Search results for: metallurgical defects and mechanical properties.
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 3629

Search results for: metallurgical defects and mechanical properties.

1469 Development of Electric Performance Testing System for Ceramic Chips using PZT Actuator

Authors: Jin-Ho Bae, Yong-Tae Kim, S K Deb Nath, Seo-Ik Kang, Sung-Gaun Kim

Abstract:

Reno-pin contact test is a method that is controlled by DC motor used to characterize electronic chips. This method is used in electronic and telecommunication devices. A new electric performance testing system is developed in which the testing method is controlled by using Piezoelectric Transducer (PZT) instead of DC motor which reduces vibration and noise. The vertical displacement of the Reno-pin is very short in the Reno-pin contact testing system. Now using a flexible guide in the new Reno-pin contact system, the vertical movement of the Reno-pin is increased many times of the existing Reno-pin contact testing method using DC motor. Using the present electric performance testing system with a flexible hinge and PZT instead of DC motor, manufacturing of electronic chips are able to characterize chips with low cost and high speed.

Keywords: PZT Actuator, Chip test, Mechanical amplifier

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1468 Hydrogen Gas Sensing Properties of Multiwalled Carbon Nanotubes Network Partially Coated with SnO2 Nanoparticles at Room Temperature

Authors: Neena Jaggi, Shivani Dhall

Abstract:

In the present work, hydrogen gas sensor of modest sensitivity utilizing functionalized multiwalled carbon nanotubes partially decorated with tin oxide nanoparticles (F-MWCNTs/SnO2) has been fabricated. This sensing material was characterized by scanning electron microscopy (SEM). In addition, a remarkable finding was that the F-MWCNTs/SnO2 sensor shows good sensitivity as compared to F-MWCNTs for low concentration (0.05-1% by volume) of H2 gas. The fabricated sensors show complete resistance recovery and good repeatability when exposed to H2 gas at the room temperature conditions.

Keywords: F-MWCNTs, SnO2 nanoparticles, Chemiresistor, I-V Characteristics, H2 Sensing.

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1467 Thermo Mechanical Design and Analysis of PEM Fuel cell Plate

Authors: Saravana Kannan Thangavelu

Abstract:

Fuel and oxidant gas delivery plate, or fuel cell plate, is a key component of a Proton Exchange Membrane (PEM) fuel cell. To manufacture low-cost and high performance fuel cell plates, advanced computer modeling and finite element structure analysis are used as virtual prototyping tools for the optimization of the plates at the early design stage. The present study examines thermal stress analysis of the fuel cell plates that are produced using a patented, low-cost fuel cell plate production technique based on screen-printing. Design optimization is applied to minimize the maximum stress within the plate, subject to strain constraint with both geometry and material parameters as design variables. The study reveals the characteristics of the printed plates, and provides guidelines for the structure and material design of the fuel cell plate.

Keywords: Design optimization, FEA, PEM fuel cell, Thermal stress

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1466 Indoor Moisture Control of Auckland Houses with Different Ventilation Systems

Authors: Bin Su

Abstract:

Auckland has a temperate climate with comfortable warm, dry summers and mild, wet winters. Auckland house design not only focus on winter thermal performance and indoor thermal condition, but also indoor moisture control, which is closely related to indirect health effects such as dust mites, fungi, etc. Most Auckland houses are designed to use temporary heating for winter indoor thermal comfort. Based on field study data of indoor microclimate conditions of two Auckland townhouses with a whole home mechanical ventilation system or a passive wind directional skylight vent, this study is to evaluate and compare indoor moisture conditions of two insulated townhouses only using temporary heating with different ventilation systems.

Keywords: House ventilation, house thermal design, indoor health condition, indoor moisture control.

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1465 Vertical Micromirror Fabrication by X-ray Lithography for Single Mode Optical Fiber Switching Applications

Authors: R. Chimchang, R. Tongta, R. Phatthanakun

Abstract:

Inthis paper, design and fabrication of vertical micromirror for optical switching applications of single mode optical fibers are proposed. The structure of micromirror will be created from negative photoresist (SU-8) on X-ray lithography using X-ray from synchrotron light source. The properties of X-ray from synchrotron light source are high-energy electrons which can construct materials that have a high aspect ratio. In addition, the technique of gold coating of reflective material has been used for change direction of light between two pairs of optical fibers. At a wavelength of 1310 nm with minimum average loss of 5.305 dB is obtained.

