Multidisciplinary optimization of gas-quenching process

Distortion as a result of the quenching process is predominantly due to the thermal gradient and phase transformations within the component. Compared with traditional liquid quenching, the thermal boundary conditions during gas quenching are relatively simple to control. By adjusting the gas-quenching furnace pressure, the flow speed, or the spray nozzle configuration, the heat-transfer coefficients can be designed in terms of both the component geometry and the quenching time. The purpose of this research is to apply the optimization methodology to design the gas-quenching process. The design objective is to minimize the distortion caused by quenching. Constraints on the average surface hardness, and its distribution and residual stress are imposed. The heat-transfer coefficients are used as design variables. DEFORM-HT is used to predict material response during quenching. The response surface method is used to obtain the analytical models of the objective function and constraints in terms of the design variables. Once the response surfaces of the objective and constraints are obtained, they are used to search for the optimum heat-transfer coefficients. This process is then used instead of the finite-element analysis. A one-gear blank case study is used to demonstrate the optimization scheme.     

Improved corrosion protection of aluminum alloys by electrodeposited silanes

Organofunctional silanes recently have emerged as outstanding, environmentally friendly corrosion protectors for metal substrates, compared with conventional chromate treatments. A simple immersion technique is typically used to coat the metal surface with silane films. However, the thickness and uniformity of the films are uncontrolled in this process. This paper proposes a new deposition technique for the silane films on the metal surface, i.e., by electrodeposition. Hydrolyzed silanes are water-soluble, ionized molecules, so they can be deposited on metals by electrodeposition. Various combinations of silane mixtures were tested at different voltages, pH values, bath concentrations, and exposure times on panels of alloy aluminum and mirror-polished ferro-plate. The surface structure was characterized by scanning electron microscopy (SEM) and ellipsometry. The resistance of the film to corrosion was investigated by direct current (DC) polarization and electrochemical impedance spectroscopy (EIS) techniques. Electrodeposition results in a more organized and uniform film with fewer pores, compared with immersed or dipped films. This paper was presented at the 2nd International Surface Engineering Congress sponsored by ASM International, on September 15–17, 2003, in Indianapolis, Indiana, and appears on pp. 320–26 of the Proceedings.     

The distribution of grain boundary planes in polycrystals

During the last ten years, techniques have been developed to measure the distribution of grain boundaries in polycrystals as a function of both lattice misorientation and grain boundary plane orientation. This paper presents a brief overview of the techniques used for these measurements and the principle findings of studies implementing these techniques. The most significant findings are that grain boundary plane distributions are anisotropic, that they are scale invariant during normal grain growth, that the most common grain boundary planes are those with low surface energies, that the grain boundary populations are inversely correlated with the grain boundary energy, and that the coincident site lattice number is a poor predictor of the grain boundary energy and population.     

Preparation of Protein-Stabilized β-Carotene Nanodispersions by Emulsification–Evaporation Method

This work was initiated to prepare protein-stabilized β-carotene nanodispersions using emulsification–evaporation. A pre-mix of the aqueous phase composed of a protein and hexane containing β-carotene was subjected to high-pressure homogenization using a microfluidizer. Hexane in the resulting emulsion was evaporated under reduced pressures, causing crystallization and precipitation of β-carotene inside the droplets and formation of β-carotene nanoparticles. Sodium caseinate (SC) was the most effective emulsifier among selected proteins in preparing the nanodispersion, with a monomodal β-carotene particle-size distribution and a 17-nm mean particle size. The results were confirmed by transmission-electron microscopy analysis. SC-stabilized nanodispersion also had considerably high ζ-potential (−27 mV at pH 7), suggesting that the nanodispersion was stable against particle aggregation. Increasing the SC concentration decreased the mean particle size and improved the polydispersity of the nanodispersions. Nanodispersions prepared with higher β-carotene concentrations and higher organic-phase ratios resulted in larger β-carotene particles. Although increased microfluidization pressure did not decrease particle size, it did improve the polydispersity of the nanodispersions. Repeating the microfluidization process at 140 MPa caused the nanodispersions to become polydisperse, indicating the loss of emulsifying capacity of SC due to protein denaturation.     

Informational Entropy: a Failure Tolerance and Reliability Surrogate for Water Distribution Networks

Evolutionary algorithms are used widely in optimization studies on water distribution networks. The optimization algorithms use simulation models that analyse the networks under various operating conditions. The solution process typically involves cost minimization along with reliability constraints that ensure reasonably satisfactory performance under abnormal operating conditions also. Flow entropy has been employed previously as a surrogate reliability measure. While a body of work exists for a single operating condition under steady state conditions, the effectiveness of flow entropy for systems with multiple operating conditions has received very little attention. This paper describes a multi-objective genetic algorithm that maximizes the flow entropy under multiple operating conditions for any given network. The new methodology proposed is consistent with the maximum entropy formalism that requires active consideration of all the relevant information. Furthermore, an alternative but equivalent flow entropy model that emphasizes the relative uniformity of the nodal demands is described. The flow entropy of water distribution networks under multiple operating conditions is discussed with reference to the joint entropy of multiple probability spaces, which provides the theoretical foundation for the optimization methodology proposed. Besides the rationale, results are included that show that the most robust or failure-tolerant solutions are achieved by maximizing the sum of the entropies.     

