A method for double-sided friction stir spot welding

A rotating anvil similar to a pinless friction stir welding (FSW) tool can be applied to friction stir spot welding (FSSW) of thin metal plates. FSSW is a solid-state joining process that is currently being used by automotive manufacturers as an alternative to rivets and traditional resistance spot welding. The principal detractor of this process is the keyhole left by pin extraction, which can be detrimental to the weld strength. A pinless tool can be used to eliminate the keyhole. However, this approach is limited to joining thin sheet (≤1 mm). Using a rotating anvil with the FSSW process permits the joining of thicker cross sections, improves the mechanical strength of the spot weld and reduces the reaction forces on the spot welding frame. A numerical model of the process, tensile shear tests and macrosection analysis are used to evaluate the spot welds.Macrosection and numerical analysis reveals that the material flow between the pinless tool and rotating anvil is complex and unique to this process. It has been found that the use of a rotating anvil for FSSW is a viable means to create quality spot welds in thicker weldments.     

Shared control of robotic friction stir welding in the presence of imperfect joint fit-up

In this paper a shared control strategy is presented that allows a skilled operator to identify irregularities that occur during robotic friction stir welding (FSW) and assist the robotic system in producing an appropriate response. Human operators are adept at identifying disturbances; however, the complexity of the friction stir welding process makes it difficult for the operator to respond. While examining the capabilities of shared control in friction stir welding, this paper focuses on responding to defects that are caused by a lack of workpiece material during butt welding, such as gaps. A compensation strategy is presented that combines the human operator's perceptual strengths with an automated procedure for adjustment of the process parameters (i.e. travel angle and plunge depth). Experiments comparing four control strategies are performed while welding 5083-H116 aluminum. Through our experiments we demonstrate that if the FSW control task is appropriately shared between the human operator and the computer control system, the weld quality (strength) can be improved (from 9 ksi to 31 ksi for a gap size of 2.5 mm) as compared with the nominal case in which no corrections are made.     

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.     

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.     

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.     

Strength assessment using destructive testing on MIAB welded alloy steel tubes and subsequent techno-economical evaluation

In this study, an attempt is being made to determine the feasibility of Magnetically Impelled Arc Butt (MIAB) welding process for joining alloy steel tubes in pressure parts. In view of this, a specially made state of art MIAB welding unit (MD1) available at WRI, BHEL, Tiruchirappalli has been employed and adequate number of welding trials is conducted to weld alloy steel tubes of 6–7 mm thickness for boiler applications. The combination of a set of values provided as input is varied for each trial. The welding current and the welding time are divided into three and four stages respectively. For each trial, either the current in stage II is varied or the time for stage III is varied while maintaining the other input parameters constant. These trials are carried out mainly to develop an optimum window (working range) for the process parameters. Further, the strength of MIAB welded specimens are examined by subjecting the welded specimens to various destructive tests. It is observed that the weld region is stronger than the base metal in most of the cases.In the next part of the study, the characteristics of MIAB welded joints for T11 steel tubes are compared with those using flash butt welding and induction pressure welding that is presently employed for alloy steel tube joining in pressure parts. It is found that the manufacturing time and incurred cost per weld drastically reduces while simultaneously increasing the productivity. Hence, the feasibility of MIAB welding process for pressure part is established.     

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.     

Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections with constant heat input: A study using numerical simulation and experimental validation

The temperature distribution and residual stresses for a GTAW circumferential butt joint of AISI 304 stainless steel using numerical simulation have been evaluated. For evaluation of weld induced residual stresses, the analysis of heat source fitting was carried out with heat inputs ranging from 200 to 500 J/mm to arrive at optimal heat input for obtaining proper weld penetration and heat affected zone (HAZ). For this chosen heat input, the influence of different weld speeds and powers on the temperature distribution and the residual stresses is studied. The heat source analysis revealed the best choice of heat input as 300 J/mm. The residual stresses on the inner and outer surfaces, and along the radial direction were computed. Increase in temperature distribution as well as longitudinal and circumferential residual stresses was observed with the increase in weld speed and power. The validity of the results obtained from numerical simulation is demonstrated with full scale shop floor welding experiments.     

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.     

