Abstract: A transient three-dimensional computational fluid dynamics (CFD) model is developed to determine the velocity and temperature distribution in different positions cold room during pre-cooling of dates. The turbulence model used is the k-ω Shear Stress Transport (SST) with the standard wall function, the air. The numerical results obtained show that cooling rate is not uniform inside the room; the product at the medium of room has a slower cooling rate. This cooling heterogeneity has a large effect on the energy consumption during cold storage.
Abstract: Conducting crystallization in an agitated vessel requires a proper selection of mixing parameters that would result in a production of crystals of specific properties. In dual impeller systems, which are characterized by a more complex hydrodynamics due to the possible fluid flow interactions, revealing a clear link between mixing parameters and crystallization kinetics is still an open issue. The aim of this work is to establish this connection by investigating how fluid flow patterns, generated by two impellers mounted on the same shaft, reflect on metastable zone width of borax decahydrate, one of the most important parameters of the crystallization process. Investigation was carried out in a 15-dm3 bench scale batch cooling crystallizer with an aspect ratio (H/T) equal to 1.3. For this reason, two radial straight blade turbines (4-SBT) were used for agitation. Experiments were conducted at different impeller spacings at the state of complete suspension. During the process of an unseeded batch cooling crystallization, solution temperature and supersaturation were continuously monitored what enabled a determination of the metastable zone width. Hydrodynamic conditions in the vessel achieved at different impeller spacings investigated were analyzed in detail. This was done firstly by measuring the mixing time required to attain the desired level of homogeneity. Secondly, fluid flow patterns generated in a described dual impeller system were both photographed and simulated by VisiMix Turbulent software. Also, a comparison of these two visualization methods was performed. Experimentally obtained results showed that metastable zone width is definitely affected by the hydrodynamics in the crystallizer. This means that this crystallization parameter can be controlled not only by adjusting the saturation temperature or cooling rate, as is usually done, but also by choosing a suitable impeller spacing that will result in a formation of crystals of wanted size distribution.
Abstract: The heat flow in weldment changes its nature from 2D to 3D with the increase in plate thickness. For welding of thicker plates the heat loss in thickness direction increases the cooling rate of plate. Since the cooling rate changes, the various bead parameters like bead penetration, bead height and bead width also got affected by it. The present study incorporates the effect of variable plate thickness on penetration and bead width. The penetration reduces with increase in plate thickness due to heat loss in thickness direction for same heat input, while bead width increases for thicker plate due to faster cooling.
Abstract: Proper selection of welding parameters for getting
excellent weld is a challenge. HAZ simulation helps in identifying
suitable welding parameters like heating rate, cooling rate, peak
temperature, and energy input. In this study, the influence of weld
thermal cycle of heat affected zone (HAZ) is simulated for
Submerged Arc Welding (SAW) using Gleeble ® 3800 thermomechanical
simulator. A (Micro-alloyed) MA steel plate of thickness
18 mm having yield strength 450MPa is used for making test
specimens. Determination of the mechanical properties of weld
simulated specimens including Charpy V-notch toughness and
hardness is performed. Peak temperatures of 1300°C, 1150°C,
1000°C, 900°C, 800°C, heat energy input of 22KJ/cm and preheat
temperatures of 30°C have been used with Rykalin-3D simulation
model. It is found that the impact toughness (75J) is the best for the
simulated HAZ specimen at the peak temperature 900ºC. For parent
steel, impact toughness value is 26.8J at -50°C in transverse
direction.
Abstract: In this current contribution, authors are dedicated to
investigate influence of the crystal lamellae orientation on
electromechanical behaviors of relaxor ferroelectric Poly
(vinylidene fluoride –trifluoroethylene -chlorotrifluoroethylene)
(P(VDF-TrFE-CTFE)) films by control of polymer microstructure,
aiming to picture the full map of structure-property relationship. In
order to define their crystal orientation films, terpolymer films were
fabricated by solution-casting, stretching and hot-pressing process.
Differential scanning calorimetry, impedance analyzer, and tensile
strength techniques were employed to characterize crystallographic
parameters, dielectric permittivity, and elastic Young’s modulus
respectively. In addition, large electrical induced out-of-plane
electrostrictive strain was obtained by cantilever beam mode.
Consequently, as-casted pristine films exhibited surprisingly high
electrostrictive strain 0.1774% due to considerably small value of
elastic Young’s modulus although relatively low dielectric
permittivity. Such reasons contributed to large mechanical elastic
energy density. Instead, due to 2 folds increase of elastic Young’s
modulus and less than 50% augmentation of dielectric constant, fullycrystallized
film showed weak electrostrictive behavior and
mechanical energy density as well. And subjected to mechanical
stretching process, Film C exhibited stronger dielectric constant and
out-performed electrostrictive strain over Film B because edge-on
crystal lamellae orientation induced by uniaxially mechanical stretch.
