A numerical model to predict the powder–binder separation during micro-powder injection molding

The micro-powder injection molding (micro-PIM) process has the potential to bridge the gap between the design and manufacturing of micro-components that are often used in small and handy devices. Numerical modeling helps to analyze and overcome various difficulties of micro-PIM. In the present work, a numerical model is developed to predict the powder–binder separation (a common defect in PIM and especially severe in micro-PIM) during the injection of an alumina feedstock. A powder–binder separation criterion is proposed dealing with applied injection pressure and friction force between the powder and binder. An indirect comparison of feedstock travel time between two locations is used to validate the model. The predicted segregation from the simulated result is supported by a qualitative experimental measurement. The developed model can be used to optimize injection parameters to get a defect-free product.     

Profiling hot isostatically pressed canister–wasteform interaction for Pu-bearing zirconolite-rich wasteforms

Zirconolite-rich full ceramic wasteforms designed to immobilize Pu-bearing wastes were produced via hot isostatic pressing (HIP) using stainless steel (SS) and nickel (Ni) HIP canisters. A detailed profiling of the elemental compositions of the major and minor phases over the canister–wasteform interaction zone was performed using scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM-EDS) characterization. Bulk sample analyses from regions near the center of the HIP canister were also conducted for both samples using X-ray diffraction and SEM-EDS. The sample with the Ni HIP canister showed almost no interaction zone with only minor diffusion of Ni from the inner wall of the canister into the near-surface region of the wasteform. The sample with the SS HIP canister showed ∼100–120 μm of interaction zone dominated by high-temperature Cr diffusion from canister materials to the wasteform with the Cr predominantly incorporated into the durable zirconolite phase. We also examined, for the first time, changes to the HIP canister wall thickness caused by HIPing and demonstrated that no canister wall thinning occurred. Instead, in the areas examined, the canister wall thickness was observed to increase (up to ∼20%) due to the compression occurring during the HIP cycle. Further, only sparse formation of (Cr, Mn)-rich oxide particles were noted within the HIP canister inner wall area immediately adjacent to the ceramic material, with no evidence for reverse diffusion of ceramic materials. Though the HIP canister–wasteform interaction extends to ∼120 μm when using an SS HIP canister for the system investigated, this translates to <<1 vol.% for an industrial scale HIPed wasteform. Importantly, the HIP canister–wasteform interactions did not produce any obviously less durable phases in the wasteform or had any detrimental impact on the HIP canister properties.     

A novel foam glass obtained from solid waste: A sustainable strategy for application in the degradation of an environmental pollutant

Foams glass were obtained from solid waste of flat glass and exhausted alkaline batteries. The physical, chemical, crystalline and morphological properties of the samples were obtained using the Archimedes principle, X-ray diffractometry (XRD), scanning electron microscopy (SEM). The results revealed glass foams with apparent porosities in the range of 55–64% and apparent densities in the range of 0.40–0.79 g cm^?3. The manganese oxide and graphite contained within the cathode of alkaline batteries acted as both oxidizing agents and as foaming agents. The zinc contained in the anode acted as a pore stabilizing agent and the zinc oxide as a semiconductor material. The foam glass that was composed of flat glass with an anode of Zn and ZnO, and a cathode of Mn₂O₃ and Mn₃O₄ (named An8), showed the greatest potential for heterogeneous photocatalysis, with a maximum efficiency of 95.9% after 3 h of treatment of solution containing dye. These results suggest the feasibility of producing foam glass from waste, as well as its potential application in photocatalytic systems, such as in the low-cost treatment of water.     

