Search results for: Rotary friction weld

Authors: Young Mun Lee, Seon Ho Kim, Seok Min Choi, JeongJu Kim, Seungyeong Choi, Hyung Hee Cho

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To decrease sulfur oxide in the flue gas from coal power plant, a flue gas de-sulfurization facility is operated. In the reactor, a chemical reaction occurs with a temperature change of the gas so that sulfur oxide is removed and cleaned air is emitted. In this process, temperature change induces a serious problem which is a cold erosion of stack. To solve this problem, the rotary heat exchanger is managed before the stack. In the heat exchanger, a heating element is equipped to increase a heat transfer area. Heat transfer and pressure loss is a big issue to improve a performance. In this research, thermal-fluid characteristics of the heating element are analyzed by computational fluid dynamics. Fouling simulation is also conducted to calculate a performance of heating element. Numerical analysis is performed on the situation where plugging phenomenon has already occurred and existed in the inlet region of the heating element. As the pressure of the rear part of the plugging decreases suddenly and the flow velocity becomes slower, it is found that the flow is gathered from both sides as it develops in the flow direction, and it is confirmed that the pressure difference due to plugging is increased.

Keywords: Heating element, plugging, rotary heat exchanger, thermal fluid characteristics.

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Authors: Rafał Urbaniak, Robert Kłosowiak, Michał Ciałkowski, Jarosław Bartoszewicz

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The Chair of Thermal Engineering at Poznan University of Technology has been conducted research works on the possibilities of using carbon nanostructures in energy and mechanics applications for a couple of years. Those studies have provided results in a form of co-operation with foreign research centres, numerous publications and patent applications. Authors of this paper have studied the influence of multi-walled carbon nanostructures on changes in static friction arising when steel surfaces were moved. Tests were made using the original test stand consisting of automatically controlled inclined plane driven by precise stepper motors. Computer program created in the LabView environment was responsible for monitoring of the stand operation, accuracy of measurements and archiving the obtained results. Such a solution enabled to obtain high accuracy and repeatability of all conducted experiments. Tests and analysis of the obtained results allowed us to determine how additional layers of carbon nanostructures influenced on changes of static friction coefficients. At the same time, we analyzed the potential possibilities of applying nanostructures under consideration in mechanics.

Keywords: Carbon nanotubes, static friction, dynamic friction.

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Authors: S. D. El Wakil

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The research work reported here was aimed at investigating the feasibility of joining high-porosity stainless steel discs and wrought iron bars by friction welding. The sound friction-welded joints were then subjected to a metallurgical investigation and an analysis of failure resulting from tensile loading. Discs having 50 mm diameter and 10 mm thickness were produced by loose sintering of stainless steel powder at a temperature of 1350 ^oC in an argon atmosphere for one hour. Minor machining was then carried out to control the dimensions of the discs, and the density of each disc could then be determined. The level of porosity was calculated and was found to be about 40% in all of those discs. Solid wrought iron bars were also machined to facilitate tensile testing of the joints produced by friction welding. Using our previously gained experience, the porous stainless steel disc and the wrought iron tube were successfully friction welded. SEM was employed to examine the fracture surface after a tensile test of the joint in order to determine the type of failure. It revealed that the failure did not occur in the joint, but rather in the in the porous metal in the area adjacent to the joint. The load carrying capacity was actually determined by the strength of the porous metal and not by that of the welded joint. Macroscopic and microscopic metallographic examinations were also performed and showed that the welded joint involved a dense heat-affected zone where the porous metal underwent densification at elevated temperature, explaining and supporting the findings of the SEM study.

Keywords: Fracture of friction-welded joints, metallurgy of friction welding, solid-porous structures, strength of joint.

