Lean Production to Increase Reproducibility and Work Safety in the Laser Beam Melting Process Chain

Additive Manufacturing processes are becoming increasingly established in the industry for the economic production of complex prototypes and functional components. Laser beam melting (LBM), the most frequently used Additive Manufacturing technology for metal parts, has been gaining in industrial importance for several years. The LBM process chain – from material storage to machine set-up and component post-processing – requires many manual operations. These steps often depend on the manufactured component and are therefore not standardized. These operations are often not performed in a standardized manner, but depend on the experience of the machine operator, e.g., levelling of the build plate and adjusting the first powder layer in the LBM machine. This lack of standardization limits the reproducibility of the component quality. When processing metal powders with inhalable and alveolar particle fractions, the machine operator is at high risk due to the high reactivity and the toxic (e.g., carcinogenic) effect of the various metal powders. Faulty execution of the operation or unintentional omission of safety-relevant steps can impair the health of the machine operator. In this paper, all the steps of the LBM process chain are first analysed in terms of their influence on the two aforementioned challenges: reproducibility and work safety. Standardization to avoid errors increases the reproducibility of component quality as well as the adherence to and correct execution of safety-relevant operations. The corresponding lean method 5S will therefore be applied, in order to develop approaches in the form of recommended actions that standardize the work processes. These approaches will then be evaluated in terms of ease of implementation and their potential for improving reproducibility and work safety. The analysis and evaluation showed that sorting tools and spare parts as well as standardizing the workflow are likely to increase reproducibility. Organizing the operational steps and production environment decreases the hazards of material handling and consequently improves work safety.

The Reproducibility and Repeatability of Modified Likelihood Ratio for Forensics Handwriting Examination

The forensic use of handwriting depends on the analysis, comparison, and evaluation decisions made by forensic document examiners. When using biometric technology in forensic applications, it is necessary to compute Likelihood Ratio (LR) for quantifying strength of evidence under two competing hypotheses, namely the prosecution and the defense hypotheses wherein a set of assumptions and methods for a given data set will be made. It is therefore important to know how repeatable and reproducible our estimated LR is. This paper evaluated the accuracy and reproducibility of examiners' decisions. Confidence interval for the estimated LR were presented so as not get an incorrect estimate that will be used to deliver wrong judgment in the court of Law. The estimate of LR is fundamentally a Bayesian concept and we used two LR estimators, namely Logistic Regression (LoR) and Kernel Density Estimator (KDE) for this paper. The repeatability evaluation was carried out by retesting the initial experiment after an interval of six months to observe whether examiners would repeat their decisions for the estimated LR. The experimental results, which are based on handwriting dataset, show that LR has different confidence intervals which therefore implies that LR cannot be estimated with the same certainty everywhere. Though the LoR performed better than the KDE when tested using the same dataset, the two LR estimators investigated showed a consistent region in which LR value can be estimated confidently. These two findings advance our understanding of LR when used in computing the strength of evidence in handwriting using forensics.

Cost Efficient Receiver Tube Technology for Eco-Friendly Concentrated Solar Thermal Applications

The world is in need of efficient energy conversion technologies which are affordable, accessible, and sustainable with eco-friendly nature. Solar energy is one of the cornerstones for the world’s economic growth because of its abundancy with zero carbon pollution. Among the various solar energy conversion technologies, solar thermal technology has attracted a substantial renewed interest due to its diversity and compatibility in various applications. Solar thermal systems employ concentrators, tracking systems and heat engines for electricity generation which lead to high cost and complexity in comparison with photovoltaics; however, it is compatible with distinct thermal energy storage capability and dispatchable electricity which creates a tremendous attraction. Apart from that, employing cost-effective solar selective receiver tube in a concentrating solar thermal (CST) system improves the energy conversion efficiency and directly reduces the cost of technology. In addition, the development of solar receiver tubes by low cost methods which can offer high optical properties and corrosion resistance in an open-air atmosphere would be beneficial for low and medium temperature applications. In this regard, our work opens up an approach which has the potential to achieve cost-effective energy conversion. We have developed a highly selective tandem absorber coating through a facile wet chemical route by a combination of chemical oxidation, sol-gel, and nanoparticle coating methods. The developed tandem absorber coating has gradient refractive index nature on stainless steel (SS 304) and exhibited high optical properties (α ≤ 0.95 & ε ≤ 0.14). The first absorber layer (Cr-Mn-Fe oxides) developed by controlled oxidation of SS 304 in a chemical bath reactor. A second composite layer of ZrO2-SiO2 has been applied on the chemically oxidized substrate by So-gel dip coating method to serve as optical enhancing and corrosion resistant layer. Finally, an antireflective layer (MgF2) has been deposited on the second layer, to achieve > 95% of absorption. The developed tandem layer exhibited good thermal stability up to 250 °C in open air atmospheric condition and superior corrosion resistance (withstands for > 200h in salt spray test (ASTM B117)). After the successful development of a coating with targeted properties at a laboratory scale, a prototype of the 1 m tube has been demonstrated with excellent uniformity and reproducibility. Moreover, it has been validated under standard laboratory test condition as well as in field condition with a comparison of the commercial receiver tube. The presented strategy can be widely adapted to develop highly selective coatings for a variety of CST applications ranging from hot water, solar desalination, and industrial process heat and power generation. The high-performance, cost-effective medium temperature receiver tube technology has attracted many industries, and recently the technology has been transferred to Indian industry.

