Abstract: An attempt has been made to investigate the
machinability of zirconia toughened alumina (ZTA) inserts while
turning AISI 4340 steel. The insert was prepared by powder
metallurgy process route and the machining experiments were
performed based on Response Surface Methodology (RSM) design
called Central Composite Design (CCD). The mathematical model of
flank wear, cutting force and surface roughness have been developed
using second order regression analysis. The adequacy of model has
been carried out based on Analysis of variance (ANOVA) techniques.
It can be concluded that cutting speed and feed rate are the two most
influential factor for flank wear and cutting force prediction. For
surface roughness determination, the cutting speed & depth of cut
both have significant contribution. Key parameters effect on each
response has also been presented in graphical contours for choosing
the operating parameter preciously. 83% desirability level has been
achieved using this optimized condition.
Abstract: Homogeneous composites of alumina and zirconia
with a small amount of MgO (99%) were obtained for ZTA ceramic containing 0.05 wt% MgO in
1500 °C.
Abstract: In industrial scale of Gas to Liquid (GTL) process in
Fischer-Tropsch (FT) synthesis, a part of reactor outlet gases such as
CO2 and CH4 as side reaction products, is usually recycled. In this
study, the influence of CO2 and CH4 on the performance and
selectivity of Co-Ru/Al2O3 catalyst is investigated by injection of
these gases (0-20 vol. % of feed) to the feed stream. The effect of
temperature and feed flow rate, are also inspected. The results show
that low amounts of CO2 in the feed stream, doesn`t change the
catalyst activity significantly but increasing the amount of CO2 (more
than 10 vol. %) cause the CO conversion to decrease and the
selectivity of heavy components to increase. Methane acts as an inert
gas and doesn`t affect the catalyst performance. Increasing feed flow
rate has negative effect on both CO conversion and heavy component
selectivity. By raising the temperature, CO conversion will increase
but there are more volatile components in the product. The effect of
CO2 on the catalyst deactivation is also investigated carefully and a
mechanism is suggested to explain the negative influence of CO2 on
catalyst deactivation.
Abstract: Thermally insulating ceramic coatings also known as
thermal barrier coatings (TBCs) have been essential technologies to
improve the performance and efficiency of advanced gas turbines in
service at extremely high temperatures. The damage mechanisms of
air-plasma sprayed YSZ thermal barrier coatings (TBC) with various
microstructures were studied by microscopic techniques after thermal
cycling. The typical degradation of plasma TBCs that occurs during
cyclic furnace testing of an YSZ and alumina coating on a Titanium
alloy are analyzed. During the present investigation the effects of
topcoat thickness, bond coat oxidation, thermal cycle lengths and test
temperature are investigated using thermal cycling. These results
were correlated with stresses measured by a spectroscopic technique
in order to understand specific damage mechanism. The failure
mechanism of former bond coats was found to involve fracture
initiation at the thermally grown oxide (TGO) interface and at the
TGO bond coat interface. The failure mechanism of the YZ was
found to involve combination of fracture along the interface between
TGO and bond coat.
Abstract: Selective oxidation of H2S to elemental sulfur in a
fixed bed reactor over newly synthesized alumina nanocatalysts was
physio-chemically investigated and results compared with a
commercial Claus catalyst. Amongst these new materials, Al2O3-
supported sodium oxide prepared with wet chemical technique and
Al2O3 nanocatalyst prepared with spray pyrolysis method were the
most active catalysts for selective oxidation of H2S to elemental
sulfur. Other prepared nanocatalysts were quickly deactivated,
mainly due to the interaction with H2S and conversion into sulfides.
Abstract: The steady mixed convection boundary layer flow from
a vertical cone in a porous medium filled with a nanofluid is
numerically investigated using different types of nanoparticles as Cu
(copper), Al2O3 (alumina) and TiO2 (titania). The boundary value
problem is solved by using the shooting technique by reducing it
into an ordinary differential equation. Results of interest for the local
Nusselt number with various values of the constant mixed convection
parameter and nanoparticle volume fraction parameter are evaluated.
It is found that dual solutions exist for a certain range of mixed
convection parameter.