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Authors: Musthafah b. Mohd.Tahir, Noboru Yamada, Tetsuya Hoshino

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This paper describes the experimental efficiency of a compact organic Rankine cycle (ORC) system with a compact rotary-vane-type expander. The compact ORC system can be used for power generation from low-temperature heat sources such as waste heat from various small-scale heat engines, fuel cells, electric devices, and solar thermal energy. The purpose of this study is to develop an ORC system with a low power output of less than 1 kW with a hot temperature source ranging from 60°C to 100°C and a cold temperature source ranging from 10°C to 30°C. The power output of the system is rather less due to limited heat efficiency. Therefore, the system should have an economically optimal efficiency. In order to realize such a system, an efficient and low-cost expander is indispensable. An experimental ORC system was developed using the rotary-vane-type expander which is one of possible candidates of the expander. The experimental results revealed the expander performance for various rotation speeds, expander efficiencies, and thermal efficiencies. Approximately 30 W of expander power output with 48% expander efficiency and 4% thermal efficiency with a temperature difference between the hot and cold sources of 80°C was achieved.

Keywords: Organic Rankine cycle, Thermodynamic cycle, Thermal efficiency, Turbine efficiency, Waste heat recovery, Powergeneration, Low temperature heat engine.

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Authors: Azad A. Mohammed, Gulan B. Hassan

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Analytical procedure was carried out in this paper to calculate the ultimate load capacity of reinforced concrete corbels strengthened or repaired externally with CFRP sheets. Strut and tie method and shear friction method proposed earlier for analyzing reinforced concrete corbels were modified to incorporate the effect of external CFRP sheets bonded to the corbel. The points of weakness of any method that lead to an inaccuracy, especially when overestimating test results were checked and discussed. Comparison of prediction with the test data indicates that the ratio of test / calculated ultimate load is 0.82 and 1.17 using strut and tie method and shear friction method, respectively. If the limits of maximum shear stress is followed, the calculated ultimate load capacity using shear friction method was found to underestimates test data considerably.

Keywords: Corbel, Strengthening, Strut and Tie Model, Shear Friction

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Authors: T. Saeid, A. Abdollah-zadeh, T. Shibayanagi, K. Ikeuchi, H. Assadi

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Electron back-scattered diffraction was used to follow the evolution of microstructure from the base metal to the stir zone (SZ) in a duplex stainless steel subjected to friction stir welding. In the stir zone (SZ), a continuous dynamic recrystallization (CDRX) was evidenced for ferrite, while it was suggested that a static recrystallization together with CDRX may occur for austenite. It was found that ferrite and austenite grains in the SZ take a typical shear texture of bcc and fcc materials respectively.

Keywords: Friction stir welding, Dynamic recrystallization, Electron backscattering diffraction (EBSD), Duplex stainless steel

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Authors: Wei Zha, Jingzeng Zhang, Chen Zhao, Ran Cai, Xueyuan Nie

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Cathodic plasma electrolysis (CPE) is used to create surface textures on cast iron samples for improving the tribological properties. Micro craters with confined size distribution were successfully formed by CPE process. These craters can generate extra hydrodynamic pressure that separates two sliding surfaces, increase the oil film thickness and accelerate the transition from boundary to mixed lubrication. It was found that the optimal crater size was 1.7 μm, at which the maximum lubrication efficiency was achieved. The Taguchi method was used to optimize the process parameters (voltage and roughness) for CPE surface texturing. The orthogonal array and the signal-to-noise ratio were employed to study the effect of each process parameter on the coefficient of friction. The results showed that with higher voltage and lower roughness, the lower friction coefficient can be obtained, and thus the lubrication can be more efficiently used for friction reduction.

Keywords: Cathodic plasma electrolysis, friction, lubrication, plasma surface texturing.

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Authors: C. S. Tsai, Yung-Chang Lin

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In order to upgrade the seismic resistibility of structures and enhance the functionality of an isolator, a new base isolator called the multiple trench friction pendulum system (MTFPS) is proposed in this study. The proposed MTFPS isolator is composed of a trench concave surface and several intermediate sliding plates in two orthogonal directions. Mathematical formulations have been derived to examine the characteristics of the proposed MTFPS isolator possessing multiple intermediate sliding plates. By means of mathematical formulations, it can be inferred that the natural period and damping effect of the MTFPS isolator with several intermediate sliding plates can be altered continually and controllably during earthquakes. Furthermore, results obtained from shaking table tests demonstrate that the proposed isolator provides good protection to structures for prevention of damage from strong earthquakes.

