Abstract: In recent years asymmetric cross section aluminum
alloy stock has been finding increasing use in various industrial manufacturing areas such as general structures and automotive
components. In these areas, components are generally required to have
complex curved configuration and, as such, a bending process is required during manufacture. Undesirable deformation in bending
processes such as flattening or wrinkling can easily occur when thin-walled sections are bent. Hence, a thorough understanding of the
bending behavior of such sections is needed to prevent these undesirable deformations. In this study, the bending behavior of
asymmetric channel section was examined using finite element analysis (FEA). Typical methods of preventing undesirable
deformation, such as asymmetric laminated elastic mandrels were included in FEA model of draw bending. Additionally, axial tension
was applied to prevent wrinkling. By utilizing the FE simulations effect of restriction dies and axial tension on undesirable deformation during the process was clarified.
Abstract: A series of Ti based shape memory alloys with
composition of Ti50Ni49Cr1, Ti50Ni47Cr3 and Ti50Ni45Cr5 were
developed by vacuum arc-melting under a purified argon atmosphere.
The histometric and corrosion evaluation of Ti-Ni-Cr shape memory
alloys have been considered in this research work. The alloys were
developed by vacuum arc melting and implanted subcutaneously in
rabbits for 4, 8 and 12 weeks. Metallic implants were embedded in
order to determine the outcome of implantation on histometric and
corrosion evaluation of Ti-Ni-Cr metallic strips. Encapsulating
membrane formation around the alloys was minimal in the case of all
materials. After histomorphometric analyses it was possible to
demonstrate that there were no statistically significant differences
between the materials. Corrosion rate was also determined in this
study which is within acceptable range. The results showed the Ti-
Ni-Cr alloy was neither cytotoxic, nor have any systemic reaction on
living system in any of the test performed. Implantation shows good
compatibility and a potential of being used directly in vivo system.
Abstract: Martensitic stainless steels have been extensively used for their good corrosion resistance and better mechanical properties. Heat treatment was suggested as one of the most excellent ways to this regard; hence, it affects the microstructure, mechanical and corrosion properties of the steel. In the current research work the microstructural changes and corrosion behavior in an AISI 420A stainless steel exposed to temperatures in the 980-1035oC range were investigated. The heat treatment is carried out in vacuum furnace within the said temperature range. The quenching of the samples was carried out in oil, brine and water media. The formation and stability of passive film was studied by Open Circuit Potential, Potentiodynamic polarization and Electrochemical Scratch Tests. The Electrochemical Impedance Spectroscopy results simulated with Equivalent Electrical Circuit suggested bilayer structure of outer porous and inner barrier oxide films. The quantitative data showed thick inner barrier oxide film retarded electrochemical reactions. Micrographs of the quenched samples showed sigma and chromium carbide phases which prove the corrosion resistance of steel alloy.
Abstract: Scatter behavior of fatigue life in die-cast AM60B
alloy was investigated. For comparison, those in rolled AM60B alloy
and die-cast A365-T5 aluminum alloy were also studied. Scatter
behavior of pore size was also investigated to discuss dominant
factors for fatigue life scatter in die-cast materials. Three-parameter
Weibull function was suitable to explain the scatter behavior of both
fatigue life and pore size. The scatter of fatigue life in die-cast
AM60B alloy was almost comparable to that in die-cast A365-T5
alloy, while it was significantly large compared to that in the rolled
AM60B alloy. Scatter behavior of pore size observed at fracture
nucleation site on the fracture surface was comparable to that
observed on the specimen cross-section and also to that of fatigue
life. Therefore, the dominant factor for large scatter of fatigue life in
die-cast alloys would be the large scatter of pore size. This
speculation was confirmed by the fracture mechanics fatigue life
prediction, where the pore observed at fatigue crack nucleation site
was assumed as the pre-existing crack.
