Search results for: Aluminum foil

Authors: A. Genç, R. Hacıoğlu, B. Bakırcı

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Synthetic oily wastewaters were prepared from metal working fluids (MWF). Electrocoagulation experiments were performed under constant voltage application. The current, conductivity, pH, dissolved oxygen concentration and temperature were recorded on line at every 5 seconds during the experiments. Effects of applied voltage differences, electrode materials and distance between electrodes on removal efficiency have been investigated. According to the experimental results, the treatment of MWF wastewaters by iron electrodes rather than aluminum and stainless steel was much quicker; and the distance between electrodes should be less than 1cm. The electrocoagulation process was modeled by using block oriented approach and found out that it can be modeled as a single input and multiple output system. Modeling studies indicates that the electrocoagulation process has a nonlinear model structure.

Keywords: Electrocoagulation, oily wastewater, SIMO systems.

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Authors: K. Kalaiselvan, A. Elango, N.M. Nagarajan

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Laser beam welding is an important joining technique for Titanium/Aluminum thin sheet alloys with their increasing applications in aerospace, aircraft, automotive, electronics and other industries. In this paper the research and progress in laser welding of Ti/Al thin sheets are critically reviewed from different perspectives. Some important aspects such as microstructure, metallurgical defects and mechanical properties in weldments are discussed. Also the recent progress in laser welding of Ti/Al dissimilar thin sheets to provide a basis for further research work is reported.

Keywords: Laser welding, Titanium/Aluminium sheets, microstructure, metallurgical defects and mechanical properties.

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Authors: Vanessa Romanovicz, Beatriz A. Berns, Stephen D. Carpenter, Deyse Carpenter

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This article deals with the carbon nanotubes (CNT) synthesized from a novel precursor, sugar cane and Anodic Aluminum Oxide (AAO). The objective was to produce CNTs to be used as catalyst supports for Proton Exchange Membranes. The influence of temperature, inert gas flow rate and concentration of the precursor is presented. The CNTs prepared were characterized using TEM, XRD, Raman Spectroscopy, and the surface area determined by BET. The results show that it is possible to form CNT from sugar cane by pyrolysis and the CNTs are the type multi-walled carbon nanotubes. The MWCNTs are short and closed at the two ends with very small surface area of S_BET= 3.691m^,/g.

Keywords: Carbon nanotubes, sugar cane, fuel cell, catalyst support.

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Authors: Nhat Khoa Tran, Yee Cheong Lam, Chee Yoon Yue, Ming Jen Tan

Abstract:

Metallic micro parts are playing an important role in micro-fabrication industry. Recently, we have demonstrated a new deformation mechanism for micro-formability of polycrystalline materials. Different depressed micro-features smaller than the grain size have been successfully fabricated on 6061 aluminum alloy (AA6061) substrates with good fidelity. To further verify this proposed deformation mechanism that grain size is not a limiting factor, we demonstrate here that in addition of depressed features, protruded micro-features on a polycrystalline substrate can similarly be fabricated.

Keywords: Deformation mechanism, grain size, microfabrication, polycrystalline materials.

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Authors: Kanate Pantusavase, Jaramporn Hassamontr

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This research aims to develop an algorithm to generate a schedule of multiple cranes that will maximize load throughputs in anodizing operation. The algorithm proposed utilizes an enumerative strategy to search for constant time between successive loads and crane covering range over baths. The computer program developed is able to generate a near-optimal crane schedule within reasonable times, i.e. within 10 minutes. Its results are compared with existing solutions from an aluminum extrusion industry. The program can be used to generate crane schedules for mixed products, thus allowing mixed-model line balancing to improve overall cycle times.

Keywords: Crane scheduling, anodizing operations, cycle time minimization.

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Authors: M. J. Kao, S.F. Chang, C.C. Chen, C.G. Kuo

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This paper aims to fabricated high quality anodic aluminum oxide (AAO) film by anodization method. AAO pore size, pore density, and film thickness can be controlled in 10~500 nm, 108~1011 pore．cm-2, and 1~100 μm. AAO volume and surface area can be computed based on structural parameters such as thickness, pore size, pore density, and sample size. Base on the thetorical calculation, AAO has 100 μm thickness with 15 nm, 60 nm, and 500 nm pore diameters AAO surface areas are 1225.2 cm2, 3204.4 cm2, and 549.7 cm2, respectively. The large unit surface area which is useful for adsorption application. When AAO adsorbed pH indictor of bromphenol blue presented a sensitive pH detection of solution change. This testing method can further be used for the precise measurement of biotechnology, convenience measurement of industrial engineering.