Keywords: vertical micromirror, negative photoresist, X-ray lithography

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1464 A Study of the Variability of Very Low Resolution Characters and the Feasibility of Their Discrimination Using Geometrical Features

Authors: Farshideh Einsele, Rolf Ingold

Abstract:

Current OCR technology does not allow to accurately recognizing small text images, such as those found in web images. Our goal is to investigate new approaches to recognize very low resolution text images containing antialiased character shapes. This paper presents a preliminary study on the variability of such characters and the feasibility to discriminate them by using geometrical features. In a first stage we analyze the distribution of these features. In a second stage we present a study on the discriminative power for recognizing isolated characters, using various rendering methods and font properties. Finally we present interesting results of our evaluation tests leading to our conclusion and future focus.

Keywords: World Wide Web, document analysis, pattern recognition, Optical Character Recognition.

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1463 The Effect of the Disc Coulters Forms on Cutting of Spring Barley Residues in No-Tillage

Authors: E. Šarauskis, L. Masilionytė, K. Romaneckas, Z. Kriaučiūnienė, A. Jasinskas

Abstract:

The introduction of sowing technologies into minimum- or no-tillage soil has a number of economical and environmental virtues, such as improving soil properties, decreasing soil erosion and degradation, and saving working time and fuel. However, the main disadvantage of these technologies is that plant residues on the soil surface reduce the quality of the planted crop seeds, thus requiring plant residues to be removed or cut. This paper presents a analysis of disc coulter parameters and an experimental investigation of cutting spring barley straw containing various amounts of moisture with different disc coulters (smooth and notched).

Keywords: Disc coulter, Spring barley residue, No-till, Straw moisture

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1462 The Performance of PVD Coated Grade in Milling of ADI 800

Authors: M. Ibrahim Sadik, Toril Myrtveit

Abstract:

The aim of this investigation is to study the performance of the new generation of the PVD coated grade and to map the influence of cutting conditions on the tool life in milling of ADI (Austempered Ductile Iron). The results show that chipping is the main wear mechanism which determines the tool life in dry condition and notch wear in wet condition for this application. This due to the different stress mechanisms and preexisting cracks in the coating. The wear development shows clearly that the new PVD coating (C20) has the best ability to delay the chipping growth. It was also found that a high content of Al in the new coating (C20) was especially favorable compared to a TiAlN multilayer with lower Al content (C30) or CVD coating. This is due to fine grains and low compressive stress level in the coating which increase the coating ability to withstand the mechanical and thermal impact. It was also found that the use of coolant decreases the tool life with 70-80% compare to dry milling.

Keywords: Austempered Ductile Iron (ADI), coating, chipping, milling, tool performance.

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1461 Temperature-Dependent Barrier Characteristics of Inhomogeneous Pd/n-GaN Schottky Barrier Diodes Surface

Authors: K. Al-Heuseen, M. R. Hashim

Abstract:

The current-voltage (I-V) characteristics of Pd/n-GaN Schottky barrier were studied at temperatures over room temperature (300-470K). The values of ideality factor (n), zero-bias barrier height (φB0), flat barrier height (φBF) and series resistance (Rs) obtained from I-V-T measurements were found to be strongly temperature dependent while (φBo) increase, (n), (φBF) and (Rs) decrease with increasing temperature. The apparent Richardson constant was found to be 2.1x10-9 Acm-2K-2 and mean barrier height of 0.19 eV. After barrier height inhomogeneities correction, by assuming a Gaussian distribution (GD) of the barrier heights, the Richardson constant and the mean barrier height were obtained as 23 Acm-2K-2 and 1.78eV, respectively. The corrected Richardson constant was very closer to theoretical value of 26 Acm-2K-2. 

