Failure Analysis of AISI 440C Steel Ball Screws Used in the Actuator System of a Satellite Launch Vehicle

In view of its excellent wear and corrosion resistance, AISI 440C steel is the material of choice for the fabrication of ball screws used in actuator systems of satellite launch vehicles. During the routine acceptance test of a ball screw, longitudinal cracks were observed at the shaft location of the ball screw. The optical microstructure of the ball screw material (AISI 440C) revealed the presence of aligned carbides (carbide banding). Fractographic observations revealed the cracking to be along the carbide bands. Based on detailed optical and scanning electron microscopic observations, the cracking of the ball screws was attributed to the carbide bands.     

Progressive cutting tool wear detection from machined surface images using Voronoi tessellation method

Tool condition monitoring by machine vision approach has been gaining popularity day by day since it is a low cost and flexible method. In this paper, a tool condition monitoring technique by analysing turned surface images has been presented. The aim of this work is to apply an image texture analysis technique on turned surface images for quantitative assessment of cutting tool flank wear, progressively. A novel method by the concept of Voronoi tessellation has been applied in this study to analyse the surface texture of machined surface after the creation of Voronoi diagram. Two texture features, namely, number of polygons with zero cross moment and total void area of Voronoi diagram of machined surface images have been extracted. A correlation study between measured flank wear and extracted texture features has been done for depicting the tool flank wear. It has been found that number of polygons with zero cross moment has better linear relationship with tool flank wear than that of total void area.     

Linked Simulation-Optimization based Dedicated Monitoring Network Design for Unknown Pollutant Source Identification using Dynamic Time Warping Distance

Implementation of monitoring strategy for increasing the efficiency of groundwater pollutant source characterization is often necessary, especially when only inadequate and arbitrary concentration measurement data are initially available. Two main parameters that need to be estimated for efficient and accurate characterization of groundwater pollution sources are: location of the source and the time when the source became active. Complexities involved with the explicit estimation of the time of start and source activity have not been addressed so far in previous studies. The main complexity arises due to the fact that the spatial location and time of activity are inter-related. Therefore, specifying one and solving for the other simplifies the source characterization problem. Hence, in this study, both the source location and time of initiation are treated as unknowns. The developed methodology uses dynamic time warping distance in the linked simulation-optimization model to address some complex issues in designing a monitoring network to efficiently estimate source characteristics including the time of first activity of unknown groundwater source. Performance of the developed methodology is evaluated on illustrative contaminated aquifer. These evaluation results demonstrate the potential use of the developed methodology.     

Optimal Dynamic Monitoring Network Design and Identification of Unknown Groundwater Pollution Sources

The identification of unknown pollution sources is a prerequisite for designing of a remediation strategy. In most of the real world situations, it is difficult to identify the pollution sources without a scientifically designed efficient monitoring network. The locations of the contaminant concentration measurement sites would determine the efficiency of the unknown source identification process to a large extent. Therefore coupled and iterative sequential source identification and dynamic monitoring network design framework is developed. The coupled approach provides a framework for necessary sequential exchange of information between monitoring network and source identification methodology. The preliminary identification of unknown sources, based on limited concentration data from existing arbitrarily located wells provides the initial rough estimate of the source fluxes. These identified source fluxes are then utilized for designing an optimal monitoring network for the first stage. Both the monitoring network and source identification process is repeated by sequential identification of sources and design of monitoring network which provides the feedback information. In the optimal source identification model, the Jacobian matrix which is the determinant for the search direction in the nonlinear optimization model links the groundwater flow-transport simulator and the optimization method. For the optimal monitoring network design, the integer programming based optimal design model requires as input, simulated sets of concentration data. In the proposed methodology, the concentration measurement data from the designed and implemented monitoring network are used as feedback information for sequential identification of unknown pollution sources. The potential applicability of the developed methodology is demonstrated for an illustrative study area.     

Simplified Impedance Model for Adhesively Bonded Piezo-Impedance Transducers

The electromechanical impedance technique employs surface-bonded lead zirconate titanate piezoelectric ceramic patches as impedance transducers for structural health monitoring and nondestructive evaluation. The patches are bonded to the monitored structures using finitely thick adhesive bond layer, which introduces shear lag effect, thus invariably influencing the electromechanical admittance signatures. This paper presents a new simplified impedance model to incorporate shear lag effect into electromechanical admittance formulations, both one-dimensional and two-dimensional. This provides a closed-form analytical solution of the inverse problem, i.e. to derive the true structural impedance from the measured conductance and susceptance signatures, thus an improvement over the existing models. The influence of various parameters (associated with the bond layer) on admittance signatures is investigated using the proposed model and the results compared with existing models. The results show that the new model, which is far simpler than the existing models, models the shear lag phenomenon reasonably well besides providing direct solution of a complex inverse problem.     

