Rapid Laminated Tooling by a Brazing and Soldering Process

Laminated tooling is a relatively fast and simple method to make metal tools directly for injection molding or resin transfer molding in the rapid prototyping field. Metal sheets are usually cut, stacked, aligned, and joined. Joining of metal sheets is usually accomplished by brazing or soldering. In the joining process, all the metal sheet layers should be rigidly joined, and thus heat should be applied to the whole volume of the laminate. Therefore, furnace brazing or diffusion bonding processes are considered suitable in laminated tooling.In this study, a rapid laminated tooling system composed of a CO₂ laser, a furnace, and a high-speed milling machine was developed. From the three-dimensional information of a product, slicing into two-dimensional contours was performed and low-carbon steel sheets were cut with the CO₂ laser along the paths that were created from the slicing results. The metal sheets were joined by furnace brazing and by dip soldering. Furnace brazing was for relatively high-temperature tooling processes such as injection molding, and dip soldering was for low-temperature tooling processes such as reactive injection molding (RIM). Dip soldering was introduced as a new, simple, and fast joining process of steel laminates. In both joining methods, wetting experiments were performed to ensure the optimal values of the process parameters. Finally, laminate tools were machined with a high-speed milling machine to improve the surface quality.     

Environmental assessment of laser assisted manufacturing: case studies on laser shock peening and laser assisted turning

Laser assisted manufacturing processes, when compared with traditional manufacturing processes, have the potential to reduce cost, increase surface resistance to wear and fatigue, extend part/tool life, and expand the range of manufacturable materials. These processes have found niche applications in automotive, aerospace, and defense industries. However, very limited research has been conducted to evaluate and compare the environmental performance of laser assisted processes with traditional methods. This paper conducts case studies on two representative laser based processes, i.e. laser shock peening of 7075-T7351 Aluminum and laser assisted turning of compacted graphite iron. Life cycle assessment is used to benchmark the environmental performance of these two processes to conventional processes, i.e. shot peening and turning, respectively. The life cycle inventory of both the laser based processes and conventional processes are developed using SimaPro 7.1 and the Ecoinvent 2.0 database and life cycle impact assessment is performed using US EPA TRACI. The results of this study show that the environmental performance of the two laser based processes is significantly better than conventional processes. For laser shock peening of aluminum, contribution analysis indicates that this is mainly due to the significant extension of fatigue life of the workpiece being treated. For laser assisted turning of compacted graphite iron, the improved performance is mainly due to the extended tool life since cutting tool manufacturing is an energy intensive process. Development of high-power laser with a lower wavelength (e.g. direct diode system) could eliminate the use of paint in laser assisted turning. This, along with improved wall plug efficiency, makes laser assisted turning even more environmentally benign compared to conventional process. A brief cost analysis suggests that both laser shock peening and laser assisted turning can be economically viable with payback period less than three years for niche applications.     

Environmental comparison of MESO-CLAD® process and conventional machining implementing life cycle assessment

CLAD^® process (Direct additive laser manufacturing, Construction Laser Additive Directe in French) allows the direct manufacturing of small parts, and especially in case of complex shapes, giving equivalent properties with traditional processes such as conventional machining or casting techniques. Present environmental considerations are very important for updates in legislation or in order to make economic allowances. A specified mechanical Ti₆Al₄V part is used as a support and SimaPro software allows to perform Life Cycle Assessment. This study suggests that the absence of chips production, which represents up to 80% of the titanium consumption, provides to CLAD^® process an unquestionable advantage. This process requires longer times of execution, which increase additional energy consumptions, and the comparison of this process with conventional machining demonstrates that damages to resources and to human health are highly reduced. In both cases a large part of the environmental impacts are due to the powder elaboration. Finally, CLAD^® process can add shapes on machined/casted parts and it is possible to consider the manufacture of a mechanical part via a hybrid process.     

Welding processes for wear resistant overlays

This paper presents a comprehensive survey of welding processes used to deposit wear resistant overlays. It is based on both literature review and research work performed at the Canadian Centre for Welding and Joining. The focus is on the two most popular material systems used for wear resistant overlays: nickel-base with the addition of tungsten carbide particles, and iron-base in which chromium carbides of the form M₇C₃ nucleate during solidification. The processes surveyed in detail are plasma transfer arc welding, submerged arc welding, laser beam welding, gas metal arc welding-related processes using tubular wires, oxy-acetylene flame brazing, and the still-experimental applications of friction stir processing. Cost and market are key factors influencing technical decisions on wear protection overlays, but the information is scarce and often tightly guarded. An informal survey from our industrial partners is included.     