Keywords: Electrical properties, Gaussian distribution, Pd-GaN Schottky diodes, thermionic emission.

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1460 Assessing the Effect of Thermodynamic, Hydrodynamic and Geometric of an Air Cooled Condenser on COP of Vapor Compression Cycle

Authors: Hosein Shokohmand, Mahmood Hosein Zare, Abdorreza Qolibeik

Abstract:

In this paper, the effects of thermodynamic, hydrodynamic and geometric of an air cooled condenser on COP of vapor compression cycle are investigated for a fixed condenser facing surface area. The system is utilized with a scroll compressor, modeled based on thermodynamic and heat transfer equations employing Matlab software. The working refrigerant is R134a whose thermodynamic properties are called from Engineering Equation Software. This simulation shows that vapor compression cycle can be designed by different configurations and COPs, economical and optimum working condition can be obtained via considering these parameters.

Keywords: Vapor compression cycle, air cooled condenser, COP, heat exchanger, thermal modeling.

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1459 Research on Modern Semiconductor Converters and the Usage of SiC Devices in the Technology Centre of Ostrava

Authors: P. Vaculík, P. Kaňovský

Abstract:

The following article presents Technology Centre of Ostrava (TCO) in the Czech Republic describing the structure and main research areas realized by the project ENET - Energy Units for Utilization of non Traditional Energy Sources. More details are presented from the research program dealing with transformation, accumulation and distribution of electric energy. Technology Centre has its own energy mix consisting of alternative sources of fuel sources that use of process gases from the storage part and also the energy from distribution network. The article will be focus on the properties and application possibilities SiC semiconductor devices for power semiconductor converter for photovoltaic systems.

Keywords: SiC, Si, Technology Centre of Ostrava, Photovoltaic Systems, DC/DC Converter, Simulation.

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1458 Effect of Shear Theories on Free Vibration of Functionally Graded Plates

Authors: M. Karami Khorramabadi, M. M. Najafizadeh, J. Alibabaei Shahraki, P. Khazaeinejad

Abstract:

Analytical solution of the first-order and third-order shear deformation theories are developed to study the free vibration behavior of simply supported functionally graded plates. The material properties of plate are assumed to be graded in the thickness direction as a power law distribution of volume fraction of the constituents. The governing equations of functionally graded plates are established by applying the Hamilton's principle and are solved by using the Navier solution method. The influence of side-tothickness ratio and constituent of volume fraction on the natural frequencies are studied. The results are validated with the known data in the literature.

Keywords: Free vibration, Functionally graded plate, Naviersolution method.

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1457 Analyzing the Factors Effecting the Passenger Car Breakdowns using Com-Poisson GLM

Authors: N. Mamode Khan, V. Jowaheer

Abstract:

Number of breakdowns experienced by a machinery is a highly under-dispersed count random variable and its value can be attributed to the factors related to the mechanical input and output of that machinery. Analyzing such under-dispersed count observations as a function of the explanatory factors has been a challenging problem. In this paper, we aim at estimating the effects of various factors on the number of breakdowns experienced by a passenger car based on a study performed in Mauritius over a year. We remark that the number of passenger car breakdowns is highly under-dispersed. These data are therefore modelled and analyzed using Com-Poisson regression model. We use quasi-likelihood estimation approach to estimate the parameters of the model. Under-dispersion parameter is estimated to be 2.14 justifying the appropriateness of Com-Poisson distribution in modelling under-dispersed count responses recorded in this study.

Keywords: Breakdowns, under-dispersion, com-poisson, generalized linear model, quasi-likelihood estimation

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1456 Unconventional Calculus Spreadsheet Functions

Authors: Chahid K. Ghaddar

Abstract:

The spreadsheet engine is exploited via a non-conventional mechanism to enable novel worksheet solver functions for computational calculus. The solver functions bypass inherent restrictions on built-in math and user defined functions by taking variable formulas as a new type of argument while retaining purity and recursion properties. The enabling mechanism permits integration of numerical algorithms into worksheet functions for solving virtually any computational problem that can be modelled by formulas and variables. Several examples are presented for computing integrals, derivatives, and systems of deferential-algebraic equations. Incorporation of the worksheet solver functions with the ubiquitous spreadsheet extend the utility of the latter as a powerful tool for computational mathematics.

