Search results for: Austenitic Stainless Steel AISI 304/ Mechanical Property/ Welding Gas Shield/ Gas Shield

Authors: S. K. Tiwari, Dinesh Kumar Shukla, R. Chandra

Abstract:

Friction stir welding is a solid state joining process. High strength aluminum alloys are widely used in aircraft and marine industries. Generally, the mechanical properties of fusion welded aluminum joints are poor. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phases common in fusion welding of high strength aluminum alloys. In this review the process parameters, microstructural evolution, and effect of friction stir welding on the properties of weld specific to aluminum alloys have been discussed.

Keywords: Aluminum alloys, Friction stir welding (FSW), Microstructure, Properties.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 5308

Authors: Ramesh S., Sasiraaju A. S., Sidhaarth K., Sudhan Rajkumar N., Manivel Muralidaran V.

Abstract:

This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: Chromoly, Gas Metal Arc Weld (GMAW), Hardness, Multi pass weld, Shielding gas composition.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2953

Authors: C.C. Chen, C.C. Wei, S.H. Chen, S.J. Hsieh, W.G. Diau

Abstract:

This paper aims to scale up Dye-sensitized Solar Cell (DSSC) production using a commonly available industrial material – stainless steel - and industrial plasma equipment. A working DSSC electrode formed by (1) coating titania nanotube (TiO2 NT) film on 304 stainless steel substrate using a plasma spray technique; then, (2) filling the nano-pores of the TiO2 NT film using a TiF4 sol-gel method. A DSSC device consists of an anode absorbed photosensitive dye (N3), a transparent conductive cathode with platinum (Pt) nano-catalytic particles adhered to its surface, and an electrolytic solution sealed between the anode and the transparent conductive cathode. The photo-current conversion efficiency of the DSSC sample was tested under an AM 1.5 Solar Simulator. The sample has a short current (Isc) of 0.83 mA cm-2, open voltage (Voc) of 0.81V, filling factor (FF) of 0.52, and conversion efficiency (η) of 2.18% on a 0.16 cm2 DSSC work-piece.

Keywords: DSSC, Spray, stainless steel, TiO2 NT, efficiency

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2120

Authors: G. H. Senussi

Abstract:

The present work is concerned with the effect of turning process parameters (cutting speed, feed rate, and depth of cut) and distance from the center of work piece as input variables on the chip micro-hardness as response or output. Three experiments were conducted; they were used to investigate the chip micro-hardness behavior at diameter of work piece for 30[mm], 40[mm], and 50[mm]. Response surface methodology (R.S.M) is used to determine and present the cause and effect of the relationship between true mean response and input control variables influencing the response as a two or three dimensional hyper surface. R.S.M has been used for designing a three factor with five level central composite rotatable factors design in order to construct statistical models capable of accurate prediction of responses. The results obtained showed that the application of R.S.M can predict the effect of machining parameters on chip micro-hardness. The five level factorial designs can be employed easily for developing statistical models to predict chip micro-hardness by controllable machining parameters. Results obtained showed that the combined effect of cutting speed at it?s lower level, feed rate and depth of cut at their higher values, and larger work piece diameter can result increasing chi micro-hardness.

Keywords: Machining Parameters, Chip Micro-Hardness, CNCMachining, 304-Austenic Stainless Steel.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3231

Authors: Chansiri Singhtaun, Nattaporn Prasartthong

Abstract:

The purpose of this research is to reduce the amount of incomplete coating of stainless steel washers in the electrodeposition painting process by using an experimental design technique. The surface preparation was found to be a major cause of painted surface quality. The influence of pretreating and painting process parameters, which are cleaning time, chemical concentration and shape of hanger were studied. A 23 factorial design with two replications was performed. The analysis of variance for the designed experiment showed the great influence of cleaning time and shape of hanger. From this study, optimized cleaning time was determined and a newly designed electrical conductive hanger was proved to be superior to the original one. The experimental verification results showed that the amount of incomplete coating defects decreased from 4% to 1.02% and operation cost decreased by 10.5%.