Hot-press films were compared in term of cooling rate. Rather large
electrostrictive strain of 0.2788% for hot-pressed Film D in
quenching process was observed although its dielectric permittivity
equivalent to that of pristine as-casted Film A, showing highest
mechanical elastic energy density value of 359.5 J/m3. In hot-press
cooling process, dielectric permittivity of Film E saw values at 48.8
concomitant with ca.100% increase of Young’s modulus. Films with
intermediate mechanical energy density were obtained.
Abstract: In this paper, we have reported birefringence
manipulation in regenerated high birefringent fiber Bragg grating
(RPMG) by using CO2 laser annealing method. The results indicate
that the birefringence of RPMG remains unchanged after CO2 laser
annealing followed by slow cooling process, but reduced after fast
cooling process (~5.6×10-5). After a series of annealing procedures
with different cooling rates, the obtained results show that slower the
cooling rate, higher the birefringence of RPMG. The volume, thermal
expansion coefficient (TEC) and glass transition temperature (Tg)
change of stress applying part in RPMG during cooling process are
responsible for the birefringence change. Therefore, these findings
are important to the RPMG sensor in high and dynamic temperature
environment. The measuring accuracy, range and sensitivity of
RPMG sensor is greatly affected by its birefringence value. This
work also opens up a new application of CO2 laser for fiber annealing
and birefringence modification.
Abstract: This research paper portrays a comparative analysis of
thermomechanical behaviour of Shielded Metal Arc Welding
(SMAW) and Gas Tungsten Arc Welding (GTAW) of low carbon
steel of AISI 1020 grade butt joints. The thermal history has been
obtained by experimental work. We have focused on temperature
dependent cooling rate as depicted by Adam’s two-dimensional
model. The effect of moving point heat source of SMAW and GTAW
on mechanical properties has been judged by optical and scanning
electron micrographs of different regions in weld joints. The
microhardness study has been carried to visualize the joint strength
due to formation of different phases.
Abstract: Micro-alloyed steel components are used in
automotive industry for the necessity to make the manufacturing
process cycles shorter when compared to conventional steel by
eliminating heat treatment cycles, so an important saving of costs and
energy can be reached by reducing the number of operations. Microalloying
elements like vanadium, niobium or titanium have been
added to medium carbon steels to achieve grain refinement with or
without precipitation strengthening along with uniform
microstructure throughout the matrix. Present study reports the
applicability of medium carbon vanadium micro-alloyed steel in hot
forging. Forgeability has been determined with respect to different
cooling rates, after forging in a hydraulic press at 50% diameter
reduction in temperature range of 900-11000C. Final microstructures,
hardness, tensile strength, and impact strength have been evaluated.
The friction coefficients of different lubricating conditions, viz.,
graphite in hydraulic oil, graphite in furnace oil, DF 150 (Graphite,
Water-Based) die lubricant and dry or without any lubrication were
obtained from the ring compression test for the above micro-alloyed
steel. Results of ring compression tests indicate that graphite in
hydraulic oil lubricant is preferred for free forging and dry lubricant
is preferred for die forging operation. Exceptionally good forgeability
and high resistance to fracture, especially for faster cooling rate has
been observed for fine equiaxed ferrite-pearlite grains, some amount
of bainite and fine precipitates of vanadium carbides and
carbonitrides. The results indicated that the cooling rate has a
remarkable effect on the microstructure and mechanical properties at
room temperature.
Abstract: In this research article a comprehensive investigation
has been carried out to determine the effect of thermal cycle on
temperature dependent process parameters developed during gas
tungsten arc (GTA) welding of high carbon (AISI 1090) steel butt
joints. An experiment based thermal analysis has been performed to
obtain the thermal history. We have focused on different
thermophysical properties such as thermal conductivity, heat transfer
coefficient and cooling rate. Angular torch model has been utilized to
find out the surface heat flux and its variation along the fusion zone as
well as along the longitudinal direction from fusion boundary. After
welding and formation of weld pool, heat transfer coefficient varies
rapidly in the vicinity of molten weld bead and heat affected zone. To
evaluate the heat transfer coefficient near the fusion line and near the
rear end of the plate (low temperature region), established correlation
has been implemented and has been compared with empirical
correlation which is noted as coupled convective and radiation heat
transfer coefficient. Change in thermal conductivity has been
visualized by analytical model of moving point heat source. Rate of
cooling has been estimated by using 2-dimensional mathematical
expression of cooling rate and it has shown good agreement with
experimental temperature cycle. Thermophysical properties have been
varied randomly within 0 -10s time span.
Abstract: This work presents the result of investigations aimed
at determining the hardness of the welded Chromoly (A 4130) steel
plate of 2” thickness. Multi pass welding for the thick sections was
carried out and analyzed for the Chromoly alloy steel plates. The
study of hardness at the weld metal reveals that there is the presence
of different micro structure products which yields diverse properties.