N2O emission from nitrogen removal via nitrite in oxic-anoxic granular sludge sequencing batch reactor

Bionitrification is considered to be a potential source of nitrous oxide （N2O） emissions, which are produced as a by-product during the nitrogen removal process. To investigate the production of N2O during the process of nitrogen removal via nitrite, a granular sludge was studied using a labscale sequence batch reactor operated with real-time control. The total production of N2O generated during the nitrification and denitrification processes were 1.724 mg/L and 0.125 mg/L, respectively, demonstrating that N2O is produced during both processes, with the nitrification phase generating larger amount. In addition, due to the NEO-N mass/oxidized ammonia mass ratio, it can be concluded that nitrite accumulation has a positive influence on N2O emissions. Results obtained from PCRDGGE analysis demonstrate that a specific Nitrosomonas microorganism is related to N2O emission.     

Modeling and simulation of arc: Laser and hybrid welding process

Welding is a fabrication process to join two different materials. Among the many welding processes, the arc and laser welding processes are the most widely used. Great effort is required to understand the physical phenomena of arc and laser welding due to the complex behaviors which include liquid phase, solid phase and, gas phase. So it is necessary to conduct numerical simulation to understand the detailed procedures of welding. This paper will present the various numerical simulation methods of the arc welding processes such as arc plasma, gas tungsten arc welding, gas metal arc welding, laser welding, and laser–arc hybrid welding. These simulations are conducted by the finite element method, finite differential method and volume of fluid method to describe and analyze the various welding processes.     

Recent advances in ionic liquids-based hybrid processes for CO2 capture and utilization

CO₂ capture and utilization (CCU) is an effective strategy to mitigate global warming. Absorption, adsorption and membranes are methods used for CO₂ separation and capture, and various catalytic pathways have also been developed for CO₂ utilization. Although widely researched and used in industry, these processes are energy-intensive and this challenge needs to be overcome. To realize further optimization, novel materials and processes are continuously being developed. New generation materials such as ionic liquids (ILs) have shown promising potential for cost-effective CO₂ capture and utilization. This study reviews the current status of ILs-based solvents, adsorbents, membranes, catalysts and their hybrid processes for CO₂ capture and utilization. The special properties of ILs are integrated into new materials through hybridization, which significantly improves the performance in the process of CCU.     

河道水旁路处理中试工艺中PPCPs的去除效果及机制

城市河道水中含有微量药物及个人护理品（pharmaceuticals and personal care products,PPCPs）,具有一定生态风险.本文系统考察了两种河道水旁路处理工艺（混凝沉淀-曝气生物滤池-超滤-臭氧和混凝沉淀-膜生物反应器-臭氧）对30种高检出PPCPs的去除效果,并通过沿程去除率调查和风险商模型分别评价了目标PPCPs的降解机制及整体生态风险的降低情况.结果表明,两种旁路处理工艺对各目标PPCPs均有较好去除效果;其中四环素类抗生素及咖啡因在生物段去除率超过90%,而磺胺类及氟喹诺酮类抗生素及其他药物仅在进水化学需氧量较高和较高水温条件下具有较好去除效果,但臭氧深度处理可对其进行有效削减;经全流程处理后各PPCPs累积去除率均可达92.5%以上.旁路处理可有效降低目标PPCPs生态风险,经处理后风险商值由原水的12.6降至总出水的0.2（风险阈值RQ_tot=1）,去除率达98.4%.     

External force-assisted laser forming process for gaining high bending angles

Laser forming process is used in forming and bending of metallic and non-metallic sheets. Laser beam irradiation causes a localized temperature increase and a localized mechanical strength decrease. In this article, an external mechanical force is added to a laser beam irradiation, which is called external force-assisted laser forming process, to gain a 90-degree bending angle. Furthermore, Numerical simulation of the process is performed to achieve a good understanding of the process. Simulation results show that more than two-third of the final forming is due to the laser beam irradiation. Equivalent plastic strain values during laser forming and external force-assisted laser forming processes are compared. Results show that equivalent plastic strain in laser forming process increases in a step pattern, with increasing in scan pass numbers. This occurs because when the laser beam irradiates on the sheet surface, it reduces the yield strength of the sheet. Equivalent plastic strain in external force-assisted laser forming process has an oscillatory step nature. This attributes to simultaneous effects of strain hardening and thermal induced reduction of yield strength of the sheet. Simulations were in good accordance with experiments.     

