Modeling of friction-stir butt-welds and its application in automotive bumper impact performance Part 1. Thermo-mechanical weld process modeling

The demand for better structural performance in joining of components for road vehicles prompts the implementation of aluminum alloy friction stir welding technology in the automotive industry. The aim of current study is the creation of a 3-D finite element (FE) friction thermal model and stir welding (FSW) process of dissimilar aluminum alloy and for the estimation of crash worthiness performance of FSW fabricated shock absorber assembly. Thermo mechanical simulations and analysis are performed to understand the thermal behavior in the FSW weld zones. The developed models are correlated against published experimental results in terms of temperature profile of the weld zone. The developed models are then implemented for fabricating vehicle bumper parts to illustrate the performance of FSW welded components during an impact. Customary sled testing for low-speed guard necessities is performed utilizing a grating blend welded test apparatus at Wichita State University (WSU) at the National Institute for Aviation Research (NIAR). A few guard congregations are then appended to the test installation utilizing FSW and conventional Gas bend GMAW welding strategies. Numerical models are likewise created where limited component investigation is utilized to contrast the anticipated harm and the real harm maintained by both of the FSW and GMAW manufactured guards. During the research, a new FSW weld mold is created that allows for a better representation of the desired progressive crack propagation. The FSW fabricated bumper based on the Johnson-Cook failure model yields better failure prediction and is in good agreement to the test. The results from this study provide a guideline for an accurate finite element modeling of a FSW fabricated components and their application in the crashworthiness of such structural components.     

Synthesis and Characterization of Magnetite/Polyvinyl Alcohol Core–Shell Composite Nanoparticles

Magnetite (Fe₃O₄)/polyvinyl alcohol (PVA) core–shell composite nanoparticles were successfully synthesized using a coprecipitation of ferrous and ferric chloride followed by coating with PVA. The resulting nanoparticles were characterized using X‐ray diffraction, Fourier Transform Infrared Spectroscopy, Transmission Electron Microscopy, X‐ray photo electron spectroscopy, Zeta potential measurements, UV–Vis spectroscopy, Thermogravimetric Analysis, and Vibrating Sample Magnetometry (VSM). The average particle size was 13 nm. The presence of characteristic functional groups of PVA around the core of magnetite nanoparticles was confirmed by FTIR spectroscopy while the amount of PVA (%) bound to it was estimated by TGA analysis. Zeta potential measurements made by dispersing dilute sonicated samples in a Phosphate Buffer Saline (PBS pH 7.4) confirmed that the particles were negatively charged. The stability and retention of the coating material PVA in PBS (pH7.4) over a period of time were substantiated by UV–Vis spectroscopy. Room‐temperature magnetic measurements were made with a VSM which demonstrated the superparamagnetic nature of the particles with higher saturation magnetization of 56.41 emu/g. Furthermore, in vitro cytocompatibility testing of Fe₃O₄/PVA core–shell composite nanoparticles was carried out on human cervix cancer cells. This confirmed a 97% cell viability with no significant cytotoxicity and thereby substantiated their biocompatibility.     

Concrete filled high strength steel box columns for tall buildings: Behaviour and design

This paper presents a study of the behaviour and design of concrete filled high strength steel fabricated box columns for use in tall buildings. The many advantages that can be attributed to the use of high strength steel in concrete filled steel box column constructions are presented and discussed. The paper deals with short composite columns and presents guidelines for plate slenderness and overall column slenderness to eliminate local and overall buckling. A proposed design model is developed to calculate the strength of short columns in bending and compression. A method for constructing the strength interaction diagram is presented. Furthermore, to study the ductility of this form of column construction a cross-sectional analysis computer program was developed to consider the moment-thrust-curvature response of such members. This has been undertaken using mild structural steel and high strength steel. The study also shows that, by the use of the method considered, savings can be made in the base column design of a tall building with a negligible penalty in ductility. Finally, recommendations are given for further research into this new method of column construction, which focuses on future experimental work.     

Synthesis,microstructure and optical characterization of zirconium oxide nanostructures

Zirconium oxide (ZrO₂) nanostructures were synthesized by hydrothermal route. Surface morphology analysis depicts the formation of the nanobars and hexagonal-shaped nanodiscs at different synthesis conditions. The structural analysis confirms that the as-synthesized ZrO₂ product is of pure monoclinic phase (m-ZrO₂) with crystallite size of about 25 nm. The product consists of monodispersed nanoparticles of uniform composition, high purity, and crystallinity. The Raman spectra are quantitatively analyzed and the observed peaks are attributed to various vibration modes of the m-ZrO₂. The UV–vis absorption spectrum showed a strong absorption peak at about 292 nm and the estimated optical band gap was around 3.57 eV. Photoluminescence (PL) spectrum of ZrO₂ nanostructure showed a strong and broad emission peak at around 410 nm at room temperature, which can be attributed to the ionized oxygen vacancy in the material.     