Investigation of chipping and wear of silicon wafer dicing

Wafer dicing chipping and blade wear processes in transient and steady stages were investigated. Dicing blades with two different diamond grit sizes were used to cut wafers. In the cutting experiments, the dicing blades with two different diamond grit sizes were used to cut wafers and for a given type of wafer, the cooling water temperature, cutting feed speed, and rotational speed were fixed. The chipping size, blade surface wear area and surface roughness of the wafer were measured at cutting distances of 50, 150, 300, 975, 1350, and 1900 m, respectively. Cutting debris of cutting distances of 300 m and 1900 m was collected and analyzed. The correlation between blade surface properties and chipping size was investigated. Based on this experimental system, attention is to pay to examine the correlation between blade surface properties and chipping size for transient stage and steady stage. In transient stage, the roughness of dicing blade increases rapidly. This will rapidly increase the chipping size. In steady stage, the chipping size decreases slowly with the decreasing roughness of blade surface. This concludes that blade surface condition is an important factor that affects the chipping size. Moreover, in transient stage, diamond grits that are salient or less bonded to the blade detach leave caves on the blade surface which increases surface roughness of the blade and the chipping size. In steady stage, the heights of grits become even and the chipping size decreases accordingly.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.     

Process modification in the scouring process of textile industry

The effects of scouring parameters on the scouring efficiency, including the weight ratio of de-sizing agent and fabric (5–80 g/g fabric), temperature of de-sizing agent tank (60–90 °C) and dipping time (2–8 s), were investigated. The results demonstrated that weight loss of sizing agent was significantly observed only in the de-sizing agent tank particularly in the first de-sizing tank and was found to a small extent in water tank. The optimum condition in the scouring machine was found at a de-sizing agent to fabric ratio of 20 g/g fabric, with a temperature of the first de-sizing agent tank of 80 °C, a temperature of the second de-sizing agent tank of 90 °C, and dipping time of fabric of 7 s. According to these conditions, more than 89% of the sizing agent was eliminated and only 3.52 mg/g fabric of sizing agent remained in the scoured fabric which was in an acceptable range for feeding to the down stream process known as dyeing process. Application of our results to actual textile plant has shown that there is a cost reduction due to improved utilization of rinse water, chemicals and energy in the process and consequent decreases in the generation of wastewater. Furthermore, the production capacity was increased from 30 m/min to 34.4 m/min.     

Innovative micro hole machining with minimum burr formation by the use of newly developed micro compound tool

The study focuses on the efforts for minimization of burr formation and improvement of hole surface roughness in micro through-hole machining. It deals with the development of micro compound tool which is consisting of a micro flat drill as the drilling part and a micro diamond-electroplated-grinding part for hole finishing. The finishing diameters of each drilling and grinding parts of the fabricated micro compound tool are 90 μm and 100 μm, respectively. The study focuses mainly on the effect of drill point angle and ultrasonic vibration applied during micro hole machining to the hole entrance and exit burrs formation. The used workpiece is made of stainless steel (SUS304) with a thickness of 100 μm. From the experiment, it was found that the tool having drill point angle of 118° resulted in a smaller burr formation although hole machining was conducted for 600 holes. Furthermore, the application of ultrasonic vibration during hole machining could improve the performance of the developed micro compound tool and decreased the burr size, especially the exit burr.     

Insight into the distribution of metallic elements in membrane bioreactor: Influence of operational temperature and role of extracellular polymeric substances

The distribution of metallic elements in a submerged membrane bioreactor(MBR) was revealed at different temperatures using inductively coupled plasma-optical emission spectrometry(ICP-OES), and the role of extracellular polymeric substances(EPS) was probed by integrating scanning electron microscopy(SEM) with confocal laser scanning microscopy(CLSM) over long-term operation. More metallic elements in the influent were captured by suspended sludge and built up in the fouling layer at lower temperature. The concentration of metallic elements in the effluent was 5.60 mg/L at 10°C operational temperature, far lower than that in the influent(51.35 mg/L). The total contents of metallic elements in suspended sludge and the membrane fouling layer increased to 40.20 and 52.19 mg/g at 10°C compared to 35.14 and 32.45 mg/g at 30°C, and were dominated by the organically bound fraction. The EPS contents in suspended sludge and membrane fouling layer sharply increased to 37.88 and 101.51 mg/g at 10°C, compared to 16.87 and 30.03 mg/g at 30°C. The increase in EPS content at lower temperature was responsible for the deposition of more metallic ions. The strong bridging between EPS and metallic elements at lower temperature enhanced the compactness of the fouling layer and further decreased membrane flux. This was helpful for understanding the mechanism of membrane fouling at different operational temperatures and the role of EPS, and also of significance for the design of cleaning strategies for fouled membranes after long-term operation.     