Sewage sludge composting simulation as carbon/nitrogen concentration change

Model in composting play a very promising challenge to many scholars, this article adds on the improving ways for model the compost and composting     

Influence of overlap between the laser beam tracks on surface quality in laser polishing of AISI H13 tool steel

Polishing by laser beam radiation is a novel manufacturing process to modify the initial surface topography in order to achieve a desired level of surface finish. The performance of laser polishing (LP) is determined by an optimum combination of several key process parameters. In this regard, the overlap between two successive laser beam tracks is one of the important LP process parameters, which has a significant effect over the final surface quality. In the current study, influence of overlap between the laser beam tracks on surface quality was experimentally investigated during the laser polishing of AISI H13 tool steel. Surface areas were polished by using four different overlap percentages (e.g. 80%, 90%, 95%, and 97.5%) while applying the same energy density. The improvement of surface quality was estimated through the analysis of line profiling surface roughness R_a, areal topography surface roughness S_a, and material ratio function. Also, individual components of the surface quality, e.g. waviness and roughness, and their evolution during LP were statistically analyzed using the power spectral density and the transfer functions. Finally, as an example of the best achieved LP result, flat surface area was polished using optimum set of the process parameters improving surface quality by 86.7% through the reduction of an areal topography surface roughness S_a from 1.35 μm to 0.18 μm.     

哈尔滨城市污水处理厂不同处理工艺对微塑料的去除

城市污水处理厂出水作为微塑料（microplastics,MPs）进入自然水体的主要途径之一,对其微塑料污染物特征展开研究,有助于认识和了解人类活动对自然水体的影响.本文以哈尔滨市主城区的污水处理厂A和污水处理厂B中的3种工艺（曝气生物滤池工艺、多段AO-MBBR工艺、CASS-MBBR工艺）为研究对象,经体视显微镜观察并结合傅里叶变换红外光谱仪分析哈尔滨城市污水处理厂中MPs的浓度、颜色、粒径、类型分布特征及3种不同处理工艺对MPs的去除效果.结果表明,哈尔滨城市污水处理厂进水中MPs的最高浓度为290.87个·L^-1,颜色主要以白色和无色为主,组成成分主要为PP、PE和PS,粒径大的MPs更容易被去除;微塑料在曝气生物滤池工艺一级处理中的去除率为80.28%;多段AO-MBBR工艺与CASS-MBBR工艺的一级处理MP_S去除效率为78.39%,曝气生物滤池工艺、多段AO-MBBR工艺和CASS-MBBR工艺的二级处理去除效率分别为20.92%、13.11%和14.68%,实验结果表明MPs的去除主要依靠一级处理,二级处理中的MPs去除效果较小.研究结论可为城市污水处理厂中微塑料污染与防控研究提供科学依据.     

基于CAMx的徐州市2016年冬季PM2.5污染过程及来源分析

徐州地处江苏西北部、华北平原的东南部,为内陆资源型工业城市,近几年来环境监测数据显示,徐州地区大气复合污染问题日益突出,准确模拟大气污染物状况及来源对于空气污染的防治十分关键.2016年1月,徐州市出现了多次持续的重污染天气,研究中以此次污染事件为例,首先基于WRF-CAMx空气质量模型系统对这次细颗粒物污染过程进行全面的模拟与分析,其次利用CAMx-PSAT系统模拟和分析本次污染的区域传输过程.研究结果显示：此次细颗粒物污染中,PM_2.5组成成分以硫酸盐、元素碳、硝酸盐和铵盐为主,分别占月平均浓度的29%、15%、14%、14%;PM_2.5的区域传输贡献中,长距离传输所占比重最大,月平均贡献率达46%,其次为本地源排放,平均贡献率为39%;重污染天气期间,PM_2.5污染主要从西北方向输入,此时长距离传输的影响明显增大.     

