Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

The objective of this research is to investigate the mechanical properties including bonding, tensile strength, and impact resistance of pure copper welded using friction stir welding (FSW) method and compare them with that of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper, TIG welded copper and FSW welded copper to determine the effect of heat on the hardness of welded coppers. Tensile strength tests and notch tensile strength tests are performed to determine the mechanical properties of different weld process.In this experiment, it is found that the notch tensile strength and the notch strength ratio for FSW (212 MPa, 1.10) are significantly higher than those (190 MPa, 1.02) of TIG welding. For the impact tests, the weld zone and heat-affected zone energy absorption values for FSW (2.87 J, 2.25 J) are higher than those (1.32 J, 0 J) of TIG welding. XRD tests are performed to determine components of copper before and after welding process for TIG and FSW.     

Friction stir welding: Process,automation, and control

This article provides an introduction to the basic principles of friction stir welding (FSW) as well as a survey of the latest research and applications in the field. The basic principles covered include terminology, material flow, joint configurations, tool design, materials, and defects. Material flow is discussed from both an experimental and a modeling perspective. Process variants are discussed as well, which include self-reacting (SR-FSW), stationary shoulder, friction stir processing (FSP), friction stir spot welding (FSSW), assisted FSW, and pulsed FSW. Multiple aspects of robotic friction stir welding are covered, including sensing, control, and joint tracking. Methods of evaluating weld quality are surveyed as well. The latest applications are discussed, with an emphasis on recent advances in aerospace, automotive, and ship building. Finally, the direction of future research and potential applications are examined.     

A method for double-sided friction stir spot welding

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

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.     

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.     

Response of “Alamo” switchgrass tissue chemistry and biomass to nitrogen fertilization in West Tennessee,USA

Switchgrass (Panicum virgatum) is a perennial, warm-season grass that has been identified as a potential biofuel feedstock over a large part of North America. We examined above- and belowground responses to nitrogen fertilization in “Alamo” switchgrass grown in West Tennessee, USA. The fertilizer study included a spring and fall sampling of 5-year old switchgrass grown under annual applications of 0, 67, and 202 kg N ha^?1 (as ammonium nitrate). Fertilization changed switchgrass biomass allocation as indicated by root:shoot ratios. End-of-growing season root:shoot ratios (mean ± SE) declined significantly (P ≤ 0.05) at the highest fertilizer nitrogen treatment (2.16 ± 0.08, 2.02 ± 0.18, and 0.88 ± 0.14, respectively, at 0, 67, and 202 kg N ha^?1). Fertilization also significantly increased above- and belowground nitrogen concentrations and decreased plant C:N ratios. Data are presented for coarse live roots, fine live roots, coarse dead roots, fine dead roots, and rhizomes. At the end of the growing season, there was more carbon and nitrogen stored in belowground biomass than aboveground biomass. Fertilization impacted switchgrass tissue chemistry and biomass allocation in ways that potentially impact soil carbon cycle processes and soil carbon storage.     

Effects of irrigation,fertilization and crop straw management on nitrous oxide and nitric oxide emissions from a wheat–maize rotation field in northern China

One-year winter wheat–summer maize rotation is the most popular double cropping system in north-central China, and this highly productive system is an important source of nitrous oxide (N₂O) and nitric oxide (NO) emissions due to the high fertilizer N and irrigation water inputs. To sustain the high crop production and mitigate the detrimental impacts of N₂O and NO emissions, improved management practices are extensively applied. The aim of this study is therefore to evaluate the effects of an improved management practice of irrigation, fertilization and crop straw on grain yield and N₂O and NO emissions for a wheat–maize rotation field in northern China. Using automated and manual chamber measuring systems, we monitored N₂O and NO fluxes for the conventional (CT, 2007–2008), improved (IT, 2007–2008), straw-amended (WS, 2008–2009), straw-not-amended (NS, 2008–2009), and no N-fertilizer treatments (WS–NN, 2008–2009), respectively, for one rotation-year. The grain yields were determined for CT and IT for three rotation-years (2005–2008) and for WS, NS and WS–NN for one rotation-year (2008–2009). The improved management of irrigation and fertilization reduced the annual N fertilization rate and irrigation amount by 17% and 30%, respectively; increased the maize yield by 7–14%; and significantly decreased the N₂O and NO emissions by 7% (p < 0.05) and 29% (p < 0.01), respectively. The incorporation of wheat straw increased the cumulative N₂O and NO emissions in the following maize season by 58% (p < 0.01) and 13%, respectively, whereas the effects of maize straw application were not remarkable. The N₂O and NO emission factors of applied N were 2.32 ± 2.32% and 0.42 ± 1.69% for wheat straw and 0.67 ± 0.23% and 0.54 ± 0.15% for chemical N-fertilizers, respectively. Compared to conventional management practices using high application rates of irrigation water and chemical N-fertilizer as well as the field burning of crop straw, the improved management strategy presented here has obvious environmentally positive effects on grain yield and mitigation of N₂O and NO emissions.     