Keywords: Defect reduction, design of experiments, electrodeposition painting, stainless steel.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2226

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

Abstract:

Laser beam welding for the dissimilar Titanium and Aluminium thin sheets is an emerging area which is having wider applications in aerospace, aircraft, automotive, electronics and in other industries due to its high speed, non-contact, precision with low heat effects, least welding distortion, low labor costs and convenient operation. Laser beam welding of dissimilar metal combinations are increasingly demanded due to high energy densities with small fusion and heat affected zones. Furthermore, no filler or electrode material is required and contamination of weld is also very small. The present study is to reviews the influence of different parameters like laser power, welding speed, power density, beam diameter, focusing distance and type of shielding gas on the mechanical properties of dissimilar metal combinations like SS/Al, Cu/Al and Ti/Al focusing on aluminum to other materials. Research findings reveal that Ti/Al combination gives better metallurgical and mechanical properties than other combinations such as SS/Al and Cu/Al.

Keywords: Laser Beam Welding, dissimilar metals, SS/Al, Cu/Al and Ti/Al sheets.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2633

Authors: Lakshman Singh, Rajeshwar Singh, Naveen Kumar Singh, Davinder Singh, Pargat Singh

Abstract:

Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability.

TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.

Keywords: 5083 Aluminium alloy, Gas flow rate, TIG welding, Welding current, Welding speed and Tensile strength.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4032

Authors: A. Mostafa

Abstract:

This paper presents a numerical study on determination of ballistic limit velocity (V₅₀) of stainless steel 304 (SS 304) used in manufacturing security screens. The simulated ballistic impact tests were conducted on clamped sheets with different thicknesses using ABAQUS/Explicit nonlinear finite element (FE) package. The ballistic limit velocity was determined using three approaches, namely: numerical tests based on material properties, FE calculated residual velocities and FE calculated residual energies. Johnson-Cook plasticity and failure criterion were utilized to simulate the dynamic behaviour of the SS 304 under various strain rates, while the well-known Lambert-Jonas equation was used for the data regression for the residual velocity and energy model. Good agreement between the investigated numerical methods was achieved. Additionally, the dependence of the ballistic limit velocity on the sheet thickness was observed. The proposed approaches present viable and cost-effective assessment methods of the ballistic performance of SS 304, which will support the development of robust security screen systems.

Keywords: Ballistic velocity, stainless steel, numerical approaches, security screen.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 579

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

Abstract:

Today automobile and aerospace industries realise Laser Beam Welding for a clean and non contact source of heating and fusion for joining of sheets. The welding performance is mainly based on by the laser welding parameters. Some concepts related to Artificial Neural Networks and how can be applied to model weld bead geometry and mechanical properties in terms of equipment parameters are reported in order to evaluate the accuracy and compare it with traditional modeling schemes. This review reveals the output features of Titanium and Aluminium weld bead geometry and mechanical properties such as ultimate tensile strength, yield strength, elongation and reduction of the area of the weld using Artificial Neural Network.

Keywords: Laser Beam Welding (LBW), Artificial Neural Networks (ANN), Optimization, Titanium and Aluminium sheets.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2317

Authors: Jawad Saleem, Abdul Majid, Kent Bertilsson, Torbjörn Carlberg, Nazar Ul Islam

Abstract:

Resistance spot welding process comprises of electric, thermal and mechanical phenomenon, which makes this process complex and highly non-linear and thus, it becomes difficult to model it. In order to obtain good weld nugget during spot welding, hit and trial welds are usually done which is very costly. Therefore the numerical simulation research has been conducted to understand the whole process. In this paper three different cases were analyzed by varying the tip contact area and it was observed that, with the variation of tip contact area the nugget formation at the faying surface is affected. The tip contact area of the welding electrode becomes large with long welding cycles. Therefore in order to maintain consistency of nugget formation during the welding process, the current compensation in control feedback is required. If the contact area of the welding electrode tip is reduced, a large amount of current flows through the faying surface, as a result of which sputtering occurs.