The influence of the laser and plasma traverse cutting speed process parameter on the cut-edge characteristics and durability of Yellow Goods vehicle applications

The durability of steel components produced for service as Yellow Goods vehicle applications, are primarily influenced by the condition of their thermal cut-edges. The chassis structures of such demanding applications are manufactured with laser and plasma cut-edges left exposed after final fabrication. Over prolonged periods of service, defects formed during the cutting processes can act as initiation sites for fatigue cracks, resulting in eventual structural failure of the application. The traverse cutting speed parameter was altered for cuts performed using laser and plasma cutting processes to ascertain the changes in critical surface characteristics and microstructural properties in close proximity to the cut-edge. It was the damage formed during each cutting process which directly influenced the fatigue life of the resulting cut-edges. Manipulating the critical traverse cutting speed process parameter resulted in the generation of cut-edges that are near to optimum with the minimum number of cut-edge defects.     

河南省冬季3次重污染过程的数值模拟及输送特征分析

利用WRF-Chem模式模拟2015年11月27日—12月1日、12月5—14日、12月19—25日河南3次重污染过程,结合空气污染资料和ERA-Interim再分析资料,对比分析了这3次重污染过程的开始、持续和结束及污染物的输送特征.结果表明,静稳天气有利于污染的发展持续,3次重污染过程的结束均是由西路冷空气入侵造成的.第1次重污染过程平均风场上的风速均为小风或静风,从湖北到河南南部风向为偏南风;而第2和第3次重污染过程平均风场分别以偏东和偏北风为主.第2和第3次重污染过程中均存在明显的由北向南的污染物输送过程.3次重污染过程中,河南省本地排放对本省PM_(2.5)浓度的平均贡献率最大,而河南省周边区域对河南PM_(2.5)浓度的平均贡献率在这3次过程中不一样,第1次重污染过程,河南南部主要受偏南风影响,湖北对河南PM_(2.5)浓度的平均贡献率最大,为20.7%;第2和第3次重污染过程主要受偏东风影响,安徽和江苏对河南PM_(2.5)浓度的平均贡献率最大,分别为17.7%和18.5%.3次重污染过程中,安阳的主要污染输送源均不相同,分别来自河北、江苏和安徽、本省.     

武汉地区秋冬季清洁与重污染过程的水溶性离子特征研究

利用武汉地区2014年秋、冬季在线离子色谱分析仪Marga监测所得的大气PM_(2.5)中水溶性离子数据和武汉市环境空气质量自动监测的细颗粒物数据,分析了武汉地区秋、冬季重污染和清洁过程的大气污染特征.结果表明,PM_(2.5)是武汉地区秋、冬季大气污染的首要污染物,无论是在清洁还是重污染过程中,NO_3~-、SO_4~(2-)和NH_4~+3种成分都是PM_(2.5)的主要无机成分.重污染过程中PM_(2.5)的平均浓度是清洁过程的4.5倍,而3种主要水溶性离子平均浓度增长至清洁过程的5~6倍,且有着显著的相关性,二次生成水溶性离子的污染已成为武汉秋、冬季大气污染的主要因素.Cl-在重污染过程中的浓度及与PM_(2.5)的相关系数显著增大,表明化石燃料燃烧等过程也对重污染的形成产生了较显著的作用,值得关注的是,K~+在重污染过程中的浓度及与PM_(2.5)的相关系数增大也验证了燃烧过程对重污染起到的贡献.硫氧化率和氮氧化率的分析结果表明,重污染过程中的二次转化要多于清洁过程,可能是非均相反应生成了二次污染的硫酸盐和硝酸盐.线性回归分析的方程系数研究表明,NH_4NO_3和(NH_4)_2SO_4可能是清洁和重污染过程中主要的盐类物质.NO_3~-/SO_4~(2-)的平均质量浓度比说明移动源对武汉地区秋、冬季二次污染的形成和发展已经起到越来越大的作用,特别是重污染过程中的影响更大.     

