A new versatile in-process monitoring system for milling

Tool condition monitoring (TCM) systems can improve productivity and ensure workpiece quality, yet, there is a lack of reliable TCM solutions for small-batch or one-off manufacturing of industrial parts. TCM methods which include the characteristics of the cut seem to be particularly suitable for these demanding applications. In the first section of this paper, three process-based indicators have been retrieved from literature dealing with TCM. They are analysed using a cutting force model and experiments are carried out in industrial conditions. Specific transient cuttings encountered during the machining of the test part reveal the indicators to be unreliable. Consequently, in the second section, a versatile in-process monitoring method is suggested. Based on experiments carried out under a range of different cutting conditions, an adequate indicator is proposed: the relative radial eccentricity of the cutters is estimated at each instant and characterizes the tool state. It is then compared with the previous tool state in order to detect cutter breakage or chipping. Lastly, the new approach is shown to be reliable when implemented during the machining of the test part.     

Influence of atmosphere on high‐temperature oxidation of Fe‐Cr‐Si model alloy

The aim of this study is to show the influence of the gaseous environment on the ferritic Fe‐Cr‐Si model alloy oxidation during 70 hrs, at 900 and 950°C. Two different atmospheres have been used, air or nitrogen containing 5 vol% hydrogen (N₂–5%H₂). After air oxidation, a nonadherent chromia scale formed. In the N₂–5%H₂ gaseous environment, it clearly appears that silicon segregation near the internal scale‐metal interface is favoured. In this low oxygen‐containing gas, adherent chromia, and silica scales have been formed. Silica subscale associated to an adherent chromia scale obtained in low‐oxygen conditions are a good protection barrier against carburisation.     

Identification of Relaxation Functions in Glass by Mean of a Simple Experiment

This communication discusses the possibility of identifying the shear and structure relaxation functions in inorganic glass by means of a single, simple, and non-intrusive experiment. The latter consists of measuring the thickness variation over time of a glass plate cooled symmetrically from both sides from a temperature above the glass transition temperature down to room temperature. Results with "artificially" created experimental observations suggest that in spite of its simplicity, the thickness variation curve contains sufficient information to identify uniquely the relaxation function parameters using the Levenberg–Marquardt method.     

Reversible shift in the α-, β- and γ-proteobacteria populations of drinking water biofilms during discontinuous chlorination

As disinfection strategies could support a shift of some bacterial populations, the biodiversity of drinking water biofilms depending on the disinfectant concentrations was explored. The effect of different chlorine sequences applied for several weeks (0.1-0.4-0.1 mg Cl₂ L⁻¹ or vice versa) was tested on the abundance of the α-, β- and γ-proteobacteria populations, used as indicators of changes in bacterial populations within drinking water biofilms. Using dynamic (industrial pilot) and batch (bench scale) conditions, our work demonstrated the ability of the 3 proteobacteria subclasses to re-organize following discontinuous chlorinations. The β- and γ-proteobacteria subclasses were favoured by high free residual chlorine concentrations (0.4 mg Cl₂ L⁻¹) while α-proteobacteria population was sensitive to this oxidant level. The proteobacteria population shifts within the biofilm exposed to discontinuous chlorination were reversible. The resilience of the biofilm proteobacteria populations exposed to oxidant stress questioned the emergence of bacterial population less sensitive to chlorine.     

Comparison of sludge characteristics and performance of a submerged membrane bioreactor and an activated sludge process at high solids retention time

This work aims to compare biomass structure and performance of a submerged membrane bioreactor (SMBR) and an activated sludge process (ASP) treating the same domestic wastewater. The influence of the separation technique (membrane filtration or settling) and operation at high sludge-retention time (SRT) were investigated. Over the entire range of SRT (10-110 days), the SMBR achieved very good organic removal efficiencies, ranging from 90.8+/-0.2% to 94.2+/-1.6% based on total COD (TCOD), whereas those of ASP were between 87.4+/-1.8% and 90.3+/-0.8%. The contribution of the membrane in the increase in performance was due to total suspended solid retention and also partly due to retention of proteins and polysaccharides of the sludge supernatant. No significant difference in excess sludge production was observed between the two processes operated at the same SRT, but sludge production in SMBR decreased from 0.31 to 0.13 g(VSS)g(COD)(-1) as SRT increased from 9 to 110 days. The difference in sludge characteristics and performance was especially pronounced as SRT increased, resulting in deterioration of sludge settleability and effluent quality of the ASP (filamentous bacteria, increase of protein and polysaccharide release). Membrane filtration induced accumulation of soluble and colloidal proteins and polysaccharides which were progressively degraded in the supernatant as the SRT increased. At similar SRT, no significant difference was observed in the amount of extractable exocellular polymeric substances (bound EPS) from ASP and SMBR sludge. However as the SRT increased, the total specific amount of bound EPS in flocs decreased and the ratio proteins/polysaccharides also decreased. Concomitantly, laser diffraction analysis, microscopic observations, turbidity and DSVI measurement showed that the SRT increase induced significant modifications in sludge morphology in SMBR: decrease in floc size, densification of aggregates, and development of non-flocculating organisms.     

Mechanisms of localized corrosion of carbon steel associated with magnetite/mackinawite layers in a cement grout

Carbon steel electrodes covered with a specific low-pH cement grout (pH ~10.7 at 20°C), designed for nuclear waste management applications, were immersed for 30 days in a 0.01-M NaCl + 0.01-M NaHCO₃ solution (pH 7 measured at 20°C), in aerated conditions, at 80°C. The corrosion processes were studied by voltammetry and linear polarization resistance measurements while the corrosion product layers were analyzed by µ-Raman spectroscopy and X-ray diffraction. Most of the electrodes (75%) suffered from localized corrosion, a phenomenon associated with the formation of a heterogeneous Fe₃O₄/FeS layer. It is proposed that the mechanisms of the particular corrosion process observed here are associated with galvanic effects, the large magnetite-covered zone acting as cathode and the locally mackinawite-covered zones being anodic regions.