Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

The objective of this research is to investigate the mechanical properties including bonding, tensile strength, and impact resistance of pure copper welded using friction stir welding (FSW) method and compare them with that of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper, TIG welded copper and FSW welded copper to determine the effect of heat on the hardness of welded coppers. Tensile strength tests and notch tensile strength tests are performed to determine the mechanical properties of different weld process.In this experiment, it is found that the notch tensile strength and the notch strength ratio for FSW (212 MPa, 1.10) are significantly higher than those (190 MPa, 1.02) of TIG welding. For the impact tests, the weld zone and heat-affected zone energy absorption values for FSW (2.87 J, 2.25 J) are higher than those (1.32 J, 0 J) of TIG welding. XRD tests are performed to determine components of copper before and after welding process for TIG and FSW.     

Numerical modelling of electrohydraulic free-forming and die-forming of DP590 steel

Electrohydraulic forming (EHF) is a high energy rate forming process in which the strain rate in the sheet metal can vary from 5 × 10² to 10⁵ s⁻¹ depending on various factors. Several mechanisms have been reported to cause an improvement in formability in EHF such as material deformation mechanisms, inertial effects and the dynamic impact of the sheet against the die. EHF is a complex high speed forming process and experimental work alone is not sufficient to properly understand this process. To understand the variation of some influential variables in EHF, electrohydraulic die-forming (EHDF) and free-forming (EHFF) of DP590 dual phase steel were simulated in ABAQUS/Explicit by considering the fluid/structure interactions. Three-dimensional finite element simulations were conducted by modelling the water with Eulerian elements with a view to investigating the effect of released energy on the sheet deformation profile history, strain distribution, loading path and damage accumulation type. The Johnson–Cook constitutive material model was used to predict the sheet behaviour and the parameters in this model were calibrated based on experimental test results available for DP590 at various strain rates. The Johnson–Cook phenomenological damage model was also used to predict the ductile failure (damage accumulation) in both EHDF and EHFF. Predicted final strain values and damage accumulation type showed good agreement with the experimental observations.     

A comparative study on the effect of GTAW processes on the microstructure and mechanical properties of P91 steel weld joints

Modified 9Cr-1Mo (P91) steel is widely used in the construction of power plant components. In the present study, a comparative study on influence of activated flux tungsten inert gas (A-TIG), and gas tungsten arc (GTA) welding processes on the microstructure and the impact toughness of P91 steel welds was carried out. P91 steel welds require a minimum of 47 J during the hydrotesting of vessels as per the EN1557: 1997 specification. Toughness of P91 steel welds was found to be low in the as-weld condition. Hence post-weld heat treatment (PWHT) was carried out on weld with the objective of improving the toughness of weldments. Initially as per industrial practice, PWHT at 760 °C – 2 h was carried out in order to improve the toughness of welds. It has been found that after PWHT at 760 °C – 2 h, GTA weld (132 J) has higher toughness than the required toughness (47 J) as compared with A-TIG weld (20 J). The GTA weld has higher toughness due to enhanced tempering effects due to multipass welding, few microinclusion content and absence of δ-ferrite. The A-TIG weld requires prolonged PWHT (i.e. more than 2 h at 760 °C) than GTA weld to meet the required toughness of 47 J. This is due to harder martensite, few welding passes that introduces less tempering effects, presence of δ-ferrite (0.5%), and more alloy content. After PWHT at 760 °C – 3 h, the toughness of A-TIG weld was improved and higher than the required toughness of 47 J.     

