Compressive behaviour of thin catalyst layers. Part II - Model development and validation

In the second part of this study, a new analytical model for catalyst layers (CLs) compression is developed using effective medium theory, using a geometric “unit cell”, to accurately predict the deformation of CLs under compression. Based on SEM images, a representative unit cell is proposed using microstructural properties of CL such as porosity, pore size distribution, and ionomer to carbon weight ratio (I/C) to simplify the random complex structure of CLs. Deformation of the ionomer film that covers carbon agglomerates is found to be the main deformation compared to other mechanisms such as Hertzian compliance of carbon particles and deformation of agglomerates. The present model is validated using the experimental results obtained for five different CL designs, presented in Part 1 of this study. The analytical model is capable of predicting the non-linear compressive behaviour of CLs with a reasonable accuracy since a continuous change of CL porosity is considered in the model. The proposed geometrical model has also been used for other properties of CL in our group and successfully predicted thermal conductivity and gas diffusivity of CL.     

The dependence of fatigue crack growth on hydrogen in warm-rolled 316 austenitic stainless steel

The fatigue crack growth rate of warm-rolled AISI 316 austenitic stainless steel was investigated by controlling rolling strain and temperature in argon and hydrogen gas atmospheres. The fatigue crack growth rates of warm-rolled 316 specimens tested in hydrogen decreased with increasing rolling temperature, especially 400 °C. By controlling the deformation temperature and strain, the influences of microstructure (including dislocation structure, deformation twins and α′ martensite) and its evolution on hydrogen-induced degradation of mechanical properties were separately discussed. Deformation twins deceased and dislocations became more uniform with the increase in rolling temperature, inhibiting the formation of dynamic α′ martensite during the crack propagation. In the cold-rolled 316 specimens, deformation twins accelerated hydrogen-induced crack growth due to the α′ martensitic transformation at the crack tip. In the warm-rolled specimens, the formation of α′ martensite around the crack tip was completely inhibited, which greatly reduced the fatigue crack growth rate in hydrogen atmosphere.     

Effect of the substrate and interface on micro-scratch deformation of epoxy-polyester powder coatings

The role of the interface on the deformation response in scratch tests of epoxy-polyester films deposited by electrostatic spraying is investigated. A comparative study of the scratch deformation behaviour of films deposited on micro- and macro-corrugated rigid substrates and on ‘soft’ silicon sub-layers is made. Scratch deformation parameters were evaluated by contact gauge inductive profilometry, whilst morphological examinations of the residual scratch patterns were performed by electron microscopy.     

Anisotropic thermal expansion behaviors of copper matrix in β-eucryptite/copper composite

A β-eucryptite/copper composite was fabricated by spark plasma sintering process. The thermal expansion behaviors of Cu matrix of the composite were studied by in situ X-ray diffraction during heating process. The results show that Cu matrix exhibits anisotropic thermal expansion behaviors for different crystallographic directions, the expansion of Cu{1 1 1} plane is linear in the temperature range from 20 °C to 300 °C and the expansion of Cu{2 0 0} is nonlinear with a inflection at about 180 °C. The microstructures of Cu matrix before and after thermal expansion testing were investigated using transmission electronic microscope. The anisotropic thermal expansion behavior is related to the deformation twinning formed in the matrix during heating process. At the same time, the deformation twinning of Cu matrix makes the average coefficient of thermal expansion of the composite increase.     

Refining SiCp in reinforced Al–SiC composites using equal-channel angular pressing

Aluminum–silicon carbide composite (Al–SiC_p) is one of the most promising metal matrix composites for their enhanced mechanical properties and wear resistance. In the present study, Al–SiC (average size 55 μm) composites with 5% and 10% by volume were fabricated by stir casting technique. The equal-channel angular pressing (ECAP) was then applied on the cast composites at room temperature in order to study the effect of ECAP passes on the SiC_p size and distribution. The ECAP process was successfully carried out up to 12(8) passes for Al–5%(10%)SiC samples. Microstructure study revealed that the highest refinement by breakage of SiC_p was achieved after the first ECAP pass and that further refinement took place in the next passes. More breakage of the SiC_p was found in the composite richer in reinforcing particles so that the SiC_p reached approximately 1 μm in the Al–10%SiC after 8 passes and 4 μm in Al–5%SiC after 12 ECAP passes. The distribution of SiC reinforcement particles also improved after applying ECAP. The factors including decrease in reinforcing particle size, improvement in their distribution, decrease in porosity in addition to strain hardening and grain refining of the matrix resulted in enhancement of tensile and compressive strengths as well as hardness by more than threefold for the Al–5%SiC after 12 passes and for Al–10%SiC after 8 passes compared to the cast composites. Additionally, the composite remained ductile after the ECAP process. The fracture surface indicated good bond between the matrix and the reinforcement.     

