Abstract: Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.
Abstract: In this study, a sequential deposition process is used for the fabrication of PEDOT: PSS based inverted planar perovskite solar cell. A small amount of additive deionized water (DI-H2O) was added into PbI2 + Dimethyl formamide (DMF) precursor solution in order to increase the solubility of PbI2 in DMF, and finally to manipulate the surface morphology of the perovskite films. A morphology transition from needle like structure to hexagonal plates, and then needle-like again has been observed as the DI-H2O was added continuously (0.0 wt% to 3.0wt%). The latter one leads to full surface coverage of the perovskite, which is essential for high performance solar cell.
Abstract: Nitriding of p-type Si samples by pulsed DC glow discharge is carried out for different Ar concentrations (30% to 90%) in nitrogen-argon plasma whereas the other parameters like pressure (2 mbar), treatment time (4 hr) and power (175 W) are kept constant. The phase identification, crystal structure, crystallinity, chemical composition, surface morphology and topography of the nitrided layer are studied using X-ray diffraction (XRD), Fourier transform infra-red spectroscopy (FTIR), optical microscopy (OM), scanning electron microscopy (SEM) and atomic force microscopy (AFM) respectively. The XRD patterns reveal the development of different diffraction planes of Si3N4 confirming the formation of polycrystalline layer. FTIR spectrum confirms the formation of bond between Si and N. Results reveal that addition of Ar into N2 plasma plays an important role to enhance the production of active species which facilitate the nitrogen diffusion.
Abstract: Pure nickel coatings have been successfully
electrodeposited on copper substrates by the pulse plating technique.
The influence of current density, duty cycle and pulse frequency on
the surface morphology, crystal orientation, and microhardness was
determined. It was found that the crystallite size of the deposit
increases with increasing current density and duty cycle. The crystal
orientation progressively changed from a random texture at 1 A/dm2
to (200) texture at 10 A/dm2. Increasing pulse frequency resulted in
increased texture coefficient and peak intensity of (111) reflection.
An increase in duty cycle resulted in considerable increase in texture
coefficient and peak intensity of (311) reflection. Coatings obtained
at high current densities and duty cycle present a mixed morphology
of small and large grains. Maximum microhardness of 193 Hv was
achieved at 4 A/dm2, 10 Hz and duty cycle of 50%. Nickel coatings
with (200) texture are ductile while (111) texture improves the
microhardness of the coatings.
Abstract: The present study deals with the characterization of
CrSiN coatings obtained by PVD magnetron sputtering systems.
CrSiN films were deposited with different Si contents, in order to
check the effect of at.% variation on the different properties of the
Cr–N system. Coatings were characterized by scanning electron
microscopy (SEM) for thickness measurements, X-ray diffraction.
Surface morphology and the roughness characteristics were explored
using AFM, Mechanicals properties, elastic and plastic deformation
resistance of thin films were investigated using nanoindentation test. We observed that the Si addition improved the hardness and the
Young’s modulus of the Cr–N system. Indeed, the hardness value is
18,56 GPa for CrSiN coatings. Besides, the Young’s modulus value
is 224,22 GPa for CrSiN coatings for Si content of 1.2 at.%.
Abstract: In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation.
Abstract: Microbial fuel cells (MFCs) represent a promising
technology for simultaneous bioelectricity generation and wastewater
treatment. Catalysts are significant portions of the cost of microbial
fuel cell cathodes. Many materials have been tested as aqueous
cathodes, but air-cathodes are needed to avoid energy demands for
water aeration. The sluggish oxygen reduction reaction (ORR) rate at
air cathode necessitates efficient electrocatalyst such as carbon
supported platinum catalyst (Pt/C) which is very costly. Manganese
oxide (MnO2) was a representative metal oxide which has been
studied as a promising alternative electrocatalyst for ORR and has
been tested in air-cathode MFCs. However the single MnO2 has poor
electric conductivity and low stability. In the present work, the MnO2
catalyst has been modified by doping Pt nanoparticle. The goal of the
work was to improve the performance of the MFC with minimum Pt
loading. MnO2 and Pt nanoparticles were prepared by hydrothermal
and sol gel methods, respectively. Wet impregnation method was
used to synthesize Pt/MnO2 catalyst. The catalysts were further used
as cathode catalysts in air-cathode cubic MFCs, in which anaerobic
sludge was inoculated as biocatalysts and palm oil mill effluent
(POME) was used as the substrate in the anode chamber. The asprepared
Pt/MnO2 was characterized comprehensively through field
emission scanning electron microscope (FESEM), X-Ray diffraction
(XRD), X-ray photoelectron spectroscopy (XPS), and cyclic
voltammetry (CV) where its surface morphology, crystallinity,
oxidation state and electrochemical activity were examined,
respectively. XPS revealed Mn (IV) oxidation state and Pt (0)
nanoparticle metal, indicating the presence of MnO2 and Pt.