Irrigation of olive groves in Southern Italy with treated municipal wastewater: Effects on microbiological quality of soil and fruits

The use of municipal wastewater in agriculture requires a careful monitoring of a range of hygiene parameters. Yearly hygienic impact assessments on soil and fruit were made between 2000 and 2006 in an olive (Olea europaea L.) grove established near a municipal wastewater treatment plant in Southern Italy (Ferrandina–Basilicata region, 40°29′ N, 16°28′ E). The experimental grove was managed in two plots. The first plot, non-tilled, was drip irrigated daily with reclaimed wastewater. The second plot was unirrigated (i.e. rainfed) and subject to conventional management for the region. Samples of wetted soil from different depths and of treated wastewater were analysed for Escherichia coli, enterococci, sulphite-reducing Clostridium spores and Salmonella spp. Fruits were collected both from the canopy and from nets spread on the ground and analysed for faecal contamination. The average annual quantity of wastewater distributed was 293 mm. E. coli concentration in the wastewater varied considerably, being frequently above the stringent Italian mandatory limit of 10 CFU 100 mL^?1 and also the WHO limit of 1000 MPN 100 mL^?1. Salmonella was never detected in the wastewater, the soil or on the fruit samples. Slight increases in the other bacteria were observed in the wastewater-irrigated soil during the irrigation season and especially in the top 10 cm. Soil resilience and bacterial mortality/inactivation probably explains the seasonal decrease of soil bacteria content over the 7 years of the study. Because of their high resistance to disinfection treatments and to environmental conditions, the spores of the sulphite-reducing bacterium Clostridium could be useful as an indicator of contamination in future guidelines that might be enacted for the use of wastewater in agriculture. No significant microbial contamination was recorded on fruit harvested directly from the canopy of the wastewater-irrigated trees. Contaminations on fruits sampled from the ground in the wastewater-irrigated plot were always low and usually similar to, or lower than those observed on drupes collected from the rainfed plot. In the rainfed plot, the recorded occasional contaminations were probably due to a number of factors, such as grazing of farm stock, presence of wild animals and surface water runoff from adjacent agricultural areas. This work confirms that, under suitable conditions, low-quality wastewater can be useful as an additional water resource for olive irrigation in water-scarce Mediterranean environments.     

Headwater streams: neglected ecosystems in the EU Water Framework Directive. Implications for nitrogen pollution control

The European Union Water Framework Directive (WFD) aims to achieve the “good status” of waters by 2015, through monitoring and control of human impacts on “bodies of surface water” (BSWs), discrete elements for quality diagnosis and management. Headwater streams, however, are frequently neglected as they are not usually recognised as BSW. This poses limitations for the management of river catchments, because anthropogenic impacts on headwaters can constrain the quality of downstream rivers. To illustrate this problem, we compared nitrate levels and land use pressures in a small agricultural catchment with those recorded in the catchment in which it is embedded (Ega), and in the Ebro River Basin (NE Spain) comprising both. Agriculture greatly influenced water nitrate concentration, regardless of the size of the catchments: R² = 0.91 for headwater catchments (0.1–7.3 km²), and R² = 0.82 for Ebro tributary catchments (223–3113 km²). Moreover, nitrate concentration in the outlet of a non-BSW small river catchment was similar to that of the greater downstream BSW rivers. These results are of interest since, despite representing 76% of the length of the Ega catchment hydrographical network, only 3.1% of the length of the headwater streams has been identified as BSWs. Human activities affecting headwater streams should therefore be considered if the 2015 objective of the WFD is to be achieved.     

The influence of long term trends in pollutant emissions on deposition of sulphur and nitrogen and exceedance of critical loads in the United Kingdom

