Abstract: This paper reports on the effects of heat treatment on 3CR12 and AISI 316 stainless steel grades. Heat treatment was conducted on the steel grades and cooled using two different media; air and water in order to study the effect of each medium on the evolving properties of the samples. The heat treated samples were characterized through the evolving microstructure and hardness. It was found that there was a significant grain size reduction in both the heat treated stainless steel specimens compared to the parent materials. The finer grain sizes were achieved as a result of impediment to growth of one phase by the other. The Vickers microhardness values of the heat treated samples were higher compared to the parent materials due to the fact that each of the steel grades had a proportion of martensitic structures in their microstructures thereby improving the integrity of the material.
Abstract: The present research study focuses on the investigation of the influence of sand blasting on formed mild steel samples. The investigation involved the examinations on the parent material and a sand blasted material. The results were compared to the mechanically formed materials (sand and non-sand blasted) as well as a laser formed material (sand and non-sand blasted). Each material was characterized for the grain sizes and hardness. The percentage change in the grain sizes was quantified and correlation to the microhardness values was established. The Ultimate Tensile Strength (UTS) of the materials was also quantified using the obtained hardness values. The investigations revealed that the sand blasting causes an increase in the Vickers microhardness values of all the materials which also led to an increase in the UTS. After the forming operation, the microstructure revealed elongated grains as compared to almost equiaxed obtained from the parent non-sand blasted materials.
Abstract: The design of temperature measuring approach for a re-configured milling machine to produce friction stir welds is reported in this paper. The product design specifications for the redesigning of a milling machine were first outlined and the ranking criteria were determined. Three different concepts were generated for the temperature measurement on the reconfigured system and the preferred or the best concept was selected based on the set design ranking criteria. Further simulation and performance analysis was then conducted on the concept. The Infrared Thermography (IRT) concept was selected for the temperature measurement among other concepts generated because it is an ideal and most effective system of measurement in this regard.
Abstract: This paper proposes an effective maintenance method by considering the implementation of the Computerized Maintenance Management System (CMMS) software to plan a maintenance activity in a manufacturing industry. Globally, maintenance is a very important activity in the manufacturing sector to prolong the life span of equipment and machinery; it is also applicable to all household items. It is obvious and well known that apart from giving long life to equipment, it reduces the substantial financial losses for repairs and save the production downtime. In some cases, appropriate maintenance of plant equipment and machinery reduces the tendencies of injuries to personnel in the job floor. But before the maintenance process can be carried out, proper and effective work order planning and scheduling must be in place in other to achieve the set goals and objectives of a maintenance shop. Brief reviews of common planning tools which include the Computerized Maintenance Management System (CMMS) are presented. An interesting outline of analyses on planning and scheduling for effective job planning in a typical manufacturing industry using the CMMS is also presented and discussed. Finally, the steps to adhere to in making job planning effective in a manufacturing industry are also highlighted.
Abstract: Friction Stir Welding is a solid state welding technique which can be used to produce sound welds between similar and dissimilar materials. Dissimilar welds which include welds between the different series of aluminium alloys, aluminium to magnesium, steel and titanium has been successfully produced by many researchers. This review covers the work conducted in the above mentioned materials and further concludes by showing the need to fully understand the FSW process in order to expand the latter industrially.
Abstract: Today, canines are still used effectively in acceleration detection situation. However, this method is becoming impractical in modern age and a new automated replacement to the canine is required. This paper reports the design of an innovative accelerant detector. Designing an accelerant detector is a long process as is any design process; therefore, a solution to the need for a mobile, effective accelerant detector is hereby presented. The device is simple and efficient to ensure that any accelerant detection can be conducted quickly and easily. The design utilizes Ultra Violet (UV) light to detect the accelerant. When the UV light shines on an accelerant, the hydrocarbons in the accelerant emit florescence. The advantages of using the UV light to detect accelerant are also outlined in this paper. The mobility of the device is achieved by using a Direct Current (DC) motor to run tank tracks. Tank tracks were chosen as to ensure that the device will be mobile in the rough terrain of a fire site. The materials selected for the various parts are also presented. A Solid Works Simulation was also conducted on the stresses in the shafts and the results are presented. This design is an innovative solution which offers a user friendly interface. The design is also environmentally friendly, ecologically sound and safe to use.
