Development and characterization of microwave composite cladding

The development of cladding through microwave radiation is recently explored and very few, initial studies were reported elsewhere. In order to explore more viability of process, (EWAC (Ni based) + 20% Cr₂₃C₆ powder) composite cladding has been developed on substrate austenitic stainless steel (SS-316). The experiments were conducted in domestic microwave oven and the clad of thickness, approximate 500 m has been developed by the exposure of microwave radiation at frequency 2.45 GHz for duration of 360 s. Typical clads cross sections of composite clads showed good metallurgical bonding with the substrate by partial dilution. The back scattered electron image of clad cross section showed the reinforced chromium carbide (Cr₂₃C₆) particles are uniformly distributed and well embedded in the Ni based matrix. The developed clad is free from visible solidification cracking and has significantly less porosity which is of the order of 0.90%. The XRD pattern of the developed clad showed the presence of FeNi₃, NiSi and Cr₂₃C₆ phases. The average Vicker's microhardness of developed clad was observed as 425 ± 140 Hv.     

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.     

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.     

Hermetic joining of 316L stainless steel using a patterned nickel nanoparticle interlayer

This paper evaluates the use of a nickel nanoparticle (NiNP) interlayer for making hermetic joints in 316L stainless steel substrates via diffusion brazing. Different NiNP inks were prepared using commercial nanopowder (～9 nm) and in-house synthesized nanoparticles. Syringe pump deposition of ～9 nm NiNP ink and diffusion brazing at 900 °C for 30 min under 2 MPa resulted in a hermetic joint up to the tested pressure of 70 psi. In-house synthesis of NiNPs was carried out in ethylene glycol by the reduction of NiCl₂·6H₂O in the presence of hydrazine (N₂H₄) as a reducing agent. X-ray diffraction (XRD) analysis and transmission electron microscopy (TEM) results confirm the presence of pure fcc-Ni with an average particle size of 5.4 ± 0.9 nm. An as-synthesized suspension of NiNPs was patterned onto 316L stainless steel laminae via automated dispensing to a thickness of ～3 μm and bonded at 800 °C for 30 min at a pressure of 2 MPa. The diffusion-brazed test article was also found to be hermetic up to 70 psi. An examination of the bond line using scanning electron microscopy (SEM) showed good uniformity and continuity.     

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.     

Reduction of hexavalent chromium by polypyrrole-modified steel mesh electrode

Adherent polypyrrole (ppy) films were electropolymerized from a para-toluenesulfonic sodium (PTS) solution on stainless steel mesh (SSM). Reduced ppy-modified SSM electrode can transfer Cr(VI) to Cr(III) effectively. Lower pH (<2) or higher temperature (>35 °C) is beneficial for the removal of Cr(VI). Electro-reduction achieved 90% removal efficiency after 21 min by cyclic voltammetry. The removal efficiency is 96–56% for one–six contact cycles between ppy and Cr(VI). SEM shows that ppy films on SSM have regular morphology with small nucleus of less than 1 μm in diameter.     

Removal of naphthenic acid by microwave

The conventional deacidification methods have many disadvantages. In this paper, we reported a new method using microwave irradiation to remove the naphthenic acid from the vacuum cut #1 distillate oil of Daqing. When the distilled oil (the volume rate of solvent-to-oil was 0.23:1) was irradiated for 5 min under constant pressure (0.11 MPa), and then rested for 25 min, the acid number was reduced from 0.63 mg KOH/g to 0.0478 mg KOH/g, which was sufficient to meet the specification of Q/SHR001-95 (less than 0.05 mg KOH/g) on lubricating oil, and the recovery rate of the distilled oil was 99.3%. The microwave irradiation method has many advantages, such as, it is highly effective, it consumes less time and it is environmentally friendly.     

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.     

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 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.     

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.     