Keywords: AAO, Pore, Surface area, Adsorption, Indicator

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Authors: A. Elmikaty, Z. Thanawarothon, L. Mezeix

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This paper presents a finite element model to simulate the teeth failure of non-circular composite chainring. Model consists of the chainring and a part of the chain. To reduce the size of the model, only the first 11 rollers are simulated. In order to validate the model, it is firstly applied to a circular aluminum chainring and evolution of the stress in the teeth is compared with the literature. Then, effect of the non-circular shape is studied through three different loading positions. Strength of non-circular composite chainring and failure scenario is investigated. Moreover, two composite lay-ups are proposed to observe the influence of the stacking. Results show that composite material can be used but the lay-up has a large influence on the strength. Finally, loading position does not have influence on the first composite failure that always occurs in the first tooth.

Keywords: CFRP, composite failure, FEA, non-circular chainring.

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Authors: Krassimir Genov, Vladimir Georgiev, Todor Batakliev, Dipak K. Sarker

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The Bulgarian natural expanded mineral obtained from Bentonite AD perlite (A deposit of "The Broken Mountain" for perlite mining, near by the village of Vodenicharsko, in the municipality of Djebel), was loaded with silver (as ion form - Ag+ 2 and 5 wt% by the incipient wetness impregnation method), and as atomic silver - Ag0 using Tollen-s reagent (silver mirror reaction). Some physicochemical characterization of the samples are provided via: DC arc-AES, XRD, DR-IR and UV-VIS. The aim of this work was to obtain and test the silver-loaded catalyst for ozone decomposition. So the samples loaded with atomic silver show ca. 80% conversion of ozone 20 minutes after the reaction start. Then conversion decreases to ca. 20 % but stay stable during the prolongation of time.

Keywords: aluminum-silicates, Ag/perlite expanded glass, ozone decomposition

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Authors: M. Zielina, W. Dabrowski, E. Radziszewska-Zielina

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Several different cements have been tested to evaluate their potential to leach calcium, chromium and aluminum ions in soft water environment. The research allows comparing some different cements in order to the potential risk of water contamination. This can be done only in the same environment. To reach the results in reasonable short time intervals and to make heavy metals measurements with high accuracy, demineralized water was used. In this case the conditions of experiments are far away from the water supply practice, but short time experiments and measurably high concentrations of elements in the water solution are an important advantage. Moreover leaching mechanisms can be recognized, our experiments reported here refer to this kind of cements evaluation.

Keywords: Concrete corrosion, hydrogen sulfide, odors, reinforced concrete sewers, sewerage.

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Authors: Gürol Önal, Ahmet Avcı

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This paper presented the results of an experimental investigation into the axial fatigue behavior of a 5086 aluminum alloy which have several notch-aspect ratios a0/c0 and notch thickness ratio a/t with semi-elliptical surface cracks. Tests were conducted in la b air for stress levels of 50 % of their yield strength. Experiments were carried out for various notch to thickness ratios. Crack growth rates of test specimens both in surface and depth directions were determined by using die penetration method. Fuzzy Logic method was used to predict the deep direction crack growth because the dept of the crack is considerably difficult to measure.

Keywords: Axial fatigue, Crack growth rate, surface crack, Al-Mg alloy.

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Authors: Farhad Kolahan, Mohammad Bironro

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This paper addresses modeling and optimization of process parameters in powder mixed electrical discharge machining (PMEDM). The process output characteristics include metal removal rate (MRR) and electrode wear rate (EWR). Grain size of Aluminum powder (S), concentration of the powder (C), discharge current (I) pulse on time (T) are chosen as control variables to study the process performance. The experimental results are used to develop the regression models based on second order polynomial equations for the different process characteristics. Then, a genetic algorithm (GA) has been employed to determine optimal process parameters for any desired output values of machining characteristics.

Keywords: Regression modeling, PMEDM, GeneticAlgorithm, Optimization.

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Authors: Francesco Caputo, Giuseppe Lamanna, Alessandro Soprano

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This work is focused on the numerical prediction of the fracture resistance of a flat stiffened panel made of the aluminium alloy 2024 T3 under a monotonic traction condition. The performed numerical simulations have been based on the micromechanical Gurson-Tvergaard (GT) model for ductile damage. The applicability of the GT model to this kind of structural problems has been studied and assessed by comparing numerical results, obtained by using the WARP 3D finite element code, with experimental data available in literature. In the sequel a home-made procedure is presented, which aims to increase the residual strength of a cracked stiffened aluminum panel and which is based on the stochastic design improvement (SDI) technique; a whole application example is then given to illustrate the said technique.