Energy based phenomenological model for optimizing the sheared edge in the trimming of steels

Attributes related to the dimensional quality of hot rolled steels are very important in commercial sectors that make direct use of this product, because delay or equipment damage can be avoided when forming in downstream operations. In this research, the steel sheet edge trimming process and its relationship with the defect known as broken edge is experimental and numerically studied. The type of material, horizontal clearance between knives and the energy spent during the cutting process are analyzed in detail. A metal-mechanical study is carried out for obtaining a microstructural hardness and flow stress characterization. Consequently, the edge trimming process is FEM simulated and its results in relation to knife penetration and shear stress lead to determining the energy spent during the cutting process. A mathematical model is determined under the consideration that minimum energy gives the optimum cutting conditions. The model proposes a reliable value for the horizontal clearance (H_c), between knives, taking as the principal factors: energy consumed during the edge trimming process, sheet thickness (T_h), carbon content (C) and/or its ultimate tensile strength, expressed as: H_c = α + βT_h − γC. A comparison of the recommended numerical results with the best practical conditions is carried out and a high coincidence is successfully found. This model is expected to be easily adopted as a tool where operators can adjust and control the parameters of process, and then, as a result, produce a sheet without edge trimming defects as well as a reduction in efficiency costs.     

Inhibitive effects of chlortetracycline on performance of the nitritation-anaerobic ammonium oxidation (anammox) process and strategies for recovery

The short-and long-term effects of chlortetracycline(CTC) on the nitritation-anaerobic ammonium oxidation(anammox) process were evaluated. The half maximal inhibitory concentration of CTC in the batch tests of the nitritation-anammox process was 278.91 mg/L at an exposure time of 12 hr. The long-term effects of CTC on the process were examined in a continuous-flow nitritation-anammox reactor. Within 14 days, the nitrogen removal rate significantly decreased from 0.61 to 0.25 kg N/m~3/day with 60 mg/L CTC in the influent.The performance suppressed by CTC barely recovered, even after CTC was removed from the influent. Furthermore, the inhibition of CTC also reduced the relative abundance of ammonium oxidizing bacteria(AOB) and anaerobic ammonium oxidizing bacteria(An AOB)in the reactor, resulting in both a decreased amount of and an imbalance between AOB and An AOB. When fresh anammox sludge was reseeded into the nitritation-anammox reactor,the nitrogen removal rate recovered to 0.09 ± 0.03 kg N/m~3/day.     

Effect of air-exposed biocathode on the performance of a Thauera-dominated membraneless single-chamber microbial fuel cell (SCMFC)

To investigate the effect of air-exposed biocathode(AEB) on the performance of singlechamber microbial fuel cell(SCMFC), wastewater quality, bioelectrochemical characteristics and the electrode biofilms were researched. It was demonstrated that exposing the biocathode to air was beneficial to nitrogen removal and current generation. In Test 1 of 95%AEB, removal rates of ammonia, total nitrogen(TN) and chemical oxygen demand(COD)reached 99.34% ± 0.11%, 99.34% ± 0.10% and 90.79% ± 0.12%, respectively. The nitrogen removal loading rates were 36.38 g N/m~3/day. Meanwhile, current density and power density obtained at 0.7 A/m3 and 104 m W/m~3 respectively. Further experiments on opencircuit(Test 2) and carbon source(Test 3) indicated that this high performance could be attributed to simultaneous biological nitrification/denitrification and aerobic denitrification, as well as bioelectrochemical denitrification. Results of community analysis demonstrated that both microbial community structures on the surface of the cathode and in the liquid of the chamber were different. The percentage of Thauera, identified as denitrifying bacteria, maintained at a high level of over 50% in water, but decreased gradually in the AEB. Moreover, the genus Nitrosomonas, Alishewanella, Arcobacter and Rheinheimera were significantly enriched in the AEB, which might contribute to both enhancement of nitrogen removal and electricity generation.     

