Effect of Residual Surface Stress on the Strenght Distribution of Brittle Materials

The introduction of residual surface stresses into a material can change the strength distribution simply due to variability in the stress intensity factor of surface cracks. This variability arises from the distribution in surface (critical) crack lengths. A fracture mechanics approach was used to determine the influence of surface compression on the average strength and the standard deviation of the strength distribution. The strengths of the stress-free samples were assumed to fit a twoparameter Weibull distribution, and the increases in strength resulting from the surface compression were determined using fracture mechanics. It was determined from the analysis that the standard deviation/average strength ratio (coefficient of variation) initially increases, passes through a maximum, and ultimately reaches a plateau value below the initial value, as one increases the depth of surface compression. The maximum increase in the strength scatter occurs when the depth of the surface compression is approximately equal to the characteristic crack size. These changes were found to be dependent on the magnitude of the surface stress, as well as the characteristic strength, Weibull modulus, and fracture toughness of the stress-free material.     

Experiences from using heat integration software to determine retrofit opportunities within a refinery process

Heat integration techniques can be used to optimize the energy requirement for both new and retrofit plant designs. Software tools for identifying retrofit options are becoming available. This paper reports our experiences from using heat exchanger network (HEN) optimization software for a retrofit case study of an oil refinery process. The HEN optimization software was used to automate the search for the most beneficial retrofit designs following the twostage process proposed by Asante and Zhu. The software provided three potential retrofit designs. Results from this analysis were used as the basis of a rigorous mass and energy balance simulation of the plant. The simulation corroborated the energy savings, but there were some important differences. The simulation required 20% more heat exchange area. Furthermore, the retrofit design involving one topology change was shown to be less economic than an alternative design. These differences are discussed and a revised methodology is proposed.     

Prevention of water pollution problems in mining: The bactericide technology

In pyritic environments, the bacteriaThiobacillus ferrooxidans catalyze acid formation by increasing the oxidation rate of pyrite by a factor of one million. This acid solubilizes metals and pollutes adjacent streams and lands. Bactericide sprays during mining and waste disposal operations attack the source of the problem by preventing acid formation and metals solubilization. Used in conjunction with current water treatment systems, bactericides can dramatically reduce operating costs. Controlled release bactericides contribute to successful reclamation by providing assurance against revegetation failure and post-reclamation water quality problems that can necessitate perpetual water treatment. While inhibitingT. ferrooxidans these organic compounds aid in the establishment of beneficial heterotrophic bacteria which support vegetation. These conditions continue to persist after the bactericide is depleted from the controlled release system. Case Studies I and II show that bactericides inhibit acid generation during hard rock and coal mining operations and they are cost effective. Case Studies III and IV illustrate the improvement in water quality and vegetation after reclamation when controlled release bactericides were used. Economic analyses show cost benefits are achieved when controlled-release bactericides are part of the reclamation plan.     

Sand corrosion,thermal expansion,and ablation of medium- and high-entropy compositionally complex fluorite oxides

Sand corrosion, thermal expansion, and ablation properties of a new class of medium- and high-entropy compositionally complex fluorite oxides (CCFOs) are examined as potential protective coating materials. Five binary oxides were mixed and sintered into dense, single-phase CCFOs of the general formula: [Hf_(1-2x)/3Zr_(1-2x)/3Ce_(1-2x)/3Y_xYb_x]O_2-δ (x = 0.2, 0.074, and 0.029). These CCFOs exhibit decreased molten sand infiltration and interaction at intermediate temperatures (1200-1300°C) in comparison with a cubic yttria-stabilized zirconia (YSZ) reference; however, at higher temperatures, the trend is reversed due to the increased chemical reactivity. The equimolar high-entropy (Hf_0.2Zr_0.2Ce_0.2Y_0.2Yb_0.2)O_2-δ exhibits no grain boundary penetration by molten sand at all examined temperatures (1200°C-1500°C), although reaction and precipitation are significant. Moreover, these CCFOs exhibit higher intrinsic thermal expansion coefficients (CTE) than the YSZ reference, thereby being more compatible with Ni-based superalloys. The 8YSZ-like (Hf_0.284Zr_0.284Ce_0.284Y_0.074Yb_0.074)O_2-δ exhibits the highest CTE in this series of CCFOs due to oxygen clustering effects. Finally, these CCFOs also exhibit lower emissivities and form unique faceted microstructures in ablative environments.     