Keywords: Resistance spot welding, Finite element modeling, Nugget formation, Welding electrode, Numerical method simulation,

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3746

Authors: Sang Hwan Bak, Min Jung Kim, Dong Bok Lee

Abstract:

Fe-2%Mn-0.5%Si-0.2C steel was welded and corroded at 600, 700 and 800oC for 20 h in 1 atm of N2/H2S/H2O-mixed gas in order to characterize the high-temperature corrosion behavior of the welded joint. Corrosion proceeded fast and almost linearly. It increased with an increase in the corrosion temperature. H2S formed FeS owing to sulfur released from H2S. The scales were fragile and nonadherent.

Keywords: Fe-Mn-Si Steel, Corrosion, Welding, Sulfidation, H2S Gas.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1887

Authors: Gil Hwan Na , Woo Young Jung , Tae Kwon Ha

Abstract:

Most buildings have been using anchor bolts commonly for installing outdoor advertising structures. Anchor bolts of common carbon steel are widely used and often installed indiscriminately by inadequate installation standards. In the area where strong winds frequently blow, falling accidents of outdoor advertising structures can occur and cause a serious disaster, which is very dangerous and to be prevented. In this regard, the development of high-performance anchor bolts is urgently required. In the present study, 25Cr-8Ni-1.5Si-1Mn-0.4C alloy was produced by traditional vacuum induction melting (VIM) for the application of anchor bolt. The alloy composition is revealed as a duplex microstructure from thermodynamic phase analysis by FactSage® and confirmed by metallographic experiment. Addition of Nitrogen to the alloy was found to reduce the ferritic phase domain and significantly increase the hardness and the tensile strength. Microstructure observation revealed mixed structure of austenite and ferrite with fine carbide distributed along the grain and phase boundaries.

Keywords: Anchor bolt, Duplex stainless steel, FactSage®, Hardness, Thermodynamic phase analysis.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2821

Authors: M. P. Valles-González, A. González Meije, A. Pastor Muro, M. García-Martínez, B. González Caballero

Abstract:

This paper studies a failure case of a fuel pressure supply tube from an aircraft engine. Multiple fracture cases of the fuel pressure control tube from aircraft engines have been reported. The studied set was composed by the mentioned tube, a welded connecting pipe, where the fracture has been produced, and a union nut. The fracture has been produced in one of the most critical zones of the tube, in a region next to the supporting body of the union nut to the connector. The tube material was X6CrNiTi18-10, an austenitic stainless steel. Chemical composition was determined using an X-Ray fluorescence spectrometer (XRF) and combustion equipment. Furthermore, the material was characterized mechanically, by a hardness test, and microstructurally using a stereo microscope and an optical microscope. The results confirmed that the material was within specifications. To determine the macrofractographic features, a visual examination and an observation using a stereo microscope of the tube fracture surface were carried out. The results revealed a tube plastic macrodeformation, surface damaged and signs of a possible corrosion process. Fracture surface was also inspected by scanning electron microscopy (FE-SEM), equipped with an energy-dispersive X-ray microanalysis system (EDX), to determine the microfractographic features in order to find out the failure mechanism involved in the fracture. Fatigue striations, which are typical from a progressive fracture by a fatigue mechanism, were observed. The origin of the fracture was placed in defects located on the outer wall of the tube, leading to a final overload fracture.

Keywords: Aircraft Engine, microstructure, fatigue, FE-SEM, fractography, fracture, fuel tube, stainless steel.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 480

Authors: Jeongho Choi, Krishna Shankar, Alan Fien, Andrew Neely

Abstract:

Corrugated wire mesh laminates (CWML) are a class of engineered open cell structures that have potential for applications in many areas including aerospace and biomedical engineering. Two different methods of fabricating corrugated wire mesh laminates from stainless steel, one using a high temperature Lithobraze alloy and the other using a low temperature Eutectic solder for joining the corrugated wire meshes are described herein. Their implementation is demonstrated by manufacturing CWML samples of 304 and 316 stainless steel (SST). It is seen that due to the facility of employing wire meshes of different densities and wire diameters, it is possible to create CWML laminates with a wide range of effective densities. The fabricated laminates are tested under uniaxial compression. The variation of the compressive yield strength with relative density of the CWML is compared to the theory developed by Gibson and Ashby for open cell structures [22]. It is shown that the compressive strength of the corrugated wire mesh laminates can be described using the same equations by using an appropriate value for the linear coefficient in the Gibson-Ashby model.

