Abstract: In this paper, x-ray impact of Taguchi method and design of experiment philosophy to project relationship between various factors leading to output yield strength of rebar is studied. In bar mill of an integrated steel plant, there are two production lines called as line 1 and line 2. The metallic properties e.g. yield strength of finished product of the same material is varying for a particular grade material when rolled simultaneously in both the lines. A study has been carried out to set the process parameters at optimal level for obtaining equal value of yield strength simultaneously for both lines.
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: Lightweight construction became more and more important over the last decades in several applications, e.g. in the automotive or aircraft sector. This is the result of economic and ecological constraints on the one hand and increasing safety and comfort requirements on the other hand. In the field of lightweight design, different approaches are used due to specific requirements towards the technical systems. The use of endless carbon fiber reinforced plastics (CFRP) offers the largest weight saving potential of sometimes more than 50% compared to conventional metal-constructions. However, there are very limited industrial applications because of the cost-intensive manufacturing of the fibers and production technologies. Other disadvantages of pure CFRP-structures affect the quality control or the damage resistance. One approach to meet these challenges is hybrid materials. This means CFRP and sheet metal are combined on a material level. Therefore, new opportunities for innovative process routes are realizable. Hybrid lightweight design results in lower costs due to an optimized material utilization and the possibility to integrate the structures in already existing production processes of automobile manufacturers. In recent and current research, the advantages of two-layered hybrid materials have been pointed out, i.e. the possibility to realize structures with tailored mechanical properties or to divide the curing cycle of the epoxy resin into two steps. Current research work at the Chair for Automotive Lightweight Design (LiA) at the Paderborn University focusses on production processes for fiber-metal-laminates. The aim of this work is the development and qualification of a large-scale production process for high-performance fiber-metal-laminates (FML) for industrial applications in the automotive or aircraft sector. Therefore, the prepreg-press-technology is used, in which pre-impregnated carbon fibers and sheet metals are formed and cured in a closed, heated mold. The investigations focus e.g. on the realization of short process chains and cycle times, on the reduction of time-consuming manual process steps, and the reduction of material costs. This paper gives an overview over the considerable steps of the production process in the beginning. Afterwards experimental results are discussed. This part concentrates on the influence of different process parameters on the mechanical properties, the laminate quality and the identification of process limits. Concluding the advantages of this technology compared to conventional FML-production-processes and other lightweight design approaches are carried out.
Abstract: Increasing demands of contemporary applications for high strength and lightweight materials prompted the development of metal-matrix composites (MMCs). After the discovery of carbon nanotubes (CNTs) in 1991 (revealing an excellent set of mechanical properties) became one of the most promising strengthening materials for MMC applications. Additionally, the relatively low density of the nanotubes imparted high specific strengths, making them perfect strengthening material to reinforce MMCs. In the present study, aluminum-multiwalled carbon nanotubes (Al-MWCNTs) composite was prepared in an air induction furnace. The dispersion of the nanotubes in molten aluminum was assisted by inherent string action of induction heating at 790°C. During the fabrication process, multifunctional fluxes were used to avoid oxidation of the nanotubes and molten aluminum. Subsequently, the melt was cast in to a copper mold and cold rolled to 0.5 mm thickness. During metallographic examination using a scanning electron microscope, it was observed that the nanotubes were effectively dispersed in the matrix. The mechanical properties of the composite were significantly increased as compared to pure aluminum specimen i.e. the yield strength from 65 to 115 MPa, the tensile strength from 82 to 125 MPa and hardness from 27 to 30 HV for pure aluminum and Al-CNTs composite, respectively. To recognize the associated strengthening mechanisms in the nanocomposites, three foremost strengthening models i.e. shear lag model, Orowan looping and Hall-Petch have been critically analyzed; experimental data were found to be closely satisfying the shear lag model.