Use of cascade reduction potential for selective precipitation of Au,Cu, and Pb in hydrochloric acid solution

Optimization of reduction potential for electroseparation was studied for the recovery of gold, copper, and lead from acidic solution. A linear sweep voltammetric method enabled us to determine characteristic reduction potentials for each metal and the kinetics of the metal deposition indicated by current-voltage curves. In order to precipitate the metal species sequentially, reduction potentials were examined for the individual and mixed solutions of Au(III), Cu(II), and Pb(II). The three metals were reasonably well isolated from the mixed solutions such as Cu(II)/ Pb(II) and Au(III)/Cu(II)/Pb(II) in the order of the corresponding reduction potentials, in particular, the mass transfer controlled reduction potentials, obtained from linear sweep voltammetry (LSV) measurement.     

Effect of the use of mineral filler on the properties of concrete

Engineers of the concrete technology are increasingly concerned with the material passing through a sieve of the size under 0.149 mm. Materials called very fine aggregate or mineral filler may affect the performance of concrete in an either positive or a negative way. Discussions on aggregate containing very fine material are vitally important. Washing the aggregate residue has been the sole way to solve this matter to date. This is mainly based on the debatable opinion that materials of this kind are regarded as clay material. The goal of the study was to determine how the content of mineral filler might affect properties of concrete. Two types of aggregates with different amounts of cement and mineral filler were used. Basically, mineral filler replaced sand. The effect of applying different amounts of mineral filler on concrete was then determined. The addition of 7-10% of mineral filler to fine aggregate (0-2 mm) was found to considerably improve the properties of concrete.     

The desalting and recycling of wastewaters from textile dyeing operations using reverse osmosis

The wastewater from the textile dyeing operations was separated into a concentrate stream, rich in salts and dyes, and a purified product water stream using reverse osmosis membranes. Three membrane materials and three module configurations were used, namely : polyamide (hollow fine fiber configuration ), cellulose acetate ( spiral wound and tubular configurations ) and hydrous Zr(IV)- polyacrylate ( tubular configuration ). The modules were tested for periods ranging from 600 hours to more than 1000 hours under actual field conditions. Membrane flux and rejection were monitored throughout the operation and samples of the feed and product water were analysed chemically. The successful operation of the R.O. equipment under field conditions demonstrated the applicability of this process in the desalination of dyeing wastewater.     

Hydrodynamic characteristics of a FCC regenerator

The hydrodynamic and gas mixing characteristics have been determined in a FCC regenerator (0.48 m I.D.x3.4 m high) with FCC particles. Solids holdup in the dense bed decreases with increasing gas velocity, but it increases in the freeboard region. The bubble/void fraction increases with an increase along the bed height at a given gas velocity and increases with increasing gas velocity at a constant bed height. Backmixed tracer gas at the wall region is higher than that at the center region of the bed. The gas backmixing coefficient decreases with increasing gas velocity.     

Formation of Polymeric Lewis Acid–Lewis Base Complexes with Well-defined Organoboron Polymers

The binding of Lewis bases to organoboron polymeric Lewis acids has been studied and the parameters that determine the complexation equilibrium have been investigated, which include (i) the strength of the individual Lewis acids and Lewis bases, (ii) concentration, and (iii) temperature. While the strongly Lewis acidic borane polymers poly(4-bis(pentafluorophenyl)borylstyrene) (PS-BPf) and poly(4-(di-2-thienylboryl)styrene) (PS-BTh) form isolable complexes with strong Lewis bases such as 4-t-butylpyridine (^tPy), a temperature dependent equilibrium is established with weaker bases such as THF. Similarly, the weakly Lewis acidic boronate polymer poly(4-diethoxyborylstyrene) (PS-BOEt) undergoes a temperature dependent equilibrium with the strong Lewis base 4-dimethylaminopyridine (DMAP), while poly(4-pinacolatoborylstyrene) (PS-BPin) does not significantly bind to pyridine bases. Decomplexation of PS-BTh· ^t Py is achieved by treatment with the stronger Lewis acid, B(C₆F₅)₃, thereby confirming the reversible nature of the polymeric Lewis acid–base adducts. This paper is dedicated to Professor Ian Manners in gratitude of his guidance throughout the years and recognition of his scientific accomplishments