Lubrication in steel strip rolling in Japan

Research into, and the state of technology for, lubrication in steel strip rolling in Japan are reviewed. Both cold and hot strip rolling are discussed. Subjects covered include coefficient of friction and oil film thickness, friction pick-up, and roll wear.     

Effects of Co content and WC grain size on wear of WC cemented carbide

WC cemented carbides are used extensively to improve abrasion resistance. Co content and WC grain size influence the mechanical properties of the cemented carbides. In this study, the effects of Co content and WC grain size of cemented carbide on wear were examined. We prepared 13 different cemented carbides with different Co content and WC grain size. Wear tests were carried out against 0.45% carbon steel under dry condition at 98 N and 232 mm/s. From the results, we found that wear increased with both Co content and WC grain size. Specific wear rate of the cemented carbides tested was in the range of 10⁻⁷ mm³/(N m). We discussed the wear properties with hardness and the mean free path of the cemented carbide. These two parameters alone cannot explain the wear property.     

Observation of recording pits on phase-change film using a scanning probe microscope

A phase-change film is a key material for optical data storage media such as rewritable compact disks (CD-RW) and digital versatile disk random access memory (DVD-RAM). Data pits are recorded as differences in crystal state (crystallized state vs. amorphous state) on phase-change film. It is very important to distinguish the crystal state difference in a very small area for material research of phase-change film. Measuring size and shape of recorded data pits is also very important for the development to achieve good data reliability and high data density of optical data storage media. The crystal state difference in very small areas of phase-change film is successfully observed by Kelvin probe force microscopy (KFM) and scanning near-field optical/atomic force microscopy (SNOAM). The advantage of KFM and SNOAM for measuring physical property differences in a very small area is demonstrated.     

Tribological characteristics of bonded MoS2 films evaluated in rolling-sliding contact in a vacuum

Tribological characteristics of bonded MoS₂ films have been evaluated in air, nitrogen and vacuum using a two-roller type rolling-sliding friction apparatus. Two conventional space-proven films, polyamideimide-bonded and sodium silicate-bonded, designated as film A and film B respectively, were tested at a speed of 998 rev min^-1 under a load of 100 N at slip ratios of 1–100%, the slip ratio being defined as (V₁ - V₂)/ V₁ × 100%, in which V₁ and V₂ was rotational speed of each roller.

The wear life of the film A was more slip ratio dependent than that of the film B. The wear life of the film A tested in a vacuum was the longest at 10% slip ratio but it reduced significantly at 1%. On the contrary, the best durability of the film B was obtained at 100% slip ratio (pure sliding). The wear life of the film A shortened considerably in air and nitrogen.

In general, a solid lubricant film applied to spur gears is subjected to rolling-sliding friction of 0-10% slip ratios. To improve the endurance life of the film A at 1% slip ratio, films prepared by changing content of pigments (MoS₂ and Sb₂0₃) were evaluated. The films with a pigment content of 5-15% showed a marked improvement in wear life at a slip ratio of 1%, while maintaining excellent durability at 10%.

The wear process of an improved film was monitored using a gap sensor. It appears to be dominated by fatigue.     

Application of high-resolution scanning electron microscopy to biological macromolecules

The development of ultrahigh-resolution scanning electron microscopes (SEMs) has made the observation of biological macromolecules feasible, but adequate preparation methods have not yet been established. Although it has been possible to observe some molecules after they have been spread on a carbon substrate, this method has not proved suitable for other molecules which exhibit lower contrast, or are more susceptible to damage by the electron beam. In this study we have applied heavy-metal impregnation methods using phosphotungstic acid, uranyl acetate, or osmium tetroxide mordanted by tannic acid. In addition, contamination due to the electron beam was reduced by improving the vacuum in the specimen chamber, and by the use of a heated specimen stage. Using these measures, haemocyanin, ferritin, apoferritin, thyro-globulin and immunoglobulin M were successfully imaged. Ultrahigh-resolution SEM seems likely to become an important means for studying the morphology of biological macromolecules.     