Abstract: TiO2 particles have been added in molten aluminium to result in aluminium based cast Al/Al3Ti-Al2O3 composite, which has been added then to molten magnesium to synthesize magnesium based cast Mg-Al/Al3Ti-Al2O3 composite. The nominal compositions in terms of Mg, Al, and TiO2 contents in the magnesium based composites are Mg-9Al-0.6TiO2, Mg-9Al-0.8TiO2, Mg-9Al-1.0TiO2 and Mg-9Al-1.2TiO2 designated respectively as MA6T, MA8T, MA10T and MA12T. The microstructure of the cast magnesium based composite shows grayish rods of intermetallics Al3Ti, inherited from aluminium based composite but these rods, on hot forging, breaks into smaller lengths decreasing the average aspect ratio (length to diameter) from 7.5 to 3.0. There are also cavities in between the broken segments of rods. β-phase in cast microstructure, Mg17Al12, dissolves during heating prior to forging and re-precipitates as relatively finer particles on cooling. The amount of β-phase also decreases on forging as segregation is removed. In both the cast and forged composite, the Brinell hardness increases rapidly with increasing addition of TiO2 but the hardness is higher in forged composites by about 80 BHN. With addition of higher level of TiO2 in magnesium based cast composite, yield strength decreases progressively but there is marginal increase in yield strength over that of the cast Mg-9 wt. pct. Al, designated as MA alloy. But the ultimate tensile strength (UTS) in the cast composites decreases with the increasing particle content indicating possibly an early initiation of crack in the brittle inter-dendritic region and their easy propagation through the interfaces of the particles. In forged composites, there is a significant improvement in both yield strength and UTS with increasing TiO2 addition and also, over those observed in their cast counterpart, but at higher addition it decreases. It may also be noted that as in forged MA alloy, incomplete recovery of forging strain increases the strength of the matrix in the composites and the ductility decreases both in the forged alloy and the composites. Initiation fracture toughness, JIC, decreases drastically in cast composites compared to that in MA alloy due to the presence of intermetallic Al3Ti and Al2O3 particles in the composite. There is drastic reduction of JIC on forging both in the alloy and the composites, possibly due to incomplete recovery of forging strain in both as well as breaking of Al3Ti rods and the voids between the broken segments of Al3Ti rods in composites. The ratio of tearing modulus to elastic modulus in cast composites show higher ratio, which increases with the increasing TiO2 addition. The ratio decreases comparatively more on forging of cast MA alloy than those in forged composites.
Abstract: Clustering phenomenon of pellets was observed frequently in shaft processes operating at higher temperatures. Clustering is a result of the growth of fibrous iron precipitates (iron whiskers) that become hooked to each other and finally become crystallized during the initial stages of metallization. If the pellet clustering is pronounced, sometimes leads to blocking inside the furnace and forced shutdown takes place. This work clarifies further the relation between metallic iron whisker growth and iron ore mineralogy. Various pellet sizes (6 – 12.0 & +12.0 mm) from three different ores (A, B & C) were (completely and partially) reduced at 985 oC with H2/CO gas mixture using thermos-gravimetric technique. It was found that reducibility increases by decreasing the iron ore pellet’s size. Ore (A) has the highest reducibility than ore (B) and ore (C). Increasing the iron ore pellet’s size leads to increase the probability of metallic iron whisker formation. Ore (A) has the highest tendency for metallic iron whisker formation than ore (B) and ore (C). The reduction reactions for all iron ores A, B and C are mainly controlled by diffusion reaction mechanism.
Abstract: Ever increasing population growth of major urban centers and environmental challenges in siting new landfills have resulted in a growing trend in design of mega-landfills some with extraordinary heights and dangerously steep slopes. Landfill failure mobility risk analysis is one of the most uncertain types of dynamic rheology models due to very large inherent variabilities in the heterogeneous solid waste material shear strength properties. The waste flow of three historic dumpsite and two landfill failures were back-analyzed using run-out modeling with DAN-W model. The travel distances of the waste flow during landfill failures were calculated approach by taking into account variability in material shear strength properties. The probability distribution function for shear strength properties of the waste material were grouped into four major classed based on waste material compaction (landfills versus dumpsites) and composition (high versus low quantity) of high shear strength waste materials such as wood, metal, plastic, paper and cardboard in the waste. This paper presents a probabilistic method for estimation of the spatial extent of waste avalanches, after a potential landfill failure, to create maps of vulnerability scores to inform property owners and residents of the level of the risk.