Morphology of Pt/MnO2 observed from FESEM shows that the
doping of Pt did not cause change in needle-like shape of MnO2
which provides large contacting surface area. The electrochemical
active area of the Pt/MnO2 catalysts has been increased from 276 to
617 m2/g with the increase in Pt loading from 0.2 to 0.8 wt%. The
CV results in O2 saturated neutral Na2SO4 solution showed that
MnO2 and Pt/MnO2 catalysts could catalyze ORR with different
catalytic activities. MFC with Pt/MnO2 (0.4 wt% Pt) as air cathode
catalyst generates a maximum power density of 165 mW/m3, which
is higher than that of MFC with MnO2 catalyst (95 mW/m3). The
open circuit voltage (OCV) of the MFC operated with MnO2 cathode
gradually decreased during 14 days of operation, whereas the MFC
with Pt/MnO2 cathode remained almost constant throughout the
operation suggesting the higher stability of the Pt/MnO2 catalyst.
Therefore, Pt/MnO2 with 0.4 wt% Pt successfully demonstrated as an
efficient and low cost electrocatalyst for ORR in air cathode MFC with higher electrochemical activity, stability and hence enhanced
performance.
Abstract: Calcium oxide (CaO) as carbon dioxide (CO2)
adsorbent at the elevated temperature has been very well-received
thus far. The CaO can be synthesized from natural calcium carbonate
(CaCO3) sources through the reversible calcination-carbonation
process. In the study, cockle shell has been selected as CaO
precursors. The objectives of the study are to investigate the
performance of calcination and carbonation with respect to different
temperature, heating rate, particle size and the duration time. Overall,
better performance is shown at the calcination temperature of 850oC
for 40 minutes, heating rate of 20oC/min, particle size of < 0.125mm
and the carbonation temperature is at 650oC. The synthesized
materials have been characterized by nitrogen physisorption and
surface morphology analysis. The effectiveness of the synthesized
cockle shell in capturing CO2 (0.72 kg CO2/kg adsorbent) which is
comparable to the commercialized adsorbent (0.60 kg CO2/kg
adsorbent) makes them as the most promising materials for CO2
capture.
Abstract: This article reports on the studies of porous GaN prepared by ultra-violet (UV) assisted electrochemical etching in a solution of 4:1:1 HF: CH3OH:H2O2 under illumination of an UV lamp with 500 W power for 10, 25 and 35 minutes. The optical properties of porous GaN sample were compared to the corresponding as grown GaN. Porosity induced photoluminescence (PL) intensity enhancement was found in these samples. The resulting porous GaN displays blue shifted PL spectra compared to the as-grown GaN. Appearance of the blue shifted emission is correlated with the development of highly anisotropic structures in the morphology. An estimate of the size of the GaN nanostructure can be obtained with the help of a quantized state effective mass theory.
Abstract: The potential of economically cheaper cellulose
containing natural materials like rice husk was assessed for nickel
adsorption from aqueous solutions. The effects of pH, contact time,
sorbent dose, initial metal ion concentration and temperature on the
uptake of nickel were studied in batch process. The removal of nickel
was dependent on the physico-chemical characteristics of the
adsorbent, adsorbate concentration and other studied process
parameters. The sorption data has been correlated with Langmuir,
Freundlich and Dubinin-Radush kevich (D-R) adsorption models. It
was found that Freundlich and Langmuir isotherms fitted well to the
data. Maximum nickel removal was observed at pH 6.0. The
efficiency of rice husk for nickel removal was 51.8% for dilute
solutions at 20 g L-1 adsorbent dose. FTIR, SEM and EDAX were
recorded before and after adsorption to explore the number and
position of the functional groups available for nickel binding on to
the studied adsorbent and changes in surface morphology and
elemental constitution of the adsorbent. Pseudo-second order model
explains the nickel kinetics more effectively. Reusability of the
adsorbent was examined by desorption in which HCl eluted 78.93%
nickel. The results revealed that nickel is considerably adsorbed on
rice husk and it could be and economic method for the removal of
nickel from aqueous solutions.
Abstract: Electrochemical-oxidation of Reactive Black-5 (RB- 5) was conducted for degradation using DSA type Ti/RuO2-SnO2- Sb2O5 electrode. In the study, for electro-oxidation, electrode was indigenously fabricated in laboratory using titanium as substrate. This substrate was coated using different metal oxides RuO2, Sb2O5 and SnO2 by thermal decomposition method. Laboratory scale batch reactor was used for degradation and decolorization studies at pH 2, 7 and 11. Current density (50mA/cm2) and distance between electrodes (8mm) were kept constant for all experiments. Under identical conditions, removal of color, COD and TOC at initial pH 2 was 99.40%, 55% and 37% respectively for initial concentration of 100 mg/L RB-5. Surface morphology and composition of the fabricated electrode coatings were characterized using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) respectively. Coating microstructure was analyzed by X-ray diffraction (XRD). Results of this study further revealed that almost 90% of oxidation occurred within 5-10 minutes.
