidari, A. Safekordi, A. Zamaniyan, E. Ganji Babakhani, M. Amanipour

Abstract:

Perovskite-type membrane Ba_0.5Sr_0.5Ce_0.9Y_0.1O_3-δ (BSCY) was successfully synthesized by liquid citrate method. The hydrogen permeation and stability of BSCY perovskite-type membranes were studied at high temperatures. The phase structure of the powder was characterized by X-ray diffraction (XRD). Scanning electron microscopy (SEM) was used to characterize microstructures of the membrane sintered under various conditions. SEM results showed that increasing in sintering temperature, formed dense membrane with clear grains. XRD results for BSCY membrane that sintered in 1150 °C indicated single phase perovskite structure with orthorhombic configuration, and SEM results showed dense structure with clear grain size which is suitable for permeation tests. Partial substitution of Sr with Ba in SCY structure improved the hydrogen permeation flux through the membrane due to the larger ionic radius of Ba²⁺. BSCY membrane shows high hydrogen permeation flux of 1.6 ml/min.cm² at 900 °C and partial pressure of 0.6.

Keywords: Hydrogen separation, perovskite, proton conducting membrane.

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Authors: Syed Bahari Ramadzan Syed Adnan, Nor Sabirin Mohamed, Norwati K.A

Abstract:

In this study, Li4SiO4 powder was successfully synthesized via sol gel method followed by drying at 150oC. Lithium oxide, Li2O and silicon oxide, SiO2 were used as the starting materials with citric acid as the chelating agent. The obtained powder was then sintered at various temperatures. Crystallographic phase analysis, morphology and ionic conductivity were investigated systematically employing X-ray diffraction, Fourier Transform Infrared, Scanning Electron Microscopy and AC impedance spectroscopy. XRD result showed the formation of pure monoclinic Li4SiO4 crystal structure with lattice parameters a = 5.140 Å, b = 6.094 Å, c = 5.293 Å, β = 90o in the sample sintered at 750oC. This observation was confirmed by FTIR analysis. The bulk conductivity of this sample at room temperature was 3.35 × 10-6 S cm-1 and the highest bulk conductivity of 1.16 × 10-4 S cm-1 was obtained at 100°C. The results indicated that, the Li4SiO4 compound has potential to be used as host for LISICON structured solid electrolyte for low temperature application.

Keywords: Conductivity, LISICON, Li4SiO4, Solid electrolyte, Structure.

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Authors: A. M. R. Mosalman Yazdi, B. A. R. Mosalman Yazdi

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In industry, on of the most important subjects is die and it's characteristics in which for cutting and forming different mechanical pieces, various punch and matrix metal die are used. whereas the common parts which form the main frame die are not often proportion with pieces and dies therefore using a part as socalled common part for frames in specified dimension ranges can decrease the time of designing, occupied space of warehouse and manufacturing costs. Parts in dies with getting uniform in their shape and dimension make common parts of dies. Common parts of punch and matrix metal die are as bolster, guide bush, guide pillar and shank. In this paper the common parts and effective parameters in selecting each of them as the primary information are studied, afterward for selection and design of mechanical parts an introduction and investigation based on the Mech. Desk. software is done hence with developing this software can standardize the metal common parts of punch and matrix. These studies will be so useful for designer in their designing and also using it has with very much advantage for manufactures of products in decreasing occupied spaces by dies.

Keywords: Die, Matrix, Punch, Standardize.

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Authors: Uma Batra, Seema Kapoor

Abstract:

Commercial hydroxyapatite (HA) was reinforced by adding 2, 5, and 10 wt % of 28.5%CaO-28.5%P2O5-38%Na2 O- 5%CaF2 based glass and then sintered. Although HA shows good biocompatibility with the human body, its applications are limited to non load-bearing areas and coatings due to its poor mechanical properties. These mechanical properties can be improved substantially with addition of glass ceramics by sintering. In this study, the effects of sintering hydroxyapatite with above specified phosphate glass additions are quantified. Each composition was sintered over a range of temperatures. Scanning electron microscopy and x-ray diffraction were used to characterize the microstructure and phases of the composites. The density, microhardness, and compressive strength were measured using Archimedes Principle, Vickers Microhardness Tester (at 0.98 N), and Instron Universal Testing Machine (cross speed of 0.5 mm/min) respectively. These results were used to indicate which composition provided suitable material for use in hard tissue replacement. Composites containing 10 wt % glass additions formed dense HA/TCP (tricalcium phosphate) composite materials possessing good compressive strength and hardness than HA. In-vitro bioactivity was assessed by evaluating changes in pH and Ca2+ ion concentration of SBF-simulated body fluid on immersion of these composites in it for two weeks.