Abstract: MnO2 nanowires were developed as filtration media for wastewater treatment that uniquely combines several advantages. The resulting material demonstrated strong capability to remove the pollution of heavy metal ions and organic contents in water. In addition, the manufacture process of such material is practical and economical. In this work, MnO2 nanowires were integrated with the state-of-art bio-electrochemical system for wastewater treatment, to overcome problems currently encountered with organic, inorganic, heavy metal, and microbe removal, and to minimize the unit footprint (land/space occupation) at low cost. Results showed that coupling the bio-electrochemical with MnO2 resulted in very encouraging results with higher removal efficiencies of such pollutants.
Abstract: Insulation performance of a gas insulated system is severely affected by particle contaminants. These metallic particles adversely affect the characteristics of insulating system. These particles can produce surface charges due to partial discharge activities. These particles which are free to move enhance the local electric fields. This paper deals with the influence of conducting particle placed in a co-axial duct on the discharge characteristics of gas mixtures. Co-axial duct placed in a high pressure chamber is used for the purpose. A gas pressure of 0.1, 0.2 and 0.3 MPa have been considered with a 10:90 SF6 and N2 gas mixtures. The 2D and 3D histograms of clean duct and duct with copper particle are discussed in this paper.
Abstract: Sheet-metal parts have been widely applied in electronics, communication and mechanical industries in recent decades; but the advancement in sheet-metal part design and manufacturing is still behind in comparison with the increasing importance of sheet-metal parts in modern industry. This paper presents a methodology for automatic extraction of some common 2D internal sheet metal features. The features used in this study are taken from Unipunch ™ catalogue. The extraction process starts with the data extraction from STEP file using an object oriented approach and with the application of suitable algorithms and rules, all features contained in the catalogue are automatically extracted. Since the extracted features include geometry and engineering information, they will be effective for downstream application such as feature rebuilding and process planning.
Abstract: Partially lubricated sliding wear behaviour of a zinc-based alloy reinforced with 10wt% SiC particles has been studied as a function of applied load and solid lubricant particle size and has been compared with that of matrix alloy and conventionally used grey cast iron. The wear tests were conducted at the sliding velocities of 2.1m/sec in various partial lubricated conditions using pin on disc machine as per ASTM G-99-05. Base oil (SAE 20W-40) or mixture of the base oil with 5wt% graphite of particle sizes (7-10 µm) and (100 µm) were used for creating lubricated conditions. The matrix alloy revealed primary dendrites of a and eutectoid a + h and Î phases in the Inter dendritic regions. Similar microstructure has been depicted by the composite with an additional presence of the dispersoid SiC particles. In the case of cast iron, flakes of graphite were observed in the matrix; the latter comprised of (majority of) pearlite and (limited quantity of) ferrite. Results show a large improvement in wear resistance of the zinc-based alloy after reinforcement with SiC particles. The cast iron shows intermediate response between the matrix alloy and composite. The solid lubrication improved the wear resistance and friction behaviour of both the reinforced and base alloy. Moreover, minimum wear rate is obtained in oil+ 5wt % graphite (7-10 µm) lubricated environment for the matrix alloy and composite while for cast iron addition of solid lubricant increases the wear rate and minimum wear rate is obtained in case of oil lubricated environment. The cast iron experienced higher frictional heating than the matrix alloy and composite in all the cases especially at higher load condition. As far as friction coefficient is concerned, a mixed trend of behaviour was noted. The wear rate and frictional heating increased with load while friction coefficient was affected in an opposite manner. Test duration influenced the frictional heating and friction coefficient of the samples in a mixed manner.