Changes in soil respiration across a chronosequence of tallgrass prairie reconstructions

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

Insertable thin film thermocouples for in situ transient temperature monitoring in ultrasonic metal welding of battery tabs

Real-time monitoring and control of temperature in ultrasonic joining of battery tabs and coupons are important for the quality improvement and cost reduction of battery assembly. However, there have always been difficulties in accurate and real-time measurement of temperature by conventional sensors for practical implementation. In this study, an innovative method is developed to provide an enabling technology for the in situ transient temperature monitoring, which could provide reliable feedback signals for potential control of ultrasonic joining processes. Micro thin film thermocouples (TFTCs) were fabricated on thin silicon substrates, which were then inserted in the welding anvil as a permanent feature so that the sensors were always located about 100 μm directly under the welding spot during joining of multilayer Ni-coated Cu thin sheets for battery assembly. Good repeatability was demonstrated while a temperature rise of up to 650 °C was obtained due to the closeness of the sensors to the welding spot. The inserts with thin film sensors remained functional after welding experiments. This method has a great potential for in situ transient temperature monitoring, and thus the control of ultrasonic joining processes to realize a practical smart joining system.     

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.     

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.     

Ammonia and nitrous oxide emissions following land application of high and low nitrogen pig manures to winter wheat at three growth stages

Nitrous oxide (N₂O) and ammonia (NH₃) emissions from surface applied high (HN) and low (LN) nitrogen pig manures were measured under field conditions. Manures were band-spread to a winter wheat crop at three growth stages—mid-tillering, stem elongation and flag leaf emergence. The N₂O flux rates were measured using the static chamber technique while NH₃ volatilisation was assessed using a micrometeorological mass balance technique with passive flux samplers. The N₂O emissions were episodic in nature with flux rates observed ranging from 2.8 to 31.5 g N₂O–N ha^?1 day^?1 (P < 0.001). Higher N₂O emissions generally occurred after rainfall events. Highest N₂O losses were observed from the HN treatment with LN manure use decreasing emissions by 18% (P < 0.03). The NH₃ volatilisation rates were highest within 1 h of manure application with 95% of emissions occurring within 24 h (P < 0.001). Cumulative N loss was highest at mid-tillering as low crop canopy cover and increased wind-speeds enhanced NH₃ loss (P < 0.001). Highest emissions were measured from the HN manure (P < 0.03). Total ammoniacal N loss ranged from 6 to 11%. Crop N uptake and grain yield were unaffected by application timing or manure type. Therefore, the use of LN manures decreased gaseous emissions of N₂O and NH₃ without any adverse effects on crop performance.     

Effects of different diets on utilization of nitrogen from cattle slurry applied to grassland on a sandy soil in The Netherlands

Dietary adjustments have been suggested as a means to reduce N losses from dairy systems. Differences in fertilizing value of dairy slurry as a result of dietary adjustments were evaluated in a 1-year grassland experiment and by long-term modelling. Slurry composition of non-lactating dairy cows was manipulated by feeding diets with extreme high and low levels of dietary protein and energy. C:N_total ratio of the produced slurries ranged from 5.1 to 11.4. To evaluate their short-term fertilizer N value, the experimental slurries (n = 8) and slurries from commercial farms with variable composition (n = 4), were slit-injected in two grassland fields on the same sandy soil series in the north of The Netherlands (53°10′N, 6°04′E), with differences in sward age and ground water level. The recently established grassland field (NEW) was characterized by lower soil OM, N and moisture contents, less herbs and more modern grass varieties compared to the older grassland field (OLD). Slurry was applied in spring (100 kg N ha⁻¹) and after the first cut (80 kg N ha⁻¹) while in total four cuts were harvested. Artificial fertilizer N treatments were included in the experiment to calculate the mineral fertilizer equivalent (MFE) of slurry N. The OLD field showed a higher total N uptake whereas DM yields were similar for the two fields. Average MFE of the slurries on the OLD field (47%) was lower than on the NEW field (56%), probably as a result of denitrification of slurry N during wet conditions in spring. Slurries from high crude protein diets showed a significantly higher MFE (P < 0.05) compared to low crude protein diets. No significant differences in MFE were observed between slurries from high and low energy diets. On both fields, MFE appeared to be positively related to the ammonium content (P < 0.001) and negatively to the C:N_total ratio of the slurry DM (P = 0.001). Simulation of the effect of long-term annual application of 180 kg N ha⁻¹ with highest and lowest C:N_total ratio suggested that both slurries would lead to an increase in annual soil N mineralization. Both soil N mineralization and SOC appeared to be substantially higher in equilibrium state for the slurry with the highest C:N_total ratio. It is concluded that in a situation with slit-injection, the reduced first-year N availability of slurry with a high C:N_total ratio as observed in the grassland experiment will only be compensated for by soil N mineralization on the very long term.     