Temperature and processing effects on lithium ion conductivity of solution-deposited lithium zirconium phosphate (LiZr2P3O12) thin films

Lithium zirconium phosphate (LiZr₂P₃O₁₂) thin films have been prepared on platinized silicon substrates via a chemical solution deposition approach with processing temperatures between 700°C and 775°C. Films that were subject to a single high-temperature anneal were found to crystallize at temperatures above 725°C. Crystallization was observed in films annealed after each deposited layer at 700°C and above. In both cases, grain size was found to increase with annealing temperature. Ion conductivity was found to increase with annealing temperature in singly annealed films. In per-layer annealed films ion conductivity was found to initially increase then decrease with increasing annealing temperature. A maximum ion conductivity of 1.6 × 10⁻⁶ S/cm was observed for the singly annealed 775°C condition, while a maximum ion conductivity of 5.8 × 10⁻⁷ S/cm was observed for the 725°C per-layer annealed condition. These results are consistent with an increasing influence of cross-plane, internal interface resistance and vapor phase carrier loss in the per-layer annealed samples. This work demonstrates that post-deposition processing methods can strongly affect the ion conducting properties of LiZr₂P₃O₁₂ thin films.     

The influence of oxygen vacancies on piezoelectricity in samarium-doped Pb(Mg1/3Nb2/3)O3-PbTiO3 ceramics

A study of 0.71Pb(Mg_1/3Nb_2/3)O₃-0.29PbTiO₃ shows that, when it is doped with 2.5% Sm on the A-site, in addition to an almost threefold increase in piezoelectric charge coefficient and dielectric permittivity, there is a 2 order of magnitude reduction in conductivity, attributed to a decrease in oxygen vacancy concentration. An analysis of the nonlinearity of permittivity with respect to field amplitude shows that both the reversible and irreversible contributions increase significantly with Sm-doping, with simple models showing that these changes are consistent with a reduction in the concentration of dipolar defects that can inhibit both polarization rotation and domain wall translation. Contrary to the argument that doping increases heterogeneity, there is little change in the diffuseness of the peak in permittivity as a function temperature, whilst there is a 15% increase in spontaneous polarization with Sm addition. Through comparison of the Rayleigh law parameters with those published for other piezoelectric materials, it is concluded that a significant contribution to the observed increase in piezoelectric performance due to Sm-doping of PMN-PT is similar in origin to that seen in soft, donor-doped PZT and other conventional piezoelectric ceramics.     

Tailorable thermal expansion in leucite-pollucite materials derived from geopolymers for environmental barrier coatings

The K[AlSi₂O₆]-Cs[AlSi₂O₆] pseudo-binary system was synthesized by geopolymer crystallization. The thermal expansion properties of these materials were studied by in situ high-temperature X-ray diffraction to characterize thermal expansion behavior for potential application as environmental barrier coatings. Tailorable thermal expansion through changing cation stoichiometry allowed reduced thermal expansion mismatch with SiC_f/SiC composites compared to rare-earth-based coatings.     

Aromatic bisphenol A-based elastomers via hydrosilylation chemistry

The preparation of highly aromatic elastomers from a bisphenol A-based divinyl-terminated resin and polymerization with various aromatic silane containing compounds utilizing a room temperature hydrosilylation reaction is demonstrated. The polymers exhibit high thermal and oxidative stability with 5% weight losses around 430 and 350°C and char yields ranging from 35% to 40%. The thermosets maintained their elastomeric properties with good hardness and mechanical properties as measured by elongation measurements. The toughness of the thermosets was not improved with the inclusion of aromatic moieties but the hardness did appear to increase with the addition of more aromatic groups.     

Using a conductive sphere as a probe to characterize the sensitivity of soft piezoresistive films

Flexible piezoresistive films, such as, carbon black/polydimethylsiloxane (C-PDMS) composites, are often used as skin analogs and integrated into complex array sensors for tactile sensing. The uniformity of the sensor characteristics heavily depends on the homogeneity of the composite. Therefore, the ability to locally characterize a film that will be integrated into a complex force sensor could be critical. Here, a method to characterize the local sensitivity of flexible piezoresistive films is presented. Using a conductive sphere, which was chosen over a flat probe to eliminate misalignment issues, the surface of a thin film composite is indented to characterize the change in resistivity in terms of average strain. Experiments were performed with 15 and 18 wt% carbon black C-PDMS films of varying thickness. The contact radius of the probe with the piezoresistive film was estimated using the Johnson-Roberts-Kendall contact theory. Theoretical contact area estimates were found to agree with contact radius measurements carried out using optically transparent PDMS films observed through an optical microscope. Results show that C-PDMS with 15 wt% carbon black exhibit a higher rate if change of resistivity and gauge factor than films of same thickness with 18 wt% carbon black. On the other hand, thicker films exhibit higher gauge factors for the two tested carbon black contents. Tests carried out at multiple locations yielded consistent sensitivity values, making these types of composites suitable for array type force sensors.     

Practical applications of nondestructive materials characterization

Although nondestructive techniques have been used almost exclusively to detect macroscopic defects in structures or devices, it has become increasingly evident that it is both practical and cost-effective to expand the role of nondestructive evaluation to include all aspects of materials production. In recent years, classical nondestructive testing techniques have been augmented by more sophisticated methods for characterizing the microstructure and the associated physical and chemical properties of materials.