Abstract: The performance of organophosphorus extractants Cyanex 272 and D2EHPA on the purification of concentrate nickel sulfate solutions was evaluated. Batch scale tests were carried out at pH range of 2 to 7 using a laboratory solution simulating concentrate nickel liquors as those typically obtained when sulfate intermediates from nickel laterite are re-leached and treated for the selective removal of cobalt, zinc, manganese and copper with Cyanex 272 ([Ca] = 0.57 g/L, [Mg] = 3.2 g/L, and [Ni] = 88 g/L). The increase on the concentration of D2EHPA favored the calcium extraction. The extraction of magnesium is dependent on the pH and of ratio of extractants D2EHPA and Cyanex 272 in the organic phase. The composition of the investigated organic phase did not affect nickel extraction. The number of stages is dependent on the magnesium extraction. The most favorable operating condition to selectively remove calcium and magnesium was determined.
Abstract: Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al2O3 particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.
Abstract: In the work presented here, nitrogen-doped graphene materials were synthesized and used as metal-free electrocatalysts for oxygen reduction reaction (ORR) under alkaline conditions. Paraphenylenediamine was used as N precursor. The N-doped graphene was synthesized under hydrothermal treatment at 200°C. All the materials have been characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), Transmission electron microscopy (TEM) and X-ray photo-electron spectroscopy (XPS). Moreover, for electrochemical evaluation of samples, Rotating Disk electrode (RDE) and Cyclic Voltammetry techniques (CV) were employed. The resulting material exhibits an outstanding catalytic activity for the oxygen reduction reaction (ORR) as well as excellent resistance towards methanol crossover effects, indicating their promising potential as ORR electrocatalysts for alkaline fuel cells.
Abstract: Liquid level control of conical tank system is known to be a great challenge in many industries such as food processing, hydrometallurgical industries and wastewater treatment plant due to its highly nonlinear characteristics. In this research, an adaptive fuzzy PID control scheme is applied to the problem of liquid level control in a nonlinear tank process. A conical tank process is first modeled and primarily simulated. A PID controller is then applied to the plant model as a suitable benchmark for comparison and the dynamic responses of the control system to different step inputs were investigated. It is found that the conventional PID controller is not able to fulfill the controller design criteria such as desired time constant due to highly nonlinear characteristics of the plant model. Consequently, a nonlinear control strategy based on gain-scheduling adaptive control incorporating a fuzzy logic observer is proposed to accurately control the nonlinear tank system. The simulation results clearly demonstrated the superiority of the proposed adaptive fuzzy control method over the conventional PID controller.
Abstract: Sludge originates from the process of treatment of wastewater. It is the byproduct of wastewater treatment containing concentrated heavy metals and poorly biodegradable trace organic compounds, as well as potentially pathogenic organisms (viruses, bacteria, etc.) which are usually difficult to treat or dispose of. China, like other countries, is no stranger to the challenges posed by increase of wastewater. Treatment and disposal of sludge has been a problem for most cities in China. However, this problem has been exacerbated by other issues such as lack of technology, funding, and other factors. Suitable methods for such climatic conditions are still unavailable for modern cities in China. Against this background, this paper seeks to describe the methods used for treatment and disposal of sludge from industries and suggest a suitable method for treatment and disposal in Chongqing/China. From the research conducted, it was discovered that the highest treatment rate of sludge in Chongqing was 10.08%. The industrial waste piping system is not separated from the domestic system. Considering the proliferation of industry and urbanization, there is a likelihood that the production of sludge in Chongqing will increase. If the sludge produced is not properly managed, this may lead to adverse health and environmental effects. Disposal costs and methods for Chongqing were also included in this paper’s analysis. Research showed that incineration is the most expensive method of sludge disposal in China/Chongqing. Subsequent research therefore considered optional alternatives such as composting. Composting represents a relatively cheap waste disposal method considering the vast population, current technology and economic conditions of Chongqing, as well as China at large.