Separating Permanent and Induced Magnetic Signature: A Simple Approach

Magnetic signature detection provides sensitive detection of metal objects, especially in the natural environment. Our group is developing a tabletop setup for magnetic signatures of various small and model objects. A particular issue is the separation of permanent and induced magnetization. While the latter depends only on the composition and shape of the object, the former also depends on the magnetization history. With common deperming techniques, a significant permanent signature may still remain, which confuses measurements of the induced component. We investigate a basic technique of separating the two. Measurements were done by moving the object along an aluminum rail while the three field components are recorded by a detector attached near the center. This is done first with the rail parallel to the Earth magnetic field and then with anti-parallel orientation. The reversal changes the sign of the induced- but not the permanent magnetization so that the two can be separated. Our preliminary results on a small iron block show excellent reproducibility. A considerable permanent magnetization was indeed present, resulting in a complex asymmetric signature. After separation, a much more symmetric induced signature was obtained that can be studied in detail and compared with theoretical calculations.

Gas Permeation Behavior of Single and Mixed Gas Components Using an Asymmetric Ceramic Membrane

A dip-coating process has been used to form an asymmetric silica membrane with improved membrane performance and reproducibility. First, we deposited repeatedly silica on top of a commercial alumina membrane support to improve its structural make up. The membrane is further processed under clean room conditions to avoid dust impurity and subsequent drying in an oven for high thermal, chemical and physical stability. The resulting asymmetric membrane exhibits a gradual change in the membrane layer thickness. Compared to the support, the dual-layer process improves the gas flow rates. For the scientific applications for natural gas purification, CO2, CH4 and H2 gas flow rates were. In addition, the membrane selectively separated hydrogen.

An Optical Sensing Film for Fe(III) Determination Based on 1,1′- diethyl 2,2′- cyanine Iodide Immobilized in Nafion Film

An optical chemical sensing film based on immobilizing of 1,1′- diethyl 2,2′-cyanine (pseudocyanine iodide) in nafion film was developed for the determination of Fe(III). The sensing film was homogeneous, transparent, and mechanically stable. Decrease of the absorbance measured at 518 nm was observed when the sensing film was immersed in a solution of Fe(III). The optimum response of the sensing film to Fe(III) was obtained in a solution with pH 4.0. Linear calibration curve over an Fe(III) concentration range of 1-30 ppm with a limit of detection of 0.71 ppm was obtained. Cd(II) is the major interference. The sensing film exhibited good stability for 2 months and high reproducibility. The proposed method was applied for the determination of Fe(III) in water samples with satisfactory results.

Characterization of ZrO2/PEG Composite Film as Immobilization Matrix for Glucose Oxidase

A biosensor based on glucose oxidase (GOx) immobilized onto nanoparticles zirconium oxide with polyethylene nanocomposite for glucose monitoring has been designed. The CTAB/PEG/ZrO2/GOx nanocomposite was deposited onto screen printed carbon paste (SPCE) electrode via spin coating technique. The properties of CTAB/PEG/ZrO2/GOx were study using scanning electron microscopy (SEM). The SPE modified with the CTAB/PEG/ZrO2/GOx showed electrocatalytical response to the oxidation of glucose when ferrocene carboxaldehyde was used as an artificial redox mediator, which was studied by cyclic voltammetry (CV). Several parameters such as working potential, effect of pH and effect of ZrO2/PEG layers that governed the analytical performance of the biosensor, have been studied. The biosensor was applied to detect glucose with a linear range of 0.4 to 2.0 mmol L−1 with good repetability and reproducibility.

Design and Analysis of Gauge R&R Studies: Making Decisions Based on ANOVA Method

In a competitive production environment, critical decision making are based on data resulted by random sampling of product units. Efficiency of these decisions depends on data quality and also their reliability scale. This point leads to the necessity of a reliable measurement system. Therefore, the conjecture process and analysing the errors contributes to a measurement system known as Measurement System Analysis (MSA). The aim of this research is on determining the necessity and assurance of extensive development in analysing measurement systems, particularly with the use of Repeatability and Reproducibility Gages (GR&R) to improve physical measurements. Nowadays in productive industries, repeatability and reproducibility gages released so well but they are not applicable as well as other measurement system analysis methods. To get familiar with this method and gain a feedback in improving measurement systems, this survey would be on “ANOVA" method as the most widespread way of calculating Repeatability and Reproducibility (R&R).

Determination of EDTA in Dairy Wastewater and Adjacent Surface Water

An HPLC-UV analytical method was developed to determine ethylenediaminetetraacetic acid (EDTA) in dairy wastewater and surface water. The optimizing separation was achieved by reversed–phase ion-pair liquid chromatography on a C18 column using methanol as mobile phase solvent, tetrabutylammonium bromide as the ion-pair reagent in pH 3.3 formate buffer solution at a flow rate of 0.9 mL min-1 with a UV detector at 265 nm. No interference of Ca, Mg or NO3 - was detected. Method performance was evaluated in terms of linearity, repeatability and reproducibility. The method detection limit was 5 μg L-1. The contents of EDTA in dairy effluents were 72 ~ 261 μg L-1 at a large dairy site. A change of EDTA concentration was observed downstream of the dairy effluent discharge, but this was well under the predicted no effect concentration for aquatic ecosystem.

Fluidity of A713 Cast Alloy with and without Scrap Addition using Double Spiral Fluidity Test: A Comparison

Recycling of aluminum alloys often decrease fluidity, consequently influence the castability of the alloy. In this study, the fluidity of Al-Zn alloys, such as the standard A713 alloy with and without scrap addition has been investigated. The scrap added was comprised of contaminated alloy turning chips. Fluidity measurements were performed with double spiral fluidity test consisting of gravity casting of double spirals in green sand moulds with good reproducibility. The influence of recycled alloy on fluidity has been compared with that of the virgin alloy and the results showed that the fluidity decreased with the increase in recycled alloy at minimum pouring temperatures. Interestingly, an appreciable improvement in the fluidity was observed at maximum pouring temperature, especially for coated spirals.