Keywords: Friction Pendulum System, Multiple Friction Pendulum System, Base Isolation, Earthquake Engineering

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Authors: Chang He, Hiroshi Tamura, Hiroshi Katsuchi, Jiaqi Wang

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In this study, the aim is to infer the slip limit (static friction limit) of contact interfaces in bolt friction joints by analyzing other bolt friction joints with the same contact surface but in a different shape. By using the Weibull distribution to deal with microelements on the contact surface statistically, the slip limit of a certain type of bolt joint was predicted from other types of bolt joint with the same contact surface. As a result, this research succeeded in predicting the slip limit of bolt joins with different numbers of contact surfaces and with different numbers of bolt rows.

Keywords: Bolt joints, slip coefficient, finite element method, Weibull distribution.

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Authors: S. Djebali, S. Larbi, A. Bilek

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The present work aims at contributing to the study of the complex phenomenon of wear of pin on disc contact in dry sliding friction between two material couples (bronze/steel and unsaturated polyester virgin and charged with graphite powder/steel). The work consists of the determination of the coefficient of friction, the study of the influence of the tribological parameters on this coefficient and the determination of the mass loss and the wear rate of the pin. This study is also widened to the highlighting of the influence of the addition of graphite powder on the tribological properties of the polymer constituting the pin. The experiments are carried out on a pin-disc type tribometer that we have designed and manufactured. Tests are conducted according to the standards DIN 50321 and DIN EN 50324. The discs are made of annealed XC48 steel and quenched and tempered XC48 steel. The main results are described here after. The increase of the normal load and the sliding speed causes the increase of the friction coefficient, whereas the increase of the percentage of graphite and the hardness of the disc surface contributes to its reduction. The mass loss also increases with the normal load. The influence of the normal load on the friction coefficient is more significant than that of the sliding speed. The effect of the sliding speed decreases for large speed values. The increase of the amount of graphite powder leads to a decrease of the coefficient of friction, the mass loss and the wear rate. The addition of graphite to the UP resin is beneficial; it plays the role of solid lubricant.

Keywords: Friction coefficients, mass loss, wear rate, bronze, polyester, graphite.

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Authors: Muhammad Murtaza Nasir, Safdar Abbas Zaidi, Kamran Khan

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This work is carried out to evaluate the possibility of using to-be-wasted steel as reinforcement after welding together pieces of reinforcing steel bars, left over during construction activities. Tests were performed on a total of nine samples. These were made by welding pieces of reinforcing steel bars purchased from the local scrap steel market. The samples were tested in uniaxial tension using a universal testing machine (UTM). It was found that the failure of the welded bars is governed by the thickness of the weld. It is concluded that suitable design of the weld is essential for achieving the desired level of ductility/elongation of these bars, if they are to be used as conventional reinforcement in reinforced concrete members.

Keywords: Ductility/elongation, low cost housing, reinforced concrete, welding, welded reinforcement, wastage steel.

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Authors: A.Roshandel, N.Hedayat, H.kiamanesh

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Today, numerical simulation is a powerful tool to solve various hydraulic engineering problems. The aim of this research is numerical solutions of shallow water equations using finite volume method for Simulations of dam break over wet and dry bed. In order to solve Riemann problem, Roe-s approximate solver is used. To evaluate numerical model, simulation was done in 1D and 2D states. In 1D state, two dam break test over dry bed (with and without friction) were studied. The results showed that Structural failure around the dam and damage to the downstream constructions in bed without friction is more than friction bed. In 2D state, two tests for wet and dry beds were done. Generally in wet bed case, waves are propagated to canal sides but in dry bed it is not significant. Therefore, damage to the storage facilities and agricultural lands in wet bed case is more than in dry bed.

Keywords: dam break, dry bed, finite volume method, shallow water equations.