Modeling tensile strength of materials processed by accumulative roll bonding

Nanostructured materials are a relatively new class of materials that exhibit advanced mechanical properties, thus improving performance and capabilities of products, with potential applications in the automotive, aerospace and defense industries. Among the severe plastic deformation (SPD) methods currently used for achieving nanoscale structures, accumulative roll bonding (ARB) is the most favorable method to produce grain refinement for continuous production of metallic sheets at a bulk scale.In this article, a model that describes the evolution of material strength due to processing via accumulative roll bonding was developed. ARB experiments were conducted on CP-Ti Grade 2 at a selected set of conditions. The results showed significant grain refinement in the microstructure (down to ～120 nm) and a two-fold increase in tensile strength as compared to the as-received material. The developed model was validated using the experimental data, and exhibited a good fit over the entire range of ARB processing cycles. To further validate the model and ensure its robustness for a wider array of materials (beyond CP-Ti), a review of efforts on ARB processing was carried out for five other materials with different initial microstructures, mechanical properties, and even crystalline structures. The model was still able to capture the strengthening trends in all considered materials.     

Shape calibration of high strength metal sheets by electromagnetic forming

Electromagnetic (EM) forming is an emerging technique that is gaining acceptance for its complementary benefits to conventional metal forming techniques. In this work an innovative application of this impulse forming technique has been demonstrated: the EM shape calibration and correction of springback (sidewall curl) of DP600 and TRIP700 high strength steel (HSS) workpieces. This method has been applied as a second corrective step to previously deep drawn U-channels. The experimental results confirm the sidewall curl angle correction, achieving them with a 22 kJ discharge for DP600 samples and 24 kJ for TRIP700.On the other hand, an uncoupled multiphysical simulation strategy has been carried out in order to virtually validate the EM shape calibration method. The EM fields were simulated by Maxwell 3D and then the Pamstamp code was used to obtain the deformation process.     

Toward chemical-free reclamation of biologically pretreated greywater: solar photocatalytic oxidation with powdered activated carbon

Heterogeneous photocatalytic oxidation is a water reclamation technology which avoids chemical consumption and can be powered by solar radiation. Because this generally sustainable process is of limited efficiency for the treatment of biologically pretreated greywater, it was combined with activated carbon adsorption. The effluent of a constructed wetland for treatment of separately collected greywater was subjected to photocatalytic oxidation using the photocatalyst titanium dioxide (TiO₂) “P25” in both the absence and the presence of powdered activated carbon (PAC). Photocatalytic oxidation alone with UV fluences of about 10 Wh L^?1 was not capable of reducing total organic carbon (TOC) from an initial concentration of 5.5 mg L^?1 safely below 2 mg L^?1 as a prerequisite for high-quality water reuse purposes. However, when PAC was added, TOC concentrations subsequent to photocatalytic oxidation were less than 2 mg L^?1 even after reusing the TiO₂/PAC mixture 10 times. PAC addition is estimated to reduce the insolation area necessary to achieve this target by solar photocatalytic oxidation of biologically treated greywater by a factor 7. This combination process represents an innovative chemical-free technology within wastewater reuse schemes.     

Effect of oxide-based fluxes on mechanical and metallurgical properties of Dissimilar Activating Flux Assisted-Tungsten Inert Gas Welds

Present investigation is to study the “Effect of Activating Fluxes on Mechanical and Metallurgical Properties of Dissimilar Activated Flux-Tungsten Inert Gas Welds”. Effect of current, welding speed, joint gap and electrode diameter on weld bead dimensions on 6 mm thick dissimilar weld between carbon steel to stainless steel, was studied under Activated Flux-Tungsten Inert Gas Welding process. During this investigation three different types of oxide powders were used-TiO₂, ZnO and MnO₂. After welding samples were subject to mechanical testing, in addition to characterization via micro hardness and microstructures of Normal Tungsten Inert Gas Welds and Activated Flux-Tungsten Inert Gas Welds. Activating fluxes TiO₂ and ZnO are effective fluxes for Activated Flux-Tungsten Inert Gas Welding of dissimilar weld between CS to SS. Highest depth/width (D/W) ratio reported under TiO₂ and ZnO fluxes compare to Normal-Tungsten Inert Gas Welds. Lowest angular distortion was observed under TiO₂ flux compare to Normal-Tungsten Inert Gas Welds. Mechanical properties, Joint Efficiency of Activated Flux-Tungsten Inert Gas Welds are higher than normal-Normal Tungsten Inert Gas Welds. Tensile Test specimens of both the processes failed from the parent metal (carbon steel side). Carbon migration from CS to SS, had occurred which led to failure of weld joints from CS side.     

