Influence of Erroneous Data on the Results of Calculations From Acid–Base Surface Free Energy Theories. III. Solution of a Three-Equation Set in the Case of Homoscedastic Error

The van Oss–Chaudhury–Good theory (vOCGT) was checked for a large artificial set of work of adhesion input data calculated for 15 solids and 300 liquids. Numerical values of LW component and acid (A) and base (B) parameters were assigned to 15 solids. These 15 solids were grouped in 5 sets of 3 solids in each. Also numerical values of LW component and A and B parameters were assigned to 300 liquids (three sets of 100 liquids in each). Data for these solids and liquids were especially selected to represent real types of materials encountered in practice. For all 15 solids and 300 liquids the work of adhesion values were calculated and these values were assumed to be error-free. Next, new values of the work of adhesion were obtained by adding a random homoscedastic error (A vector of random variables is homoscedastic if it has the same finite variance.) of the normal distribution (Also called the Gaussian distribution — it is continuous probability distribution defined by two parameters: the mean and variance (standard deviation squared, σ ²).), belonging to 8 distributions of a mean value equal to the error-free work of adhesion value and standard deviations of 0.5, 1, 2, 5, 7, 10, 15 and 20 mJ/m². The LW components and A and B parameters for these solids were back-calculated for each error level. Two different methods for the solution of a 3-equation set were used and they gave practically the same results irrespective of the error level and liquids and solids used. It was found that there existed a linear correlation between the RMSE (root mean square error) of the solution and the standard deviation of the work of adhesion data. This correlation was highly significant (with a correlation coefficient higher than 0.999) and was true separately for LW component, A and B parameters as well as for the total solution vector (i.e., combinedly for the LW component, A and B parameters). The RMSE values of the total solution vector (having as elements values of the LW component, A and B parameters) as well as separately for LW component and A and B parameters were correlated with the condition number of a given 3-equation set. A very good correlation was found only for the total solution, much worse for A or B parameters, and practically there was a lack of correlation for the LW component. Based on the correlation between the RMSE and the standard deviation of the work of adhesion it was possible to determine what should have been the maximal standard deviation of the work of adhesion if the calculated value of a given LW component or A or B parameter did not differ by more than 1 mJ/m² from an error-free (true) value.     

Welded seam 3D calculation and seam location for welding robot system

Abstract

Using laser scanning techniques, scanning lens rotating around a laser diode and a circular laser trajectory was projected onto the surface of a weldment to detect it. Furthermore, one novel vision sensor based on the circular laser is developed. The three-dimensional (3D), circular laser based seam location sensor is investigated. On the basis of the light path system, 3D calculation algorithm is brought forward and used to locate the welded joint. After image denoise, filter, segmentation and thinning, characteristic points of the welded joint could be detected real time using a proposed vision sensor and confirmed by real experiments of butt welded joints with I groove and V groove, and lap, and fillet and ramp welded joints. The results show that circular laser based vision sensor can be used in seam locating and its calculation precision meets the requirement of seam tracking.     

HYDROSTATIC PRESSURE CALCULATION AND OPTIMIZATION FOR DESIGN OF BEAM ＆ SLIDE-REST GUIDEWAYS IN HEAVY DUTY CNC VERTICAL TURNING MILL

Aiming at the approximate error of commonly used methods on calculation of hydrostatic pressures of closed hydrostatic guideways with multiple pockets, a more accurate solution is proposed. Taking design of beam & slide-rest guideways for a heavy duty CNC vertical turning mill as an example, under an assumption that stiffnesses of guideways and their jointing structure are sufficiently large, the pressures of the pockets can be attained by adding a co-planarity equation that con strains pocket centers. Then, an optimization model is built to minimize the highest pocket pressure under additional constraints that are posed on the highest seal margin pressure, the highest levitating pressure of the pockets, and the maximum deformation of the guideways. The optimization problem is solved sequentially by using the methods of design of experiments and adaptive simulated annealing on iSIGHT software platform. The results show significant improvements to the original design. Optimized maximum hydrostatic pressure meets the requirement of hydraulic system.     

Effect of Mg on the evolution of non-metallic inclusions in Mn–Si–Ti deoxidised steel during solidification: experiments and thermodynamic calculations

Abstract

The effects of Mg on the evolution of non-metallic inclusions in Mn–Si–Ti deoxidised steels during solidification were investigated in a study based on experiments and thermodynamic calculations. The inclusions were composed of the MgO–MnO–Ti₂O₃–TiO₂ oxide, MnS, and TiN. With the increase of Mg concentration in steels, the phases of oxide inclusions were changed, in the order of pseudobrookite (Ti₃O₅–MnTi₂O₅), ilmenite (MgTiO₃–MnTiO₃–Ti₂O₃), spinel (Mg₂TiO₄–MgTi₂O₄–Mn₂TiO₄–MnTi₂O₄) and MgO. Thermodynamic calculations for inclusion evolutions were in good agreement with the experimental results.     

Estimation of resistance of filter media used for Prefil Footprinter tests of liquid aluminium alloys

Abstract

During the pressure filtration of molten metals, an essential parameter is the resistance of the filter medium, which is relevant to the calculation of flow velocity, pressure loss and distribution, and drag forces. The resistance has significant influences on the filtration behaviour and structure of the residual cake of inclusions retained on the filter. The Prefil Footprinter, a portable pressure filtration instrument, is usually used to determine the quality of molten aluminium alloys. To date, however, no data on the resistance of the filter medium used have been reported. The present work is an attempt to estimate the resistance. Experiments are described and analyses of flow behaviour are presented. Values of the medium resistance of the filters are determined and reported for the first time.     

