Multidisciplinary optimization of gas-quenching process

Distortion as a result of the quenching process is predominantly due to the thermal gradient and phase transformations within the component. Compared with traditional liquid quenching, the thermal boundary conditions during gas quenching are relatively simple to control. By adjusting the gas-quenching furnace pressure, the flow speed, or the spray nozzle configuration, the heat-transfer coefficients can be designed in terms of both the component geometry and the quenching time. The purpose of this research is to apply the optimization methodology to design the gas-quenching process. The design objective is to minimize the distortion caused by quenching. Constraints on the average surface hardness, and its distribution and residual stress are imposed. The heat-transfer coefficients are used as design variables. DEFORM-HT is used to predict material response during quenching. The response surface method is used to obtain the analytical models of the objective function and constraints in terms of the design variables. Once the response surfaces of the objective and constraints are obtained, they are used to search for the optimum heat-transfer coefficients. This process is then used instead of the finite-element analysis. A one-gear blank case study is used to demonstrate the optimization scheme.     

Improved corrosion protection of aluminum alloys by electrodeposited silanes

Organofunctional silanes recently have emerged as outstanding, environmentally friendly corrosion protectors for metal substrates, compared with conventional chromate treatments. A simple immersion technique is typically used to coat the metal surface with silane films. However, the thickness and uniformity of the films are uncontrolled in this process. This paper proposes a new deposition technique for the silane films on the metal surface, i.e., by electrodeposition. Hydrolyzed silanes are water-soluble, ionized molecules, so they can be deposited on metals by electrodeposition. Various combinations of silane mixtures were tested at different voltages, pH values, bath concentrations, and exposure times on panels of alloy aluminum and mirror-polished ferro-plate. The surface structure was characterized by scanning electron microscopy (SEM) and ellipsometry. The resistance of the film to corrosion was investigated by direct current (DC) polarization and electrochemical impedance spectroscopy (EIS) techniques. Electrodeposition results in a more organized and uniform film with fewer pores, compared with immersed or dipped films. This paper was presented at the 2nd International Surface Engineering Congress sponsored by ASM International, on September 15–17, 2003, in Indianapolis, Indiana, and appears on pp. 320–26 of the Proceedings.     

The distribution of grain boundary planes in polycrystals

During the last ten years, techniques have been developed to measure the distribution of grain boundaries in polycrystals as a function of both lattice misorientation and grain boundary plane orientation. This paper presents a brief overview of the techniques used for these measurements and the principle findings of studies implementing these techniques. The most significant findings are that grain boundary plane distributions are anisotropic, that they are scale invariant during normal grain growth, that the most common grain boundary planes are those with low surface energies, that the grain boundary populations are inversely correlated with the grain boundary energy, and that the coincident site lattice number is a poor predictor of the grain boundary energy and population.     

Polylactide films formed by immersion precipitation: Effects of additives,nonsolvent, and temperature

The influence of nonsolvent, crystallinity of the polymer film, and addition of dodecane (a poor solvent for the polymer and for the nonsolvent) on the morphology of polylactides films has been investigated and was related to phase separation behavior. Both amorphous poly‐DL ‐lactide (PDLLA) and crystalline poly‐L ‐lactide (PLLA) were dissolved in dichloromethane, and subsequently films were made by immersion in nonsolvent baths. PDLLA gave dense films without any internal structure, since the structure was not solidified by crystallization or glassification. PLLA films show varying structure depending on the nonsolvent. With methanol, asymmetric morphologies were observed as a result from combined liquid‐liquid demixing and crystallization, while with water symmetric spherulitic structures were formed. As a next step, dodecane was added, which is not miscible with the nonsolvent, and we found it to have a strong influence on the morphology of the films. The PDLLA films with dodecane did not collapse: a closed cell structure was obtained. In PLLA films, dodecane speeds up phase separation and induces faster crystallization in the films, and the porosity, size of the pores, and interconnectivity increased. When the PLLA solutions were subjected to a heat pretreatment, crystallization could be postponed, which yielded a cellular structure around dodecane, which did not contain spherulites anymore. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 959–971, 2007     

Determination of the solubility parameter of poly(ethylene oxide) at 25°C by gas-liquid chromatography

The solubility parameter of poly(ethylene oxide) at 25°C has been determined using the method developed by DiPaola-Baranyi and Guillet, by the extrapolation of the values of the interaction parameter χ, at high temperatures, ranging from 70°–90°, 90°–110° and 110°–130°C down to 25°C. The values of the solubility parameter obtained, depending on the temperature ranges employed, are 9.8, 9.9 and 10.1, respectively.     