Keywords: cellular solids, corrugation, foam, open-cell, metal mesh, laminate, stainless steel

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2138

Authors: Abhishek Soni, A. Kumaraswamy, M. S. Mahesh

Abstract:

Bullet penetration in steel plate is investigated with the help of three-dimensional, non-linear, transient, dynamic, finite elements analysis using explicit time integration code LSDYNA. The effect of large strain, strain-rate and temperature at very high velocity regime was studied from number of simulations of semi-spherical nose shape bullet penetration through single layered circular plate with 2 mm thickness at impact velocities of 500, 1000, and 1500 m/s with the help of Johnson Cook material model. Mie-Gruneisen equation of state is used in conjunction with Johnson Cook material model to determine pressure-volume relationship at various points of interests. Two material models viz. Plastic-Kinematic and Johnson- Cook resulted in different deformation patterns in steel plate. It is observed from the simulation results that the velocity drop and loss of kinetic energy occurred very quickly up to perforation of plate, after that the change in velocity and changes in kinetic energy are negligibly small. The physics behind this kind of behaviour is presented in the paper.

Keywords: AISI 4340 steel, ballistic impact simulation, bullet penetration, non-linear FEM.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1208

Authors: Robert Cep, Lenka Ocenasova, Jana Novakova, Karel Kouril, Jan Valicek, Branimir Barisic

Abstract:

This paper deals with the problem of thermal and mechanical shocks, which rising during operation, mostly at interrupted cut. Here will be solved their impact on the cutting edge tool life, the impact of coating technology on resistance to shocks and experimental determination of tool life in heating flame. Resistance of removable cutting edges against thermal and mechanical shock is an important indicator of quality as well as its abrasion resistance. Breach of the edge or its crumble may occur due to cyclic loading. We can observe it not only during the interrupted cutting (milling, turning areas abandoned hole or slot), but also in continuous cutting. This is due to the volatility of cutting force on cutting. Frequency of the volatility in this case depends on the type of rising chips (chip size element). For difficult-to-machine materials such as austenitic steel particularly happened at higher cutting speeds for the localization of plastic deformation in the shear plane and for the inception of separate elements substantially continuous chips. This leads to variations of cutting forces substantially greater than for other types of steel.

Keywords: Cutting Tool Life, Heating, Mechanical Shocks, Thermal Shocks

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1991

Authors: M. S. Reza, M. Hamdi, A.S. Hadi

Abstract:

The operating control parameters of injection flushing type of electrical discharge machining process on stainless steel 304 workpiece with copper tools are being optimized according to its individual machining characteristic i.e. material removal rate (MRR). Lower MRR during EDM machining process may decrease its- machining productivity. Hence, the quality characteristic for MRR is set to higher-the-better to achieve the optimum machining productivity. Taguchi method has been used for the construction, layout and analysis of the experiment for each of the machining characteristic for the MRR. The use of Taguchi method in the experiment saves a lot of time and cost of preparing and machining the experiment samples. Therefore, an L18 Orthogonal array which was the fundamental component in the statistical design of experiments has been used to plan the experiments and Analysis of Variance (ANOVA) is used to determine the optimum machining parameters for this machining characteristic. The control parameters selected for this optimization experiments are polarity, pulse on duration, discharge current, discharge voltage, machining depth, machining diameter and dielectric liquid pressure. The result had shown that the higher the discharge voltage, the higher will be the MRR.