Keywords: Calculus functions, nonlinear systems, differential algebraic equations, solvers, spreadsheet.

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1455 Sustainable Production of Oyster Mushroom (Pleurotus ostreatus) in Chiapas, Mexico

Authors: Sandoval Villa Héctor, Estrada Velazco Evaristo, Chavarría Alamilla Luis

Abstract:

Pleurotus ostreatus is a common edible mushroom with a number of properties that can help to solve the nutritional and economical problems of people in Chiapas, Mexico. The objective of this project was to produce the mushroom under a sustainable management in which only regional products were allowed as a way to promote the cultivation and consumption of Pleurotus ostreatus; 5 different substrates were tested as well as 2 sanitation methods. The obtained results showed that the highest yields were obtained using corn husk and a thermal sanitation method. Pests and diseases were not a problem during the project but they appeared more in the substrates sanitized with calcium hydroxide.

Keywords: Pleurotus ostreatus, substrates, sanitation.

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1454 Press Hardening of Tubes with Additional Interior Spray Cooling

Authors: B.-A. Behrens, H. J. Maier, A. Neumann, J. Moritz, S. Hübner, T. Gretzki, F. Nürnberger, A. Spiekermeier

Abstract:

Press-hardened profiles are used e.g. for automotive applications in order to improve light weight construction due to the high reachable strength. The application of interior water-air spray cooling contributes to significantly reducing the cycle time in the production of heat-treated tubes. This paper describes a new manufacturing method for producing press-hardened hollow profiles by means of an additional interior cooling based on a water-air spray. Furthermore, this paper provides the results of thorough investigations on the properties of press-hardened tubes in dependence of varying spray parameters.

Keywords: 22MnB5, hollow profiles, press hardening, tubes, water-air spray cooling.

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1453 Distributed Denial of Service Attacks in Mobile Adhoc Networks

Authors: Gurjinder Kaur, Yogesh Chaba, V. K. Jain

Abstract:

The aim of this paper is to explore the security issues that significantly affect the performance of Mobile Adhoc Networks (MANET)and limit the services provided to their intended users. The MANETs are more vulnerable to Distributed Denial of Service attacks (DDoS) because of their properties like shared medium, dynamic topologies etc. A DDoS attack is a coordinated attempt made by malicious users to flood the victim network with the large amount of data such that the resources of the victim network are exhausted resulting in the deterioration of the network performance. This paper highlights the effects of different types of DDoS attacks in MANETs and categorizes them according to their behavior.

Keywords: Distributed Denial, Mobile Adhoc Networks

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1452 A Compact Wearable Slot Antenna for LTE and WLAN Applications

Authors: Haider K. Raad

Abstract:

In this paper, a compact wide-band, ultra-thin and flexible slot antenna intended for wearable applications is presented. The presented antenna is designed to provide Wireless Local Area Network (WLAN) and Long Term Evolution (LTE) connectivity. The presented design exhibits a relatively wide bandwidth (1600-3500 MHz below -6 dB impedance bandwidth limit). The antenna is positioned on a 33 mm x 30 mm flexible substrate with a thickness of 50 µm. Antenna properties, such as the far-field radiation patterns, scattering parameter S11 are provided. The presented compact, thin and flexible design along with excellent radiation characteristics are deemed suitable for integration into flexible and wearable devices.

Keywords: Wearable Electronics, Slot Antenna, LTE, WLAN.

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1451 Particle Simulation of Rarefied Gas Flows witha Superimposed Wall Surface Temperature Gradient in Microgeometries

Authors: V. Azadeh Ranjbar

Abstract:

Rarefied gas flows are often occurred in micro electro mechanical systems and classical CFD could not precisely anticipate the flow and thermal behavior due to the high Knudsen number. Therefore, the heat transfer and the fluid dynamics characteristics of rarefied gas flows in both a two-dimensional simple microchannel and geometry similar to single Knudsen compressor have been investigated with a goal of increasing performance of a actual Knudsen compressor by using a particle simulation method. Thermal transpiration and thermal creep, which are rarefied gas dynamic phenomena, that cause movement of the flow from less to higher temperature is generated by using two different longitude temperature gradients (Linear, Step) along the walls of the flow microchannel. In this study the influence of amount of temperature gradient and governing pressure in various Knudsen numbers and length-to-height ratios have been examined.