CaCO3 production using liquid waste from Solvay method

Process of obtaining CaCO₃ from the waste post-distillation liquid DS and post-filtration liquid from Solvay method of the soda production at 303 K was investigated. Reagents were dosed in a stoichiometric ratio without dilution, for different concentrations of the DS and post-filtration liquids. The dosage time was varied in the range 2–30 min, the reagent stirring rate was 500 rpm. For the obtained samples of CaCO₃, the bulk and packing densities, water, paraffin oil and dibutyl phthalate absorption capacities, distribution of the particle size as well as the crystalline form were determined.     

Assessing the recycling potential of glass fibre reinforced plastic waste in concrete and cement composites

At present glass fibre reinforced plastic (GRP) waste recycling worldwide is very limited due to its intrinsic thermoset properties, lack of characterisation data and non availability of viable recycling and recovery routes. In the present study, efforts were made to recycle GRP waste powder and fibre in concrete and cement composites and assess its quality to comply with the British standards for use in construction applications. Results revealed that the mean compressive strength of concrete composites using 5%–50% GRP waste powder under water curing varied from 37 N/mm² to 19 N/mm². Increase in the concentration of GRP waste decreased the compressive strength. However, increase in curing duration (14–180 days) resulted in improving the compressive strength of concrete with 5% GRP application to 45.75 N/mm². Moreover, the density of concrete with 50% GRP waste was reduced by about 12% as compared to the control sample. The bending strength in terms of modules of rupture (MOR) of 12 mm thickness cement composites developed using 5% GRP waste fibre attained 16.5 N/mm². The findings of this work pave the way for further GRP waste recycling in precast construction products for use in various applications.     

Dairy farm CH4 and N2O emissions,from one square metre to the full farm scale

The greenhouse gas emissions from agricultural systems contribute significantly to the national budgets for most countries in Europe. Measurement techniques that can identify and quantify emissions are essential in order to improve the selection process of emission reduction options and to enable quantification of the effect of such options. Fast box emission measurements and mobile plume measurements were used to evaluate greenhouse gas emissions from farm sites. The box measurement technique was used to evaluate emissions from farmyard manure and several other potential source areas within the farm. Significant (up to 250 g CH₄ m⁻² day⁻¹and 0.4 g N₂O m⁻² day⁻¹) emissions from ditches close to stables on the farm site were found.Plume emission measurements from individual manure storages were performed at three sites. For a manure storage with 1200 m³ dairy slurry in Wageningen emission factors of 11 ± 5 g CH₄ m⁻³ manure day⁻¹ and 14 ± 8 mg N₂O m⁻³ manure day⁻¹ were obtained in February 2002.Mobile plume measurements were carried out during 4 days at distances between 30 and 300 m downwind of 20 different farms. Total farm emissions levels ranged from 14 to 95 kg CH₄ day⁻¹ for these sites. Expressed as emission per animal the levels were 0.7 ± 0.4 kg CH₄ animal⁻¹ day⁻¹ for conventional farms. For three farms that used straw bedding for the animals1.4 ± 0.2 kg CH₄ animal⁻¹ day⁻¹ was obtained. These factors include both respired methane and emission from manure in the stable and the outside storages.For a subset of these farms the CH₄ emission was compared with monthly averaged model emission calculations using FarmGHG. This model calculates imports, exports and flows of all products through the internal chains on the farm using daily time steps. The fit of modelled versus measured data has a slope of 0.97 but r² = 0.27. Measurements and model emission estimates agree well on average, for large farms within 30%. For small farms the differences can be up to a factor of 3. CH₄ emissions during winter seem to be underestimated.     

