Modeling the microstructural changes during hot tandem rolling of AA5XXX aluminum alloys: Part I. Microstructural evolution

A comprehensive mathematical model of the hot tandem rolling process for aluminum alloys has been developed. Reflecting the complex thermomechanical and microstructural changes effected in the alloys during rolling, the model incorporated heat flow, plastic deformation, kinetics of static recrystallization, final recrystallized grain size, and texture evolution. The results of this microstructural engineering study, combining computer modeling, laboratory tests, and industrial measurements, are presented in three parts. In this Part I, laboratory measurements of static recrystallization kinetics and final recrystallized grain size are described for AA5182 and AA5052 aluminum alloys and expressed quantitatively by semiempirical equations. In Part II, laboratory measurements of the texture evolution during static recrystallization are described for each of the alloys and expressed mathematically using a modified form of the Avrami equation. Finally, Part III of this article describes the development of an overall mathematical model for an industrial aluminum hot tandem rolling process which incorporates the microstructure and texture equations developed and the model validation using industrial data. The laboratory measurements for the microstructural evolution were carried out using industrially rolled material and a state-of-the-art plane strain compression tester at Alcan International. Each sample was given a single deformation and heat treated in a salt bath at 400 °C for various lengths of time to effect different levels of recrystallization in the samples. The range of hot-working conditions used for the laboratory study was chosen to represent conditions typically seen in industrial aluminum hot tandem rolling processes, i.e., deformation temperatures of 350 °C to 500 °C, strain rates of 0.5 to 100 seconds and total strains of 0.5 to 2.0. The semiempirical equations developed indicated that both the recrystallization kinetics and the final recrystallized grain size were dependent on the deformation history of the material i.e., total strain and Zener-Hollomon parameter (Z), where and time at the recrystallization temperature.     

Feature-subspace aggregating: ensembles for stable and unstable learners

This paper introduces a new ensemble approach, Feature-Subspace Aggregating (Feating), which builds local models instead of global models. Feating is a generic ensemble approach that can enhance the predictive performance of both stable and unstable learners. In contrast, most existing ensemble approaches can improve the predictive performance of unstable learners only. Our analysis shows that the new approach reduces the execution time to generate a model in an ensemble through an increased level of localisation in Feating. Our empirical evaluation shows that Feating performs significantly better than Boosting, Random Subspace and Bagging in terms of predictive accuracy, when a stable learner SVM is used as the base learner. The speed up achieved by Feating makes feasible SVM ensembles that would otherwise be infeasible for large data sets. When SVM is the preferred base learner, we show that Feating SVM performs better than Boosting decision trees and Random Forests. We further demonstrate that Feating also substantially reduces the error of another stable learner, k-nearest neighbour, and an unstable learner, decision tree.     

Musculoskeletal symptoms among mobile hand-held device users and their relationship to device use: A preliminary study in a Canadian university population

The study aims were, in a population of university students, staff, and faculty (n = 140), to: 1) determine the distribution of seven measures of mobile device use; 2) determine the distribution of musculoskeletal symptoms of the upper extremity, upper back and neck; and 3) assess the relationship between device use and symptoms. 137 of 140 participants (98%) reported using a mobile device. Most participants (84%) reported pain in at least one body part. Right hand pain was most common at the base of the thumb. Significant associations found included time spent internet browsing and pain in the base of the right thumb (odds ratio 2.21, 95% confidence interval 1.02–4.78), and total time spent using a mobile device and pain in the right shoulder (2.55, 1.25–5.21) and neck (2.72, 1.24–5.96). Although this research is preliminary, the observed associations, together with the rising use of these devices, raise concern for heavy users.     

Effectiveness of a participatory ergonomics intervention in improving communication and psychosocial exposures

A participatory ergonomics programme was implemented in an automotive parts manufacturing factory in which an ergonomics change team was formed, composed of members from management, the organized labour union and the research team. It was hypothesized that the participatory nature of this change process would result in enhanced worker perceptions of workplace communication dynamics, decision latitude and influence, which in conjunction with anticipated mechanical exposure reductions would lead to reduced worker pain severity. Utilizing a sister plant in the corporation as a referent group, a quasi-experimental design was employed with a longitudinal, repeat questionnaire approach to document pre-post intervention changes. Nine participatory activities (psychosocial interventions) were implemented as part of the process. Communication dynamics regarding ergonomics were significantly enhanced at the intervention plant compared to the referent plant. However, there were no significantly different changes in worker perceptions of decision latitude or influence between the two plants, nor did pain severity change. Possible explanations for these results include limited intervention intensity, context and co-intervention differences between the two plants, high plant turnover reducing the statistical power of the study and lack of sensitivity and specificity in the psychosocial measures used. Further research should include the development of psychosocial tools more specific to participatory ergonomic interventions and the assessment of the extent of change in psychosocial factors that might be associated with improvements in pain.     

