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.     

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.     

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.     

Comparing carbon fluxes between different stages of secondary succession of a karst grassland

Abandonment of marginal agricultural areas with subsequent secondary succession is a widespread type of land use change in Mediterranean and mountain areas of Europe, leading to important environmental consequences such as change in the water balance, carbon cycling, and regional climate. Paired eddy flux measurement design with grassland site and tree/shrub encroached site has been set-up in the Slovenian Karst (submediterranean climate region) to investigate the effects of secondary succession on ecosystem carbon cycling. The invasion of woody plant species was found to significantly change carbon balance shifting annual NEE from source to an evident sink. According to one year of data succession site stored ?126 ± 14 g C m^?2 y^?1 while grassland site emitted 353 ± 72 g C m^?2 y^?1. In addition, the seasonal course of CO₂ exchange differed between both succession stages, which can be related to differences in phenology, i.e. activity of prevailing plant species, and modified environmental conditions within forest fragments of the invaded site. Negligible effect of instrument heating was observed which proves the Burba correction in our ecosystems unnecessary. Unexpectedly high CO₂ emissions and large disagreement with soil respiration especially on the grassland site in late autumn indicate additional sources of carbon which cannot be biologically processes, such as degassing of soil pores and caves after rain events.     

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.     

Use of life cycle assessment methodology for determining phytoremediation potentials of maize-based cropping systems in fields with nitrogen fertilizer over-dose

Using the life cycle assessment (LCA) method, we analyzed the effects of different cropping systems (sole maize (CK), maize + soybean (CST) and maize + groundnut (CGT)) on the environment. The comprehensive index of environmental impacts varied in the order, sole maize > maize + groundnut > maize + soybean, with corresponding intercropping values of 0.1295, 0.1229 and 0.0945, respectively. The results showed that intercropping maize with suitable plants (e.g., groundnut and soybean) could reduce the adverse effects of over-application of nitrogen fertilizer on the environment. The study further showed that the LCA method may be a convenient and effective approach for analyzing the environmental impact of fertilizer management in agricultural fields.     

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.     

Exceedance of modern ‘background’ fine-grained sediment delivery to rivers due to current agricultural land use and uptake of water pollution mitigation options across England and Wales

Excessive loss of fine-grained sediment to rivers is widely recognised as a global environmental problem. To address this issue, policy teams and catchment managers require an estimate of the ‘gap’ requiring remediation, as represented by the excess above ‘background’ losses. Accordingly, recent work has estimated the exceedance of modern ‘background’ sediment delivery to rivers at national scale across England and Wales due to (i) current agricultural land cover, cropping and stocking, and (ii) current land use corrected for the uptake of on-farm mitigation measures. This sectoral focus recognises that, nationally, agriculture has been identified as the principal source of fine sediment loss to the aquatic environment. Two estimates of modern ‘background’ sediment loss, based on paleolimnological evidence, were used in the analysis; the target modern ‘background’ (TMBSDR) and maximum modern ‘background’ (MMBSDR) sediment delivery to rivers. For individual (n = 4485) non-coastal water bodies, the sediment ‘gap’ in excess of TMBSDR and MMBSDR, due to current land cover, cropping and stocking, was estimated to range up to 1368 kg ha⁻¹ yr⁻¹ (median 61 kg ha⁻¹ yr⁻¹) and 1321 kg ha⁻¹ yr⁻¹ (median 19 kg ha⁻¹ yr⁻¹), respectively. The respective ranges in conjunction with current land cover, cropping and stocking but corrected for the potential impact of on-farm sediment mitigation measures were up to 1315 kg ha⁻¹ yr⁻¹ (median 50 kg ha⁻¹ yr⁻¹) and 1269 kg ha⁻¹ yr⁻¹ (median 8 kg ha⁻¹ yr⁻¹). Multiplication of the estimates of excess sediment loss corrected for current measure uptake, above TMBSDR and MMBSDR, with estimated maximum unit damage costs for the detrimental impacts of sediment pollution on ecosystem goods and services, suggested respective water body ranges up to 495 £ ha⁻¹ yr⁻¹ and 478 £ ha⁻¹ yr⁻¹. Nationally, the total loss of sediment in excess of TMBSDR was estimated at 1,389,818 t yr⁻¹ equating to maximum environmental damage costs of £523 M yr⁻¹, due to current structural land use, compared to 1,225,440 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹ due the uptake of on-farm sediment control measures. The corresponding total loss of sediment in excess of MMBSDR was estimated at 1,038,764 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹, compared with 890,146 t yr⁻¹ and £335 M yr⁻¹ correcting excess agricultural sediment loss for current implementation of abatement measures supported by policy instruments. This work suggests that the current uptake of sediment control measures on farms across England and Wales is delivering limited benefits in terms of reducing loadings to rivers and associated environmental damage costs.     