Soil microbial response to herbicides applied to glyphosate-resistant canola

Adoption of glyphosate-resistant canola (Brassica napus L.) has increased glyphosate applications to this crop, and concerns have been raised about unintended consequences of these multiple applications. A field trial was conducted to evaluate the effects of pre-seed and in-crop glyphosate and alternative herbicides on soil microbial community functional structure, diversity and biomass. Pre-seed treatments were 2,4-D, glyphosate and 2,4-D + glyphosate, and in-crop treatments were glyphosate applied once, glyphosate applied twice, ethalfluralin, ethalfluralin + sethoxydim + ethametsulfuron + clopyralid, and sethoxydim + ethametsulfuron. Rhizosphere and bulk soil was collected at flowering stage of canola and analyzed for bacterial community-level substrate utilization patterns and microbial biomass C (MBC). Where differences were significant, pre-seed application of both 2,4-D and glyphosate altered the functional structure and reduced the functional diversity of soil bacteria, but increased MBC. These effects were not necessarily concurrent. The reduction in functional diversity was due to reduction in evenness, which means that the soil where both pre-seed herbicides had been applied was dominated by only few functional groups. In 1 year, two in-crop applications of glyphosate also reduced the functional diversity of soil bacteria when applied after pre-seed 2,4-D, as did in-crop sethoxydim + ethametsulfuron following pre-seed glyphosate. Even though significant differences between herbicides were fewer than non-significant differences, i.e., there were no changes in soil microbial community structure, diversity or biomass in response to glyphosate or alternative herbicides applied to glyphosate-resistant canola in most cases, the observed changes in soil microbial communities could affect soil food webs and biological processes.     

Soil-profile organic carbon and total nitrogen during 12 years of pasture management in the Southern Piedmont USA

Soil organic C (SOC) and total soil N (TSN) sequestration estimates are needed to improve our understanding of management influences on soil fertility and terrestrial C cycling related to greenhouse gas emission. We evaluated the factorial combination of nutrient source (inorganic, mixed inorganic and organic, and organic as broiler litter) and forage utilization (unharvested, low and high cattle grazing pressure, and hayed monthly) on soil-profile distribution (0–150 cm) of SOC and TSN during 12 years of pasture management on a Typic Kanhapludult (Acrisol) in Georgia, USA. Nutrient source rarely affected SOC and TSN in the soil profile, despite addition of 73.6 Mg ha^?1 (dry weight) of broiler litter during 12 years of treatment. At the end of 12 years, contents of SOC and TSN at a depth of 0–90 cm under haying were only 82 ± 5% (mean ± S.D. among treatments) of those under grazed management. Within grazed pastures, contents of SOC and TSN at a depth of 0–90 cm were greatest within 5 m of shade and water sources and only 83 ± 7% of maximum at a distance of 30 m and 92 ± 14% of maximum at a distance of 80 m, suggesting a zone of enrichment within pastures due to animal behavior. During 12 years, the annual rate of change in SOC (0–90 cm) followed the order: low grazing pressure (1.17 Mg C ha^?1 year^?1) > unharvested (0.64 Mg C ha^?1 year^?1) = high grazing pressure (0.51 Mg C ha^?1 year^?1) > hayed (?0.22 Mg C ha^?1 year^?1). This study demonstrated that surface accumulation of SOC and TSN occurred, but that increased variability and loss of SOC with depth reduced the significance of surface effects.     

Water jet guided laser as an alternative to EDM for micro-drilling of fuel injector nozzles: A comparison of machined surfaces

To characterize the inner surface of the fuel injector nozzle holes drilled by EDM and water jet guided laser drilling (Laser Micro-Jet) a specifically conceived scanning probe microscopy technique with true non-contact operating mode was used. A difference in morphology of the drilled surfaces is evident from the acquired surface topography along the hole axis for the two compared drilling techniques. Results showed that the surface texture can be characterized by (i) maximum peak-to-valley distance and (ii) periodicity. Acquired maps confirm that electro-eroded surfaces are an envelope of craters randomly distributed with total excursion up to 1.7 μm with a crater size of 15 μm. While, the efficient melt expulsion and immediate cooling of water jet guided laser generates a peak to valley distance of 800 nm with a periodicity of 18 μm. Average R_q derived from the measured cylindrical surfaces was 450 nm and 150 nm for EDM and Laser Micro-Jet, respectively. Water jet guided laser drilling has proved to be a reliable alternative to EDM from the point of view of repeatability of the results and surface quality to facilitate the atomization of the fuel jet.     

