Abstract: Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard, and fragile such as advanced ceramics, refractories, crystals, quartz etc. Present article has been targeted at investigating the impact of different experimental conditions (power rating, cobalt content, tool material, thickness of work piece, tool geometry, and abrasive grit size) on over cut in ultrasonic drilling of WC-Co composite material. Taguchi’s L-36 orthogonal array has been employed for conducting the experiments. Significant factors have been identified using analysis of variance (ANOVA) test. The experimental results revealed that abrasive grit size and tool material are most significant factors for over cut.
Abstract: Particle reinforced Metal Matrix Composite (MMC) succeeds in synergizing the metallic matrix with ceramic particle reinforcements to result in improved strength, particularly at elevated temperatures, but adversely it affects the ductility of the matrix because of agglomeration and porosity. The present study investigates the outcome of tensile properties in a cast and hot forged composite reinforced simultaneously with coarse and fine particles. Nano-sized alumina particles have been generated by milling mixture of aluminum and manganese dioxide powders. Milled particles after drying are added to molten metal and the resulting slurry is cast. The microstructure of the composites shows good distribution of both the size categories of particles without significant clustering. The presence of nanoparticles along with coarser particles in a composite improves both strength and ductility considerably. Delay in debonding of coarser particles to higher stress is due to reduced mismatch in extension caused by increased strain hardening in presence of the nanoparticles. However, higher addition of powder mix beyond a limit results in deterioration of mechanical properties, possibly due to clustering of nanoparticles. The porosity in cast composite generally increases with the increasing addition of powder mix as observed during process and on forging it has got reduced. The base alloy and nanocomposites show improvement in flow stress which could be attributed to lowering of porosity and grain refinement as a consequence of forging.
Abstract: The goal of this work is to develop sustainable and durable ceramic cellular structures using widely available natural resources- clay and milled waste glass. Present paper describes method of obtaining clay ceramic foam (CCF) with addition of milled waste glass in 5, 7 and 10 wt% by direct foaming with high speed mixer-disperser (HSMD). For more efficient clay and waste glass milling and mixing, the high velocity disintegrator was used. The CCF with 5, 7, and 10 wt% were obtained at 900, 950, 1000 and 1050 °C firing temperature and they have demonstrated mechanical compressive strength for all 12 samples ranging from 3.8 to 14.3 MPa and porosity 76-65%. Obtained CCF has compressive strength 14.3 MPa and porosity 65.3%.
Abstract: Membrane technology is convenient for separation of suspended solids, colloids and high molecular weight materials that are present. The idea is that the waste stream from edible oil industry, after the separation of oil by using skimmers is subjected to microfiltration and the obtained permeate can be used again in the production process. The wastewater from edible oil industry was used for the microfiltration. For the microfiltration of this effluent a tubular membrane was used with a pore size of 200 nm at transmembrane pressure in range up to 3 bar and in range of flow rate up to 300 L/h. Box–Behnken design was selected for the experimental work and the responses considered were permeate flux and chemical oxygen demand (COD) reduction. The reduction of the permeate COD was in the range 40-60% according to the feed. The highest permeate flux achieved during the process of microfiltration was 160 L/m2h.
Abstract: Recycling, as part of any sustainable environment, is continuously evolving and impacting on new materials in manufacturing. One example of this is the recycled solid waste of Tetra Pak ™ packaging, which is a highly pollutant waste as it is not biodegradable since it is manufactured with different materials. The Tetra Pak ™ container consists of thermally joined layers of paper, aluminum and polyethylene. Once disposed, this packaging is recycled by completely separating the paperboard from the rest of the materials. The aluminum and the polyethylene remain together and are used to create the poly-aluminum, which is widely used to manufacture roof tiles. These recycled tiles have different thermal and acoustic properties compared with traditional manufactured ceramic and cement tiles. In this work, we compare a group of tiles using nondestructive optical testing to measure the superficial micro deformations of the tiles under well controlled experiments. The results of the acoustic and thermal tests show remarkable differences between the recycled tile and the traditional ones. These results help to determine which tile could be better suited to the specific environmental conditions in countries where extreme climates, ranging from tropical, desert-like, to very cold are experienced throughout the year.
Abstract: The microstructure, mechanical properties and metalgraphic characteristics of Ni plated AlN-Astaloy Cr-M powders were investigated using specimens produced by tube furnace sintering at 1000-1400 °C temperature. A uniform nickel layer on AlN powders was deposited prior to sintering using electroless plating technique. A composite consisting of ternary additions, metallic phase, Ni and ceramic phase AlN within a matrix of Astaloy Cr-M had been prepared under Ar shroud and then tube furnace sintered. The experimental results carried out by using XRD (X-Ray Diffraction) and SEM (Scanning Electron Microscope) for composition (10% AlN-Astaloy Cr-M) 10% Ni at 1400 °C suggest that the best properties as 132.45HB and permittivity were obtained at 1400 °C.