Abstract: Aqueous ethanol and aqueous acetone extracts of
Moringa oleifera (outer pericarp of immature fruit and flower) and
Sesbania grandiflora white variety (flower and leaf) were examined
for radical scavenging capacities and antioxidant activities. Ethanol
extract of S. grandiflora (flower and leaf) and acetone extract of M.
oleifera (outer pericarp of immature fruit and flower) contained
relatively higher levels of total dietary phenolics than the other
extracts. The antioxidant potential of the extracts were assessed by
employing different in vitro assays such as reducing power assay,
DPPH˙, ABTS˙+ and ˙OH radical scavenging capacities,
antihemolytic assay by hydrogen peroxide induced method and metal
chelating ability. Though all the extracts exhibited dose dependent
reducing power activity, acetone extract of all the samples were
found to have more hydrogen donating ability in DPPH˙ (2.3% -
65.03%) and hydroxyl radical scavenging systems (21.6% - 77.4%)
than the ethanol extracts. The potential of multiple antioxidant
activity was evident as it possessed antihemolytic activity (43.2 % to
68.0 %) and metal ion chelating potency (45.16 - 104.26 mg EDTA/g
sample). The result indicate that acetone extract of M. oleifera (OPIF
and flower) and S. grandiflora (flower and leaf) endowed with
polyphenols, could be utilized as natural antioxidants/nutraceuticals.
Abstract: The laws of Newtonian mechanics allow ab-initio
molecular dynamics to model and simulate particle trajectories in
material science by defining a differentiable potential function. This
paper discusses some considerations for the coding of ab-initio
programs for simulation on a standalone computer and illustrates
the approach by C language codes in the context of embedded
metallic atoms in the face-centred cubic structure. The algorithms use
velocity-time integration to determine particle parameter evolution
for up to several thousands of particles in a thermodynamical
ensemble. Such functions are reusable and can be placed in a
redistributable header library file. While there are both commercial
and free packages available, their heuristic nature prevents dissection.
In addition, developing own codes has the obvious advantage of
teaching techniques applicable to new problems.
Abstract: Contact width and contact stress are important design parameters for optimizing corrugated metal gasket performance based on elastic and plastic contact stress. In this study, we used a three-layer metal gasket with Al, Cu, Ni as the outer layer, respectively. A finite element method was employed to develop simulation solution. The gasket model was simulated by using two simulation stages which are forming and tightening simulation. The simulation result shows that aluminum with tangent modulus, Ehal = Eal/150 has the highest slope for contact width. The slope of contact width for plastic mode gasket was higher than the elastic mode gasket.
Abstract: This paper describes the use of by-products as
adsorbents for removing heavy metals from aqueous effluent
solutions. Products of almond skin, walnut shell, saw dust, rice bran
and egg shell were evaluated as metal ion adsorbents in aqueous
solutions. A comparative study was done with commercial adsorbents
like ion exchange resins and activated carbon too. Batch experiments
were investigated to determine the affinity of all of biomasses for,
Cd(ΙΙ), Cr(ΙΙΙ), Ni(ΙΙ), and Pb(ΙΙ) metal ions at pH 5. The rate of
metal ion removal in the synthetic wastewater by the biomass was
evaluated by measuring final concentration of synthetic wastewater.
At a concentration of metal ion (50 mg/L), egg shell adsorbed high
levels (98.6 – 99.7%) of Pb(ΙΙ) and Cr(ΙΙΙ) and walnut shell adsorbed
high levels (35.3 – 65.4%) of Ni(ΙΙ) and Cd(ΙΙ). In this study, it has
been shown that by-products were excellent adsorbents for removal
of toxic ions from wastewater with efficiency comparable to
commercially available adsorbents, but at a reduced cost. Also
statistical studies using Independent Sample t Test and ANOVA Oneway
for statistical comparison between various elements adsorption
showed that there isn’t a significant difference in some elements
adsorption percentage by by-products and commercial adsorbents.