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Authors: Yashvir Singh

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Around the globe, there is demand for the development of bio-based lubricant which will be biodegradable, non -toxic and environmental friendly. This paper outlines the friction and wear characteristics of Pongamia oil (PO) contaminated bio-lubricant by using pin-on-disc tribometer. To formulate the bio-lubricants, PO was blended in the ratios 15, 30 and 50% by volume with the base lubricant SAE 20 W 40. Tribological characteristics of these blends were carried out at 3.8 m/s sliding velocity and loads applied were 50, 100, 150 N. Experimental results showed that the lubrication regime that occurred during the test was boundary lubrication while the main wear mechanisms were abrasive and the adhesive wear. During testing, the lowest wear was found with the addition of 15% PO, and above this contamination, the wear rate was increased considerably. With increase in load, viscosity of all the bio-lubricants increases and meets the ISO VG 100 requirement at 40 ^oC except PB 50. The addition of PO in the base lubricant acted as a very good lubricant additive which reduced the friction and wear scar diameter during the test. It has been concluded that the PB 15 can act as an alternative lubricant to increase the mechanical efficiency at 3.8 m/s sliding velocity and contribute in reduction of dependence on the petroleum based products.

Keywords: Pongamia oil, sliding velocity, load, friction, wear.

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

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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.

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Authors: Mohamed Ali

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The boundary layer flow and heat transfer on a stretched surface moving with prescribed skin friction is studied for permeable surface. The surface temperature is assumed to vary inversely with the vertical direction x for n = -1. The skin friction at the surface scales as (x-1/2) at m = 0. The constants m and n are the indices of the power law velocity and temperature exponent respectively. Similarity solutions are obtained for the boundary layer equations subject to power law temperature and velocity variation. The effect of various governing parameters, such as the buoyancy parameter λ and the suction/injection parameter fw for air (Pr = 0.72) are studied. The choice of n and m ensures that the used similarity solutions are x independent. The results show that, assisting flow (λ > 0) enhancing the heat transfer coefficient along the surface for any constant value of fw. Furthermore, injection increases the heat transfer coefficient but suction reduces it at constant λ.

Keywords: Stretching surface, Boundary layers, Prescribed skin friction, Suction or injection, similarity solutions, buoyancy effects.

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Authors: T. Teruzzi, S. Antonietti, C. Mosca, C. Paglia

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This paper discusses the causes of the structural failure in a tower crane. The structural collapse occurred at the upper joints of the extension element used to increase the height of the crane. The extension element consists of a steel lattice structure made with angular profiles and plates joined to the tower element by arc welding. Macroscopic inspection of the sections showed that the break was always observed on the angular profiles at the weld bead edge. The case study shows how, using mechanical characterization, chemical analysis of the steel and macroscopic and microscopic metallographic examinations, it was possible to obtain significant evidence that identified the mechanism causing the breakage. The analyses identified the causes of the structural failure as the use of materials that were not suitable for welding and poor performance in the welding joints.

Keywords: Failure, weld, microstructure, microcracks.

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Authors: K. Krishnaprasad, Raghu V. Prakash

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Constant amplitude fatigue crack growth (FCG) tests were performed on dissimilar metal welded plates of Type 316L Stainless Steel (SS) and IS 2062 Grade A Carbon steel (CS). The plates were welded by TIG welding using SS E309 as electrode. FCG tests were carried on the Side Edge Notch Tension (SENT) specimens of 5 mm thickness, with crack initiator (notch) at base metal region (BM), weld metal region (WM) and heat affected zones (HAZ). The tests were performed at a test frequency of 10 Hz and at load ratios (R) of 0.1 & 0.6. FCG rate was found to increase with stress ratio for weld metals and base metals, where as in case of HAZ, FCG rates were almost equal at high ΔK. FCG rate of HAZ of stainless steel was found to be lowest at low and high ΔK. At intermediate ΔK, WM showed the lowest FCG rate. CS showed higher crack growth rate at all ΔK. However, the scatter band of data was found to be narrow. Fracture toughness (Kc) was found to vary in different locations of weldments. Kc was found lowest for the weldment and highest for HAZ of stainless steel. A novel method of characterizing the FCG behavior using an Infrared thermography (IRT) camera was attempted. By monitoring the temperature rise at the fast moving crack tip region, the amount of plastic deformation was estimated.

Keywords: Dissimilar metal weld, Fatigue Crack Growth, fracture toughness, Infrared thermography.

