Investigating surface roughness,material removal rate and corrosion resistance in PMEDM of γ-TiAl intermetallic

Titanium aluminide intermetallics offer an attractive combination of low density and good oxidation, corrosion and ignition resistance with unique mechanical properties. In this study two series of machining tests are designed. Firstly the powder mixed electrical discharge machining (PMEDM) of γ-TiAl by means of different powders such as aluminum, chrome, silicon carbide, graphite and iron is performed to investigate the output characteristics of surface roughness and topography, material removal rate (MRR), electrochemical corrosion resistance of machined samples and also the machined surfaces are investigated by means of EDS and XRD analyses. Secondly after selection the aluminum powder as the most appropriate kind of powder, the current, pulse on time, powder size and powder concentration are changed in different levels for overall comparison between EDM and PMEDM output characteristics. In the first setting of input machining parameters, aluminum powder improves the surface roughness of TiAl sample about 32% comparing with EDM case and also aluminum particles with the size of 2 μm, in the second setting of input parameters lead to 54% enhancement of MRR comparing with EDM case. The electrochemical corrosion results show that, corrosion resistance of the samples which are machined by graphite and chrome powders respectively are about three and two times more than the sample which is machined without powder.     

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.     

Evaluation of the effectiveness of low frequency workpiece vibration in deep-hole micro-EDM drilling of tungsten carbide

The application of micro-electrical discharge machining (micro-EDM) in deep-hole drilling is still limited due to the difficulty in flushing of debris and unstable machining. Present study introduces a simplistic analytical model to evaluate the effectiveness of low frequency workpiece vibration during the micro-EDM drilling of deep micro-holes. In addition, experimental investigation has been conducted to validate the model by studying the effects of workpiece vibration on machining performance, surface quality and dimensional accuracy of the micro-holes. The effect of vibration frequency and amplitude for three different settings of aspect ratios has been studied experimentally. Moreover, the vibration experiments have been conducted at different levels of gap voltages and capacitances in order to understand the effect of electrical parameters and effectiveness of low-frequency workpiece-vibration at different levels of discharge energies. It has been shown analytically that the effectiveness of low frequency workpiece vibration during micro-EDM drilling can be evaluated by a parameter ‘K_v’ (ratio of maximum acceleration of the vibrating plate in gravitational direction to gravitational acceleration ‘g’), which can be determined from the vibration frequency, amplitude and phase angle of the vibrating workpiece. The theoretical model reveals that for K_v > 1, the position of debris particles will be above the workpiece; thus can be flushed away from machined zone effectively. The experimental reasons for improved micro-EDM drilling performance at the setting of K_v > 1 are found to be the increased effective discharge ratio, reduced short-circuits and improved dielectric flushing. The experimental results also reveal that the low frequency vibration is more effective at the low discharge energy level, thus making it more suitable for micro-EDM. Considering the effect on both the machining characteristics and micro-hole accuracy parameters, vibration frequency of 750 Hz and amplitude of 1.5 μm was found to provide improved performance for the developed vibration device.     

High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools

High speed machining (HSM) of tool steels in their hardened state is emerging as an attractive approach for the mold and die industry due to its potential for significant cost savings and productivity improvement. An experimental study was conducted to investigate the tool wear mechanism and surface integrity in high speed ball nose end milling of hardened AISI A2 tool steel using coated tungsten carbide and polycrystalline cubic boron nitride (PCBN) tools. It is found that coated carbide tools can only be used at low speed (120 m/min) while high content PCBN tools are suitable for HSM range (470 m/min). PCBN tools produce a damage free workpiece with better surface finish and less work hardening. Despite the higher tool cost, HSM with PCBN tools lead to reduction in both total cost and production time per part.     

Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy

Tool life has been a vital issue in machining titanium alloys. Recently, an atomization-based cutting fluid (ACF) application has been found to be an effective approach for cooling and lubrication in micromachining operations. In this study, an ACF spray system is developed for macro-scale turning of Ti–6Al–4V. The spray system is designed to minimize interaction between the fluid droplets, and the gas nozzle to control the divergence of the fluid droplets. Experiments are conducted to study the effect of five specific ACF spray parameters including fluid flow rate, spray distance, impingement angle, and type and pressure level of the droplet carrier gas on cutting forces, tool life, and chip characteristics. It has been observed that the combination of lower pressure (150 psi) air-mixed CO₂ with a higher flow rate (20 ml/min) and a larger spray distance (35 mm) produces a significantly longer tool life and broken chips. The results also reveal that the ACF spray system can extend tool life up to 40–50% over flood cooling.     