Effects of substrate surface finish and substrate material on durability of thermally sprayed WC cermet coating in rolling with sliding contact

In this study, using a two-roller testing machine, the authors examined the surface durability of thermally sprayed WC-Cr-Ni cermet coating in lubricated rolling with sliding contact conditions. The coating was formed onto the axially ground, blasted and circumferentially ground roller specimens made of a thermally refined carbon steel or an induction hardened carbon steel by means of the high energy type flame spraying (Hi-HVOF) method. The WC cermet coated roller finished to a mirror-like condition was mated with the carburized steel roller without coating having a surface roughness of Ry=3.05.0 μm. In the experiments, a maximum Hertzian stress of P_H=0.6 or 0.8 GPa was applied for the thermally refined carbon steel roller and P_H=1.4 GPa was applied for the induction hardened carbon steel roller in line contact condition. As a result, it was found that in the case of induction hardened steel substrate, the coated roller generally exhibits a long life without any serious damage and the surface durability is hardly affected by the substrate surface finish, while in the case of thermally refined steel substrate, the durability of coated roller is lowered and the life to flaking is very short particularly when the substrate surface is circumferentially ground and the mating surface is rough. The surface durability of coated roller was also compared with the durability of steel roller without coating. Finally, in order to discuss the durability of coated roller, the elastic-plastic behavior of the subsurface layer under repeated rolling with sliding contact was analyzed using a finite element method (FEM).     

Development of precise cylindrical grinding by ball centers: effect of dynamic stiffness on work profile

In high-precision cylindrical grinding, it is known that the accurate and inexpensive steel balls used instead of the cone centers enable accurate grinding of the work without the misalignments and the geometrical deviations of the center holes. The purpose of this study is to explain the supporting characteristics of these ball centers. In this article the work profile, supporting stiffness, and grinding force in grinding only are measured to investigate the stiffness effects on the ground profile. Moreover, the generation process of the work profile is addressed via both experimental and simulation analyses. The obtained main results are as follows: (1) The ball center enables detailed observation of the work profile, displacement, and grinding force during grinding. (2) The radial compliance of the work supporting system correlates well with the center hole profile. (3) The compliance has a strong influence on the work profile in grinding. (4) The amplitudes and the phases of the work profile components are formed at the beginning of the spark-out states.     

Evaluation of two-dimensional strain distribution by STEM/NBD

We proposed a strain mapping technique by Nano Beam electron Diffraction (NBD) combined with an energy filter (EF) and a scanning transmission electron microscopy (STEM) function. The STEM function improves the accuracy of a position where a diffraction pattern is acquired. The EF excludes inelastic scattering and enables novel numerical processing for the appropriate measurement of distances between diffraction disks. Using this technique, strain distributions were measured for two different types of p-MOSFETs, i.e., source/drain regions of each MOSFET is composed of different types of silicide, and the difference of their strain distributions in the channel region was confirmed. The proposed method was able to clarify that the strain distributions are quite different depending on the silicide materials even if the exterior of the MOSFETs was almost identical.     

A Model for Simulating Human Behavior During Emergency Evacuation Based on Classificatory Reasoning and Certainty Value Handling

Abstract: A computational model that simulates human behavior under fire and earthquake emergencies has been developed, using the object-oriented language Smalltalk-80. The present model consists of a space model, a scenario model and a human model. In the space model, the spaces in which people can move are represented by nodes connected by links. The nodes incorporate exit, guidelight and staircase facility data. Also, they feature environmental data including the darkness of the lighting system and the density of smoke. Seismic hazards such as a power failure and occurrence and expansion of fire and smoke are represented in the scenario model. This kind of information is then furnished from the scenario model to the space model as obstruction information. In the human model, a suitable knowledge-based model has been constructed for representing evacuation behavior: people choose the evacuation path based on the production rules with certainty values, and move to the target exit along the evacuation links. The present simulation model is experimentally applied to examine the behavior which masses of people take in an underground structure under an emergency condition caused by an earthquake, and the results obtained confirm that the model is able to simulate correctly the principal human behavior enacted in an emergency evacuation.     

Virus concentration from sewage

Optimal conditions for concentrating poliovirus from large volumes of raw sewage were established. Solids 1 μm or larger, present in the raw sewage, were removed by textile clarifying filters without significant retention of virus. By acidification of the clarified sewage and addition of salts to enhance virus attachment to the adsorbent, virus in the sewage was concentrated on a fibre glass depth filter, with subsequent elution of virus into small volumes suitable for assay. An 80–95 per cent efficiency of virus concentration was effected.