Metal-cored arc welding process for joining of modified 9Cr-1Mo (P91) steel

In the present work, metal-cored arc welding process was used for joining of modified 9Cr-1Mo (P91) steel. Metal-cored arc welding process is characterized by high productivity, slag-free process, defect-free weldments that can be produced with ease, and good weldability. Toughness is essential in welds of P91 steel during hydro-testing of vessels. There is a minimum required toughness of 47 J for welds that has to be met as per the EN1557:1997 specification. In the present study, welds were completed using two kinds of shielding gases, each composition being 80% Argon + 20% CO₂, and pure argon respectively. Microstructural characterization and toughness evaluation of welds were done in the as – weld, PWHT at 760 °C – 2 h and PWHT at 760 °C – 5 h conditions. The pure argon shielded welds (‘A2’ and ‘B2’) have higher toughness than 80% argon + 20% CO₂ shielded welds (‘A1’ and ‘B1’). Pure argon shielded welds show less microinclusion content with low volume fraction of δ-ferrite (<2%) phase. Themo-calc windows (TCW) was used for the prediction of equilibrium critical transformation points for the composition of the welds studied. With increase in post-weld heat treatment (PWHT) duration from 2 h to 5 h, there was increase in toughness of welds above 47 J. Using metal-cored arc welding process, it was possible to achieve the required toughness of more than 47 J after PWHT at 760 °C – 2 h in P91 steel welds.     

Innovative cleaner production for steel phosphorization using Zn–Mn phosphating solution

Phosphating prior to coating for steel is usually needed. In this paper, an innovative cleaner production has been developed for steel surface treatment using Zn–Mn phosphating solution in which there was no nitrite. The mass of the Zn–Mn layer deposited in this new process was about 1.1 g m^?2 when the temperature ranged from 3 to 35 °C. The corrosion time for the color phosphating layer in the copper sulfate spot test was in the range of 72–145 s. Adhesion test showed that the coating layers achieved a higher adhesion load than those produced by conventional methods. Washing using water was not necessary in this cleaner phosphorization, which usually follows phosphorization in traditional processes of steel phosphorization. Consequently, wastewater discharge was reduced greatly.     

Twin-roll casting of aluminum–steel clad strips

The results of experiments on twin-roll casting of aluminum–steel clad strips are presented. For the first time this energy-saving production technology for a clad material of this metals combination was implemented. Besides the experimental equipment and processing details, the results of metallographic, electron microprobe and transmission electron microscopy analysis of the aluminum–steel interface are shown. The pack rolling and deep-drawing tests of the twin-roll cast clad strips were performed to check their applicability for a further processing using plastic deformation. In addition adhesive strength of the bond was tested. The performed analysis have shown the formation of a continuous, thin and uniform layer of intermetallic phases on the materials interface of approx. 3 μm thickness having an adhesive strength over 70 MPa.     

An innovative approach to minimize excess sludge production in sewage treatment using integrated bioreactors