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Authors: H. Fazlinejad, A. Halvaee

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In this study, characteristics of ATIG welds using ZnO flux on aluminum was investigated and compared with TIG welds. Autogenously AC-ATIG bead on plate welding was applied on Al1050 plate with a coating of ZnO as the flux. Different levels of welding current and flux layer thickness was considered to study the effect of heat input and flux quantity on ATIG welds and was compared with those of TIG welds. Geometrical investigation of the weld cross sections revealed that penetration depth of the ATIG welds with ZnO flux, was increased up to 2 times in some samples compared to the TIG welds. Optical metallographic and Scanning Electron Microscopy (SEM) observations revealed similar microstructures in TIG and ATIG welds. Composition of the ATIG welds slag was also analyzed using X-ray diffraction. In both TIG and ATIG samples, the lowest values of microhardness were observed in the HAZ.

Keywords: ATIG, active flux, weld penetration, Al 1050, ZnO.

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Authors: Giovanni Incerti

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The motion planning technique described in this paper has been developed to eliminate or reduce the residual vibrations of belt-driven rotary platforms, while maintaining unchanged the motion time and the total angular displacement of the platform. The proposed approach is based on a suitable choice of the motion command given to the servomotor that drives the mechanical device; this command is defined by some numerical coefficients which determine the shape of the displacement, velocity and acceleration profiles. Using a numerical optimization technique, these coefficients can be changed without altering the continuity conditions imposed on the displacement and its time derivatives at the initial and final time instants. The proposed technique can be easily and quickly implemented on an actual device, since it requires only a simple modification of the motion command profile mapped in the memory of the electronic motion controller.

Keywords: Command shaping, residual vibrations, belt transmission, servomechanism.

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Authors: G.Ashwini, A.T.Eswara

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This paper examines the forced convection flow of incompressible, electrically conducting viscous fluid past a sharp wedge in the presence of heat generation or absorption with an applied magnetic field. The system of partial differential equations governing Falkner - Skan wedge flow and heat transfer is first transformed into a system of ordinary differential equations using similarity transformations which is later solved using an implicit finite - difference scheme, along with quasilinearization technique. Numerical computations are performed for air (Pr = 0.7) and displayed graphically to illustrate the influence of pertinent physical parameters on local skin friction and heat transfer coefficients and, also on, velocity and temperature fields. It is observed that the magnetic field increases both the coefficients of skin friction and heat transfer. The effect of heat generation or absorption is found to be very significant on heat transfer, but its effect on the skin friction is negligible. Indeed, the occurrence of overshoot is noticed in the temperature profiles during heat generation process, causing the reversal in the direction of heat transfer.

Keywords: Heat generation / absorption, MHD Falkner- Skan flow, skin friction and heat transfer

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Authors: Kamand Bagherian, Nariman Niknejad

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A vibration isolation technology for precise position control of a rotary system powered by two permanent magnet DC (PMDC) motors is proposed, where this system is mounted on an oscillatory frame. To achieve vibration isolation for this system, active damping and disturbance rejection (ADDR) technology is presented which introduces a cooperation of a main and an auxiliary PMDC, controlled by discrete-time sliding mode control (DTSMC) based schemes. The controller of the main actuator tracks a desired position and the auxiliary actuator simultaneously isolates the induced vibration, as its controller follows a torque trend. To determine this torque trend, a combination of two algorithms is introduced by the ADDR technology. The first torque-trend producing algorithm rejects the disturbance by counteracting the perturbation, estimated using a model-based observer. The second torque trend applies active variable damping to minimize the oscillation of the output shaft. In this practice, the presented technology is implemented on a rotary system with a pendulum attached, mounted on a linear actuator simulating an oscillation-transmitting structure. In addition, the obtained results illustrate the functionality of the proposed technology.

Keywords: Vibration isolation, position control, discrete-time nonlinear controller, active damping, disturbance tracking algorithm, oscillation transmitting support, stability robustness.

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Authors: Khalid Alammar

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Aim of this study is to evaluate a new three-equation turbulence model applied to flow and heat transfer through a pipe. Uncertainty is approximated by comparing with published direct numerical simulation results for fully-developed flow. Error in the mean axial velocity, temperature, friction, and heat transfer is found to be negligible.

Keywords: Heat Transfer, Nusselt number, Skin friction, Turbulence.