Abstract: The alumosilicate ceramics with mullite crystalline phase are used in various branches of science and technique. The mullite refractory ceramics with high porosity serve as a heat insulator and as a constructional materials [1], [2]. The purpose of the work was to sinter high porosity ceramic and to increase the quantity of mullite phase in this mullite, mullite-corundum ceramics. Two types of compositions were prepared at during the experiment. The first type is compositions with commercial alumina and silica oxides. The second type is from mixing these oxides with 10, 20 and 30 wt.%. of kaolin. In all samples the Al2O3 and SiO2 were in 2.57:1 ratio, because that was conformed to mullite stechiometric compositions (3Al2O3.2SiO2). The types of alumina oxides were α-Al2O3 (d50=4µm) and γ-Al2O3 (d50=80µm). Ratios of α-: γ-Al2O3 were (1:1) or (1:3). The porous materials were prepared by slip casting of suspension of raw materials. The aluminium paste (0.18 wt.%) was used as a pore former. Water content in the suspensions was 26-47 wt.%. Pore formation occurred as a result of hydrogen formation in chemical reaction between aluminium paste and water [2]. The samples were sintered at the temperature of 1650°C and 1750°C for one hour. The increasing amount of kaolin, α-: γ-Al2O3 at the ratio (1:3) and sintering at the highest temperature raised the quantity of mullite phase. The mullite phase began to dominate over the corundum phase.
Abstract: The present research focus on the processing of mullite-based ceramics from oil refinery industrial wastes and byproducts of agricultural industry and on the investigating of silane modified surface of ceramics. Two waste products were used as initial material – waste aluminum oxide and waste rice husk. The burning - out additives used were waste rise husk. It is known that the oxide ceramics surface is hydrophilic due to the presence of – OH groups in it. The nature of ceramic surface regarding permeation of water and hydrocarbons can be changed by further treatment with silanes. The samples were studied mainly by X-ray analysis, FT-IR absorbance measurements and microscopic analysis. The X-ray analyses showed the phase composition depends on the firing temperature and on the purity of the starting alumina. Two kind of silanes were used for the transformation of surface from hydrophilic to hydrophobic – trimethoxymethylsilane (TMMS) and trimethylclorsilane (TMCS).
Abstract: Alumina matrix composites with addition of hexagonal boron nitride (hBN), acting as solid lubricant, were produced. Main purpose of solid lubricants is to dispose the necessity of using cooling lubricants in machining process. Hot pressing was used as a consolidating process for Al2O3-x%wt.hBN (x=1/ 2,5/ 5 /7,5 /10) composites. Properties of sinters such as relative density, hardness, Young-s modulus and fracture toughness were examined. Obtained samples characterize by high relative density. Hardness and fracture toughness values allow the use of alumina – hBN composites for machining steels even in hardened condition. However it was observed that high weight content of hBN can negatively influence the mechanical properties of composites.
Abstract: Anodizing is an electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally suited to anodizing, although other nonferrous metals, such as magnesium and titanium, also can be anodized. The anodic oxide structure originates from the aluminum substrate and is composed entirely of aluminum oxide. This aluminum oxide is not applied to the surface like paint or plating, but is fully integrated with the underlying aluminum substrate, so cannot chip or peel. It has a highly ordered, porous structure that allows for secondary processes such as coloring and sealing. In this experimental paper, we focus on a reliable method for fabricating nanoporous alumina with high regularity. Starting from study of nanostructure materials synthesize methods. After that, porous alumina fabricate in the laboratory by anodization of aluminum oxide. Hard anodization processes are employed to fabricate the nanoporous alumina using 0.3M oxalic acid and 90, 120 and 140 anodized voltages. The nanoporous templates were characterized by SEM and FFT. The nanoporous templates using 140 voltages have high ordered. The pore formation, influence of the experimental conditions on the pore formation, the structural characteristics of the pore and the oxide chemical reactions involved in the pore growth are discuss.