Micro-flood (MF) technology for sustainable manufacturing operations that are coolant less and occupationally friendly

This paper presents a new technology for minimizing the use of metalworking fluids (MWFs) during the machining process that is atomization-less and occupational friendly. Micro-flood (MF) technology utilizes direct contact between the cutting tool and the MWF without the interaction of a gas medium. Experiments were conducted in high volume mass production environment turning HSLA (high strength low alloy) SAE 070Y steel. Machining performance and total air mass particulates were investigated in dry machining, Near dry machining (NDM) via atomized spray mist and MF technology. Open-atmosphere air monitoring indicated that total mass particulates behaved in an almost linear fashion with respect to gas atomization pressure, whereas the MWF flow rate demonstrated logarithmic trends in NDM applications using an atomized spray. Nozzle orientations directed upward into the air also produced higher mg/m³ concentrations (such as flank) than chip and rake face orientations that were directed down. Greater separation existed at higher gas atomization pressures, MWF flow rates and by changing the MWF type. At extreme limits, nozzle orientation affected mg/m³ concentration as much as 4–5 mg/m³ for water-miscible MWFs and 15–22 mg/m³ for non-water-miscible MWFs. Tool-life performance varied greatly among MWF type and flow rate, and in all cases MF technology performed better than NDM using an atomized spray mist. Direct and consistent MWF penetration to cutting zone using MF technology lowered tool-wear on the average of 12–75% compared to NDM at the same MWF flow rate. Compared to dry machining, NDM improved tool-wear on the average by 20–243%. In one case, tool-wear performance was improved by 616% at 0.15 mm using MF technology compared to dry machining at a nominal 0.925 mm tool-wear. Overall, a large mass reduction of particulates can be achieved employing MF technology that would have been unrealistic for an open-atmosphere machining environment employing an atomized spray mist. On the average, MF technology can maintain a total air mass particulate of less than 0.4 mg/m³ in the occupational work zone using MWF flow rates up to 1260 ml/h, regardless of the MWF classification. Atomized spray mist applications are capable meeting the 5 mg/m³ OSHA limit if MWF flow rates are less than 160 ml/h, air pressures are less than 0.137 MPa (20 psi) using water-miscible MWFs and air pressures are less than 0.0344 MPa (5 psi) using non-water-miscible MWFs.     

Modulation-assisted high speed machining of compacted graphite iron (CGI)

The application of controlled, low-frequency modulation (～100 Hz) superimposed onto the cutting process in the feed-direction – modulation-assisted machining (MAM) – is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>500 m/min). The tool life is at least 20 times greater than in conventional machining. This significant reduction in wear is a consequence of the multiple effects realized by MAM, including periodic disruption of the tool–workpiece contact, formation of discrete chips, enhanced fluid action and lower cutting temperatures. The propensity for thermochemical wear of CBN, the principal wear mode at high speeds in CGI machining, is thus reduced. The tool wear in MAM is also found to be smaller at the higher cutting speeds (730 m/min) tested. The feed-direction MAM appears feasible for implementation in industrial machining applications involving high speeds.     

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.     

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.     

Modelling soil phosphorus decline: Expectations of Water Framework Directive policies

Depletion of plant-available soil phosphorus (P) from excessive to agronomically optimum levels is a measure being implemented in Ireland to reduce the risk of diffuse P transfer from land to water. Within the Nitrates and Water Framework Directive regulations the policy tool is designed to help achieve good status by 2015 in water bodies at risk from eutrophication. To guide expectation, this study used soil plot data from eight common soil associations to develop a model of Soil Test P (STP) (Morgan's extract) decline following periods of zero P amendment. This was used to predict the time required to move from excessive (Index 4) to the upper boundary of the optimum (Index 3) soil P concentration range. The relative P balance (P balance : Total soil P) best described an exponential decline (R² = 63%) of STP according to a backwards step-wise regression of a range of soil parameters. Using annual field P balance scenarios (?30 kg P ha^?1, ?15 kg P ha^?1, ?7 kg P ha^?1), average time to the optimum soil P boundary condition was estimated from a range of realistic Total P and STP starting points. For worst case scenarios of high Total P and STP starting points, average time to the boundary was estimated at 7–15 years depending on the field P balance. However, uncertainty analysis of the regression parameter showed that variation can be from 3 to >20 years. Combined with variation in how soil P source changes translate to resulting P delivery to water bodies, water policy regulators are advised to note this inherent uncertainty from P source to receptor with regard to expectations of Water Framework Directive water quality targets and deadlines.     