Abstract: This study reports an empirical investigation of
fatigue crack initiation and propagation in 2024 T351 aluminium
alloy using constant amplitude loading. In initiation stage, local
strain approach at the notch was used and in stable propagation stage
NASGRO model was applied.
In this investigation, the flat plate of double through crack at hole
is used. Based on experimental results (AFGROW Database), effect
of stress ratio, R, is highlights on fatigue initiation life (FIL) and
fatigue crack growth rate (FCGR). The increasing of dimension of
hole characterizing the notch effect decrease the fatigue life.
Abstract: The knowledge of the nature of loading is very
important in order to hold account on the total behavior such as
vibration, shock, fatigue, etc. Fatigue present 90% of failure when
loadings fatigues are very complex. In this paper a study of double
through crack at hole for plate subjected to fatigue loading is
presented. Various modes loading are studied where the applied load
is the same one. The fatigue life is given where the effect of stress
ratio is highlighted. This work is conducted on aluminum alloy 2024
T351 used for much aerospace and aeronautics applications. The
fatigue crack growth behavior with constant amplitude is studied
using the AFGROW code when Forman model is applied. The
fatigue crack growth rate and fatigue life for different loading modes
are compared with variation of others geometrical parameter such as
thickness and dimensions of notch hole.
Abstract: The paper discusses a 3D numerical solution of the inverse boundary problem for a continuous casting process of alloy. The main goal of the analysis presented within the paper was to estimate heat fluxes along the external surface of the ingot. The verified information on these fluxes was crucial for a good design of a mould, effective cooling system and generally the whole caster. In the study an enthalpy-porosity technique implemented in Fluent package was used for modeling the solidification process. In this method, the phase change interface was determined on the basis of the liquid fraction approach. In inverse procedure the sensitivity analysis was applied for retrieving boundary conditions. A comparison of the measured and retrieved values showed a high accuracy of the computations. Additionally, the influence of the accuracy of measurements on the estimated heat fluxes was also investigated.
Abstract: Laser Metal Deposition (LMD) is an additive manufacturing process with capabilities that include: producing new
part directly from 3 Dimensional Computer Aided Design (3D CAD)
model, building new part on the existing old component and repairing an existing high valued component parts that would have
been discarded in the past. With all these capabilities and its advantages over other additive manufacturing techniques, the
underlying physics of the LMD process is yet to be fully understood probably because of high interaction between the processing
parameters and studying many parameters at the same time makes it
further complex to understand. In this study, the effect of laser power
and powder flow rate on physical properties (deposition height and
deposition width), metallurgical property (microstructure) and
mechanical (microhardness) properties on laser deposited most
widely used aerospace alloy are studied. Also, because the Ti6Al4V
is very expensive, and LMD is capable of reducing buy-to-fly ratio
of aerospace parts, the material utilization efficiency is also studied.
Four sets of experiments were performed and repeated to establish repeatability using laser power of 1.8 kW and 3.0 kW, powder flow
rate of 2.88 g/min and 5.67 g/min, and keeping the gas flow rate and
scanning speed constant at 2 l/min and 0.005 m/s respectively. The
deposition height / width are found to increase with increase in laser
power and increase in powder flow rate. The material utilization is favoured by higher power while higher powder flow rate reduces
material utilization. The results are presented and fully discussed.
Abstract: This paper presents a portable robot that is to use for
welding process in shipbuilding yard. It has six degree of freedom and
3kg payload capability. Its weight is 21.5kg so that human workers can
carry it to the work place. Its body mainly made of magnesium alloy
and aluminum alloy for few parts that require high strength. Since the
distance between robot and controller should be 50m at most, the robot
controller controls the robot through EtherCAT. RTX and KPA are
used for real time EtherCAT control on Windows XP. The
performance of the developed robot was satisfactory, in welding of U
type cell in shipbuilding yard.