Abstract: Reinforced Concrete (RC) structures strengthened
with fiber reinforced polymer (FRP) lack in thermal resistance under
elevated temperatures in the event of fire. This phenomenon led to
the lining of strengthened concrete with thin high performance
cementitious composites (THPCC) to protect the substrate against
elevated temperature. Elevated temperature effects on THPCC, based
on different cementitious materials have been studied in the past but
high-alumina cement (HAC)-based THPCC have not been well
characterized. This research study will focus on the THPCC based on
HAC replaced by 60%, 70%, 80% and 85% of ground granulated
blast furnace slag (GGBS). Samples were evaluated by the
measurement of their mechanical strength (28 & 56 days of curing)
after exposed to 400°C, 600°C and 28°C of room temperature for
comparison and corroborated by their microstructure study. Results
showed that among all mixtures, the mix containing only HAC
showed the highest compressive strength after exposed to 600°C as
compared to other mixtures. However, the tensile strength of THPCC
made of HAC and 60% GGBS content was comparable to the
THPCC with HAC only after exposed to 600°C. Field emission
scanning electron microscopy (FESEM) images of THPCC
accompanying Energy Dispersive X-ray (EDX) microanalysis
revealed that the microstructure deteriorated considerably after
exposure to elevated temperatures which led to the decrease in
mechanical strength.
Abstract: This paper present some preliminary work on the
preparation and physicochemical caracterization of nanocomposite
MFI-alumina structures based on alumina hollow fibres. The fibers
are manufactured by a wet spinning process. α-alumina particles were
dispersed in a solution of polysulfone in NMP. The resulting slurry is
pressed through the annular gap of a spinneret into a precipitation
bath. The resulting green fibres are sintered. The mechanical strength
of the alumina hollow fibres is determined by a three-point-bending
test while the pore size is characterized by bubble-point testing. The
bending strength is in the range of 110 MPa while the average pore
size is 450 nm for an internal diameter of 1 mm and external diameter
of 1.7 mm. To characterize the MFI membranes various techniques
were used for physicochemical characterization of MFI–ceramic
hollow fibres membranes: The nitrogen adsorption, X-ray
diffractometry, scanning electron microscopy combined with X
emission microanalysis. Scanning Electron Microscopy (SEM) and
Energy Dispersive Microanalysis by the X-ray were used to observe
the morphology of the hollow fibre membranes (thickness,
infiltration into the carrier, defects, homogeneity). No surface film,
has been obtained, as observed by SEM and EDX analysis and
confirmed by high temperature variation of N2 and CO2 gas
permeances before cation exchange. Local analysis and characterise
(SEM and EDX) and overall (by ICP elemental analysis) were
conducted on two samples exchanged to determine the quantity and
distribution of the cation of cesium on the cross section fibre of the
zeolite between the cavities.
Abstract: The paper relates to a catalyst, comprising copperchromium
spinel, coated on carrier γ-Al2O3. The effect of preparation
conditions on the active component composition and activity
behavior of the catalysts is discussed. It was found that the activity of
carbon monoxide, DME, formaldehyde and methanol oxidation
reaches a maximum at an active component content of 20 – 30 wt. %.
Temperature calcination at 500oC seems to be optimal for the γ–
alumina supported CuO-Cr2O3 catalysts for CO, DME, formaldehyde
and methanol oxidation. A three months industrial experiment was
carried out to elucidate the changes in the catalyst composition
during industrial exploitation of the catalyst and the main reasons for
catalyst deactivation.
It was concluded that the CuO–Cr2O3/γ–alumina supported
catalysts have enhanced activity toward CO, DME, formaldehyde
and methanol oxidation and that these catalysts are suitable for
industrial application. The main reason for catalyst deactivation
seems to be the deposition of iron and molybdenum, coming from the
main reactor, on the active component surface.
Abstract: The conventional production of biodiesel from crude
palm oil which contains large amounts of free fatty acids in the
presence of a homogeneous base catalyst confronts the problems of
soap formation and very low yield of biodiesel. To overcome these
problems, free fatty acids must be esterified to their esters in the
presence of an acid catalyst prior to alkaline-catalyzed
transesterification. Sulfated metal oxides are a promising group of
catalysts due to their very high acidity. In this research, aluminadoped
sulfated tin oxide (SO4
2-/Al2O3-SnO2) catalysts were prepared
and used for esterification of free fatty acids in crude palm oil in a
batch reactor. The SO4
2-/Al2O3-SnO2 catalysts were prepared from
different Al precursors. The results showed that different Al
precursors gave different activities of the SO4
2-/Al2O3-SnO2 catalysts.
The esterification of free fatty acids in crude palm oil with methanol
in the presence of SO4
2-/Al2O3-SnO2 catalysts followed first-order
kinetics.