Optimisation of method for reducing residual stresses after cold bar drawing

Abstract

A new method to reduce the residual stresses after cold bar drawing has been proposed and optimised. This new method addresses the disadvantages of previous methods proposed by the authors, and needs neither the use of an extra finishing die nor an intricate die geometry. The application of axial tension to the bar or wire after drawing is all that is required, and by adjusting the magnitude of the tension it is possible to control the residual stresses in the final product. Axisymmetric elastic-plastic finite element analysis was carried out to examine quantitatively the influence of tension, followed by laboratory experiments using a thick, not thin, bar for convenience of measurement of residual stresses. The optimum value of tension was then determined. The applicability of the proposed method is discussed in the present paper. The new method is especially effective when applied to high speed cold drawing of an extremely thin wire, because the tension applied to the wire after finishing can be readily controlled simply by adjusting the peripheral speed of the rollers/pulleys.     

DMA thermal analysis of different parts of potato tuber

Dynamic mechanical analysis (DMA) was applied to three potato tissues (‘cortex’, ‘pith’, and ‘side’ surface) of two cultivars (more waxy ‘Nicola’ and more mealy ‘Saturna’) in temperature scans in the range 30–90 °C and constant air humidity of 90%. The obtained scans indicate peaks in both storage and loss module of elasticity (SM and LM, respectively) at temperatures higher than 70 °C – so called ‘starch’ peak (SP) – as was observed previously. The peak value increase with increasing potato dry matter (DM) content, below DM content approximately 14% no SP is observed (‘Nicola pith’). Slope analysis of the basic parameters: SM, LM, and loss tangent (LT) was performed and further characteristic points on the temperature plots were found: (i) in temperature range A (30–40 °C) maximum of SM and LM and minimum of LT, (ii) in temperature range B (40–50 °C) minimum of SM and LM slopes corresponding to point of inflection on SM-T and LM-T plots, (iii) at about 50 °C, big peak in LT in side tissue only, (iv) at about 70 °C just prior the ‘starch’ peak, big peak in LT that is more marked in ‘pith’; this peak denoted as ‘I’ influenced the ‘starch’ peak ‘II’. It was found that both cultivar and part of the tuber influences the DMA temperature plots.     

Deformation-induced austenite grain rotation and transformation in TRIP-assisted steel

Uniaxial straining experiments were performed on a rolled and annealed Si-alloyed TRIP (transformation-induced plasticity) steel sheet in order to assess the role of its microstructure on the mechanical stability of austenite grains with respect to martensitic transformation. The transformation behavior of individual metastable austenite grains was studied both at the surface and inside the bulk of the material using electron back-scattered diffraction (EBSD) and X-ray diffraction (XRD) by deforming the samples to different strain levels up to about 20%. A comparison of the XRD and EBSD results revealed that the retained austenite grains at the surface have a stronger tendency to transform than the austenite grains in the bulk of the material. The deformation-induced changes of individual austenite grains before and after straining were monitored with EBSD. Three different types of austenite grains can be distinguished that have different transformation behaviors: austenite grains at the grain boundaries between ferrite grains, twinned austenite grains, and embedded austenite grains that are completely surrounded by a single ferrite grain. It was found that twinned austenite grains and the austenite grains present at the grain boundaries between larger ferrite grains typically transform first, i.e. are less stable, in contrast to austenite grains that are completely embedded in a larger ferrite grain. In the latter case, straining leads to rotations of the harder austenite grain within the softer ferrite matrix before the austenite transforms into martensite. The analysis suggests that austenite grain rotation behavior is also a significant factor contributing to enhancement of the ductility.     

Dislocation interactions with grain boundaries

Recent progress in understanding dislocation interactions with grain boundaries and interfaces in metallic systems via static and in situ dynamic experimental approaches is reviewed.