Modelling of a downdraft biomass gasifier with finite rate kinetics in the reduction zone

A model of a downdraft gasifier has been developed based on chemical equilibrium in the pyro‐oxidation zone and finite rate kinetic‐controlled chemical reactions in the reduction zone. The char reactivity factor (C_RF) in the reduction zone, representing the number of active sites on the char and its degree of burn out, has been optimized by comparing the model predictions against the experimental results from the literature. The model predictions agree well with the temperature distribution and exit gas composition obtained from the experiments at C_RF=100. A detailed parametric study has been performed at different equivalence ratios (between 2 and 3.4) and moisture content (in the range of 0–40%) in the fuel to obtain the composition of the producer gas as well as its heating value. It is observed that the heating value of the producer gas increases with the increase in the equivalence ratio and decrease in the biomass moisture content. The effect of divergence angle of the reduction zone geometry (in the range of 30–150°) on the temperature and species concentration distributions in the gasifier has been studied. An optimum divergence angle, giving the best quality of the producer gas, has been identified for a particular height of the reduction zone. Copyright © 2009 John Wiley & Sons, Ltd.     

Nanoscale adhesion,friction and wear studies of biomolecules on silane polymer-coated silica and alumina-based surfaces

Proteins on biomicroelectromechanical systems (BioMEMS) confer specific molecular functionalities. In planar FET sensors (field-effect transistors, a class of devices whose protein-sensing capabilities we demonstrated in physiological buffers), interfacial proteins are analyte receptors, determining sensor molecular recognition specificity. Receptors are bound to the FET through a polymeric interface, and gross disruption of interfaces that removes a large percentage of receptors or inactivates large fractions of them diminishes sensor sensitivity. Sensitivity is also determined by the distance between the bound analyte and the semiconductor. Consequently, differential properties of surface polymers are design parameters for FET sensors. We compare thickness, surface roughness, adhesion, friction and wear properties of silane polymer layers bound to oxides (SiO₂ and Al₂O₃, as on AlGaN HFETs). We compare those properties of the film–substrate pairs after an additional deposition of biotin and streptavidin. Adhesion between protein and device and interfacial friction properties affect FET reliability because these parameters affect wear resistance of interfaces to abrasive insult in vivo. Adhesion/friction determines the extent of stickage between the interface and tissue and interfacial resistance to mechanical damage. We document systematic, consistent differences in thickness and wear resistance of silane films that can be correlated with film chemistry and deposition procedures, providing guidance for rational interfacial design for planar AlGaN HFET sensors.     

Study on TL and OSL characteristics of indigenously developed CaF2:Mn phosphor

CaF₂:Mn phosphor is known for its high thermoluminescent sensitivity and dose linearity up to few kGy. In the present study CaF₂ phosphor with different concentration of Mn dopant was prepared and was characterized through different techniques. The phosphor was prepared through chemical root using CaCO₃, HF acid and MnCl₂ as raw materials following co-precipitation method. TL sensitivity of the prepared phosphor was compared with other well established phosphors used for radiation dosimetry. It was found that the TL sensitivity is higher by a factor of 10 with respect to LiF:Mg, Ti, TLD-100 and half to that of CaSO₄:Dy (0.05 mol%) phosphor. X-ray diffraction, TL emission spectrum and ESR spectrum taken of the prepared phosphor confirms the crystal structure, Mn²⁺ emission and incorporation Mn in the crystal, respectively. No significant fading of the dosimetric peak was observed of the prepared phosphor for a storage period of 45 days. The dose linearity of the phosphor was found to be in the range of 50 Gy-3 kGy within an uncertainty of about 10%. An attempt was made to determine the kinetic parameters of TL glow curve and the parameters related to optically stimulated luminescence. In view of its long range of dose linearity, it can be used for the dosimetry of commercial irradiator generally used for the irradiation of food and grains in our country.     

Zincated Nanoclay Polymer Composites (ZNCPCs): Synthesis,Characterization, Biodegradation and Controlled Release Behaviour in Soil

Novel zincated nanoclay polymer composites (ZNCPCs) with variable percentage of commercial bentonite and nanobentonite (8%, 10% and 12% of monomer for each case) were synthesized. Polyacrylic acid-Polyacrylamide copolymer was synthesized using N, N-Methylene bisacrylamide as crosslinker and ammonium persulfate as initiator. Clays as well as ZNCPCs were characterized by XRD, SEM, TEM and FTIR. 12% nanoclay containing formulation showed slowest release rate. ZNCPCs containing 8% clay recorded highest Zn content as well as highest equilibrium water absorbency. Biodegradation study revealed that Aspergillus spp was more effective as compared with Trichoderma spp in degradation of ZNCPCs.