Keywords: DSMC, Thermal transpiration, Thermal creep, MEMS, Knudsen Compressor.

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1450 Monte Carlo Simulation of the Transport Phenomena in Degenerate Hg0.8Cd0.2Te

Authors: N. Dahbi, M. Daoudi, A.Belghachi

Abstract:

The present work deals with the calculation of transport properties of Hg0.8Cd0.2Te (MCT) semiconductor in degenerate case. Due to their energy-band structure, this material becomes degenerate at moderate doping densities, which are around 1015 cm-3, so that the usual Maxwell-Boltzmann approximation is inaccurate in the determination of transport parameters. This problem is faced by using Fermi-Dirac (F-D) statistics, and the non-parabolic behavior of the bands may be approximated by the Kane model. The Monte Carlo (MC) simulation is used here to determinate transport parameters: drift velocity, mean energy and drift mobility versus electric field and the doped densities. The obtained results are in good agreement with those extracted from literature.

Keywords: degeneracy case, Hg0.8Cd0.2Te semiconductor, Monte Carlo simulation, transport parameters.

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1449 Immobilization of Simulated High Level Nuclear Wastes with Li2O-CeO2-Fe2O3-P2O5 Glasses

Authors: Toshinori Okura, Naoya Yoshida

Abstract:

The leaching behavior and structure of Li2O-CeO2- Fe2O3-P2O5 glasses incorporated with simulated high level nuclear wastes (HLW) were studied. The leach rates of gross and each constituent element were determined from the total weight loss of the specimen and the leachate analyses by inductively coupled argon plasma spectroscopy (ICP). The gross leach rate of the 4.5Li2O- 9.7CeO2-34.7Fe2O3-51.5P2O5 glass waste form containing 45 mass% simulated HLW is of the order of 10

Keywords: FT-IR spectra, Leach rates, Li2O-CeO2-Fe2O3-P2O5 glasses, Nuclear waste immobilization, Thermal properties

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1448 Object Recognition in Color Images by the Self Configuring System MEMORI

Authors: Michela Lecca

Abstract:

System MEMORI automatically detects and recognizes rotated and/or rescaled versions of the objects of a database within digital color images with cluttered background. This task is accomplished by means of a region grouping algorithm guided by heuristic rules, whose parameters concern some geometrical properties and the recognition score of the database objects. This paper focuses on the strategies implemented in MEMORI for the estimation of the heuristic rule parameters. This estimation, being automatic, makes the system a self configuring and highly user-friendly tool.

Keywords: Automatic Object Recognition, Clustering, Contentbased Image Retrieval System, Image Segmentation, Region Adjacency Graph, Region Grouping.

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1447 Psyllium (Plantago) Gum as an Effective Edible Coating to Improve Quality and Shelf Life of Fresh-cut Papaya (Carica papaya)

Authors: Basharat Yousuf, Abhaya K. Srivastava

Abstract:

Psyllium gum alone and in combination with sunflower oil was investigated as a possible alternative edible coating for improvement of quality and shelf life of fresh-cut papaya. Different concentrations including 0.5, 1 and 1.5 percent of psyllium gum were used for coating of fresh-cut papaya. In some samples, refined sunflower oil was used as a lipid component to increase the effectiveness of coating in terms of water barrier properties. Soya lecithin was used as an emulsifier in coatings containing oil. Pretreatment with 1% calcium chloride was given to maintain the firmness of fresh-cut papaya cubes. 1% psyllium gum coating was found to yield better results. Further, addition of oil helped to maintain the quality and acted as a barrier to water vapour, therefore, minimizing the weight loss.

Keywords: Coating, fresh-cut, gum, papaya, psylllium.

