Optimization of steel bar manufacturing process using six sigma

Optimization of a manufacturing process results in higher productivity and reduced wastes. Production parameters of a local steel bar manufacturing industry of Pakistan is optimized by using six Sigma-Define, measure, analyze, improve, and control- methodology. Production data is collected and analyzed. After analysis, experimental design result is used to identify significant factors affecting process performance. The significant factors are controlled to optimized level using two-level factorial design method. A regression model is developed that helps in the estimation of response under multi variable input values. Model is tested, verified, and validated by using industrial data collected at a local steel bar manufacturing industry of Peshawar(Khyber Pakhtunkhwa, Pakistan). The sigma level of the manufacturing process is improved to 4.01 from 3.58. The novelty of the research is the identification of the significant factors along with the optimum levels that affects the process yield, and the methodology to optimize the steel bar manufacturing process.     

SIMULATION AND EXPERIMENTAL IMPLEMENTATION OF A NEURAL-NETWORK-BASED INTERNAL-MODEL CONTROL STRATEGY ON A REACTOR SYSTEM

The use of inverse-model-based control strategy for nonlinear system has been increasing lately. However it is hampered by the difficulty in obtaining the inverse of nonlinear systems analytically. Since neural networks has the ability to model such inverses, it has become a viable alternative. Although many simulations using neural network inverse models For controls have been reported recently, no actual experimental application has been reported on a reactor system. In this paper we describe a novel experimental application of a neural network inverse-model based control method on a partially simulated pilot plant reactor, exhibiting steady state parametric sensitivity and designed to test the use of such nonlinear algorithms. The implementation involved the control of the reactor temperature under set point changes, disturbance rejection and set point regulation with plant/model mismatches. Simulation tests on the model of the system were also carried out to enable better design of the neural network models and to highlight the differences between simulation and actual online results. The online implementation results obtained were sufficient to demonstrate the capability of applying these neural-network-based control methods in real systems.     

Synthesis of biodegradable Mg-Zn alloy by mechanical alloying: Statistical prediction of elastic modulus and mass loss using fractional factorial design

Biodegradable Mg-Zn alloy was synthesized using mechanical alloying where a statistical model was developed using fractional factorial design to predict elastic modulus and mass loss of the bulk alloy. The effects of mechanical alloying parameters (i.e., milling time, milling speed, ball-to-powder mass ratio and Zn content) and their interactions were investigated involving 4 numerical factors with 2 replicates, thus 16 runs of two-level fractional factorial design. Results of analysis of variance (ANOVA), regression analysis and R² test indicated good accuracy of the model. The statistical model determined that the elastic modulus of biodegradable Mg-Zn alloy was between 40.18 and 47.88 GPa, which was improved and resembled that of natural bone (30–57 GPa). Corrosion resistance (mass loss of pure Mg, 33.74 mg) was enhanced with addition of 3%–10% Zn (between 9.32 and 15.38 mg). The most significant independent variable was Zn content, and only the interaction of milling time and ball-to-powder mass ratio was significant as P-value was less than 0.05. Interestingly, mechanical properties (represented by elastic modulus) and corrosion resistance (represented by mass loss) of biodegradable Mg-Zn alloy can be statistically predicted according to the developed models.     

Microstructural Evolution in Solution Heat Treatment of Gas-Atomized Al Alloy (7075) Powder for Cold Spray

Cold gas dynamic spray is being explored as a repair technique for high-value metallic components, given its potential to produce pore and oxide-free deposits of between several micrometers and several millimeters thick with good levels of adhesion and mechanical strength. However, feedstock powders for cold spray experience rapid solidification if manufactured by gas atomization and hence can exhibit non-equilibrium microstructures and localized segregation of alloying elements. Here, we used sealed quartz tube solution heat treatment of a precipitation hardenable 7075 aluminum alloy feedstock to yield a consistent and homogeneous powder phase composition and microstructure prior to cold spraying, aiming for a more controllable heat treatment response of the cold spray deposits. It was shown that the dendritic microstructure and solute segregation in the gas-atomized powders were altered, such that the heat-treated powder exhibits a homogeneous distribution of solute atoms. Micro-indentation testing revealed that the heat-treated powder exhibited a mean hardness decrease of nearly 25% compared to the as-received powder. Deformation of the powder particles was enhanced by heat treatment, resulting in an improved coating with higher thickness (~ 300 μm compared to ~ 40 μm for untreated feedstock). Improved particle–substrate bonding was evidenced by formation of jets at the particle boundaries.     