The welding carried out using GMAW with ER70s-2 electrode.
Single V groove design was selected for the butt joint configuration.
The presence of hydrogen has been suppressed by selecting low
hydrogen electrode. Preheating of the plate prior to welding reduces
the cooling rate which also affects the weld metal microstructure. The
shielding gas composition used in this analysis is 80% Ar-20% CO2.
The experimental analysis gives the detailed study of the hardness of
the material.
Abstract: The use of a conventional air plasma-sprayed thermal barrier coating (TBC) and a porous, functionally graded TBC as a thermal insulator for Al7075 alloy was explored. A quench test at 1200°C employing fast heating and cooling rates was setup to represent a dynamic thermal condition of an aerospace component. During the test, coated samples were subjected the ambient temperature of 1200°C for a very short time. This was followed by a rapid drop in temperature resulting in cracking of the coatings. For the conventional TBC, it was found that the temperature of the Al7075 substrate decreases with the increase in the ZrO2 topcoat thickness. However, at the topcoat thickness of 1100 µm, large horizontal cracks can be observed in the topcoat and at the topcoat thickness of 1600 µm, the topcoat delaminate during cooling after the quench test. The porous, functionally graded TBC with 600 µm thick topcoat, on the other hand, was found to be as effective at reducing the substrate temperature as the conventional TBC with 1100 µm thick topcoat. The maximum substrate temperature is about 213°C for the former and 208°C for the latter when a heating rate of 38°C/s was used. When the quench tests were conducted with a faster heating rate of 128°C/s, the Al7075 substrate heat up faster with a reduction in the maximum substrate temperatures. The substrate temperatures dropped from 297 to 212°C for the conventional TBC and from 213 to 155°C for the porous TBC, both with 600 µm thick topcoat. Segmentation cracks were observed in both coating after the quench test.
Abstract: Slag sample from copper smelting operation in a
water jacket furnace from DRC plant was used. The study intends to
determine the effect of cooling in the extraction of base metals. The
cooling methods investigated were water quenching, air cooling and
furnace cooling. The latter cooling ways were compared to the
original as received slag. It was observed that, the cooling rate of the
slag affected the leaching of base metals as it changed the phase
distribution in the slag and the base metals distribution within the
phases. It was also found that fast cooling of slag prevented
crystallization and produced an amorphous phase that encloses the
base metals. The amorphous slags from the slag dumps were more
leachable in acidic medium (HNO3) which leached 46%Cu, 95% Co,
85% Zn, 92% Pb and 79% Fe with no selectivity at pH0, than in
basic medium (NH4OH). The leachability was vice versa for the
modified slags by quenching in water which leached 89%Cu with a
high selectivity as metal extractions are less than 1% for Co, Zn, Pb
and Fe at ambient temperature and pH12. For the crystallized slags,
leaching of base metals increased with the increase of temperature
from ambient temperature to 60°C and decreased at the higher
temperature of 80°C due to the evaporation of the ammonia solution
used for basic leaching, the total amounts of base metals that were
leached in slow cooled slags were very low compared to the
quenched slag samples.
Abstract: Porcelain specimens were fired at 6C/min to 1250C (dwell time 0.5-3h) and cooled at 6C/min to room temperature. Additionally, three different slower firing/cooling cycles were tried. Sintering profile and effects on MOR, crystalline phase content and morphology were investigated using dilatometry, 4-point bending strength, XRD and FEG-SEM respectively. Industrial-sized specimens prepared using the promising cycle were tested basing on the ANSI standards. Increasing dwell time from 1h to 3h at peak temperature of 1250C resulted in neither a significant effect on the quartz and mullite content nor MOR. Reducing the firing/cooling rate to below 6C/min, for peak temperature of 1250C (dwell time of 1h) does not result in improvement of strength of porcelain. The industrial sized specimen exhibited flashover voltages of 20.3kV (dry) and 9.3kV (wet) respectively, transverse strength of 12.5kN and bulk density of 2.27g/cm3, which are satisfactory. There was however dye penetration during porosity test. KeywordsDwell time, Microstructure, Porcelain, Strength.
Abstract: This study reports the preparation of soft magnetic
ribbons of Fe-based amorphous alloys using the single-roller melt-spinning technique. Ribbon width varied from 142 mm to 213
mm and, with a thickness of approximately 22 μm ± 2 μm. The microstructure and magnetic properties of the ribbons were
characterized by differential scanning calorimeter (DSC), X-ray diffraction (XRD), vibrating sample magnetometer (VSM), and electrical resistivity measurements (ERM). The amorphous material
properties dependence of the cooling rate and nozzle pressure have uneven surface in ribbon thicknesses are investigated. Magnetic
measurement results indicate that some region of the ribbon exhibits good magnetic properties, higher saturation induction and lower coercivity. However, due to the uneven surface of 213 mm wide
ribbon, the magnetic responses are not uniformly distributed. To
understand the transformer magnetic performances, this study analyzes the measurements of a three-phase 2 MVA amorphous-cored transformer. Experimental results confirm that the transformer with a
ribbon width of 142 mm has better magnetic properties in terms of lower core loss, exciting power, and audible noise.