Abstract: Modal analysis of a FGM plate containing the ceramic phase of Al2O3 and metal phase of stainless steel 304 was performed using ABAQUS, with the assumptions that the material has an elastic mechanical behavior and its Young modulus and density are varying in thickness direction. For this purpose, a subroutine was written in FOTRAN and linked with ABAQUS. First, a simulation was performed in accordance to other researcher’s model, and then after comparing the obtained results, the accuracy of the present study was verified. The obtained results for natural frequency and mode shapes indicate good performance of user-written subroutine as well as FEM model used in present study. After verification of obtained results, the effect of clamping condition and the material type (i.e. the parameter n) was investigated. In this respect, finite element analysis was carried out in fully clamped condition for different values of n. The results indicate that the natural frequency decreases with increase of n, since with increase of n, the amount of ceramic phase in FGM plate decreases, while the amount of metal phase increases, leading to decrease of the plate stiffness and hence, natural frequency, as the Young modulus of Al2O3 is equal to 380 GPa and the Young modulus of stainless steel 304 is equal to 207 GPa.
Abstract: The present work is devoted to the investigation of two series of doped bismuth molybdates: Bi26-2xMn2xMo10O69-d and
Bi26Mo10-2yMn2yO69-d. Complex oxides were synthesized by conventional solid state technology and by co-precipitation method. The products were identified by powder diffraction. The powders and ceramic samples were examined by means of densitometry, laser diffraction, and electron microscopic methods. Porosity of the ceramic materials was estimated using the hydrostatic method. The electrical conductivity measurements were carried out using impedance spectroscopy method.
Abstract: In this study, we investigated the thixotropic behavior
of two clays used in fabrication of ceramic. The structural kinetic
model (SKM) was used to characterize the thixotropic behavior of
two different kinds of clays used in fabrication of ceramic. The SKM
postulates that the change in the rheological behavior is associated
with shear-induced breakdown of the internal structure of the clays.
This model for the structure decay with time at constant shear rate
assumes nth order kinetics for the decay of the material structure with
a rate constant.
Abstract: The ferrites ZnFe2O4, CdFe2O4 and CuFe2O4 are
synthesized in laboratory conditions using ceramic technology. Their
homogeneity and structure are proven by X-Ray diffraction analysis
and Mössbauer spectroscopy. The synthesized ferrites are subjected
to strong acid and high temperature leaching with solutions of H2SO4,
HCl and HNO3. The results indicate that the highest degree of
leaching of Zn, Cd and Cu from the ferrites is achieved by use of
HCl. The charging of five zinc sulfide concentrates was optimized using
the criterion of minimal amount of zinc ferrite produced when
roasting the concentrates in a fluidized bed. The results obtained are
interpreted in terms of the hydrometallurgical zinc production and
maximum recovery of zinc, copper and cadmium from initial zinc
concentrates after their roasting.
Abstract: Ceramic obtained on the base of aluminum oxide has
wide application range, because it has unique properties, for example,
wear-resistance, dielectric characteristics, and exploitation ability at
high temperatures and in corrosive atmosphere. Low temperature
synthesis of α-Al2O3 is energo-economical process and it is topical
for developing technologies of corundum ceramics fabrication. In the present work possibilities of low temperature transformation
of oxyhydroxides in α-Al2O3, during the presence of small amount of
rare–earth elements compounds (also Th, Re), have been discussed.
Aluminum unstable oxyhydroxides have been obtained by hydrolysis
of aluminium isopropoxide, nitrates, sulphate, and chloride in
alkaline environment at 80-90ºC temperatures. β-Al(OH)3 has been
received from aluminum powder by ultrasonic development. Drying
of oxyhydroxide sol has been conducted with presence of various
types seeds, which amount reaches 0,1-0,2% (mas). Neodymium,
holmium, thorium, lanthanum, cerium, gadolinium, disprosium
nitrates and rhenium carbonyls have been used as seeds and they
have been added to the sol specimens in amount of 0.1-0.2% (mas)
calculated on metals. Annealing of obtained gels is carried out at 70–
1100ºC for 2 hrs. The same specimen transforms in α-Al2O3 at
1100ºC. At this temperature in case of presence of lanthanum and
gadolinium transformation takes place by 70-85%. In case of
presence of thorium stabilization of γ-and θ-phases takes place. It is
established, that thorium causes inhibition of α-phase generation at
1100ºC, and at the time when in all other doped specimens α-phase is
generated at lower temperatures (1000-1050ºC). Synthesis of various
type compounds and simultaneous consolidation has developed in the
furnace of OXY-GON. Composite materials containing oxide and
non-oxide components close to theoretical data have been obtained in
this furnace respectively. During the work the following devices have
been used: X-ray diffractometer DRON-3M (Cu-Kα, Ni filter,
2º/min), High temperature vacuum furnace OXY-GON, electronic
scanning microscopes Nikon ECLIPSE LV 150, NMM-800TRF,
planetary mill Pulverisette 7 premium line, SHIMADZU Dynamic
Ultra Micro Hardness Tester, DUH-211S, Analysette 12 Dyna sizer.