Life-cycle environmental and economic impacts of energy-crop fuel-chains: an integrated assessment of potential GHG avoidance in Ireland

This paper combines life-cycle analyses and economic analyses for Miscanthus and willow heat and electricity fuel-chains in Ireland. Displaced agricultural land-uses and conventional fuels were considered in fuel-chain permutations. Avoided greenhouse gas (GHG) emissions ranged from 7.7 to 35.2 t CO₂ eq. ha⁻¹ a⁻¹. Most fuel-chain permutations exhibited positive discounted financial returns, despite losses for particular entities at a farm-gate processed-biomass price of €100 t⁻¹ dry-matter. Attributing a value of €10 t⁻¹ CO₂ eq. to avoided GHG emissions, but subtracting financial returns associated with displaced fuel supplies, resulted in discounted annual national economic benefits (DANEBs) ranging from −457 to 1887€ ha⁻¹ a⁻¹. Extrapolating a plausible combination of fuel-chains up to a national indicative scenario resulted in GHG emission avoidance of 3.56 Mt CO₂ eq. a⁻¹ (5.2% of national emissions), a DANEB of 167 M€, and required 4.6% of national agricultural land area. As cost-effective national GHG avoidance options, Miscanthus and willow fuel-chains are robust to variation in yields and CO₂ price, and appear to represent an efficient land-use option (e.g. compared with liquid biofuel production). Policies promoting utilisation of these energy-crops could avoid unnecessary, and environmentally questionable, future purchase of carbon credits, as currently required for national Kyoto compliance.     

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.     

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

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

Risky business: Engaging the public on sea level rise and inundation

To examine whether U.S. public opinion may become as sharply polarized on adaptation responses as it has been on mitigation policies, we surveyed a sample of urban coastal residents in Maryland (n = 378). We then tested the impact of a community deliberative event (n = 40) with small-group sea level rise discussions as a depolarization strategy. Cultural worldviews which contribute to politically polarized beliefs about climate were predictive of perceptions of sea level rise risk. Living close to flooding hazards also significantly predicted respondents’ perceptions of household or neighborhood risks, but not of risks to the entire county. The event significantly increased topic knowledge among all participants and, among those with a worldview predisposing them to lower risk perceptions, significantly increased problem identification and concern about impacts. These results suggest small-group deliberation focused on local problem-solving may be an effective tool for reducing the polarizing effects of cultural worldviews on decision-making.     

Study on machinability of a stellite alloy with uncoated and coated carbide tools in turning

Stellite alloys, which have been widely used in the aerospace, automotive and chemical industries, are hard-to-cut cobalt-based materials. This study investigates the machinability of stellite 12 alloys with uncoated carbide cutting tool grades YG610 (K01-K10) and YT726 (K05-K10/M20) and SANDVIK coated carbide tool SNMG150612-SM1105 under dry cutting conditions. Both wear mechanisms and failure modes of the uncoated and coated tools were investigated with turning experiments. The results show that the coated tool SM1105 remarkably outperforms the uncoated tools; and the cutting tool YG610 generally outperforms YT726 under all cutting conditions. Built-up edge was found with YG610 in some cutting conditions and with SM1105 at cutting speed of 16 m/min. Tool surface burning marks were observed on YT726 at relatively higher cutting speeds. Wear develops slowly with coated tools SM1105 until VB reaches 0.2 mm at most conditions (except at v = 43 m/min, f = 0.25 mm/r). Excessive tool flank typically resulted in tool breakage at the cutting edge for uncoated tools. Abrasive and adhesive wear of cutting tools were observed at low cutting speeds while diffusion and chemical wear occurred at higher cutting speeds.     

Investigation on mechanism of phosphate removal on carbonized sludge adsorbent

For the removal of phosphate (PO₄^3 -) from water, an adsorbent was prepared via carbonization of sewage sludge from a wastewater treatment plant: carbonized sludge adsorbent (CSA). The mechanism of phosphate removal was determined after studying the structure and chemical properties of the CSA and its influence on phosphate removal. The results demonstrate that phosphate adsorption by the CSA can be fitted with the pseudo second-order kinetics and Langmuir isotherm models, indicating that the adsorption is single molecular layer adsorption dominated by chemical reaction. The active sites binding phosphate on the surface are composed of mineral particles containing Si/Ca/Al/Fe. The mineral containing Ca, calcite, is the main factor responsible for phosphate removal. The phosphate removal mechanism is a complex process including crystallization via the interaction between Ca^2 + and PO₄^3 -; formation of precipitates of Ca^2 +, Al^3 +, and PO₄^3 -; and adsorption of PO₄^3 - on some recalcitrant oxides composed of Si/Al/Fe.