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1446 A Preliminary Study on Effects of Community Structures on Epidemic Spreading and Detection in Complex Networks

Authors: Yi Yu, Gaoxi Xiao

Abstract:

Community structures widely exist in almost all real-life networks. Extensive researches have been carried out on detecting community structures in complex networks. However, many aspects of how community structures may affect the dynamics and properties of complex networks still remain unclear. In this work, we examine the impacts of community structures on the epidemic spreading and detection in complex networks. Extensive simulation results show that community structures may not help decrease the infection size at steady state, yet they could indeed help slow down the infection spreading. Also, networks with strong community structures may expect to have a smaller average infection size when equipped with a number of sparsely deployed monitors.

Keywords: Complex network, epidemic spreading, infection size, infection monitoring.

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1445 Dissipation of Higher Mode using Numerical Integration Algorithm in Dynamic Analysis

Authors: Jin Sup Kim, Woo Young Jung, Minho Kwon

Abstract:

In general dynamic analyses, lower mode response is of interest, however the higher modes of spatially discretized equations generally do not represent the real behavior and not affects to global response much. Some implicit algorithms, therefore, are introduced to filter out the high-frequency modes using intended numerical error. The objective of this study is to introduce the P-method and PC α-method to compare that with dissipation method and Newmark method through the stability analysis and numerical example. PC α-method gives more accuracy than other methods because it based on the α-method inherits the superior properties of the implicit α-method. In finite element analysis, the PC α-method is more useful than other methods because it is the explicit scheme and it achieves the second order accuracy and numerical damping simultaneously.

Keywords: Dynamic, α-Method, P-Method, PC α-Method, Newmark method.

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1444 The Prospective Assessment of Zero-Energy Dwellings

Authors: Jovana Dj. Jovanovic, Svetlana M. Stevovic

Abstract:

The highest priority of so called, projected passive houses is to meet the appropriate energy demand. Every single material and layer which is injected into a dwelling has a certain energy quantity stored. The passive houses include optimized insulation levels with minimal thermal bridges, minimum of air leakage through the building, utilization of passive solar and internal gains, and good circulation of air which leans on mechanical ventilation system. The focus of this paper is on passive house features, benefits and targets, their feasibility and energy demands which are set up during each project. Numerous passive house-standards outline the very significant role of zero-energy dwellings towards the modern label of sustainable development. It is clear that the performance of both built and existing housing stock must be addressed if the population across the world sets out the energy objectives. This scientific article examines passive house features since the many passive house cases are launched.

Keywords: Benefits, energy demands, passive houses, sustainable development.

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1443 The Rail Traffic Management with Usage of C-OTDR Monitoring Systems

Authors: Andrey V. Timofeev, Dmitry V. Egorov, Viktor M. Denisov

Abstract:

This paper presents development results of usage of C-OTDR monitoring systems for rail traffic management. The COTDR method is based on vibrosensitive properties of optical fibers. Analysis of Rayleigh backscattering radiation parameters changes which take place due to microscopic seismoacoustic impacts on the optical fiber allows to determine seismoacoustic emission source positions and to identify their types. This approach proved successful for rail traffic management (moving block system, weigh- in-motion system etc.).

Keywords: C-OTDR systems, moving block-sections, rail traffic management, Rayleigh backscattering, weigh-in-motion.

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1442 Thermal Fatigue Behavior of 400 Series Ferritic Stainless Steels

Authors: Seok Hong Min, Tae Kwon Ha

Abstract:

In this study, thermal fatigue properties of 400 series ferritic stainless steels have been evaluated in the temperature ranges of 200-800oC and 200-900oC. Systematic methods for control of temperatures within the predetermined range and measurement of load applied to specimens as a function of temperature during thermal cycles have been established. Thermal fatigue tests were conducted under fully constrained condition, where both ends of specimens were completely fixed. It has been revealed that load relaxation behavior at the temperatures of thermal cycle was closely related with the thermal fatigue property. Thermal fatigue resistance of 430J1L stainless steel is found to be superior to the other steels.