Abstract: The ventilated façade has great advantages when
compared to traditional façades as it reduces the air conditioning
thermal loads due to the stack effect induced by solar radiation in the
air chamber. Optimizing energy consumption by using a ventilated
façade can be used not only in newly built buildings but also it can be
implemented in existing buildings, opening the field of
implementation to energy building retrofitting works. In this sense, the following three prototypes of façade where
designed, built and further analyzed in this research: non-ventilated
façade (NVF); slightly ventilated façade (SLVF) and strongly
ventilated façade (STVF). The construction characteristics of the
three facades are based on the Spanish regulation of building
construction “Technical Building Code”. The façades have been
monitored by type-k thermocouples in a representative day of the
summer season in Madrid (Spain). Moreover, an analysis of variance
(ANOVA) with repeated measures, studying the thermal lag in the
ventilated and no-ventilated façades has been designed. Results show that STVF façade presents higher levels of thermal
inertia as the thermal lag reduces up to 17% (daily mean) compared
to the non-ventilated façade. In addition, the statistical analysis
proves that an increase of the ventilation holes size in STVF façades
can improve the thermal lag significantly (p >0.05) when compared
to the SLVF façade.
Abstract: The conventional ceramic route was utilized to
prepare a hard magnetic powder (M-type strontium ferrite,
SrFe12O19). The stoichiometric mixture of iron oxide and strontium
carbonate were calcined at 1000oC and then fired at various
temperatures. The influence of various reaction parameters such as
mixing ratio, calcination temperature, firing temperature and firing
time on the magnetic behaviors of the synthesized magnetic powder
were investigated. The magnetic properties including Coercivity
(Hc), Magnetic saturation (Ms), and Magnetic remnance (Mr) were
measured by vibrating sample magnetometer. Morphologically the
produced magnetic powder has a dense hexagonal grain shape
structure.
Abstract: The primary objective of this work was to study the
effect of resin chemistry, pH and molarity of binding and elution
buffer on aggregate removal using Cation Exchange Chromatography
and find the optimum conditions which can give efficient aggregate
removal with minimum loss of yield. Four different resins were used
for carrying out the experiments: Fractogel EMD SO3
-(S), Fractogel EMD COO-(M), Capto SP ImpRes and S Ceramic HyperD. Runs
were carried out on the AKTA Avant system. Design of Experiments
(DOE) was used for analysis using the JMP software. The
dependence of the yield obtained using different resins on the
operating conditions was studied. Success has been achieved in
obtaining yield greater than 90% using Capto SP ImpRes and
Fractogel EMD COO-(M) resins. It has also been found that a change
in the operating conditions generally has different effects on the
yields obtained using different resins.
Abstract: In order to obtain efficient pollutants removal in
small-scale wastewater treatment plants, uniform water flow has to be
achieved. The experimental setup, designed for treating high-load
wastewater (leachate), consists of two aerobic biological reactors and
a lamellar settler. Both biological tanks were aerated by using three
different types of aeration systems - perforated pipes, membrane air
diffusers and tube ceramic diffusers. The possibility of homogenizing
the water mass with each of the air diffusion systems was evaluated
comparatively. The oxygen concentration was determined by optical
sensors with data logging. The experimental data was analyzed
comparatively for all three different air dispersion systems aiming to
identify the oxygen concentration variation during different
operational conditions. The Oxygenation Capacity was calculated for
each of the three systems and used as performance and selection
parameter. The global mass transfer coefficients were also evaluated
as important tools in designing the aeration system. Even though
using the tubular porous diffusers leads to higher oxygen
concentration compared to the perforated pipe system (which
provides medium-sized bubbles in the aqueous solution), it doesn’t
achieve the threshold limit of 80% oxygen saturation in less than 30
minutes. The study has shown that the optimal solution for the
studied configuration was the radial air diffusers which ensure an
oxygen saturation of 80% in 20 minutes. An increment of the values
was identified when the air flow was increased.