Preparation of Protein-Stabilized β-Carotene Nanodispersions by Emulsification–Evaporation Method

This work was initiated to prepare protein-stabilized β-carotene nanodispersions using emulsification–evaporation. A pre-mix of the aqueous phase composed of a protein and hexane containing β-carotene was subjected to high-pressure homogenization using a microfluidizer. Hexane in the resulting emulsion was evaporated under reduced pressures, causing crystallization and precipitation of β-carotene inside the droplets and formation of β-carotene nanoparticles. Sodium caseinate (SC) was the most effective emulsifier among selected proteins in preparing the nanodispersion, with a monomodal β-carotene particle-size distribution and a 17-nm mean particle size. The results were confirmed by transmission-electron microscopy analysis. SC-stabilized nanodispersion also had considerably high ζ-potential (−27 mV at pH 7), suggesting that the nanodispersion was stable against particle aggregation. Increasing the SC concentration decreased the mean particle size and improved the polydispersity of the nanodispersions. Nanodispersions prepared with higher β-carotene concentrations and higher organic-phase ratios resulted in larger β-carotene particles. Although increased microfluidization pressure did not decrease particle size, it did improve the polydispersity of the nanodispersions. Repeating the microfluidization process at 140 MPa caused the nanodispersions to become polydisperse, indicating the loss of emulsifying capacity of SC due to protein denaturation.     

Surface Areas of Nitrated Hydrotalcites

Hydrotalcites in the nitrate form were prepared using microwave irradiation in the hydrotreatment step. The surface area (BET) of nitrated hydrotalcites was evaluated. Solids were characterized by atomic absorption, X-ray diffraction and BET analysis. Thermal pretreatment temperature determined the surface area of the hydrotalcites.     

Informational Entropy: a Failure Tolerance and Reliability Surrogate for Water Distribution Networks

Evolutionary algorithms are used widely in optimization studies on water distribution networks. The optimization algorithms use simulation models that analyse the networks under various operating conditions. The solution process typically involves cost minimization along with reliability constraints that ensure reasonably satisfactory performance under abnormal operating conditions also. Flow entropy has been employed previously as a surrogate reliability measure. While a body of work exists for a single operating condition under steady state conditions, the effectiveness of flow entropy for systems with multiple operating conditions has received very little attention. This paper describes a multi-objective genetic algorithm that maximizes the flow entropy under multiple operating conditions for any given network. The new methodology proposed is consistent with the maximum entropy formalism that requires active consideration of all the relevant information. Furthermore, an alternative but equivalent flow entropy model that emphasizes the relative uniformity of the nodal demands is described. The flow entropy of water distribution networks under multiple operating conditions is discussed with reference to the joint entropy of multiple probability spaces, which provides the theoretical foundation for the optimization methodology proposed. Besides the rationale, results are included that show that the most robust or failure-tolerant solutions are achieved by maximizing the sum of the entropies.     

Near-Surface Deformation in an Alumina–Silicon Carbide-Whisker Composite due to Surface Machining

Deformation due to two different surface-machining conditions—grinding (126 μm diamond) and polishing (3 μm diamond)—in an uniaxial hot-pressed Al₂O₃–30%-SiC-whisker composite has been investigated. A Warren–Averbach analysis of grazing incidence X-ray diffractometry data shows that the deformation is localized to the very top surface zone. The cell size and the root mean square of the strain show a gradient in the deformed layer. Transmission electron microscopy studies, in cross-sectional view, also show a near-surface deformation zone containing dislocations, twins, and cracks. This is seen for both machining procedures, but the depth of the zone and the degree of deformation, in terms of dislocation density and number of cracks, is much higher in the roughly ground specimen than in the polished one. For comparison, a monolithic Al₂O₃ sample also has been studied after grinding. The deformation zone is very similar to the Al₂O₃–SiC sample with the same grinding condition, but cracks and dislocations are present at a slightly larger depth. The deformation depth for the polished Al₂O₃–SiC sample is ∼50 nm. In the ground Al₂O₃–SiC sample, the deformation depth is 1–1.5 μm and corresponds to the grain size. The deformation zone in the ground monolithic Al₂O₃ sample is 1.5–2 μm deep. The observed grain-boundary cracks are almost parallel to the surface and may originate from nonaccommodated plastic flow between grains.     

Use of cascade reduction potential for selective precipitation of Au,Cu, and Pb in hydrochloric acid solution

Optimization of reduction potential for electroseparation was studied for the recovery of gold, copper, and lead from acidic solution. A linear sweep voltammetric method enabled us to determine characteristic reduction potentials for each metal and the kinetics of the metal deposition indicated by current-voltage curves. In order to precipitate the metal species sequentially, reduction potentials were examined for the individual and mixed solutions of Au(III), Cu(II), and Pb(II). The three metals were reasonably well isolated from the mixed solutions such as Cu(II)/ Pb(II) and Au(III)/Cu(II)/Pb(II) in the order of the corresponding reduction potentials, in particular, the mass transfer controlled reduction potentials, obtained from linear sweep voltammetry (LSV) measurement.