Abstract: The aluminum bronze matrix alumina composites using hot press and resin infiltration were investigated to study their porosities, hardness, bending strengths, and microstructures. The experiment results show that the hardness of the sintered composites with the decrease of porosity increases. The composites without and with resin infiltration have about HRF 42-61 of about 34-40% of porosity and about HRF 62-83 of about 30-36% of porosity, respectively. Besides, the alumina composites contain a more amount of iron and nickel powders would cause a lower bending strength due to forming some weaker bonding among the iron, nickel, copper, aluminum under this hot pressing of shorter time.
Abstract: Cs-type nanocomposite zeolite membrane was successfully synthesized on an alumina ceramic hollow fibre with a mean outer diameter of 1.7 mm; cesium cationic exchange test was carried out inside test module with mean wall thickness of 230 μm and an average crossing pore size smaller than 0.2 μm. Separation factor of n-butane/H2 obtained indicate that a relatively high quality closed to 20. Maxwell-Stefan modeling provides an equivalent thickness lower than 1 µm. To compare the difference an application to CO2/N2 separation has been achieved, reaching separation factors close to (4,18) before and after cation exchange on H-zeolite membrane formed within the pores of a ceramic alumina substrate.
Abstract: The main aim of this work is to develop a model of hydrogen sulfide (H2S) separation from natural gas by using membrane separation technology. The model is developed by incorporating three diffusion mechanisms which are Knudsen, viscous and surface diffusion towards membrane selectivity and permeability. The findings from the simulation result shows that the permeability of the gas is dependent toward the pore size of the membrane, operating pressure, operating temperature as well as feed composition. The permeability of methane has the highest value for Poly (1-trimethylsilyl-1-propyne ) PTMSP membrane at pore size of 0.1nm and decreasing toward a minimum peak at pore range 1 to 1.5 nm as pore size increased before it increase again for pore size is greater than 1.5 nm. On the other hand, the permeability of hydrogen sulfide is found to increase almost proportionally with the increase of membrane pore size. Generally, the increase of pressure will increase the permeability of gas since more driving force is provided to the system while increasing of temperature would decrease the permeability due to the surface diffusion drop off effect. A corroboration of the simulation result also showed a good agreement with the experimental data.
Abstract: For relatively small particles of aluminum (5%) is observed to
corrode before passivation occurs at moderate temperatures (>50oC)
in de-ionized water within one hour. Physical contact with alumina
powder results in a significant increase in both the rate of corrosion
and the extent of corrosion before passivation. Whereas the resulting
release of hydrogen gas could be of commercial interest for portable
hydrogen supply systems, the fundamental aspects of Al corrosion
acceleration in presence of dispersed alumina particles are equally
important. This paper investigates the effects of various amounts of
alumina on the corrosion rate of aluminum powders in water and the
effect of multiple additions of aluminum into a single reactor.
Abstract: Solar energy is the most “available", ecological and clean energy. This energy can be used in active or passive mode. The active mode implies the transformation of solar energy into a useful energy. The solar energy can be transformed into thermal energy, using solar collectors. In these collectors, the active and the most important element is the absorber, material which performs the absorption of solar radiation and, in at the same time, limits its reflection. The paper presents some aspects regarding the IR absorbing material – a type of cermets, used as absorber in the solar collectors, by X Ray Diffraction Technique (XRD) characterization.
Abstract: Nowadays, engineering ceramics have significant
applications in different industries such as; automotive, aerospace,
electrical, electronics and even martial industries due to their
attractive physical and mechanical properties like very high hardness
and strength at elevated temperatures, chemical stability, low friction
and high wear resistance. However, these interesting properties plus
low heat conductivity make their machining processes too hard,
costly and time consuming. Many attempts have been made in order
to make the grinding process of engineering ceramics easier and
many scientists have tried to find proper techniques to economize
ceramics' machining processes. This paper proposes a new diamond
plunge grinding technique using ultrasonic vibration for grinding
Alumina ceramic (Al2O3). For this purpose, a set of laboratory
equipments have been designed and simulated using Finite Element
Method (FEM) and constructed in order to be used in various
measurements. The results obtained have been compared with the
conventional plunge grinding process without ultrasonic vibration
and indicated that the surface roughness and fracture strength
improved and the grinding forces decreased.