Mg gas infiltration for the fabrication of MgB2 pellets using nanosized and microsized B powders

MgB₂ superconductor pellets were synthesized through Mg gas infiltration method using nanosized- and microsized B powders. There was a marked difference in the superconducting properties of the two samples, particularly in the pinning force and dominant pinning mechanism. The microstructures of the samples were observed using HR-TEM and STEM-HAADF, and the results showed that the primary reason for the difference in the superconducting properties is the distribution of the nanosized second-phase particle MgO. Additionally, a feasible reaction model for the Mg gas infiltration method was established. Compared to the Mg liquid infiltration method, the gas infiltration showed better penetrability ability with a small amount of residual Mg. This study presents a novel synthesis process to fabricate an MgB₂ pellet with superior density and superconducting properties. This method can be used in multiple applications such as superconducting bearings, compact superconductor magnets, and magnetic shielding.     

红心火龙果发酵液喷雾干燥工艺优化及红心火龙果籽油的研究

以红心火龙果发酵液作为研究对象,通过优化喷雾干燥工艺制备粉剂,最佳工艺条件为:20%麦芽糊精,进液量:10mL/min,进口温度为120℃,出口温度为65℃;得到的粉剂为紫红色粉末,益生菌含量达到108cfu/g以上,口感酸甜。将发酵后的火龙果籽进行提取,得到的火龙果籽油含有丰富的十六酸、亚油酸和油酸。     

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

One of the main challenges in the laser powder bed fusion (LPBF) process is making dense and defect-free components. These porosity defects are dependent upon the melt pool geometry and the processing conditions. Power-velocity (PV) processing maps can aid in visualizing the effects of LPBF processing variables and mapping different defect regimes such as lack-of-fusion, under-melting, balling, and keyholing. This work presents an assessment of existing analytical equations and models that provide an estimate of the melt pool geometry as a function of material properties. The melt pool equations are then combined with defect criteria to provide a quick approximation of the PV processing maps for a variety of materials. Finally, the predictions of these processing maps are compared with experimental data from the literature. The predictive processing maps can be computed quickly and can be coupled with dimensionless numbers and high-throughput (HT) experiments for validation. The present work provides a boundary framework for designing the optimal processing parameters for new metals and alloys based on existing analytical solutions.     

Improvement of gaseous bioenergy production from spent coffee grounds Co-digestion with pulp wastewater by physical/chemical pretreatments

Two steps of hydrolysis and anaerobic biogas production processes was investigated in this study. In the first step, subcritical water (SBW) hydrolysis and chemical (acid/alkali) pretreatments were carried out to enhance hydrolysis efficiency by obtaining and analyzing the total volatile fatty acids (TVFA), chemical oxygen demand (COD), and total sugar productions from spent coffee grounds (SCG) hydrolysate. The subcritical water (SBW) hydrolysis under the condition of temperature 150 °C for 30 min can greatly improve the organic matter breakdown and reached the COD concentration of 1010 g/L which was 30% higher than the untreated raw SCG. For chemical pretreatments, it was found that the alkaline hydrolysis of SCG resulted in the greatest total sugar concentration of 181 g/L whereas the operation conditions were 2.0 M NaOH at 60 °C for 1 h. The peak of TVFA concentration 3725 mg/L was found at the acid hydrolysis of SCG with 1.0 M H₂SO₄ acid, 60 °C for 1 h. The optimal biomethane yield of 115 mL/g COD was obtained when 1.0 M H₂SO₄ acid hydrolysate co-digestion with pulp wastewater which increase methane yield production 8 times of raw pulp wastewater. The pretreatment process was confirmed in this study can significant improve the converting of the biowastes to bioenergy efficiency.     