Keywords: Residual strength, R-Curve, Gurson model, SDI.

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Authors: Shigeyuki Haruyama, I Made Gatot Karohika, Akinori Sato, Didik Nurhadiyanto, Ken Kaminishi

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Contact width and contact stress are important design parameters for optimizing corrugated metal gasket performance based on elastic and plastic contact stress. In this study, we used a three-layer metal gasket with Al, Cu, Ni as the outer layer, respectively. A finite element method was employed to develop simulation solution. The gasket model was simulated by using two simulation stages which are forming and tightening simulation. The simulation result shows that aluminum with tangent modulus, Eh_al = E_al/150 has the highest slope for contact width. The slope of contact width for plastic mode gasket was higher than the elastic mode gasket.

Keywords: Contact width, contact stress, layer, metal gasket, corrugated, simulation.

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Authors: Jung-Ho Moon, Tae Kwon Ha

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In the present study, the effect of Si, Al, Ti, Zr, and Nb addition on the microstructure and hot workability of cast M42 tool steels, basically consisting of 1.0C, 0.2Mn, 3.8Cr, 1.5W, 8.5Co, 9.2Mo, and 1.0V in weight percent has been investigated. Tool steels containing Si of 0.25 and 0.5wt.%, Al of 0.06 and 0.12wt.%, Ti of 0.3wt.%, Zr of 0.3wt.%, and Nb of 0.3wt.% were cast into ingots of 140mm ´ 140mm ´ 330mm by vacuum induction melting. After solution treatment at 1150^oC for 1.5hr followed by furnace cooling, hot rolling at 1180^oC was conducted on the ingots. Addition of titanium, zirconium and niobium was found to retard the decomposition of the eutectic carbides and result in the deterioration of hot workability of the tool steels, while addition of aluminum and silicon showed relatively well decomposed carbide structure and resulted in sound hot rolled plates.

Keywords: High speed steels, alloying elements, eutectic carbides, microstructure, hot workability.

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Authors: Ali Baladi, Alireza Fallahi Arezoodar

Abstract:

in dissimilar material joints, failure often occurs along the interface between two materials due to stress singularity. Stress distribution and its concentration depend on materials and geometry of the junction. Inhomogenity of stress distribution at the interface of junction of two materials with different elastic modules and stress concentration in this zone are the main factors resulting in rupture of the junction. Effect of joining angle in the interface of aluminum-polycarbonate will be discussed in this paper. Computer simulation and finite element analysis by ABAQUS showed that convex interfacial joint leads to stress reduction at junction corners in compare with straight joint. This finding is confirmed by photoelastic experimental results.

Keywords: Elastic Modules, Stress Concentration, JoiningAngle, Photoelastic.

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Authors: V. E. Messerle, O. A. Lavrichshev, A. B. Ustimenko

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The article presents a plasma chemical technology for processing solid fuels, using examples of bituminous and brown coals. Thermodynamic and experimental investigation of the technology was made. The technology allows producing synthesis gas from the coal organic mass and valuable components (technical silicon, ferrosilicon, aluminum, and carbon silicon, as well as microelements of rare metals, such as uranium, molybdenum, vanadium, etc.) from the mineral mass. The thusly produced highcalorific synthesis gas can be used for synthesis of methanol, as a high-calorific reducing gas instead of blast-furnace coke as well as power gas for thermal power plants.

Keywords: Gasification, mineral mass, organic mass, plasma, processing, solid fuel, synthesis gas, valuable components.

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Authors: J. Wozniak, M. Kostecki, K. Broniszewski, W. Bochniak, A. Olszyna

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The influence of extrusion parameters on surface quality and properties of AA6061+x% vol. SiC (x = 0; 2,5; 5; 7,5;10) composites was discussed in this paper. The averages size of AA6061 and SiC particles were 10.6 μm and 0.42 μm, respectively. Two series of composites (I - compacts were preheated at extrusion temperature through 0.5 h and cooled by water directly after process; II - compacts were preheated through 3 hours and were not cooled) were consolidated via powder metallurgy processing and extruded by KoBo method. High values of density for both series of composites were achieved. Better surface quality was observed for II series of composites. Moreover, for these composites lower (compared to I series) but more uniform strength properties over the cross-section of the bar were noticed. Microstructure and Young-s modulus investigations were made.