Nanosecond pulsed laser micromachining of PMMA-based microfluidic channels

This paper reports an investigation into the effects of nanosecond laser processing parameters on the geometry of microchannels fabricated from polymethylmethacrylate (PMMA). The Nd:YAG solid-state pulsed laser has a wavelength of 1064 nm and a measured maximum power of 4.15 W. The laser processing parameters are varied in a scanning speed range of 400–800 pulses/mm, a pulse frequency range of 5–11 Hz, a Q-switch delay time range of 170–180 μs. Main effects plots and microchannel images are utilized to identify the effects of the process parameters for improving material removal rate and surface quality simultaneously for laser micromachining of microchannels in PMMA polymer. It is observed that channel width and depth decreased linearly with increasing Q-switch delay time (hence average power) and increased non-linearly with higher scanning rates and not much affected by the increase in pulse frequency.     

Effects of grazing intensity and prescribed fire on soil physical and hydrological properties and pasture yield in the savanna woodlands of Burkina Faso

In West Africa policies for prescribed early fire and livestock grazing in the savanna woodlands are rarely based on long-term experimental studies. The inherently different management characteristics and their effects on the vegetation dynamics make landscape degradation a contentious issue. The effects of grazing intensity were investigated by a comparison of non-grazed areas, lightly grazed areas, moderately grazed areas, heavily grazed areas and very heavily grazed areas that received one of two fire treatments: early burning and fire protection in a long-term 12-year study. The parameters assessed reflected changes in herbaceous plant cover, biomass as well as soil physical and hydrological properties. The main findings were by and large specific for the grazing level. This supports the argument for devolution of management responsibility to the local level where there is indigenous site-specific knowledge but at the same time insufficient management capacity.A comparison of composite soil samples taken at a depth of 0–10 cm did not differentiate significantly between treatments. This is probably because the composite soil sampling procedure hid the properties of the top first few centimeters. Grazing pressure had a tendency to reduce total above ground biomass (p = 0.081). This was related to increased biomass removal and the trampling pressure (static load) exerted by the animals. The infiltration measurements indicated that the deleterious impact of cattle trampling increased as stocking rate increased. Livestock grazing significantly (p = 0.038) lowered the infiltrability. Prescribed early fire had a tendency (p = 0.073) to reduce the soil water infiltration rate. The subplots subjected to prescribed burning had a lower steady state infiltration rate compared to unburnt areas (means of 49.2 ± 27.5 mm h⁻¹ versus 78 ± 70.5 mm h⁻¹ for burnt and unburnt subplots, respectively). A partial least squares projection to latent structures showed that 34% of the steady state infiltrability was explained by the stocking rate and soil organic matter. Also all soil characteristics were significantly connected to steady state infiltrability suggesting that they are related to the soil hydrological response to trampling.From a management perspective, adoption of a short duration grazing system should avoid high stocking rates because they may adversely affect soil infiltrability, increase susceptibility to erosion in the savannas and decrease biomass productivity.     

Changes in soil fertility parameters and the environmental effects in a rapidly developing region of China

An extensive knowledge of the temporal variability of soil fertility parameters and how this variation affects the environment is imperative to a wide range of disciplines within agricultural science for optimal crop production and ecosystem preservation. This paper examines the temporal variability of soil pH, organic matter (OM), cation exchange capacity (CEC), total nitrogen (TN), total phosphorus (TP), available phosphorus (P_Av), and available potassium (K_Av) on Cambosols (Entisols) (n = 179) and Anthrosols (Inceptisols) (n = 95) in Zhangjiagang County, China from 1980 to 2004. Nutrient input was monitored from 1983 to 2004. Annual N fertilizer rates were significantly different during three periods (1983–1989, 1989–1999, 1999–2004), where annual rates increased significantly after 1989 and then decreased after 1999. Annual P fertilizer rates were significantly different during two periods (1983–1993, 1993–2004) where annual rates increased after 1993. No change was found in K fertilizer rates. Soil pH marginally increased by 0.14 units in Cambosols, but significantly decreased by 1.02 units in Anthrosols. OM, CEC, and TN increased in both soil orders an average of 2.15 g kg^?1, 1.6 cmol kg^?1, and 0.21 g kg^?1, respectively. TP decreased in Anthrosols by 70 mg kg^?1, P_Av increased in Cambosols by 4.83 mg kg^?1, and K_Av decreased in Cambosols by 15 mg kg^?1. Fertilizer input rates are causing nutrient imbalances, contributing to acidification in Anthrosols, and decreasing C/N ratios. Nutrient loading of N and deficiency of K is also a potential problem in the area. Efforts should be made to readjust soil nutrient inputs to reach an optimal, sustainable level.     