A promising clean process for production of diosgenin from Dioscorea zingiberensis C. H. Wright

This study proposes a new approach for diosgenin production from Dioscorea zingiberensis C. H. Wright tubers with respect to resources utilization and clean production. This process consisted of two successive parts, i.e., recovery of starch from raw material, and microbial hydrolysis of the residue to produce diosgenin by Trichoderma reesei. In the first step, about 75.4% of hemicellulose and 98.0% of starch were removed from the tubers. In the second step, about 90.2% of diosgenin was released from saponins by T. reesei at 30 °C, at an aeration of 0.80 vvm and agitation rate of 300 rpm in a 5.0 L bioreactor. Significant reduction of pollutant production was detected by replacing the traditional approach with the proposed new method. About 99.2% of reducing sugar, 99.4% of chemical oxygen demand, 99.2% of total organic carbon, 100% of SO₄^2?, and 100% of acid was reduced in the new processing wastewater.     

Emissions of N2O and NH3, and nitrogen leaching from direct seeded rice under different tillage practices in central China

Tillage practices affect the fate of fertilizer nitrogen (N) through influencing transformations of N, but few studies have examined N₂O and NH₃ emissions, and N leaching from different rice tillage systems. Thus the objective of this study was to assess N₂O emission, NH₃ volatilization and N leaching from direct seeded rice in conventional tillage (CT) and no-tillage (NT) production systems in the subtropical region of China during the 2008 and 2009 rice growing seasons. Treatments were established following a split-plot design of a randomized complete block with tillage practices as the main plot and N fertilizer level as the sub-plot treatment, and there were four treatments: NT + no fertilizer (NT0), CT + no fertilizer (CT0), NT + compound fertilizer (NTC) and CT + compound fertilizer (CTC), respectively. Results showed that N fertilization significantly increased (p < 0.01) N₂O emissions, NH₃ volatilization and N leaching from rice fields in both years. In general, there was no significant difference in N₂O emissions and NH₃ volatilization between NT0 and CT0 in both years, while NTC had significantly higher (p < 0.05) N₂O emissions and NH₃ volatilization compared to CTC. Over the two rice growing seasons, NTC showed 32% and 47% higher N₂O emissions, and 29% and 52% higher NH₃ losses than CTC. Higher (p < 0.05) N₂O emissions from NTC than CTC were presumably due to higher soil organic C and greater denitrification. Total N and NO₃^? concentrations were higher (p < 0.05) in CTC than NTC, but larger volumes of percolation water in NTC than CTC resulted in no significant difference in leakage of total N and NO₃^?. Hence, application of N fertilizer in combination with NT appeared to be ineffective in reducing N losses from N fertilizer in paddy fields.     

Soil C storage as affected by tillage and straw management: An assessment using field measurements and model predictions

Soil tillage and straw management are both known to affect soil organic matter dynamics. However, it is still unclear whether, or how, these two practices interact to affect soil C storage, and data from long term studies are scarce. Soil C models may help to overcome some of these problems. Here we compare direct measurements of soil C contents from a 9 year old tillage experiment to predictions made by RothC and a cohort model. Soil samples were collected from plots in an Irish winter wheat field that were exposed to either conventional (CT) or shallow non-inversion tillage (RT). Crop residue was removed from half of the RT and CT plots after harvest, allowing us to test for interactive effects between tillage practices and straw management. Within the 0–30 cm layer, soil C contents were significantly increased both by straw retention and by RT. Tillage and straw management did not interact to determine the total amount of soil C in this layer. The highest average soil C contents (68.9 ± 2.8 Mg C ha^?1) were found for the combination of RT with straw incorporation, whereas the lowest average soil C contents (57.3 ± 2.3 Mg C ha^?1) were found for CT with straw removal. We found no significant treatment effects on soil C contents at lower depths. Both models suggest that at our site, RT stimulates soil C storage largely by decreasing the decomposition of old soil C. Extrapolating our findings to the rest of Ireland, we estimate that RT will lead to C mitigation ranging from 0.18 to 1.0 Mg C ha^?1 y^?1 relative to CT, with the mitigation rate depending on the initial SOC level. However, on-farm assessments are still needed to determine whether RT management practices can be adopted under Irish conditions without detrimental effects on crop yield.     