Keywords: ANOVA, EDM, Injection Flushing, L18 OrthogonalArray, MRR, Stainless Steel 304

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1777

Authors: Abed Ahmed, Mehrdad Asadi, Jennifer Martay

Abstract:

Stainless steel pipelines are crucial components to transportation and storage in the oil and gas industry. However, the rise of random attacks and vandalism on these pipes for their valuable transport has led to more security and protection for incoming surface impacts. These surface impacts can lead to large global deformations of the pipe and place the pipe under strain, causing the eventual failure of the pipeline. Therefore, understanding how these surface impact loads affect the pipes is vital to improving the pipes’ security and protection. In this study, experimental test and finite element analysis (FEA) have been carried out on EN3B stainless steel specimens to study the impact behaviour. Low velocity impact tests at 9 m/s with 16 kg dome impactor was used to simulate for high momentum impact for localised failure. FEA models of clamped and deformable boundaries were modelled to study the effect of the boundaries on the pipes impact behaviour on its impact resistance, using experimental and FEA approach. Comparison of experimental and FE simulation shows good correlation to the deformable boundaries in order to validate the robustness of the FE model to be implemented in pipe models with complex anisotropic structure.

Keywords: Dynamic impact, deformable boundary conditions, finite element modeling, FEM, finite element, FE, LS-DYNA, Stainless steel pipe.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 633

Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma

Abstract:

Deep cold rolling (DCR) and low plasticity burnishing (LPB) process are cold working processes, which easily produce a smooth and work-hardened surface by plastic deformation of surface irregularities. The present study focuses on the surface roughness and surface hardness aspects of AISI 4140 work material, using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in order to identify the predominant factors amongst the selected parameters. They were then categorized in order of significance followed by setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. In the present work, the influence of main process parameters (force, feed rate, number of tool passes/overruns, initial roughness of the work piece, ball material, ball diameter and lubricant used) on the surface roughness and the hardness of AISI 4140 steel were studied for both LPB and DCR process and the results are compared. It was observed that by using LPB process surface hardness has been improved by 167% and in DCR process surface hardness has been improved by 442%. It was also found that the force, ball diameter, number of tool passes and initial roughness of the workpiece are the most pronounced parameters, which has a significant effect on the work piece-s surface during deep cold rolling and low plasticity burnishing process.

Keywords: Deep cold rolling, burnishing, surface roughness, surface hardness, design of experiments, AISI4140 steel.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3729

Authors: K. Kalaiselvan, A. Elango

Abstract:

Laser beam welding of dissimilar sheet metal combinations such as Ti/Al, SS/Al and Cu/Al are increasingly demanded due to high energy densities with less fusion and heat affected zones. A good weld joint strength involves combinations of dissimilar metals and the formation of solid solution in the weld pool. Many metal pairs suffer from significant intermetallic phase formation during welding which greatly reduces their strength. The three different sheet metal mentioned above is critically reviewed and phase diagram for the combinations are given. The aim of this study is to develop an efficient metal combinations and the influence on their interfacial characteristics. For that the following parameters such as weld geometry, residual distortion, micro hardness, microstructure and mechanical properties are analyzed systematically.

Keywords: Laser Beam Welding (LBW), dissimilar metals, Ti/Al, SS/Al and Cu/Al sheets.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2936

Authors: Rehan Waheed, Hasan Aftab Saeed, Wasim Tarar, Khalid Mahmood, Sajid Ullah Butt

Abstract:

Electromagnetic Interference (EMI) shielded doors made from brass extruded channels need to be welded with shielded enclosures to attain optimum shielding performance. Control of welding induced distortion is a problem in welding dissimilar metals like steel and brass. In this research, soldering of the steel-brass joint has been proposed to avoid weld distortion. The material used for brass channel is UNS C36000. The thickness of brass is defined by the manufacturing process, i.e. extrusion. The thickness of shielded enclosure material (ASTM A36) can be varied to produce joint between the dissimilar metals. Steel sections of different gauges are soldered using (91% tin, 9% zinc) solder to the brass, and strength of joint is measured by standard test procedures. It is observed that thin steel sheets produce a stronger bond with brass. The steel sections further require to be welded with shielded enclosure steel sheets through TIG welding process. Stresses and deformation in the vicinity of soldered portion is calculated through FE simulation. Crack formation in soldered area is also studied through experimental work. It has been found that in thin sheets deformation produced due to applied force is localized and has no effect on soldered joint area whereas in thick sheets profound cracks have been observed in soldered joint. The shielding effectiveness of EMI shielded door is compromised due to these cracks. The shielding effectiveness of the specimens is tested and results are compared.