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Authors: Hassan M. Alkomy, Hesham A. Elkaranshawy, Ahmed S. Ashour, Khaled T. Mohamed

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For a rigid body sliding on a rough surface, a range of uncertainty or non-uniqueness of solution could be found, which is termed: Painlevé paradox. Painlevé paradox is the reason of a wide range of bouncing motion, observed during sliding of robotic manipulators on rough surfaces. In this research work, the existence of the paradox zone during the sliding motion of a two-link (P-R) robotic manipulator with a unilateral constraint is investigated. Parametric study is performed to investigate the effect of friction, link-length ratio, total height and link-mass ratio on the paradox zone.

Keywords: Dynamical system, friction, multibody system, Painlevé paradox, robotic systems, sliding robots, unilateral constraint.

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Authors: Hesham A. Elkaranshawy, Amr M. Abdelrazek, Hosam M. Ezzat

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The system of ordinary nonlinear differential equations describing sliding velocity during impact with friction for a three-dimensional rigid-multibody system is developed. No analytical solutions have been obtained before for this highly nonlinear system. Hence, a power series solution is proposed. Since the validity of this solution is limited to its convergence zone, a suitable time step is chosen and at the end of it a new series solution is constructed. For a case study, the trajectory of the sliding velocity using the proposed method is built using 6 time steps, which coincides with a Runge- Kutta solution using 38 time steps.

Keywords: Impact with friction, nonlinear ordinary differential equations, power series solutions, rough collision.

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Authors: Yilmaz Bayhan, Emin Güzel, Ömer Barış Özlüoymak, Ahmet İnce, Abdullah Sessiz

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In this study, determining of reduced tillage techniques in green bean farming as a second crop after harvesting wheat was targeted. To this aim, four different soil tillage methods namely, heavy-duty disc harrow (HD), rotary tiller (ROT), heavy-duty disc harrow plus rotary tiller (HD+ROT) and no-tillage (NT) (seeding by direct drill) were examined. Experiments were arranged in a randomized block design with three replications. The highest green beans yields were obtained in HD+ROT and NT as 5,862.1 and 5,829.3 Mg/ha, respectively. The lowest green bean yield was found in HD as 3,076.7 Mg/ha. The highest fuel consumption was measured 30.60 L ha^-1 for HD+ROT whereas the lowest value was found 7.50 L ha^-1 for NT. No tillage method gave the best results for fuel consumption and effective power requirement. It is concluded that no-tillage method can be used in second crop green bean in the Thrace Region due to economic and erosion conditions.

Keywords: Soil tillage, green bean, vegetative, generative, yield.

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Authors: Yu Chen, Weiwei Ren, Xiaojing Mu, Feng Zhang, Yi Xu

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The superhydrophobic surface is widely used to reduce friction for the flow inside micro-channel and can be used to control/manipulate fluid, cells and even proteins in lab-on-chip. Fabricating micro grooves on hydrophobic surfaces is a common method to obtain such superhydrophobic surface. This study utilized the numerical method to investigate the effect of eccentric micro-grooves on the friction of flow inside micro-channel. A detailed parametric study was conducted to reveal how the eccentricity of micro-grooves affects the micro-channel flow under different grooves sizes, channel heights, Reynolds number. The results showed that the superhydrophobic surface with eccentric micro-grooves induces less friction than the counter part with aligning micro-grooves, which means requiring less power for pumps.

Keywords: Superhydrophobic, transverse grooves, heat transfer, slip length, microfluidics.

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Authors: G. Karakaya, C. Türker, M. Anaklı

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It is necessary to test to see if optical devices such as camera, night vision devices are working properly. Therefore, a precision biaxial rotary system (gimbal) is required for mounting Unit Under Test, UUT. The Gimbal systems can be utilized for precise positioning of the UUT; hence, optical test can be performed with high accuracy. The weight of UUT, which is placed outside the axis of rotation, causes an off-axis moment to the mounting armature. The off-axis moment can act against the direction of movement for some orientation, thus the electrical motor, which rotates the gimbal axis, has to apply higher level of torque to guide and stabilize the system. Moreover, UUT and its mounting fixture to the gimbal can be changed, which causes change in applied resistance moment to the gimbals electrical motor. In this study, a preloaded spring is added to the gimbal system for minimizing applied off axis moment with the help of four bar mechanism. Two different possible methods for preloading spring are introduced and system optimization is performed to eliminate all moment which is created by off axis weight.