Abstract: New environmental regulations and the increasing
market preference for companies that respect the ecosystem had
encouraged the industry to look after new treatments for its effluents.
The sugar industry, one of the largest emitter of environmental
pollutants, follows this tendency. Membrane technology is
convenient for separation of suspended solids, colloids and high
molecular weight materials that are present in a wastewater from
sugar industry. The idea is to microfilter the wastewater, where the
permeate passes through the membrane and becomes available for
recycle and re-use in the sugar manufacturing process. For
microfiltration of this effluent a tubular ceramic membrane was used
with a pore size of 200 nm at transmembrane pressure in range of 1–3
bars and in range of flow rate of 50–150 l/h. Kenics static mixer was
used for permeate flux enhancement. Turbidity and suspended solids
were removed and the permeate flux was continuously monitored
during the microfiltration process. The flux achieved after 90 minutes
of microfiltration was in a range of 50–70 l/m2h. The obtained
turbidity decrease was in the range of 50-99 % and total amount of
suspended solids was removed.
Abstract: Ceramic Waste Aggregates (CWAs) were made from
electric porcelain insulator wastes supplied from an electric power
company, which were crushed and ground to fine aggregate sizes. In
this study, to develop the CWA mortar as an eco–efficient, ground
granulated blast–furnace slag (GGBS) as a Supplementary
Cementitious Material (SCM) was incorporated. The water–to–binder
ratio (W/B) of the CWA mortars was varied at 0.4, 0.5, and 0.6. The
cement of the CWA mortar was replaced by GGBS at 20 and 40% by
volume (at about 18 and 37% by weight). Mechanical properties of
compressive and splitting tensile strengths, and elastic modulus were
evaluated at the age of 7, 28, and 91 days. Moreover, the chloride
ingress test was carried out on the CWA mortars in a 5.0% NaCl
solution for 48 weeks. The chloride diffusion was assessed by using an
electron probe microanalysis (EPMA). To consider the relation of the
apparent chloride diffusion coefficient and the pore size, the pore size
distribution test was also performed using a mercury intrusion
porosimetry at the same time with the EPMA. The compressive
strength of the CWA mortars with the GGBS was higher than that
without the GGBS at the age of 28 and 91 days. The resistance to the
chloride ingress of the CWA mortar was effective in proportion to the
GGBS replacement level.
Abstract: RF magnetron sputtering is used on the ceramic targets,
each of which contains zinc oxide (ZnO), zinc oxide doped with
aluminum (AZO) and zinc oxide doped with gallium (GZO). The XRD
analysis showed a preferred orientation along the (002) plane for ZnO,
AZO, and GZO films. The AZO film had the best electrical properties;
it had the lowest resistivity of 6.6 × 10-4 cm, the best sheet resistance of
2.2 × 10-1 Ω/square, and the highest carrier concentration of 4.3 × 1020
cm-3, as compared to the ZnO and GZO films.
Abstract: Cemented carbides, owing to their excellent
mechanical properties, have been of immense interest in the field of
hard materials for the past few decades. A number of processing
techniques have been developed to obtain high quality carbide tools,
with a wide range of grain size depending on the application and
requirements. Microwave sintering is one of the heating processes,
which has been used to prepare a wide range of materials including
ceramics. A deep understanding of microwave sintering and its
contribution towards control of grain growth and on deformation of
the resulting carbide materials requires further studies and attention.
In addition, the effect of binder materials and their behavior during
microwave sintering is another area that requires clear understanding.
This review aims to focus on microwave sintering, providing
information of how the process works and what type of materials it is
best suited for. In addition, a closer look at some microwave sintered
Tungsten Carbide-Cobalt samples will be taken and discussed,
highlighting some of the key issues and challenges faced in this
research area.
Abstract: This study investigates the effects of the lead angle
and chip thickness variation on surface roughness during the
machining of compacted graphite iron using ceramic cutting tools
under dry cutting conditions. Analytical models were developed for
predicting the surface roughness values of the specimens after the
face milling process. Experimental data was collected and imported
to the artificial neural network model. A multilayer perceptron model
was used with the back propagation algorithm employing the input
parameters of lead angle, cutting speed and feed rate in connection
with chip thickness. Furthermore, analysis of variance was employed
to determine the effects of the cutting parameters on surface
roughness. Artificial neural network and regression analysis were
used to predict surface roughness. The values thus predicted were
compared with the collected experimental data, and the
corresponding percentage error was computed. Analysis results
revealed that the lead angle is the dominant factor affecting surface
roughness. Experimental results indicated an improvement in the
surface roughness value with decreasing lead angle value from 88° to
45°.