Keywords: Dissimilar metals, soldering, joint strength, EMI shielding.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 664

Authors: A. Traidia, F. Roger, A. Chidley, J. Schroeder, T. Marlaud

Abstract:

A transient finite element model has been developed to study the heat transfer and fluid flow during spot Gas Tungsten Arc Welding (GTAW) on stainless steel. Temperature field, fluid velocity and electromagnetic fields are computed inside the cathode, arc-plasma and anode using a unified MHD formulation. The developed model is then used to study the influence of different helium-argon gas mixtures on both the energy transferred to the workpiece and the time evolution of the weld pool dimensions. It is found that the addition of helium to argon increases the heat flux density on the weld axis by a factor that can reach 6.5. This induces an increase in the weld pool depth by a factor of 3. It is also found that the addition of only 10% of argon to helium decreases considerably the weld pool depth, which is due to the electrical conductivity of the mixture that increases significantly when argon is added to helium.

Keywords: GTAW, Thermal plasmas, Fluid flow, Marangoni effect, Shielding Gases.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3068

Authors: H. Nouri, A. Tabbel, N. Douib, H. Aitsaid, Y. Zebboudj

Abstract:

This study and the field test comparisons were carried out on the Algerian Derguna – Setif transmission systems. The transmission line of normal voltage 225 kV is 65 km long, transported and uses twin bundle conductors protected with two shield wires of transposed galvanized steel. An iterative finite-element method is used to solve Poisons equation. Two algorithms are proposed for satisfying the current continuity condition and updating the space-charge density. A new approach to the problem of corona discharge in transmission system has been described in this paper. The effect of varying the configurations and wires number is also investigated. The analysis of this steady is important in the design of HVDC transmission lines. The potential and electric field have been calculating in locations singular points of the system.

Keywords: Corona discharge, Electric field, Finite element method, HVDC.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2215

Authors: Dhananjayulu Avula, Ratnesh Kumar Raj Singh, D.K.Dwivedi, N.K.Mehta

Abstract:

This study demonstrates the feasibility of joining the commercial pure copper plates by friction stir welding (FSW). Microstructure, microhardness and tensile properties in terms of the joint efficiency were found 94.03 % compare to as receive base material (BM). The average hardness at the top was higher than bottom. Hardness of weld zone was higher than the base material. Different microstructure zones were revealed by optical microscopy and scanning electron microscopy. The stirred zone (SZ) exhibited primary two phases namely, recrystallized grains and fine precipitates in matrix of copper.

Keywords: Welding; FSW, Commercial Copper, Mechanical properties

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4476

Authors: N. H. Othman, N. Udin, M. Ishak, L. H. Shah

Abstract:

This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.

Keywords: Friction stir welding, magnesium AZ31, cylindrical taper tool, taper pin ratio.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1566

Authors: Inom Sh. Normatov, Nurmakhmad Shermatov, Rajabali Barotov, Rano Eshankulova

Abstract:

The results of the studies for the hydrogen production by the application of water electrolysis and plasma-chemical processing of gas condensate-waste of natural gas production methods are presented. Thin coating covers the electrode surfaces in the process of water electrolysis. Therefore, water for electrolysis was first exposed to electrosedimentation. The threshold voltage is shifted to a lower value compared with the use of electrodes made of stainless steel. At electrolysis of electrosedimented water by use of electrodes from stainless steel, a significant amount of hydrogen is formed. Pyrolysis of gas condensates in the atmosphere of a nitrogen was followed by the formation of acetylene (3-7 vol.%), ethylene (4-8 vol.%), and pyrolysis carbon (10-15 wt.%).