Keywords: Ferritic stainless steel, automotive exhaust, thermal fatigue, microstructure, load relaxation.

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1441 Characterization of Fabricated A 384.1-MgO Based Metal Matrix Composite and Optimization of Tensile Strength using Taguchi Techniques

Authors: Nripjit, Anand K Tyagi, Nirmal Singh

Abstract:

The present work consecutively on synthesis and characterization of composites, Al/Al alloy A 384.1 as matrix in which the main ingredient as Al/Al-5% MgO alloy based metal matrix composite. As practical implications the low cost processing route for the fabrication of Al alloy A 384.1 and operational difficulties of presently available manufacturing processes based in liquid manipulation methods. As all new developments, complete understanding of the influence of processing variables upon the final quality of the product. And the composite is applied comprehensively to the acquaintance for achieving superiority of information concerning the specific heat measurement of a material through the aid of thermographs. Products are evaluated concerning relative particle size and mechanical behavior under tensile strength. Furthermore, Taguchi technique was employed to examine the experimental optimum results are achieved, owing to effectiveness of this approach.

Keywords: MMC, Thermographs, Tensile strength, Taguchi technique, Optimal parameters

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1440 Study of Influencing Factors on the Flowability of Jute Nonwoven Reinforced Sheet Molding Compound

Authors: Miriam I. Lautenschläger, Max H. Scheiwe, Kay A. Weidenmann, Frank Henning, Peter Elsner

Abstract:

Due to increasing environmental awareness jute fibers are more often used in fiber reinforced composites. In the Sheet Molding Compound (SMC) process, the mold cavity is filled via material flow allowing more complex component design. But, the difficulty of using jute fibers in this process is the decreased capacity of fiber movement in the mold. A comparative flow study with jute nonwoven reinforced SMC was conducted examining the influence of the fiber volume content, the grammage of the jute nonwoven textile and a mechanical modification of the nonwoven textile on the flowability. The nonwoven textile reinforcement was selected to support homogeneous fiber distribution. Trials were performed using two SMC paste formulations differing only in filler type. Platy-shaped kaolin with a mean particle size of 0.8 μm and ashlar calcium carbonate with a mean particle size of 2.7 μm were selected as fillers. Ensuring comparability of the two SMC paste formulations the filler content was determined to reach equal initial viscosity for both systems. The calcium carbonate filled paste was set as reference. The flow study was conducted using a jute nonwoven textile with 300 g/m² as reference. The manufactured SMC sheets were stacked and centrally placed in a square mold. The mold coverage was varied between 25 and 90% keeping the weight of the stack for comparison constant. Comparing the influence of the two fillers kaolin yielded better results regarding a homogeneous fiber distribution. A mold coverage of about 68% was already sufficient to homogeneously fill the mold cavity whereas for calcium carbonate filled system about 79% mold coverage was necessary. The flow study revealed a strong influence of the fiber volume content on the flowability. A fiber volume content of 12 vol.-% and 25 vol.-% were compared for both SMC formulations. The lower fiber volume content strongly supported fiber transport whereas 25 vol.-% showed insignificant influence. The results indicate a limiting fiber volume content for the flowability. The influence of the nonwoven textile grammage was determined using nonwoven jute material with 500 g/m² and a fiber volume content of 20 vol.-%. The 500 g/m² reinforcement material showed inferior results with regard to fiber movement. A mold coverage of about 90 % was required to prevent the destruction of the nonwoven structure. Below this mold coverage the 500 g/m² nonwoven material was ripped and torn apart. Low mold coverages led to damage of the textile reinforcement. Due to the ripped nonwoven structure the textile was modified with cuts in order to facilitate fiber movement in the mold. Parallel cuts of about 20 mm length and 20 mm distance to each other were applied to the textile and stacked with varying orientations prior to molding. Stacks with unidirectional orientated cuts over stacks with cuts in various directions e.g. (0°, 45°, 90°, -45°) were investigated. The mechanical modification supported tearing of the textile without achieving benefit for the flowability.

Keywords: Filler, flowability, jute fiber, nonwoven, sheet molding compound.

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