饱和块状混合回填土地基的一维固结分析

用块状渣土置换软弱地基和回填低洼谷地等是处置工程渣土的有效途径。为了分析饱和块状混合回填土地基的固结性状，运用混合物理论建立了其一维固结模型。首先，假定块状土固相和充填土固相之间满足等应变条件，获得了饱和块状混合回填土中各相应变与块状土孔隙变形和充填土孔隙变形的关系式。其次，在小应变条件下，根据自由能势函数方程建立了饱和块状混合回填土的一维线弹性本构方程，再结合达西定律和应力平衡方程获得了一维固结控制方程。再次，利用分离变量法得到一维固结解析解，通过退化本文模型与已有模型进行对比，验证了本文模型的正确性。最后，基于所得解析解，分析了充填土孔隙渗透系数、块状土孔隙渗透系数以及流体交换参数等因素对饱和块状混合回填土地基固结性状的影响。分析结果表明：充填土孔隙渗透系数对饱和块状混合回填土地基整体固结性状起主导作用；在固结初期，块状土超孔压会有一定程度的上升，且3个参数具有相似的作用机理。     

Direct shear behavior of gravel-rubber mixtures: Discrete element modeling and microscopic investigations

In this paper, a newly developed 3-dimentional discrete element model (DEM) for gravel-rubber mixtures (GRMs), namely DEM4GRM, that is capable of accurately describing the macro-scale shear response (from small to large deformation) of GRMs in a direct shear box apparatus is presented. Rigid gravel grains are modelled as simple multi-shape clumps, while soft rubber particles are modeled by using deformable 35-ball body-centered-cubic clusters. Mixtures are prepared with different volumetric rubber content (VRC) at 0, 10, 25, 40 and 100%, statically compressed under 30, 60 and 100 kPa vertical stress and then sheared, by closely simulating a reference laboratory test procedure. The variation of micro-scale factors such as fabric, normal and tangential force anisotropy is carefully examined throughout the shearing process and described by means of novel micro-mechanical relationships valid for GRMs. Moreover, strong-force chains are scrutinized to identify the transition from rigid to soft granular skeleton and gain insights on the load transfer and deformation mechanisms of GRMs. It is shown that the development of the fabric and force anisotropy during shearing is closely related to the macro-scale shear strength of GRMs, and strongly depends on the VRC. Besides, strong-force chains appear to be primarily formed by gravel-gravel contacts (resulting in a rigid-like mechanical behavior) up to VRC = 30%, and by rubber-rubber contacts (causing a soft-like mechanical response) beyond VRC = 60%. Alternatively, at 30% < VRC < 60%, gravel-rubber contacts are predominant in the strong-force network and an intermediate mechanical behavior is observed. This is consistent with the behavioral trends observed in the macro- and micro-mechanical responses.     

Effect of coral sand powders and seawater salinity on the impact mechanical properties of cemented coral sand

Coral sand is one kind of the important building materials in coral reef engineering practice. The use of cement as a stabilizing agent can significantly improve the mechanical properties of coral sands and is widely applied in the subbase engineering construction in coral reef islands. Cement-stabilized coral sand structures may contain high contents of fine coral particles and salinity because of the high crushability of coral sands and the existence of seawater surrounding them. In this study, the effects of coral sand powders and seawater salinity on the dynamic mechanical properties of cemented coral sand (CCS) were investigated through the split Hopkinson pressure bar (SHPB) tests and Scanning Electron Microscope (SEM) analysis. It was found that the strength (i.e., the peak stress) of CCS specimens increased firstly and then decreased with the increase of powder content. The specimens reached the maximum peak stress when 3% powder content was included. The initial improvement of CCS strength was attributed to the pore-filling effect of coral powders, namely, the micro pores of the CCS specimens could be more effectively filled with higher percentages of coral powders being used in the experiments. However, excessive coral powders resulted in the reduction of specimen strength because these powders could easily be cemented into agglomerates by absorbing water from the specimens. These agglomerates could reduce the cementation strength between the coarse coral particles and the cement. Meanwhile, the peak stress of CCS specimens was found to be negatively correlated with the average strain rate and the ultimate strain. The degree of specimen fracture was found to be correlated with the amount of specific energy absorption during the tests. Furthermore, the “sulfate attack” caused by the inclusion of salinity of water had different influences on the CCS specimens with different coral powder contents. The ettringite and gypsum produced in “sulfate attack” could fill the pores and lead to cracking of the specimens, significantly affecting the specimen strength.