Keywords: Electrolyze, gas condensate, hydrogen, pyrolysis.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 983

Authors: Natural Frequency Analysis of a Porous Functionally Graded Shaft System

Abstract:

The vibration characteristics of a functionally graded (FG) rotor model having porosities and micro-voids is investigated using three-dimensional finite element analysis. The FG shaft is mounted with a steel disc located at the midspan. The shaft ends are supported on isotropic bearings. The FG material is composed of a metallic (stainless-steel) and ceramic phase (zirconium oxide) as its constituent phases. The layer wise material property variation is governed by power law. Material property equations are developed for the porosity modelling. Python code is developed to assign the material properties to each layer including the effect of porosities. ANSYS commercial software is used to extract the natural frequencies and whirl frequencies for the FG shaft system. The obtained results show the influence of porosity volume fraction and power-law index, on the vibration characteristics of the ceramic-based FG shaft system.

Keywords: Finite element method, functionally graded material, porosity volume fraction, power law.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 733

Authors: Naveen Beri, S. Maheshwari, C. Sharma, Anil Kumar

Abstract:

In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.

Keywords: Electrical discharge machining (EDM), Powder Metallurgy (PM), Taguchi method, Material Removal Rate (MRR), Surface Roughness (SR).

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4249

Authors: Chiang-Ho Cheng, An-Shik Yang, Hong-Yih Cheng, Ming-Yu Lai

Abstract:

This paper presents the design and fabrication of a novel piezoelectric actuator for a gas micro pump with check valve having the advantages of miniature size, light weight and low power consumption. The micro pump is designed to have eight major components, namely a stainless steel upper cover layer, a piezoelectric actuator, a stainless steel diaphragm, a PDMS chamber layer, two stainless steel channel layers with two valve seats, a PDMS check valve layer with two cantilever-type check valves and an acrylic substrate. A prototype of the gas micro pump, with a size of 52 mm × 50 mm × 5.0 mm, is fabricated by precise manufacturing. This device is designed to pump gases with the capability of performing the self-priming and bubble-tolerant work mode by maximizing the stroke volume of the membrane as well as the compression ratio via minimization of the dead volume of the micro pump chamber and channel. By experiment apparatus setup, we can get the real-time values of the flow rate of micro pump and the displacement of the piezoelectric actuator, simultaneously. The gas micro pump obtained higher output performance under the sinusoidal waveform of 250 Vpp. The micro pump achieved the maximum pumping rates of 1185 ml/min and back pressure of 7.14 kPa at the corresponding frequency of 120 and 50 Hz.

Keywords: PDMS, Check valve, Micro pump, Piezoelectric.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1977

Authors: M. S. Reza, M. Hamdi, S. H. Tomadi, A. R. Ismail

Abstract:

The operating control parameters of injection flushing type of electrical discharge machining process on stainless steel 304 workpiece using copper tools are being optimized according to its individual machining characteristic i.e. Electrode Wear Ratio (EWR). Higher EWR would give bad dimensional precision for the EDM machined workpiece because of high electrode wear. Hence, the quality characteristic for EWR is set to lower-the-better to achieve the optimum dimensional precision for the machined workpiece. Taguchi method has been used for the construction, layout and analysis of the experiment for EWR machining characteristic. The use of Taguchi method in the experiment saves a lot of time and cost of preparing and machining the experiment samples. Therefore, an L18 Orthogonal array which was the fundamental component in the statistical design of experiments has been used to plan the experiments and Analysis of Variance (ANOVA) is used to determine the optimum machining parameters for this machining characteristic. The control parameters selected for this optimization experiments are polarity, pulse on duration, discharge current, discharge voltage, machining depth, machining diameter and dielectric liquid pressure. The result had shown that negative polarity machining parameter setting will decreases EWR.

Keywords: ANOVA, EDM, Injection Flushing, L18Orthogonal Array, EWR, Stainless Steel 304

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1810