Abstract: Herein, we report the different types of surface morphology due to the interaction between the pure protein Insulin (INS) and catanionic surfactant mixture of Sodium Dodecyl Sulfate (SDS) and Cetyl Trimethyl Ammonium Bromide (CTAB) at air/water interface obtained by the Langmuir-Blodgett (LB) technique. We characterized the aggregations by Scanning Electron Microscopy (SEM), Atomic Force Microscopy (AFM) and Fourier transform infrared spectroscopy (FTIR) in LB films. We found that the INS adsorption increased in presence of catanionic surfactant at air/water interface. The presence of small amount of surfactant induces two-stage growth kinetics due to the pure protein absorption and protein-catanionic surface micelle interaction. The protein remains in native state in presence of small amount of surfactant mixture. Smaller amount of surfactant mixture with INS is producing surface micelle type structure. This may be considered for drug delivery system. On the other hand, INS becomes unfolded and fibrillated in presence of higher amount of surfactant mixture. In both the cases, the protein was successfully immobilized on a glass substrate by the LB technique. These results may find applications in the fundamental science of the physical chemistry of surfactant systems, as well as in the preparation of drug-delivery system.
Abstract: This study describes the preparation of a novel proton
conducting membranes based on bacterial cellulose (BC) modified by
grafting of 2-acrylamido-2-methyl-1 -propanesulfonic acid (AMPS)
through UV-induced graft polymerization. These AMPS-g-BC
membranes have been characterized by various techniques including
FTIR, SEM and TGA, to find their successful grafting of AMPS on
BC, surface morphology and thermal stability, respectively. Physical
properties of AMPS-g-BC membranes have been assessed in terms of
Lamda value( λ ), ion exchange capacity(IEC) and proton
conductivity. The relationship between degree of grafting and AMPS
concentration used for grafting has been determined by weight gain
method. An optimum proton conductivity equal to 2.89x10-2 S cm-1
and IEC value equal to 1.79 mmol g-1 have been obtained when 20
wt% AMPS concentration is used for grafting (i.e. the corresponding
membrane is notated as AMPS20-g-BC).
Abstract: ZnO-SnO2 i.e. Zinc-Tin-Oxide (ZTO) thin films were
deposited on glass substrate with varying concentrations (ZnO:SnO2
- 100:0, 90:10, 70:30 and 50:50 wt.%) at room temperature by flash
evaporation technique. These deposited ZTO film were annealed at
450 0C in vacuum. These films were characterized to study the effect
of annealing on the structural, electrical, and optical properties.
Atomic force microscopy (AFM) and Scanning electron microscopy
(SEM) images manifest the surface morphology of these ZTO thin
films. The apparent growth of surface features revealed the formation
of nanostructure ZTO thin films. The small value of surface
roughness (root mean square RRMS) ensures the usefulness in
optical coatings. The sheet resistance was also found to be decreased
for both types of films with increasing concentration of SnO2. The
optical transmittance found to be decreased however blue shift has
been observed after annealing.
Abstract: In this paper, Zinc Oxide (ZnO) thin films are deposited on glass substrate by sol-gel method. The ZnO thin films with well defined orientation were acquired by spin coating of zinc acetate dehydrate monoethanolamine (MEA), de-ionized water and isopropanol alcohol. These films were pre-heated at 275°C for 10 min and then annealed at 350°C, 450°C and 550°C for 80 min. The effect of annealing temperature and different thickness on structure and surface morphology of the thin films were verified by Atomic Force Microscopy (AFM). It was found that there was a significant effect of annealing temperature on the structural parameters of the films such as roughness exponent, fractal dimension and interface width. Thin films also were characterizied by X-ray Diffractometery (XRD) method. XRD analysis revealed that the annealed ZnO thin films consist of single phase ZnO with wurtzite structure and show the c-axis grain orientation. Increasing annealing temperature increased the crystallite size and the c-axis orientation of the film after 450°C. Also In this study, ZnO thin films in different thickness have been prepared by sol-gel method on the glass substrate at room temperature. The thicknesses of films are 100, 150 and 250 nm. Using fractal analysis, morphological characteristics of surface films thickness in amorphous state were investigated. The results show that with increasing thickness, surface roughness (RMS) and lateral correlation length (ξ) are decreased. Also, the roughness exponent (α) and growth exponent (β) were determined to be 0.74±0.02 and 0.11±0.02, respectively.