Aero-lap polishing of poly crystalline diamond inserts using Multicon media

Increasing use of poly crystalline diamond (PCD) inserts as cutting tools and wear parts is vividly seen in automobile, aerospace, marine and precision engineering applications. The PCD inserts undergo series of manufacturing processes such as: grinding that forms the required shape and polishing that gives a fine finish. These operations are not straight forward as PCD is extremely resistant to grinding and polishing. Single crystal diamond can easily be polished by choosing a direction of easy abrasion, but polishing a PCD imposes serious difficulties as the grains are randomly oriented. Prior research on polishing of PCD inserts includes electro discharge grinding (EDG), dynamic friction polishing and grinding by a vitrified bonded diamond wheel. The surface textures of PCD produced using an EDG process often contains: micro cavities, particle pullout, micro-grooves, chipped edges, cracks and gouch marks. While applying the dynamic friction polishing method the PCD material undergoes phase transformation and hence increased polishing rate was apparently seen. However the phase transformation of PCD deteriorates the strength of the insert. Furthermore the inserts produced using the dynamic polishing method often exhibits cracks, chip off and edge damage while using as a cutting tool. Therefore, a new method “aero-lap polishing” was attempted as it applies controlled amount of impinging force by which the surface damage can be significantly reduced. The study did establish an improvement of surface finish of PCD from R_a = 0.55 μm, R_t = 4.5 μm to R_a = 0.29 μm, R_t = 1.6 μm within 15–25 min of polishing time along with significant reduction in surface defects.     

Linking spatio-temporal variation of crop response with sediment deposition along paddy rice terraces

In tropical mountainous regions of South East Asia, intensive cultivation of annual crops on steep slopes makes the area prone to erosion resulting in decreasing soil fertility. Sediment deposition in the valleys, however, can enhance soil fertility, depending on the quality of the sediments, and influence crop productivity. The aim of the study was to assess (i) the spatio-temporal variation in grain yield along two rice terrace cascades in the uplands of northern Viet Nam, (ii) possible linkage of sediment deposition with the observed variation in grain yield, and (iii) whether spatial variation in soil water or nitrogen availability influenced the obtained yields masking the effect of inherent soil fertility using carbon isotope (¹³C) discrimination and ¹⁵N natural abundance techniques. In order to evaluate the impact of seasonal conditions, fertilizer use and sediment quality on rice performance, ¹⁵N and ¹³C stable isotope compositions of rice leaves and grains taken after harvest were examined and combined with soil fertility information and rice performance using multivariate statistics. The observed grain yields for the non-fertilized fields, averaged over both cascades, accounted for 4.0 ± 1.4 Mg ha^?1 and 6.6 ± 2.5 Mg ha^?1 in the spring and summer crop, respectively, while for the fertilized fields, grain yields of 6.5 ± 2.1 Mg ha^?1 and 6.9 ± 2.1 Mg ha^?1 were obtained. In general, the spatial variation of rice grain yield was strongly and significantly linked to sediment induced soil fertility and textural changes, such as soil organic carbon (r 0.34/0.77 for Cascades 1 and 2, respectively) and sand fraction (r ?0.88/?0.34). However, the observed seasonal alteration in topsoil quality, due to sediment deposition over two cropping cycles, was not sufficient to fully account for spatial variability in rice productivity. Spatial variability in soil water availability, assessed through ¹³C discrimination, was mainly present in the spring crop and was linearly related to the distance from the irrigation channel, and overshadowed in Cascade 2 the expected yield trends based on sediment deposition. Although δ¹⁵N signatures in plants indicated sufficient N uptake, grain yields were not found to be always significantly influenced by fertilizer application. These results showed the importance of integrating sediment enrichment in paddy fields within soil fertility analysis. Furthermore, where the effect of inherent soil fertility on rice productivity is masked by soil water or nitrogen availability, the use of ¹³C and ¹⁵N stable isotopes and its integration with conventional techniques showed potential to enhance the understanding of the influence of erosion – sedimentation and nutrient fluxes on crop productivity, at toposequence level.