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.     

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.     

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.     

The effect of pitting corrosion on split sleeve cold hole expanded,bare 7075-T651 aluminium alloy

As part of an aircraft fleet fatigue life improvement program, investigation has been carried out into the effect pitting corrosion has on bare 7075-T651 which had undergone split sleeve cold hole expansion. Constant amplitude sinusoidal loading was applied to fatigue test coupons which had pitting corrosion induced upon them by a modified cyclic immersion process using a 3.5% NaCl solution. A pit depth of 39–58 μm was found to significantly reduce the increased fatigue life gains achieved by carrying out cold hole expansion. At 137.9 MPa fatigue life was reduced from achieving run out of ten million cycles to an average 371 × 10³ cycles, while at 165.5 MPa average fatigue life was reduced from 810 × 10³ to 65 × 10³ cycles. The fracture surfaces were analysed under a scanning electron microscope where each displayed an individual crack initiation site located on the material surface within the zone of residual circumferential stress.     

Comparing intensive,extensified and organic grassland farming in southern Germany by process life cycle assessment

To reduce the environmental burden of agriculture, suitable methods to comprehend and assess the impact on natural resources are needed. One of the methods considered is the life cycle assessment (LCA) method, which was used to assess the environmental impacts of 18 grassland farms in three different farming intensities — intensive, extensified, and organic — in the Allgäu region in southern Germany. Extensified and organic compared with intensive farms could reduce negative effects in the abiotic impact categories of energy use, global warming potential (GWP) and ground water mainly by renouncing mineral nitrogen fertilizer. Energy consumption of intensive farms was 19.1 GJ ha⁻¹ and 2.7 GJ t⁻¹ milk, of extensified and organic farms 8.7 and 5.9 GJ ha⁻¹ along with 1.3 and 1.2 GJ t⁻¹ milk, respectively. Global warming potential was 9.4, 7.0 and 6.3 CO₂-equivalents ha⁻¹ and 1.3, 1.0 and 1.3 CO₂-equivalents t⁻¹ milk for the intensive, extensified and organic farms, respectively. Acidification calculated in SO₂-equivalents was high, but the extensified (119 kg SO₂ ha⁻¹) and the organic farms (107 kg SO₂ ha⁻¹) emit a lower amount compared with the intensive farms (136 kg SO₂ ha⁻¹). Eutrophication potential computed in PO₄-equivalents was higher for intensive (54.2 kg PO₄ ha⁻¹) compared with extensified (31.2 kg PO₄ ha⁻¹) and organic farms (13.5 kg PO₄ ha⁻¹). Farmgate balances for N (80.1, 31.4 and 31.1 kg ha⁻¹) and P (5.3, 4.5 and −2.3 kg ha⁻¹) for intensive, extensified and organic farms, respectively, indicate the different impacts on ground and surface water quality. Analysing the impact categories biodiversity, landscape image and animal husbandry, organic farms had clear advantages in the indicators number of grassland species, grazing cattle, layout of farmstead and herd management, but indices in these categories showed a wide range and are partly independent of the farming system.     

Material flows in the life cycle of leather

This paper presents a study on the resource and environmental profile of leather for communicating to the consumers about the environmental burdens of leather products. The results indicate that significant environmental impacts were caused during the tanning and finishing of leather as well as the electricity production and transportation required in the life cycle. The use of fossil fuels in the production of energy has greater impact with increased emissions leading to about 15190 kg CO₂ equivalent of global warming and about 73 kg SO₂ equivalent of acidification while producing 100 m² of leather for shoe uppers. Further resource use of 174 kg of coal, 6.5 kg of fuel oil, 17.4 m³ of water and 348 kg of chemicals of which about 204 kg are hazardous are consumed, and wastewater of about 17 m³, BOD of 55 kg, COD of about 146 kg, TDS of 732 kg and solid waste of about 1445 kg are generated during the life cycle for the production of 100 m² of leather. The total solid waste generated is 1317 kg, out of which about 80% is biodegradable contributed by slaughtering, tanning and finishing stage, 14% is non-biodegradable contributed by tanning, finishing and electricity production stages and 6% is hazardous mainly from tanning and finishing stage of leather.     

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.     

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.