Keywords: Bioglass, Composite, Hydroxyapatite, Sintering.

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Authors: Alan C. Lin, Ricky N. Joevan

Abstract:

This paper focuses on developing a system to transfer mold base plates and standard parts faster during the stage of injection mold design. This system not only provides a way to compare the file version, but also it utilizes Siemens NX 10 to isolate the updated information into a single executable file (.dll), and then, the file can be transferred without the need of transferring the whole file. By this way, the system can help the user to download only necessary mold base plates and standard parts, and those parts downloaded are only the updated portions.

Keywords: CAD, injection molding, mold base, data retrieval.

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Authors: Hisashi Imai, Kuan-Yu Chen, Katsuyoshi Kondoh, Hung-Yin Tsai, Junko Umeda

Abstract:

Microstructural and electrical properties of Cu-chromium alloy (Cu-Cr) dispersed with vapor-grown carbon fiber (VGCF) prepared by powder metallurgy (P/M) process have been investigated. Cu-0.7 mass% Cr pre-alloyed powder (Cu-Cr) made by water atomization process was used as raw materials, which contained solid solute Cr elements in Cu matrix. The alloy powder coated with un-bundled VGCF by using oil coating process was consolidated at 1223 K in vacuum by spark plasma sintering, and then extruded at 1073 K. The extruded Cu-Cr alloy (monolithic alloy) had 209.3 MPa YS and 80.4 IACS% conductivity. The extruded Cu-Cr with 0.1 mass% VGCF composites revealed a small decrease of YS compared to the monolithic Cu-Cr alloy. On the other hand, the composite had a higher electrical conductivity than that of the monolithic alloy. For example, Cu-Cr with 0.1 mass% VGCF composite sintered for 5 h showed 182.7 MPa YS and 89.7 IACS% conductivity. In the case of Cu-Cr with VGCFs composites, the Cr concentration was observed around VGCF by SEM-EDS analysis, where Cr23C6 compounds were detected by TEM observation. The amount of Cr solid solution in the matrix of the Cu-Cr composites alloy was about 50% compared to the monolithic Cu-Cr sintered alloy, and resulted in the remarkable increment of the electrical conductivity.

Keywords: Powder metallurgy Cu-Cr alloy powder, vapor-grown carbon fiber, electrical conductivity.

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Authors: Anis Gharbi

Abstract:

This paper considers the problem of scheduling maintenance actions for identical aircraft gas turbine engines. Each one of the turbines consists of parts which frequently require replacement. A finite inventory of spare parts is available and all parts are ready for replacement at any time. The inventory consists of both new and refurbished parts. Hence, these parts have different field lives. The goal is to find a replacement part sequencing that maximizes the time that the aircraft will keep functioning before the inventory is replenished. The problem is formulated as an identical parallel machine scheduling problem where the minimum completion time has to be maximized. Two models have been developed. The first one is an optimization model which is based on a 0-1 linear programming formulation, while the second one is an approximate procedure which consists in decomposing the problem into several two-machine subproblems. Each subproblem is optimally solved using the first model. Both models have been implemented using Lingo and have been tested on two sets of randomly generated data with up to 150 parts and 10 turbines. Experimental results show that the optimization model is able to solve only instances with no more than 4 turbines, while the decomposition procedure often provides near-optimal solutions within a maximum CPU time of 3 seconds.

Keywords: Aircraft turbines, Scheduling, Identical parallel machines, 0-1 linear programming, Heuristic.

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Authors: D. H. Park, Y. H. Tak, H. H. Kwon, G. J. Kwon, H. G. Kim

Abstract:

The purpose of this study is to develop a forging process of automotive parts that satisfies the deformation characteristics. The analyses of temperature variation and deformation behavior of the material are important to obtain the optimal forging products. The hot compression test was carried out to know formability at high temperature. In order to define the optimum forging conditions including material temperature, strain and forging load, the commercial finite element analysis code was used to simulate the forging procedure of engine mounting parts. Experimental results were compared with the simulation results by finite element analysis. Test results were in good agreement with the simulations.