Keywords: aluminum alloy, extrusion, metal matrix composites, microstructure

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Authors: K. Kalaiselvan, A. Elango, N.M. Nagarajan, N. Mathiazhagan

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Dissimilar joining of Titanium and Aluminum thin sheets has potential applications in aerospace and automobile industry which can reduce weight and cost and improve strength, corrosion resistance and high temperature properties. However successful welding of Titanium/Aluminium sheets is of challenge due to differences in physical, chemical and metallurgical properties between the two. This paper describes research results of Laser Beam Welding (LBW) of Ti/Al thin sheets in which many researchers have recently performed and critically reviewed from different perspectives. Also some of notable works in the field of laser welding with changes in mechanical properties, crack propagation, diffusion behavior, chemical potential, interfacial reaction and the microstructure are reported.

Keywords: Laser Beam Welding (LBW), Mechanical properties, Titanium and Aluminium thin sheets.

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Authors: Srikanta Bose, Sudip K. Mazumder

Abstract:

We report here, the results of molecular dynamics simulation of p-doped (Ga-face)GaN over n-doped (Siface)( 0001)4H-SiC hetero-epitaxial material system with one-layer each of Ga-flux and (Al-face)AlN, as the interface materials, in the form of, the total Density of States (DOS). It is found that the total DOS at the Fermi-level for the heavily p-doped (Ga-face)GaN and ndoped (Si-face)4H-SiC hetero-epitaxial system, with one layer of (Al-face)AlN as the interface material, is comparatively higher than that of the various cases studied, indicating that there could be good vertical conduction across the (Ga-face)GaN over (Si-face)(0001)4HSiC hetero-epitaxial material system.

Keywords: Molecular dynamics, GaN, 4H-SiC, hetero-epitaxy.

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Authors: Samir A. Emam, Ali El Domiaty

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Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.

Keywords: Friction-stir welding, Energy, Aluminum Alloys.

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Authors: Tadeusz Pieczonka, Jan Kazior

Abstract:

The influence of SiC powder addition on densification of Al-SiC compacts during sintering in different atmospheres was investigated. It was performed in a dilatometer in flowing nitrogen, nitrogen/hydrogen (95/5 by volume) and argon. Fine, F500 grade of SiC powder was used. Mixtures containing 10 and 30 vol.% of SiC reinforcement were prepared in a Turbula mixer. Green compacts of about 82% of theoretical density were made of each mixture. For comparison, compacts made of pure aluminum powder were also investigated. It was shown that nitrogen is the best sintering atmosphere because only in this atmosphere did shrinkage take place. Its amount is lowered by ceramic powder addition, i.e. the more SiC the less densification occurs. Additionally, the formation of clusters, enhanced in compacts containing 30 vol.% SiC, is also responsible for limiting the shrinkage. Microstructural examinations of sintered composites revealed that sintering of compacts occurs in the presence of the liquid phase exclusively in nitrogen.

Keywords: Al-SiC composites, densification, sintering atmosphere.

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Authors: Kartikaningsih Danis, Yao-Hui Huang

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

Keywords: Electrocoagulation, chemical coagulation, aluminum electrode, boron removal.

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Authors: A. Soualem

Abstract:

A lot of research made during these last 15 years showed that the quantification of the springback has a significant role in the industry of sheet metal forming. These studies were made with the objective of finding techniques and methods to minimize or completely avoid this permanent physical variation. Moreover, the use of steel and aluminum alloys in the car industry and aviation poses every day the problem of the springback. The determination in advance of the quantity of the springback allows consequently the design and manufacture of the tool. The aim of this paper is to study experimentally the influence of the blank holder force BHF and the radius of curvature of the die on the springback and their influence on the strain in various zone of specimen. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback according to displacement.

Keywords: Blank holder force, Deep-Drawing, Die radius, Forming, Springback.

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Authors: Richard E. Miller

Abstract:

12.7-mm thick plates of 6061-T6511 aluminum alloy and high hardness steel (528 HV) were successfully joined by a friction stir bonding process using a tungsten-rhenium stir tool. Process parameter variation experiments, which included tool design geometry, plunge and traverse rates, tool offset, spindle tilt, and rotation speed, were conducted to develop a parameter set which yielded a defect free joint. Laboratory tensile tests exhibited yield stresses which exceed the strengths of comparable AA6061-to-AA6061 fusion and friction stir weld joints. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis also show atomic diffusion at the material interface region.