Abstract: Magnesium alloys have gained increased attention in recent years in automotive, electronics, and medical industry. This because of magnesium alloys have better properties than aluminum alloys and steels in respects of their low density and high strength to weight ratio. However, the main problems of magnesium alloy welding are the crack formation and the appearance of porosity during the solidification. This paper proposes a unique technique to weld two thin sheets of AZ31B magnesium alloy using a paste containing Ag nanoparticles. The paste containing Ag nanoparticles of 5 nm in average diameter and an organic solvent was used to coat the surface of AZ31B thin sheet. The coated sheet was heated at 100 °C for 60 s to evaporate the solvent. The dried sheet was set as a lower AZ31B sheet on the jig, and then lap fillet welding was carried out by using a pulsed Nd:YAG laser in a closed box filled with argon gas. The characteristics of the microstructure and the corrosion behavior of the joints were analyzed by opticalmicroscopy (OM), energy dispersive spectrometry (EDS), electron probe micro-analyzer (EPMA), scanning electron microscopy (SEM), and immersion corrosion test. The experimental results show that the wrought AZ31B magnesium alloy can be joined successfully using Ag nanoparticles. Ag nanoparticles insert promote grain refinement, narrower the HAZ width and wider bond width compared to weld without and insert. Corrosion rate of welded AZ31B with Ag nanoparticles reduced up to 44 % compared to base metal. The improvement of corrosion resistance of welded AZ31B with Ag nanoparticles due to finer grains and large grain boundaries area which consist of high Al content. β-phase Mg17Al12 could serve as effective barrier and suppressed further propagation of corrosion. Furthermore, Ag distribution in fusion zone provide much more finer grains and may stabilize the magnesium solid solution making it less soluble or less anodic in aqueous
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.
Abstract: The results of the two-phase gas-solid jet in pneumatic
powder injection process analysis were presented in the paper. The
researches were conducted on model set-up with high speed camera
jet movement recording. Then the recorded material was analyzed to
estimate main particles movement parameters. The values obtained
from this direct measurement were compared to those calculated with
the use of the well-known formulas for the two-phase flows
(pneumatic conveying). Moreover, they were compared to
experimental results previously achieved by authors. The analysis led
to conclusions which to some extent changed the assumptions used
even by authors, regarding the two-phase jet in pneumatic powder
injection process. Additionally, the visual analysis of the recorded
clips supplied data to make a more complete evaluation of the jet
behavior in the lance outlet than before.
Abstract: This work focuses on analysis of classical heat transfer equation regularized with Maxwell-Cattaneo transfer law. Computer simulations are performed in MATLAB environment. Numerical experiments are first developed on classical Fourier equation, then Maxwell-Cattaneo law is considered. Corresponding equation is regularized with a balancing diffusion term to stabilize discretizing scheme with adjusted time and space numerical steps. Several cases including a convective term in model equations are discussed, and results are given. It is shown that limiting conditions on regularizing parameters have to be satisfied in convective case for Maxwell-Cattaneo regularization to give physically acceptable solutions. In all valid cases, uniform convergence to solution of initial heat equation with Fourier law is observed, even in nonlinear case.
Abstract: The study of human hand morphology reveals that developing an artificial hand with the capabilities of human hand is an extremely challenging task. This paper presents the development of a robotic prosthetic hand focusing on the improvement of a tendon driven mechanism towards a biomimetic prosthetic hand. The design of this prosthesis hand is geared towards achieving high level of dexterity and anthropomorphism by means of a new hybrid mechanism that integrates a miniature motor driven actuation mechanism, a Shape Memory Alloy actuated mechanism and a passive mechanical linkage. The synergy of these actuators enables the flexion-extension movement at each of the finger joints within a limited size, shape and weight constraints. Tactile sensors are integrated on the finger tips and the finger phalanges area. This prosthesis hand is developed with an exact size ratio that mimics a biological hand. Its behavior resembles the human counterpart in terms of working envelope, speed and torque, and thus resembles both the key physical features and the grasping functionality of an adult hand.