Extremes in the complexity of computing metric distances between partitions

Day [3] describes an analytical model of minimum-length sequence (MLS) metrics measuring distances between partitions of a set. By selecting suitable values of model coordinates, a user may identify within the model that metric most appropriate to his classification application. Users should understand that within the model similar metrics may nevertheless exhibit extreme differences in their computational complexities. For example, the asymptotic time complexities of two MLS metrics are known to be linear in the number of objects being partitioned; yet we establish below that the computational problem for a closely related MLS metric is NP-complete.     

Relationships between psychophysically acceptable and maximum voluntary hand force capacity in the context of underlying biomechanical limitations

This research investigated if proportional relationships between psychophysically acceptable and maximum voluntary hand forces are dependent on the underlying biomechanical factor (i.e. whole body balance or joint strength) that limited the maximum voluntary hand force. Eighteen healthy males completed two unilateral maximal exertions followed by a 30 min psychophysical load-adjust protocol in each of nine pre-defined standing scenarios. Center of pressure (whole body balance) and joint moments (joint strength) were calculated to evaluate whether balance or joint strength was most likely limiting maximum voluntary hand force. The ratio of the psychophysically acceptable force to the maximal force was significantly different depending on the underlying biomechanical factor. Psychophysically acceptable hand forces were selected at 86.3 ± 19.7% of the maximum voluntary hand force when limited by balance (pulling exertions), 67.5 ± 15.2% when limited by joint strength (downward pressing) and 78 ± 23% when the limitation was undefined in medial exertions.     

Cryogenic and elevated temperature hypervelocity impact facility

The hypervelocity impact facility at Space Research Institute (SRI), Auburn University has recently completed a facility upgrade that permits the impact testing of space materials within the cryogenic and elevated temperature range. Sample temperatures within the range of 40–450 K have been achieved for polymer films. These wide temperature range capabilities add to the facilities current testing experience with impact initiated plasma discharge testing for solar cell arrays. The facility utilizes a plasma drag gun to accelerate a variety simulated micrometeorite materials in the 50–150 μm range to velocities between 5 and 12 km/s. For each test 5–50 particles impact the surface of the target sample within an impact area of approximately 15 cm in diameter. The test chamber can accommodate samples up to a meter wide for ambient and heated tests, and 48 cm for cryogenic samples. The gun and test chambers are evacuated by He cryopumps and dry roughing pumps to produce a clean, oil free environment. Utilizing a streak camera and PMT detection system, the correspondence between individual particle size, speed and impact site can be determined. Standard post-analysis yields: micrographs of each impact site, dimensions of the pertinent impact characteristics, individual particle velocity and size estimates.     

Effect of subsurface thermocouple installation on the discrepancy of the measured thermal history and predicted surface heat flux during a quench operation

Water quenching plays an important role in metallurgical and materials manufacturing operations to control both the temperature of the product during processing and its final microstructure. In order to control a water-quench process, the surface heat-transfer coefficient or heat flux must be quantified accurately. A common procedure to do this is to use an inverse heat conduction (IHC) model to estimate the heat-transfer boundary condition (heat flux or heat- transfer coefficient) based on the measured thermal history during the quench operation at a known interior location in the sample. Traditionally, thermocouples (TCs) have been extensively used during quench tests to measure the sample temperature history. This article will examine the effect of the hole used to insert the thermocouple into the sample and its orientation with respect to the quenched surface, on the perturbation in the thermal field around the TC measurement point during water-quench operations characterized by boiling heat transfer. The effect of some other factors on the perturbation of the thermal field at the TC measurement point during water-quench operations such as the diameter of the thermocouple hole, thermocouple distance from the quench surface, sample thermal conductivity, and quench intensity were also investigated. A two-dimensional (2-D) axisymmetric IHC model developed at the University of British Columbia is used to estimate the error in the predicted heat fluxes based on the thermal history measured at the thermocouple measurement point. The study showed, for some quench conditions, that the thermocouple hole must be included in the IHC analysis as an independent body with its own thermophysical and geometrical characteristics. Validation of these model-predicted results was done using water-quench experiments performed on samples of steel and aluminum plates at the University of British Columbia. Using the Biot number (Bi), a simple criterion is developed to determine when the TC hole needs to be included in the heat-transfer analysis.