Keywords: Dissimilar materials, friction stir, welding.

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Authors: A. Benyahia, M. Zergoug, M. Amir, M. Fodil

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The main objective of this work is to enhance the Pulsed Eddy Current (PEC) response from the aluminum structure using signal processing. Cracks and metal loss in different structures cause changes in PEC response measurements. In this paper, time-frequency analysis is used to represent PEC response, which generates a large quantity of data and reduce the noise due to measurement. Power Spectral Density (PSD) after Wavelet Decomposition (PSD-WD) is proposed for defect detection. The experimental results demonstrate that the cracks in the surface can be extracted satisfactorily by the proposed methods. The validity of the proposed method is discussed.

Keywords: NDT, pulsed eddy current, continuous wavelet transform, Mexican hat wavelet mother, defect detection, power spectral density.

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Authors: Tao Quang Bang, Insu Jeon

Abstract:

Most CT reconstruction system x-ray computed tomography (CT) is a well established visualization technique in medicine and nondestructive testing. However, since CT scanning requires sampling of radiographic projections from different viewing angles, common CT systems with mechanically moving parts are too slow for dynamic imaging, for instance of multiphase flows or live animals. A large number of X-ray projections are needed to reconstruct CT images, so the collection and calculation of the projection data consume too much time and harmful for patient. For the purpose of solving the problem, in this study, we proposed a method for tomographic reconstruction of a sample from a limited number of x-ray projections by using linear interpolation method. In simulation, we presented reconstruction from an experimental x-ray CT scan of a Aluminum phantom that follows to two steps: X-ray projections will be interpolated using linear interpolation method and using it for CT reconstruction based upon Ordered Subsets Expectation Maximization (OSEM) method.

Keywords: CT reconstruction, X-ray projections, Interpolation technique, OSEM

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

Abstract:

Metallic foams have good potential for lightweight structures for impact and blast mitigation. Therefore it is important to find out the optimized foam structure (i.e. cell size, shape, relative density, and distribution) to maximise energy absorption. In this paper, quasistatic compression and microstructural characterization of closed-cell aluminium foams of different pore size and cell distributions have been carried out. We present results for two different aluminium metal foams of density 0.49-0.51 g/cc and 0.31- 0.34 g/cc respectively that have been tested in quasi-static compression. The influence of cell geometry and cell topology on quasistatic compression behaviour has been investigated using optical microscope and computed tomography (micro-CT) analysis. It is shown that the deformation is not uniform in the structure and collapse begins at the weakest point.

Keywords: Metal foams, micro-CT, cell topology, quasistatic compression.

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Authors: Joon Ho Kim, Tae Kwon Ha

Abstract:

Effect of aging treatment on microstructural aspects of interfacial layers of the Cu/Al clad sheet produced by differential speed rolling (DSR) process were studied by electron back scattered diffraction (EBSD). Clad sheet of Al/Cu has been fabricated by using DSR, which caused severe shear deformation between Al and Cu plate to easily bond to each other. Rolling was carried out at 100^oC with speed ratio of 2, in which the total thickness reduction was 45%. Interface layers of clad sheet were analyzed by EBSD after subsequent annealing at 400^oC for 30 to 120min. With increasing annealing time, thickness of interface layer and fraction of high angle grain boundary were increased and average grain size was decreased.

Keywords: Aluminum/Copper clad sheet, differential speed rolling, interface layer, microstructure, annealing, electron back scattered diffraction.

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Authors: A.K. Birru, D Benny Karunakar, M. M. Mahapatra

Abstract:

Recycling of aluminum alloys often decrease fluidity, consequently influence the castability of the alloy. In this study, the fluidity of Al-Zn alloys, such as the standard A713 alloy with and without scrap addition has been investigated. The scrap added was comprised of contaminated alloy turning chips. Fluidity measurements were performed with double spiral fluidity test consisting of gravity casting of double spirals in green sand moulds with good reproducibility. The influence of recycled alloy on fluidity has been compared with that of the virgin alloy and the results showed that the fluidity decreased with the increase in recycled alloy at minimum pouring temperatures. Interestingly, an appreciable improvement in the fluidity was observed at maximum pouring temperature, especially for coated spirals.

Keywords: A713 alloy, Fluidity, Hexachloroethane, Pouring temperature, Recycling.

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Authors: Ridvan Yamanoglu, Erdinc Efendi, Ismail Daoud

Abstract:

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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