Mitigation of Caesium and Cobalt Contamination on the Surfaces of Ram Packages

Abstract

Techniques for mitigating the adsorption of ¹³⁷Cs and ⁶⁰Co on metal surfaces (e.g. RAM packages) exposed to contaminated water (e.g. spent-fuel pools) have been developed and experimentally verified. The techniques are also effective in removing some of the ⁶⁰Co and ¹³⁷Cs that may have been adsorbed on the surfaces after removal from the contaminated water. The principle for the ¹³⁷Cs mitigation technique is based upon ion-exchange processes. In contrast, ⁶⁰Co contamination primarily resides in minute particles of crud that become lodged on cask surfaces. Crud is an insoluble Fe–Ni–Cr oxide that forms colloidal-sized particles as reactor cooling systems corrode. Because of the similarity between Ni²⁺ and Co²⁺, crud is able to scavenge and retain traces of cobalt as it forms. A number of organic compounds have a great specificity for combining with nickel and cobalt. Ongoing research is investigating the effectiveness of chemical complexing agent EDTA with regard to its ability to dissolve the host phase (crud) thereby liberating the entrained ⁶⁰Co into a solution where it can be rinsed away.     

Influence of erroneous data on the results of calculations from acid–base surface free energy theories. II. Why are negative values of square roots obtained?

The occurrence of negative square roots of the Lifshitz–van der Waals (LW) component and acid and base (A and B) parameters calculated from the van Oss–Chaudhury–Good theory was checked for a small artificial set of the work of adhesion input data calculated for 9 solids and 7 liquids. Taking from the literature the data for the LW component and A and B parameters for 7 liquids and the values of such component and parameters for 9 solids (close to those in the literature), the work of adhesion was calculated and its value was assumed to be error-free (un-biased). Next, new values of the work of adhesion were obtained by adding a random error having normal distribution belonging to 8 distributions of a mean value equal to the error-free work of adhesion value and standard deviations of 1, 5, 7, 10, 20, 25, 30 and 40% of the mean value. The LW components and A and B parameters for the nine solids were back-calculated for each solid and the error (bias) level by solving the overdetermined system of equations (of matrix 7 × 3) for 7 liquids. These 9 solids were grouped in 3 sets of 3 solids in each. It was found that an experimental error caused the work of adhesion data for real systems to be biased. This bias caused the solution of the equation system also to be biased and both biases were linearly dependent. This paper confirms that the appearance of negative roots of A and B parameters is caused by a specific bias in the components of the work of adhesion matrix. If the work of adhesion matrix is negatively biased there is a greater possibility of obtaining a negative value of the square root of γ ⁺, and the smaller the value of this parameter the greater is the possibility of obtaining a negative square root for it. Both the negative and positive biases in the work of adhesion matrix almost equally influence the bias in γ ^?. The smaller this parameter the greater is its bias and greater the possibility of obtaining its negative square root.     

Measurement of ladle slag oxygen activity using electrochemical sensor

Abstract

The oxygen activity of the ladle slag may be measured in situ with an electrochemical sensor. The measurement principle of this sensor needs further clarification. An experimental and computational study has been carried out of the contribution of specific components to the oxygen activity of the slag and of the factors that influence oxygen activity measurement with the sensor. Experiments on an industrial and on a laboratory scale show that FeO_x, SiO₂ and MnO exert a measurable influence on the results. The measurements also show a marked influence of the dissolved oxygen content in the steel. The oxygen activity of the slags has been calculated thermodynamically and compared with the sensor measurements. A systematic difference is observed. A hypothesis on the working principle of the sensor and on the cause of occasional problematic measurement values is proposed.     

Hatfield Memorial Lecture 2007 Railways and materials: synergetic progress

Abstract

Railways were originally uniquely identified with the material of their initial construction and now are technically identified by the characteristic contact of 'steel wheel on steel rail'. Over 160 years ago failures of iron railway axles led to research into what we now know as metal fatigue. Accidents throughout the ages have acted as catalysts for research and improvements: this lecture will identify some key incidents. The change from iron to steel, following Bessemer's discovery of a method of bulk production and its implementation in Sheffield, resulted in fewer materials failures and enabled greater loads to be carried at greater speeds. Today's railways rely on a wide variety of materials from all the major classes of materials. The requirements of cost, weight, reliability, crashworthiness, maintainability and inspection are often in conflict as the service loadings imposed by the modern railway on materials have become more severe. It is not therefore surprising that despite our advances in knowledge and capabilities, costly failures still occasionally occur. Nevertheless, railways have benefited from, and contributed to, advances in material engineering way beyond the initial emphasis on iron.     

Wear of water lubricated silicon nitride in ball on disc test

Abstract

The ball on disc test configuration is preferred to the flat ended pin on disc because the ball is self-aligned and measurement of wear on the ball is of higher accuracy, compared to the pin. Silicon nitride, sliding on itself in water, was tested with the ball on disc tribometer. Misalignment of the test ball from its proper position behind the disc axis of rotation leads to friction measurement errors, which were analysed. The disc wears non-uniformly, the wear track depth and width vary in longitudinal direction by a factor of 2–3. The uneven wear of the disc is explained by the combined effects of sliding surface anisotropy and disc material non-homogeneity on the one hand and by the friction force and the normal load periodic variation on the other hand. During the running-in process at particular sliding velocity amplitude modulated friction force was observed and an explanation by the mechanical vibration 'beating' phenomenon was suggested. Predictive model of the running-in process is presented, which describes the evolution of the ball wear scar area, the contact pressure and the wear rate. The model predictions are consistent with the experimental data.