The present investigation deals with an application of integrated sequential oxic and anoxic bioreactor(SOABR) and fluidized immobilized cell carbon oxidation(FICCO) reactor for the treatment of domestic wastewater with minimum sludge generation. The performance of integrated SOABR-FICCO system was evaluated on treating the domestic wastewater at hydraulic retention time(HRT) of 3 hr and 6 hr for 120 days at organic loading rate(OLR)of 191 ± 31 mg/(L·hr). The influent wastewater was characterized by chemical oxygen demand(COD) 573 ± 93 mg/L; biochemical oxygen demand(BOD5) 197 ± 35 mg/L and total suspended solids(TSS) 450 ± 136 mg/L. The integrated SOABR-FICCO reactors have established a significant removal of COD by 94% ± 1%, BOD5 by 95% ± 0.6% and TSS by 95% ± 4% with treated domestic wastewater characteristics COD 33 ± 5 mg/L; BOD59 ± 0.8 mg/L and TSS 17 ± 9 mg/L under continuous mode of operation for 120 days. The mass of dry sludge generated from SOABR-FICCO system was 22.9 g/m~3. The sludge volume index of sludge formed in the SOABR reactor was 32 mL/g and in FICCO reactor it was 46 mL/g. The sludge formed in SOABR and FICCO reactor was characterized by TGA, DSC and SEM analysis. Overall, the results demonstrated that the integrated SOABR-FICCO reactors substantially removed the pollution parameters from domestic wastewater with minimum sludge production.     

Recycling thin film transistor liquid crystal display (TFT-LCD) waste glass produced as glass–ceramics

The waste electrical and electronic equipment (WEEE) directives are designed to deal with the rapidly increasing waste stream comprised of electrical and electronic equipment. Recycling electrical and electronic equipment reduces the quantity of waste going to final disposal. The demand for thin film transistor liquid crystal display (TFT-LCD) panels, commonly used in everyday electronic products, is increasing. Conventionally adopted treatments of TFT-LCD waste glass cannot meet WEEE directives. This study adopts the following operating conditions in fabricating glass–ceramics: sintering temperature of 800–950 °C; sintering time of 6 h; and, temperature increase rate of 5 °C/min. The glass–ceramic samples then underwent a series of tests, including the Vickers hardness, water absorption and porosity tests, to determine product quality. The Vickers hardness was 12.1 GPa when fired at 900 °C for 6 h, and density was 2.4 g/cm³ and water absorption was 0%. Thus, TFT-LCD waste glass can be regarded as a good glass–ceramic material.     

Effect of Silicon Powder Mixed EDM on Machining Rate of AISI D2 Die Steel

In this paper, the effect of silicon powder mixing into the dielectric fluid of EDM on machining characteristics of AISI D2 (a variant of high carbon high chrome) die steel has been studied. Six process parameters, namely peak current, pulse-on time, pulse-off time, concentration of powder, gain, and nozzle flushing have been considered. The process performance is measured in terms of machining rate (MR). The research outcome will identify the important parameters and their effect on MR of AISI D2 in the presence of suspended silicon powder in a kerosene dielectric of EDM. The study indicated that all the selected parameters except nozzle flushing have a significant effect on the mean and variation in MR (S/N ratio). Optimization to maximize MR has also been undertaken using the Taguchi method. The ANOVA analysis indicates that the percentage contribution of peak current and powder concentration toward MR is maximum among all the parameters. The confirmation runs showed that the setting of peak current at a high level (16 A), pulse-on time at a medium level (100 μs), pulse-off time at a low level (15 μs), powder concentration at a high level (4 g/l), and gain at a low level (0.83 mm/s) produced optimum MR from AISI D2 surfaces when machined by silicon powder mixed EDM.     

Using micro deep drawing with ironing stages to form stainless steel 304 micro cups

The needs of stainless steel 304 micro cups have been increasing tremendously due to the trend of miniaturization in medical and electronic devices, etc. For application purpose, it is highly desired to have stainless steel micro cups with high CH/OD (cup height/outer diameter) ratios. Due to the constraints of the limit draw ratio (LDR) of stainless steel 304 sheets in micro deep drawing, forming a micro cup with high CH/OD ratio at room temperature cannot be achieved by using a single stage deep drawing die. A process consisting of one micro deep drawing and two ironing stages was proposed for achieving this goal; three micro dies were designed, fabricated and used for experimental validation. A series of experiments were conducted by using the stainless steel 304 sheets of 200 μm thickness annealed at four different temperatures to understand the influence of size effects on this process for generating knowledge, know-how and technologies to form high quality stainless steel micro cups with large CH/OD ratio. No lubricant was used in this study. It was proven that the proposed process is a robust process as long as the sheets are annealed at the temperature no less than 900 °C for more than 3 min.     