Abstract: In this paper the combination of thermal oxidation and
electrochemical anodizing processes is used to produce titanium
oxide layers. The response of titanium alloy Ti6Al4V to oxidation
processes at various temperatures and electrochemical anodizing in
various voltages are investigated. Scanning electron microscopy
(SEM); X-Ray Diffraction (XRD) and porosity determination have
been used to characterize the oxide layer thickness, surface
morphology, oxide layer-substrate adhesion and porosity. In the first
experiment, samples modified by thermal oxidation process then
followed by electrochemical anodizing. Second experiment consists
of surfaces modified by electrochemical anodizing process and then
followed by thermal oxidation. The first method shows better
properties than other one. In second experiment, Surfaces modified
were achieved by thicker and more adherent thick oxide layers on
titanium surface. The existence of an electrochemical anodized oxide
layer did not improve the adhesion of thermal oxide layer. The high
temperature, thermal formation of an oxide layer leads to a coarse
oxide grain morphology and a complete oxidative particle. In
addition, in high temperature oxidation porosity content is increased.
The oxide layer of thermal oxidation and electrochemical anodizing
processes; on Ti–6Al–4V substrate was covered with different
colored oxide layers.
Abstract: In this paper we will develop further the sequential
life test approach presented in a previous article by [1] using an
underlying two parameter Weibull sampling distribution. The
minimum life will be considered equal to zero. We will again provide
rules for making one of the three possible decisions as each
observation becomes available; that is: accept the null hypothesis H0;
reject the null hypothesis H0; or obtain additional information by
making another observation. The product being analyzed is a new
type of a low alloy-high strength steel product. To estimate the shape
and the scale parameters of the underlying Weibull model we will use
a maximum likelihood approach for censored failure data. A new
example will further develop the proposed sequential life testing
approach.
Abstract: An effect of rolling temperature on the mechanical properties and microstructural evolution of an Al-Mg-Si alloy was studied. The material was rolled up to a true strain of ~0.7 at three different temperatures viz; room temperature, liquid propanol and liquid nitrogen. The liquid nitrogen rolled sample exhibited superior properties with a yield and tensile strength of 332 MPa and 364 MPa, respectively, with a reasonably good ductility of ~9%. The liquid nitrogen rolled sample showed around 54 MPa increase in tensile strength without much reduction in the ductility as compared to the as received T6 condition alloy. The microstructural details revealed equiaxed grains in the annealed and solutionized sample and elongated grains in the rolled samples. In addition, the cryorolled samples exhibited fine grain structure compared to the room temperature rolled samples.
Abstract: In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.
Abstract: This paper presented the results of an experimental
investigation into the axial fatigue behavior of a 5086 aluminum
alloy which have several notch-aspect ratios a0/c0 and notch
thickness ratio a/t with semi-elliptical surface cracks. Tests were
conducted in la b air for stress levels of 50 % of their yield
strength. Experiments were carried out for various notch to
thickness ratios. Crack growth rates of test specimens both in
surface and depth directions were determined by using die
penetration method. Fuzzy Logic method was used to predict the
deep direction crack growth because the dept of the crack is
considerably difficult to measure.
Abstract: Aluminum alloy sheets have several advantages such
as the lightweight, high-specific strength and recycling efficiency.
Therefore, aluminum alloy sheets in sheet forming have been used in various areas as automotive components and so forth. During the
process of sheet forming, wrinkling which is caused by compression stress might occur and the formability of sheets was affected by
occurrence of wrinkling. A few studies of uniaxial compressive test by
using square tubes, pipes and sheets were carried out to clarify the each wrinkling behavior. However, on uniaxial compressive test,
deformation behavior of the sheets hasn-t be cleared. Then, it is necessary to clarify the relationship between the buckling behavior
and the forming conditions. In this study, the effect of dimension of the sheet in the buckling behavior on compression test of aluminum alloy sheet was cleared by experiment and FEA. As the results, the buckling
deformation was classified by three modes in terms of the distribution of equivalent plastic strain.