Laser tempering based turning process for efficient machining of hardened AISI 52100 steel

Cost-effective machining of hardened steel components such as a large wind turbine bearing has traditionally posed a significant challenge. This paper presents an approach to machine hardened steel parts efficiently at higher material removal rates and lower tooling cost. The approach involves a two-step process consisting of laser tempering of the hardened workpiece surface followed by conventional machining at higher material removal rates with lower cost ceramic tools to efficiently remove the tempered material. The laser scanning parameters that yield the highest depth of tempered layer are obtained from a kinetic phase change model. Machining experiments are performed to demonstrate the possibility of higher material removal rates and improved tool wear behavior compared to the conventional hard turning process. Tool wear performance, cutting forces, and surface finish of Cubic Boron Nitride (CBN) tools as well as low cost ceramic tools are compared in machining of hardened AISI 52100 steel (~63 HRC). In addition, cutting forces and surface finish are compared for the laser tempering based turning and conventional hard turning processes. Experimental results show the potential benefits of the laser tempering based turning process over the conventional hard turning process.     

厌氧酸化在焦化废水脱氮和毒性削减中的作用

分别用厌氧酸化-缺氧-好氧(A₁-A₂-O)生物膜法和缺氧-好氧(A/O)生物膜法处理焦化废水,比较了二者对废水毒性的削减效果.试验结果表明,焦化废水的毒性大于0.19mg/L氯化汞的毒性.其毒性削减与有机氮去除有一定关系,厌氧酸化在提高废水有机氮去除率和降低废水的毒性方面起到了重要的作用.废水经A₁-A₂-O生物膜系统处理后,毒性大大降低,当HRT为37.9h时,出水对发光菌的相对发光度可达96.8%,其毒性相当于0.023mg/L氯化汞的毒性.     

A new process of combined pretreatment and dyeing: REST

Use of enzymes in textile processes has many advantages as far as the environmentally friendly processes are concerned. These advantages include water and energy savings, less chemical use, less fabric damage, mild and environmentally friendly process conditions. In this work, C.I. Reactive Yellow 15, C.I. Reactive Red 21 and C.I. Reactive Blue 19 were used to dye untreated woven cotton fabric in a laboratory scale dyeing machine, on a pilot scale jig and on a pilot scale winch by using a single bath combined process, in which various enzymes, namely, amylase, pectinase, and catalase were employed. This new process was named as the “Rapid Enzymatic Single-bath Treatment” (REST), since it was completed almost in half of the conventional dyeing time, and all of the stages, namely, desizing, scouring, bleaching and dyeing were carried out in a single bath without replacing the process water with fresh water until the end of the dyeing. In the REST process, the untreated, starch-sized fabric was first desized by amylase enzyme, and this was followed by a pectinase treatment in the same bath. The fabric was then bleached by H₂O₂ in the same bath, and after the hydrogen peroxide bleaching; the catalase enzyme was added to the bath to remove H₂O₂ residues before reactive dyeing. Without carrying out intermediate washings/rinsings between these processes, the reactive dyeing was carried out in a conventional way in the same bath, and finally, the fabric was taken from the bath and washed out. The colour yield was compared with the dyeings which were carried out conventionally in separate baths. Finally, the REST has many benefits in terms of water saving, reduced process time and energy consumptions compared to the conventional preparatory and dyeing process of cotton fabrics.     

Reaction mechanism and metal ion transformation in photocatalytic ozonation of phenol and oxalic acid with Ag+/TiO2

Photocatalytic ozonation of phenol and oxalic acid （OA） was conducted with a Ag^＋/TiO2 catalyst and different pathways were found for the degradation of different compounds. Ag^＋ greatly promoted the photocatalytic degradation of contaminants due to its role as an electron scavenger. It also accelerated the removal rate of OA in ozonation and the simultaneous process for its complex reaction with oxalate. Phenol could be degraded both in direct ozonation and photolysis, but the TOC removal rates were much higher in the simultaneous processes due to the oxidation of hydroxyl radicals resulting from synergetic effects. The sequence of photo-illumination and ozone exposure in the combined process showed quite different effects in phenol degradation and TOC removal. The synergetic effects in different combined processes were found to be highly related to the properties of the target pollutants. The color change of the solution and TEM result confirmed that Ag＋ was easily reduced and deposited on the surface of Tit2 under photo-illumination, and dissolved again into solution in the presence of ozone. This simple cycle of enrichment and distribution of Ag^＋ can greatly benefit the design of advanced oxidation processes, in which the sequences of ozone and photo-illumination can be varied according to the needs for catalyst recycling and the different properties of pollutants.