Abstract: The localized corrosion behavior of laser surface
melted 304L austenitic stainless steel was studied by
potentiodynamic polarization test. The extent of improvement in
corrosion resistance was governed by the preferred orientation and
the percentage of delta ferrite present on the surface of the laser
melted sample. It was established by orientation imaging microscopy
that the highest pitting potential value was obtained when grains were
oriented in the most close- packed [101] direction compared to the
random distribution of the base metal and other laser surface melted
samples oriented in [001] direction. The sample with lower
percentage of ferrite had good pitting resistance.
Abstract: Laser beam forming is a novel technique developed for the joining of metallic components. In this study, an overview of the laser beam forming process, areas of application, the basic mechanisms of the laser beam forming process, some recent research
studies and the need to focus more research effort on improving the
laser-material interaction of laser beam forming of titanium and its
alloys are presented.
Abstract: The study of effect of laser scanning speed on
material efficiency in Ti6Al4V application is very important because unspent powder is not reusable because of high temperature oxygen
pick-up and contamination. This study carried out an extensive study
on the effect of scanning speed on material efficiency by varying the
speed between 0.01 to 0.1m/sec. The samples are wire brushed and
cleaned with acetone after each deposition to remove un-melted
particles from the surface of the deposit. The substrate is weighed before and after deposition. A formula was developed to calculate the
material efficiency and the scanning speed was compared with the
powder efficiency obtained. The results are presented and discussed.
The study revealed that the optimum scanning speed exists for this study at 0.01m/sec, above and below which the powder efficiency
will drop
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 reports the tensile fracture location
characterizations of dissimilar friction stir welds between 5754
aluminium alloy and C11000 copper. The welds were produced using
three shoulder diameter tools; namely, 15, 18 and 25 mm by varying
the process parameters. The rotational speeds considered were 600,
950 and 1200 rpm while the feed rates employed were 50, 150 and
300 mm/min to represent the low, medium and high settings
respectively. The tensile fracture locations were evaluated using the
optical microscope to identify the fracture locations and were
characterized. It was observed that 70% of the tensile samples failed
in the Thermo Mechanically Affected Zone (TMAZ) of copper at the
weld joints. Further evaluation of the fracture surfaces of the pulled
tensile samples revealed that welds with low Ultimate Tensile
Strength either have defects or intermetallics present at their joint
interfaces.
Abstract: Friction Stir Welding (FSW) is a solid state welding
process invented and patented by The Welding Institute (TWI) in the
United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding
process as an energy efficient and a green technology process in the
field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining
similar and dissimilar materials are also presented.
Abstract: The purpose of this research study is to investigate the manner in which various loads affect the mechanical properties of the formed mild steel plates. The investigation focuses on examining the cross-sectional area of the metal plate at the centre of the formed mild steel plate. Six mild steel plates were deformed with different loads. The loads applied on the plates had a magnitude of 5 kg, 10 kg, 15 kg, 20 kg, 25 kg and 30 kg. The radius of the punching die was 120 mm and the loads were applied at room temperature. The investigations established that the applied load causes the Vickers microhardness at the cross-sectional area of the plate to increase due to strain hardening. Hence, the percentage increase of the hardness due to the load was found to be directly proportional to the increase in the load. Furthermore, the tensile test results for the parent material showed that the average Ultimate Tensile Strength (UTS) for the three samples was 308 MPa while the average Yield Strength and Percentage Elongation were 227 MPa and 38 % respectively. Similarly, the UTS of the formed components increased after the deformation of the plate, as such it can be concluded that the forming loads alter the mechanical properties of the materials by improving and strengthening the material properties.