Heat Treatment of Cold-Sprayed C355 Al for Repair: Microstructure and Mechanical Properties

Cold gas dynamic spraying of commercially pure aluminum is widely used for dimensional repair in the aerospace sector as it is capable of producing oxide-free deposits of hundreds of micrometer thickness with strong bonding to the substrate, based on adhesive pull-off tests, and often with enhanced hardness compared to the powder prior to spraying. There is significant interest in extending this application to structural, load-bearing repairs. Particularly, in the case of high-strength aluminum alloys, cold spray deposits can exhibit high levels of porosity and microcracks, leading to mechanical properties that are inadequate for most load-bearing applications. Here, heat treatment was investigated as a potential means of improving the properties of cold-sprayed coatings from Al alloy C355. Coatings produced with process conditions of 500 °C and 60 bar were heat-treated at 175, 200, 225, 250 °C for 4 h in air, and the evolution of the microstructure and microhardness was analyzed. Heat treatment at 225 and 250 °C revealed a decreased porosity (~ 0.14% and 0.02%, respectively) with the former yielding slightly reduced hardness (105 versus 130 HV_0.05 as-sprayed). Compressive residual stress levels were approximately halved at all depths into the coating after heat treatment, and tensile testing showed an improvement in ductility.     

Nanocrystalline Nickel Deposition on the Titanium Alloys Using High Solution Flow Velocity

An innovative process has been developed for electroplating of nickel on titanium surface using fast solution flow technique. Nickel was directly deposited on a titanium alloy without using any pre-treatment process. Level of adhesion was determined using quantitative peel test and characterization of the deposition was performed by scanning electron microscopy. Results showed that the rate of nickel deposition at 60 °C was higher than that of the rate of nickel deposition at 40 °C. Moreover, Watts solution provided higher rate of nickel deposition compared to the sulfate-based nickel solution. The rate of deposition increased with increasing the solution flow velocity from 1.5 to 3 m/s and raising current density from 0.4 × 10⁴ to 1.6 × 10⁴ A/m² for both solution baths. Adhesion test indicated good level of adhesion between the deposited nickel and titanium surface. The bonding toughness increased to 4 J/m² for 1.2 × 10⁴ A/m² as a result of higher deposition rate. However, the mechanism responsible for the coating process was discussed in detail.     

Eutectoid WxC embedded WS2 nanosheets as a hybrid composite anode for lithium-ion batteries

A novel eutectoid structure, W_xC-embedded WS₂ nanosheets hybrids composite, was developed by hydrothermal reaction followed by a carbonization process. The fabricated WS₂–W_xC hybrid nanosheets electrode was used for lithium-ion batteries as an anode material, and demonstrated the specific capacity of 272 mA h·g^?1 at 0.01 A g^?1 with enhanced rate competence and cycling behavior when compared with individual WS₂ and W₂C electrode. While the large interlayer spacing in WS₂ facilitates rapid Li⁺ transport, the extremely high electronic conductivity of W_xC provides a highly conductive electron transfer pathway, which facilitates fast and reversible (de)lithiation reactions during charging and discharging. Further, these outcomes point the way for developing future eutectoid hybrid systems for advanced energy-storage applications.     

Fracture behaviour,microstructure, and performance of various layered-structured Al2O3-TiC-WC-Co composites

In this study, layered-structured Al₂O₃-based composites containing WC-Co, TiC, and MgO additives were prepared using hot-pressing sintering. The best comprehensive mechanical characteristics were acquired for the sample with a layer number (N_LN) of 7 and thickness ratio (η_TR) of 6. Its composite exhibited a fracture toughness of 8.5 and 8.4 MPa m^1/2 in the X and Z directions, respectively. Analysis of the micro characteristics of the fracture surfaces of the Al₂O₃-TiC-WC-Co layered composites revealed a significant enhancement in the bending strength, which could be attributed to the mixed fracture modes in the composite, including intergranular and trans-granular modes. As the displacement increased, first, the bending stress of all the composites increased gradually, after which all the samples showed abrupt elevation in stress. The enhancement in the damage resistance of Al₂O₃-TiC-WC-Co layered composites could be attributed to the microscopic and macroscopic crack deflection, bridging, and partial surface bonding that occurred in the layers. Finally, a new theoretical perspective was employed to discuss the mechanism of the effect of the layered structure on the toughness of the composites.