Abstract: A novel nanofinishing process using improved ball
end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled
ball end of smart MR polishing fluid is generated at the tip surface of
the tool which is used as a finishing medium and it is guided to
follow the surface to be finished through computer controlled 3-axes
motion controller. The experiments were performed on ferromagnetic
workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance
of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning
electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface
roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace,
automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.
Abstract: n-CdO/p-Si heterojunction diode was fabricated using
sol-gel spin coating technique which is a low cost and easily scalable
method for preparing of semiconductor films. The structural and
morphological properties of CdO film were investigated. The X-ray
diffraction (XRD) spectra indicated that the film was of
polycrystalline nature. The scanning electron microscopy (SEM)
images indicate that the surface morphology CdO film consists of the
clusters formed with the coming together of the nanoparticles. The
electrical characterization of Au/n-CdO/p–Si/Al heterojunction diode
was investigated by current-voltage. The ideality factor of the diode
was found to be 3.02 for room temperature. The reverse current of
the diode strongly increased with illumination intensity of 100
mWcm-2 and the diode gave a maximum open circuit voltage Voc of
0.04 V and short-circuits current Isc of 9.92×10-9 A.
Abstract: In this investigation, anatase TiO2 thin films were
grown by radio frequency magnetron sputtering on glass substrates at
a high sputtering pressure and room temperature. The anatase films
were then annealed at 300-600 °C in air for a period of 1 hour. To
examine the structure and morphology of the films, X-ray diffraction
(XRD) and atomic force microscopy (AFM) methods were used
respectively. From X-ray diffraction patterns of the TiO2 films, it was
found that the as-deposited film showed some differences compared
with the annealed films and the intensities of the peaks of the
crystalline phase increased with the increase of annealing
temperature. From AFM images, the distinct variations in the
morphology of the thin films were also observed. The optical
constants were characterized using the transmission spectra of the
films obtained by UV-VIS-IR spectrophotometer. Besides, optical
thickness of the film deposited at room temperature was calculated
and cross-checked by taking a cross-sectional image through SEM.
The optical band gaps were evaluated through Tauc model. It was
observed that TiO2 films produced at room temperatures exhibited
high visible transmittance and transmittance decreased slightly with
the increase of annealing temperatures. The films were found to be
crystalline having anatase phase. The refractive index of the films
was found from 2.31-2.35 in the visible range. The extinction
coefficient was nearly zero in the visible range and was found to
increase with annealing temperature. The allowed indirect optical
band gap of the films was estimated to be in the range from 3.39 to
3.42 eV which showed a small variation. The allowed direct band
gap was found to increase from 3.67 to 3.72 eV. The porosity was
also found to decrease at a higher annealing temperature making the
film compact and dense.
Abstract: This paper was aimed at developing a computer aided
design and manufacturing system for spatial cylindrical cams. In the
proposed system, a milling tool with a diameter smaller than that of the
roller, instead of the standard cutter for traditional machining process,
was used to generate the tool path for spatial cams. To verify the
feasibility of the proposed method, a multi-axis machining simulation
software was further used to simulate the practical milling operation of
spatial cams. It was observed from computer simulation that the tool
path of small-sized cutter were within the motion range of a standard
cutter, no occurrence of overcutting. Examination of a finished cam
component clearly verifies the accuracy of the tool path generated for
small-sized milling tool. It is believed that the use of small-sized cutter
for the machining of the spatial cylindrical cams can generate a better
surface morphology with higher accuracy. The improvement in
efficiency and cost for the manufacturing of the spatial cylindrical cam
can be expected through the proposed method.
Abstract: Group-III nitride material as particularly AlxGa1-xN is
one of promising optoelectronic materials to require for shortwavelength
devices. To achieve the high-quality AlxGa1-xN films for
a high performance of such devices, AlN-nucleation layers are the
important factor. To improve the AlN-nucleation layers with a
variation of Ga-addition, XRD measurements were conducted to
analyze the crystalline quality of the subsequent Al0.1Ga0.9N with the
minimum ω-FWHMs of (0002) and (10-10) reflections of 425 arcsec
and 750 arcsec, respectively. SEM and AFM measurements were
performed to observe the surface morphology and TEM
measurements to identify the microstructures and orientations.
Results showed that the optimized Ga-atoms in the Al(Ga)Nnucleation
layers improved the surface diffusion to form moreuniform
crystallites in structure and size, better alignment of each
crystallite, and better homogeneity of island distribution. This, hence,
improves the orientation of epilayers on the Si-surface and finally
improves the crystalline quality and reduces the residual strain of
subsequent Al0.1Ga0.9N layers.