Octane number enhancement studies of naphtha over noble metal loaded zeolite catalysts

An Indian industrial naphtha containing mixture of various hydrocarbons belong to n-paraffins, isoparaffins, naphthenes and aromatics falling in C₅ to C₉ carbon range has been studied for its octane boosting through the production of isoparaffins over various Pt loaded zeolite catalysts possessing different acidity and porosity properties. Optimum balance of acid and metal functionalities in 0.6 wt.% Pt loaded on BEA zeolite helped in achieving highest increase in research octane number (RON) from 44 to 80, suitable for gasoline applications, through the production of lower isoparaffins (iC₄-iC₆) along with C₇+ isoparaffins.     

An experimental investigation of the optimum geometry for the cold end orifice of a vortex tube

A vortex tube is a simple mechanical device, which splits a compressed gas stream into a cold and hot stream without any chemical reactions or external energy supply. This paper presents the results of a series of experiments focusing on various geometries of the “cold end side” for different inlet pressures and cold fractions. Specifically, the tests were conducted using different cold end orifice diameters.Energy separation and energy flux separation efficiencies are defined and used to recover characteristic properties of the vortex tube. These are used to show an appropriate scale to non-dimensionalize the energy separation effect. The experimental results indicate that there is an optimum diameter of cold end orifice for achieving maximum energy separation. The results also show that the maximum value of energy separation was always reachable at a 60% cold fraction irrespective of the orifice diameter and the inlet pressure. The results are compared with the previous studies on internal flow structure, and optimal operating parameters are shown to be consistent with a matching of orifice size with the secondary circulation being observed.     

Application of electromagnetic impact technique for welding copper-to-stainless steel sheets

The ability to manufacture a product using different metal combinations greatly increases flexibility in design and production. Joining of dissimilar metal combinations like Copper-to-Stainless Steel (Cu-to-SS) is, however, a challenging task owing to the large differences in physical and chemical properties. The application of electromagnetic (EM) impact technique is demonstrated for welding copper (Cu) to stainless steel (SS) sheets. The welding Cu-to-SS is accomplished by using Al drivers to accelerate Cu and SS work sheets. The tensile shear strength test and the metallographic studies are carried out for Cu-to-SS EM welds.     

Renewable elastomers based on blends of maleated polypropylene and plasticized starch

Most recent developments in polymers from renewable resources have focused on thermoplastics, whereas there has been no comparable development of plastics with elastomeric properties. Here we evaluate the possibility of developing renewable elastomers based on starch. Potato starch plasticized with glycerol (called plasticized starch, or PLS) was melt‐blended with small quantities (5 wt % or 15 wt%) of maleated polypropylene (MAPP). The maleic anhydride groups of the polypropylene are expected to react with the hydroxy groups of starch under melt blending conditions. The resulting blends of MAPP and PLS were characterized by mechanical testing, SEM, DMA, and DSC. SEM, solubility and adhesion tests indicate that the blends are two‐phase materials, in which the continuous phase PLS is physically crosslinked by polypropylene domains. The materials showed rubbery properties as judged by a low glass transition temperature (～?50°C independent of polypropylene content), and a wide rubbery plateau in DMA experiments that extended from room temperature to as high as 170°C. The tensile properties are also characteristic of elastomers. However, slow aging due to starch crystallization, and extraction of glycerol upon water exposure remain two challenges that must be overcome before the materials can be used as practical elastomers. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Comparison of deformation induced precipitation behaviour in Alloy 718 under two microstructural conditions

Alloy 718 samples under two initial microstructural conditions, viz., solution annealed to form only γ phase (ST) and aged to precipitate only δ particles (DELTA), were deformed in tension till fracture in the temperatures range from 200°C–700°C. From the comparison of the evolved microstructure of deformed and undeformed specimens that have been subjected to similar thermal history, deformation induced precipitation could be identified. Deformation in the range of 550°C to 650°C promoted the precipitation of γ′ and γ″ phases in both structures. In case of DELTA alloy, the γ′ precipitation was found to precede the γ′ phase precipitation while no such preference for precipitation could be identified in ST specimens. This difference in the precipitation behaviour and the sequence of precipitation has been explained on the basis of the relative concentration of solutes in the matrix of the starting microstructures of ST and DELTA specimens.     

Bulk modulus and thermal expansion coefficient of mechano-chemically synthesized Mg2FeH6 from high temperature and high pressure studies

Mg₂FeH₆ was synthesized by ball milling MgH₂ and Fe (2:1 molar ratio) mixture for 72 h followed by heating at 400 °C under H₂ pressure. The hydride formation, its structure and homogeneity were investigated by scanning electron microscopy, X-ray diffraction, transmission electron microscopy and Raman spectroscopy. High pressure in situ synchrotron X-ray diffraction and Vienna ab initio simulation were used to determine bulk modulus of the sample. The bulk modulus of Mg₂FeH₆ was found to be 75.4(4) GPa by optimized experiment and 76.3 GPa by theoretical simulation. From high temperature in situ X-ray diffraction study the volumetric thermal expansion coefficient of Mg₂FeH₆ was found to be α_v = 5.85(3) × 10⁻⁵ + 7.47(7) × 10⁻⁸ (T − T_o)/°C. Decomposition of Mg₂FeH₆ was observed at 425 °C and the decomposition products were Mg, Fe and H₂.