Keywords: Balancing, gimbal, tension, preload, spring.

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Authors: Dongho Kim, Sung Choi, Kyowoong Pee, Youngsik Cho, Seungwoo Jeong, Soo-Ho Kim

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This study is about the orbital TIG welding robot system which travels on the guide rail installed on the pipe, and welds and tracks the pipe seam using the LVS (Laser Vision Sensor) joint profile data. The orbital welding robot system consists of the robot, welder, controller, and LVS. Moreover we can define the relationship between welding travel speed and wire feed speed, and we can make the linear equation using the maximum and minimum amount of weld metal. Using the linear equation we can determine the welding travel speed and the wire feed speed accurately corresponding to the area of weld captured by LVS. We applied this orbital TIG welding robot system to the stainless steel or duplex pipe on DSME (Daewoo Shipbuilding and Marine Engineering Co. Ltd.,) shipyard and the result of radiographic test is almost perfect. (Defect rate: 0.033%).

Keywords: Adaptive welding, automatic welding, Pipe welding, Orbital welding, Laser vision sensor, LVS, welding D/B.

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Authors: A. Lauvray, F. Poulhaon, P. Michaud, P. Joyot, E. Duc

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Additive Friction Stir Manufacturing, or AFSM, is a new industrial process that follows the emergence of friction-based processes. The AFSM process is a solid-state additive process using the energy produced by the friction at the interface between a rotating non-consumable tool and a substrate. Friction depends on various parameters like axial force, rotation speed or friction coefficient. The feeder material is a metallic rod that flows through a hole in the tool. There is still a lack in understanding of the physical phenomena taking place during the process. This research aims at a better AFSM process understanding and implementation, thanks to numerical simulation and experimental validation performed on a prototype effector. Such an approach is considered a promising way for studying the influence of the process parameters and to finally identify a process window that seems relevant. The deposition of material through the AFSM process takes place in several phases. In chronological order these phases are the docking phase, the dwell time phase, the deposition phase, and the removal phase. The present work focuses on the dwell time phase that enables the temperature rise of the system due to pure friction. An analytic modeling of heat generation based on friction considers as main parameters the rotational speed and the contact pressure. Another parameter considered influential is the friction coefficient assumed to be variable, due to the self-lubrication of the system with the rise in temperature or the materials in contact roughness smoothing over time. This study proposes through a numerical modeling followed by an experimental validation to question the influence of the various input parameters on the dwell time phase. Rotation speed, temperature, spindle torque and axial force are the main monitored parameters during experimentations and serve as reference data for the calibration of the numerical model. This research shows that the geometry of the tool as well as fluctuations of the input parameters like axial force and rotational speed are very influential on the temperature reached and/or the time required to reach the targeted temperature. The main outcome is the prediction of a process window which is a key result for a more efficient process implementation.

Keywords: numerical model, additive manufacturing, frictional heat generation, process

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Authors: Saad Alkhaldi, Fadi Ghammas, Tariq Alghamdi, Stefano Alexandirs

Abstract:

The operating conditions and corrosive nature of the process fluid in the Haradh and Hawiyah areas are subjecting facility piping to undesirable corrosion phenomena. Therefore, production headers inside remote headers have been internally cladded with high alloy material to mitigate the corrosion damage mechanism. Corrosion mitigation in the jump-over lines, constructed between the existing flowlines and the newly constructed facilities to provide operational flexibility, is proposed. This corrosion mitigation system includes the application of fusion bond epoxy (FBE) coating on the internal surface of the pipe and depositing corrosion-resistant alloy (CRA) weld layers at pipe and fittings ends to protect the carbon steel material. In addition, high alloy CRA weld material is used to deposit the girth weld between the 90-degree elbows and mating internally coated segments. A rigorous testing and qualification protocol was established prior to actual adoption at the Haradh and Hawiyah Field Gas Compression Program, currently being executed by Saudi Aramco. The proposed mitigation system, aimed at applying the cladding at the ends of the internally FBE coated pipes/elbows, will resolve field joint coating challenges, eliminate the use of approximately 1700 breakout flanges, and prevent the potential hydrocarbon leaks.

Keywords: Corrosion, FBE coated sour service, cost savings.

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