In the United Kingdom, as with other European countries, land-based emissions of NO_x and SO₂ have fallen significantly over the last few decades. SO₂ emissions fell from a peak of 3185 Gg S in 1970 to 344 Gg S in 2005 and are forecast by business-as-usual emissions scenarios to fall to 172 Gg by 2020. NO_x emissions were at a maximum of 951 Gg N in 1970 and fell to 378 by 2005 with a further decrease to 243 Gg N forecast by 2020. These large changes in emissions have not been matched by emissions changes for NH₃ which decreased from 315 Gg N in 1990 to 259 in 2005 and are forecast to fall to 222 by 2020. The Fine Resolution Atmospheric Multi-pollutant Exchange model (FRAME) has been applied to model the spatial distribution of sulphur and nitrogen deposition over the United Kingdom during a 15-year time period (1990–2005) and compared with measured deposition of sulphate, nitrate and ammonium from the national monitoring network. Wet deposition of nitrogen and sulphur was found to decrease more slowly than the emissions reductions rate. This is attributed to a number of factors including increases in emissions from international shipping and changing rates of atmospheric oxidation. The modelled time series was extended to a 50-year period from 1970 to 2020. The modelled deposition of SO_x, NO_y and NH_x to the UK was found to fall by 87%, 52% and 25% during this period. The percentage area of sensitive habitats in the United Kingdom for which critical loads are exceeded is estimated to fall from 85% in 1970 to 37% in 2020 for acidic deposition and from 73% to 49% for nutrient nitrogen deposition. The significant reduction in land emissions of SO₂ and NO_x focuses further attention in controlling emissions from international shipping. Future policies to control emissions of ammonia from agriculture will be required to effect further significant reductions in nitrogen deposition.     

Changes in soil respiration across a chronosequence of tallgrass prairie reconstructions

Close relationships among climatic factors and soil respiration (R_s) are commonly reported. However, variation in R_s across the landscape is compounded by site-specific differences that impede the development of spatially explicit models. Among factors that influence R_s, the effect of ecosystem age is poorly documented. We hypothesized that R_s increases with grassland age and tested this hypothesis in a chronosequence of tallgrass prairie reconstructions in central Iowa, U.S.A. We also assessed changes in root biomass, root ingrowth, aboveground net primary productivity (ANPP), and the strength of soil temperature and moisture in predicting R_s. We found a significant increase in total growing season R_s with prairie age (R² = 0.79), ranging from 714 g C m^?2 in the youngest reconstruction (age 4) to 939 g C m^?2 in the oldest prairie (age 12). Soil temperature was a strong predictor of intra-seasonal R_s among prairies (R² = 0.78–0.87) but mean growing season soil temperature and moisture did not relate to total R_s. The increase in R_s with age was positively correlated with root biomass (r = 0.80) and ANPP (r = 0.87) but not with root ingrowth. Our findings suggest that growing season R_s increases with tallgrass prairie age, root biomass, and ANPP during young grassland development.     

On the relationship between PM2.5 concentrations and regional-scale primary PM emissions for the United Kingdom: an issue of subsidiarity

A site-specific particulate matter PM source apportionment model has been used to estimate the contributions from local primary PM emissions, regional primary PM emissions and the regional background to PM_2.5 concentrations at 102 monitoring site locations and to the centres of 1 km × 1 km grid squares across the United Kingdom. The local primary PM contributions have then been compared with Europe-wide urban PM_2.5 increments estimated at 50 km × 50 km in European-scale integrated assessment models. It is concluded that Europe-wide PM increments used in policy analyses grossly underestimate urban PM concentrations obtained from the site-specific PM source apportionment model for the United Kingdom. Europe-wide urban PM_2.5 increments estimated at 5 km × 5 km scale are significantly improved, particularly for London, but underestimate those for smaller towns and cities by factors of 2–3. These underestimations have important air quality policy ramifications. Although environmental policies may well be best formulated at the European scale, the underpinning air quality modelling may be best carried out at the local scale.     

Analysis of temperature effects on seasonal and interannual variation in CH4 emission from rice-planted pots

Rice (Oryza sativa L.) paddies are one of the major sources of atmospheric methane (CH₄), a greenhouse gas. To elucidate the quantitative relationship between CH₄ emission from rice paddies and temperature, 6 years data of CH₄ emission from pot experiments were analyzed in terms of the sum of effective temperature (∑(T−15); T is the daily mean air temperature (°C)). The base temperature of 15 °C was adopted as the 0 °C physiological temperature for methanogens. Significant positive correlations between total CH₄ emission throughout the rice growth period and ∑(T−15) were observed for pots with rice straw (RS) application at a rate of 6 g kg⁻¹ soil, which corresponds to 6 t ha⁻¹ (r=0.830⁷¹), and those without RS application (r=0.818⁷¹). It was confirmed that temperature is a major factor affecting the interannual variation in CH₄ emission. For the 1993 and 1995 data sets that include seven and four levels of RS application, the relationship between seasonal CH₄ emission and RS application rate could be expressed using linear functions (r=0.988⁷¹, 0.996⁷¹), the slopes of which were similar to each other. Based on these findings, we confirmed that the dependence of seasonal CH₄ emission on both temperature and RS application rate can be described by a single linear equation.