Keywords: Cold forging, hot forging, engine mounting, automotive parts, optimization.

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Authors: Liubov A. Magerramova, Mikhail A. Petrov, Vladimir V. Isakov, Liana A. Shcherbinina, Suren G. Gukasyan, Daniil V. Povalyukhin, Olga G. Klimova-Korsmik, Darya V. Volosevich

Abstract:

Aircraft engines are developing along the path of increasing resource, strength, reliability, and safety. The building of gas turbine engine body parts is a complex design and technological task. Particularly complex in the design and manufacturing are the casings of the input stages of helicopter gearboxes and central drives of aircraft engines. Traditional technologies, such as precision casting or isothermal forging, are characterized by significant limitations in parts production. For parts like housing, additive technologies guarantee spatial freedom and limitless or flexible design. This article presents the results of computational and experimental studies. These investigations justify the applicability of additive technologies (AT) to reduce the weight of aircraft housing gearbox parts by up to 32%. This is possible due to geometrical optimization compared to the classical, less flexible manufacturing methods and as-casted aircraft parts with over-insured values of safety factors. Using an example of the body of the input stage of an aircraft gearbox, visualization of the layer-by-layer manufacturing of a part based on thermal deformation was demonstrated.

Keywords: Additive technologies, gas turbine engines, geometric optimization, weight reduction.

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Authors: Suhartini M. Jainury, Rizauddin Ramli, Mohd Nizam A. Rahman

Abstract:

Lean, which was initially developed by Toyota, is widely implemented in other companies to improve competitiveness. This research is an attempt to identify the adoption of lean in the production system of Malaysian car manufacturer, Proton using case study approach. To gain the in-depth information regarding lean implementation, an activity on the assembly line called Set Parts Supply (SPS) was studied. The result indicates that by using lean principles, tools and techniques in the implementation of SPS enabled to achieve the goals on safety, quality, cost, delivery and morale. The implementation increased the size of the workspace, improved the quality of assembly and the delivery of parts supply, reduced the manpower, achieved cost savings on electricity and also increased the motivation of manpower in respect of attendance at work. A framework of SPS implementation is suggested as a contribution for lean practices in production system.

Keywords: Assembly line, lean manufacturing, production, parts supply.

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Authors: Matthias Schmidt, Steffen C. Eickemeyer, Prof. Peter Nyhuis

Abstract:

Guaranteeing the availability of the required parts at the scheduled time represents a key logistical challenge. This is especially important when several parts are required together. This article describes a tool that supports the positioning in the area of conflict between low stock costs and a high service level for a consumer.

Keywords: Systems Modeling, Manufacturing Systems, Simulation & Control, logistics and supply chain management

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Authors: Dr. H. B. Kekre, Sudeep D. Thepade

Abstract:

Panoramic view generation has always offered novel and distinct challenges in the field of image processing. Panoramic view generation is nothing but construction of bigger view mosaic image from set of partial images of the desired view. The paper presents a solution to one of the problems of image seascape formation where some of the partial images are color and others are grayscale. The simplest solution could be to convert all image parts into grayscale images and fusing them to get grayscale image panorama. But in the multihued world, obtaining the colored seascape will always be preferred. This could be achieved by picking colors from the color parts and squirting them in grayscale parts of the seascape. So firstly the grayscale image parts should be colored with help of color image parts and then these parts should be fused to construct the seascape image. The problem of coloring grayscale images has no exact solution. In the proposed technique of panoramic view generation, the job of transferring color traits from reference color image to grayscale image is done by palette based method. In this technique, the color palette is prepared using pixel windows of some degrees taken from color image parts. Then the grayscale image part is divided into pixel windows with same degrees. For every window of grayscale image part the palette is searched and equivalent color values are found, which could be used to color grayscale window. For palette preparation we have used RGB color space and Kekre-s LUV color space. Kekre-s LUV color space gives better quality of coloring. The searching time through color palette is improved over the exhaustive search using Kekre-s fast search technique. After coloring the grayscale image pieces the next job is fusion of all these pieces to obtain panoramic view. For similarity estimation between partial images correlation coefficient is used.

Keywords: Panoramic View, Similarity Estimate, Color Transfer, Color Palette, Kekre's Fast Search, Kekre's LUV

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