Community structures and population dynamics of “Candidatus Accumulibacter” in activated sludges of wastewater treatment plants using ppk1 as phylogenetic marker

Candidatus Accumulibacter has been identified as dominant polyphosphate-accumulating organisms(PAOs) in enhanced biological phosphorus(P) removal(EBPR) from wastewater.This study revealed the relevance of community structure, abundance and seasonal population dynamics of Candidatus Accumulibacter to process operation of wastewater treatment plants(WWTPs) in China using ppk1 gene as phylogenetic marker. All sludge samples had properties of denitrifying P removal using nitrate as an electron acceptor.Accumulibacter abundance in the anaerobic-anoxic-oxic(A~2O) process was the highest(26%of total bacteria), and higher in winter than in summer with a better EBPR performance.Type-II was the dominant Accumulibacter in all processes, and type-I accounted for a small proportion of total Accumulibacter. The abundance of Clade-IIC as the most dominant clade reached 2.59 × 10~9 cells/g MLSS and accounted for 87.3% of total Accumulibacter. Clade IIC mainly contributed to denitrifying P removal. Clades IIA, IIC and IID were found in all processes, while clade-IIF was only found in oxidation ditch process through phylogenetic analysis. High proportion of clade IID to total Accumulibacter led to poor performance of aerobic P-uptake in inverted A~2O process. Therefore, Accumulibacter clades in WWTPs were diverse, and EBPR performance was closely related to the clade-level community structures and abundances of Accumulibacter.     

Carbon footprint of sugar produced from sugarcane in eastern Thailand

Carbon footprint (CFP) of sugar produced from sugarcane in eastern Thailand was estimated from greenhouse gas emissions (CO₂, CH₄, and N₂O) during the sugarcane cultivation and milling process. The use of fossil fuels, chemical and organic fertilizer and sugarcane biomass data during cultivation were collected from field surveys, questionnaires and interviews. Sugar mill emissions, fossil fuel utilization and greenhouse gas emission from wastewater treatments were included. The results show that sugar production has a carbon footprint of 0.55 kg CO₂e kg^?1 sugar. This carbon footprint was a sum of 0.49 kg CO₂e kg^?1 sugar from sugarcane cultivation and 0.06 kg CO₂e kg^?1 sugar from the milling process. For the cultivation part, most of the GHGs emissions were from fertilizer, fossil fuel use and biomass burning. The CFP in eastern Thailand is sensitive to the type of data selected for calculation and of variations of farm inputs during sugarcane cultivation. There was no significant difference of CFP among farm sizes, although small farms tended to give a relatively higher CFP than that of medium and large farms.     

Soil carbon sequestration in tropical agroforestry systems: a feasibility appraisal

Agroforestry is recognized as a strategy for soil carbon sequestration (SCS) under the afforestation/reforestation activities, but our understanding of soil carbon (C) dynamics under agroforestry systems (AFS) is not adequate. Although some SCS estimates are available, many of them lack scientific rigor. Several interrelated and site-specific factors ranging from agroecological conditions to system management practices influence the rate and extent of SCS under AFS, so that generalizations tend to become unrealistic. Furthermore, widely and easily adoptable methodologies are not available for estimating the SCS potential under different conditions. In spite of these, there is an increasing demand for developing “best-bet estimates” based on the current level of knowledge and experience. This document presents an attempt in that direction. The appraisal validates the conjecture that AFS can contribute to SCS, and presents indicative ranges of SCS under different AFS in the major agroecological regions of the tropics. The suggested values range from 5 to 10 kg C ha^?1 in about 25 years in extensive tree-intercropping systems of arid and semiarid lands to 100–250 kg C ha^?1 in about 10 years in species-intensive multistrata shaded perennial systems and homegardens of humid tropics.