Abstract: The paper presents the results of microhardness and
microstructure of low carbon steel surface melted using carbon
dioxide laser with a wavelength of 10.6μm and a maximum output
power of 2000W. The processing parameters such as the laser power,
and the scanning rate were investigated in this study. After surface
melting two distinct regions formed corresponding to the melted zone
MZ, and the heat affected zone HAZ. The laser melted region
displayed a cellular fine structures while the HAZ displayed
martensite or bainite structure. At different processing parameters,
the original microstructure of this steel (Ferrite+Pearlite) has been
transformed to new phases of martensitic and bainitic structures. The
fine structure and the high microhardness are evidence of the high
cooling rates which follow the laser melting. The melting pool and
the transformed microstructure in the laser surface melted region of
carbon steel showed clear dependence on laser power and scanning
rate.
Abstract: Among the chemicals used for ammunition production, TNT (Trinitrotoluene) play a significant role since World War I and II. Various types of military weapon utilize TNT in casting process. However, the TNT casting process for warhead is difficult to control the cooling rate of the liquid TNT. This problem occurs because the casting process lacks the equipment to detect the temperature during the casting procedure This study presents the temperature detected by infrared camera to illustrate the cooling rate and cooling zone of curing, and demonstrates the optimization of TNT condition to reduce the risk of air gap occurred in the warhead which can result in the destruction afterward. Premature initiation of explosive-filled projectiles in response to set-back forces during gunfiring cause by casting defects. Finally the study can help improving the process of the TNT casting. The operators can control the curing of TNT inside the case by rising up the heating rod at the proper time. Consequently this can reduce tremendous time of rework if the air gaps occur and increase strength to lower elastic modulus. Therefore, it can be clearly concluded that the use of Infrared Cameras in this process is another method to improve the casting procedure.
Abstract: Powder of La0.6Sr0.4CoO3-α (LSCO) was synthesized
by a combined citrate-EDTA method. The as-synthesized LSCO
powder was calcined, respectively at temperatures of 800, 900 and
1000 °C with different heating/cooling rates which are 2, 5, 10 and
15 °C min-1. The effects of heat treatments on the phase formation of
perovskite phase of LSCO were investigated by powder X-ray
diffraction (XRD). The XRD patterns revealed that the rate of
5 °C min-1 is the optimum heating/cooling rate to obtain a single
perovskite phase of LSCO with calcination temperature of 800 °C.
This result was confirmed by a thermogravimetric analysis (TGA) as
it showed a complete decomposition of intermediate compounds to
form oxide material was also observed at 800 °C.
Abstract: This research was conducted to develop a correlation
between microstructure of HSLA steel and the mechanical properties
that occur as a result of both laser and mechanical forming processes
of the metal. The technique of forming flat metals by applying laser
beams is a relatively new concept in the manufacturing industry.
However, the effects of laser energy on the stability of metal alloy
phases have not yet been elucidated in terms of phase
transformations and microhardness. In this work, CO2 laser source
was used to irradiate the surface of a flat metal then the
microstructure and microhardness of the metal were studied on the
formed specimen. The extent to which the microstructure changed
depended on the heat inputs of up to 1000 J/cm2 with cooling rates of
about 4.8E+02 K/s. Experimental results revealed that the irradiated
surface of a HSLA steel had transformed to austenitic structure
during the heating process.
Abstract: This study reports the preparation of soft magnetic ribbons of Fe-based amorphous alloys using the single-roller melt-spinning technique. Ribbon width varied from 142 mm to 213 mm and, with a thickness of approximately 22 μm 2 μm. The microstructure and magnetic properties of the ribbons were characterized by differential scanning calorimeter (DSC), X-ray diffraction (XRD), vibrating sample magnetometer (VSM), and electrical resistivity measurements (ERM). The amorphous material properties dependence of the cooling rate and nozzle pressure have uneven surface in ribbon thicknesses are investigated. Magnetic measurement results indicate that some region of the ribbon exhibits good magnetic properties, higher saturation induction and lower coercivity. However, due to the uneven surface of 213 mm wide ribbon, the magnetic responses are not uniformly distributed. To understand the transformer magnetic performances, this study analyzes the measurements of a three-phase 2 MVA amorphous-cored transformer. Experimental results confirm that the transformer with a ribbon width of 142 mm has better magnetic properties in terms of lower core loss, exciting power, and audible noise.