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.     

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.     

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.     

Long-term impact of a gliricidia-maize intercropping system on carbon sequestration in southern Malawi

Tree/crop systems under agroforestry practice are capable of sequestering carbon (C) in the standing biomass and soil. Although studies have been conducted to understand soil organic C increases in some agroforestry technologies, little is known about C sequestered in simultaneous tree/crop intercropping systems. The main objective of this study was to determine the effect of agroforestry practice on C sequestration and CO₂-C efflux in a gliricidia-maize intercropping system. The experiment was conducted at an experimental site located at the Makoka Agricultural Research Station, in Malawi. The studies involved two field plots, 7-year (MZ21) and 10-year (MZ12), two production systems (sole-maize and gliricidia-maize simultaneous intercropping systems). A 7-year-old grass fallow (Grass-F) was also included. Gliricidia prunings were incorporated at each time of tree pruning in the gliricidia-maize. The amount of organic C recycled varied from 0.8 to 4.8 Mg C ha⁻¹ in gliricidia-maize and from 0.4 to 1.0 Mg C ha⁻¹ in sole-maize. In sole-maize, net decreases of soil carbon of 6 Mg C ha⁻¹ at MZ12 and 7 Mg C ha⁻¹ at MZ21 in the topsoil (0–20 cm) relative to the initial soil C were observed. After 10 years of continuous application of tree prunings C was sequestered in the topsoil (0–20 cm) in gliricidia-maize was 1.6 times more than in sole-maize. A total of 123–149 Mg C ha⁻¹ were sequestered in the soil (0–200 cm depth), through root turnover and pruning application in the gliricidia-maize system. Carbon dioxide evolution varied from 10 to 28 kg ha⁻¹ day⁻¹ in sole-maize and 23 to 83 kg ha⁻¹ day⁻¹ in gliricidia-maize. We concluded that gliricidia-maize intercropping system could sequester more C in the soil than sole-maize.     

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.     

The role of indicator choice in quantifying the threat of atmospheric ammonia to the ‘Natura 2000’ network

New ‘critical levels’ (CLE) for assessing the effects of atmospheric ammonia on sensitive ecosystems have recently been adopted by the United Nations Economic Commission for Europe (UNECE) of 1 and 3 [2–4] μg NH₃ m^?3 of ambient air (including water vapour), for different species sensitivities and their associated habitats. Based on these values, we examined how indicator choice affects estimates of stock-at-risk in the European ‘Natura 2000’ network.We applied an atmospheric model, FRAME, to estimate surface air concentrations of ammonia at 5 km and 1 km resolution for the UK network of Natura sites, optionally including calibration with the National Ammonia Monitoring Network. As a base indicator, we estimated the overall percentage area of the UK Natura network that exceeded critical level thresholds (‘Area Weighted Indicator’, AWI). We compared this with an alternative approach, estimating the percentage number of Natura sites where the critical level was exceeded (‘Designation Weighted Indicator’, DWI), which we consider more relevant under the terms of the Habitats Directive.Using the AWI (with 1 km calibrated ammonia), we estimate that 11.2%, 1.3% and 0.2% area of the UK Natura network exceeds the critical level values of 1, 2 and 3 μg NH₃ m^?3, respectively. By contrast, using the DWI, the equivalent exceedances are 59.1%, 23.6% and 9.8%. The highest regional exceedance (DWI, critical level 1 μg NH₃ m^?3) was calculated for England (91.9% exceeded), and the lowest for Scotland (24.0% exceeded). High resolution maps show that the larger threat estimated by the DWI approach is explained by (i) an anti-correlation between NH₃ concentration and Natura site area and (ii) the fact that exceedance over part of a Natura site is considered to represent a threat to the integrity of the whole site.     

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.