Aluminide coating formation on nickel-base superalloys by pack cementation process

A detailed study was carried out to investigate the effects of pack powder compositions, coating temperature and time on the aluminide coating formation process on a superalloy CMSX-4 by pack cementation. With the aid of recently developed thermodynamic analytical tools, powder mixtures that are activated by a series of fluoride and chloride salts were analysed and the effectiveness of these activators in transferring and depositing Al was evaluated at a range of coating temperatures. The Al chloride vapours formed at coating temperatures from 900°C to 1100°C were also analysed thermodynamically as a function of Al concentration in the original pack for the powder mixtures activated by 4 wt% CrCl₃·6H₂O. Based on the thermochemical calculations, a series of coating experiments was carried out. Aluminide coatings were formed at temperatures from 850°C to 1100°C for periods varying from 4 hours to 8 hours using powder mixtures activated by NH₄Cl, NaCl and CrCl₃·6H₂O and AlF₃. The effects of changing Al concentration as well as adding small quantities of Cr in the powder mixtures on the coating formation process were also investigated. The aluminide coatings were analysed using a range of techniques including SEM, EDX and XRD. The relationships between the mass gain and coating thickness and structure were investigated. The experimental results were compared with the predictions from thermochemical calculations. Based on the understandings established, an effective approach to control the aluminide coating parameters and structures was identified, which made it possible to optimise powder mixture compositions and coating conditions for different coating requirements.     

Microwave puffing: Determination of optimal conditions using a coupled multiphase porous media - Large deformation model

Increased interest in microwave puffing is due to its ability to obtain low-fat and ready-to-eat healthy products. Determination of optimal conditions for this complex process has been difficult and although several patents exist on the concept, we are yet to see any large scale commercial use. A fundamental physics based modeling approach integrated with relevant experimentation, developed in this work, is an ideal framework to understand and optimize microwave puffing. The results showed that puffing may not be successful unless carried out using an intensive heating source such as microwaves. Addition of infrared and hot air leads to better quality product whereas using forced air convection is not desirable. There is an optimum initial moisture content depending on the puffing conditions. The study provides critical guidelines to food product/process developers for successful development, control and automation of microwave puffing, thereby leading to value-added nutritious products.     

Thermal transformation in a chrysotile asbestos

Structural changes accompanying thermal transformation in a chrysotile asbestos sample of Indian origin upto a temperature of 900°C have been investigated by x-ray method. The changes in lattice parameters have been systematically measured by applying a least square refinement technique and the crystallite size and strain defects at different stages have been estimated by line profile analysis of the diffraction peaks. The present study also confirms the earlier results on stepwise transformation of chrysotile fibres. This sequence of transformation has been explained assuming two different types of crystallites as reported in kaolinite.     

Hall effects on hydromagnetic flow over an impulsively started porous plate

Summary An exact solution has been obtained for the problem of Hall effects on the hydromagnetic flow due to an impulsive start of a porous flat plate. It is observed that in the initial stages there is no inertial oscillation while at large time the steady state is reached through inertial oscillations. The time to attain the steady state increases with increase in Hall parameter.

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Hall-Effekte bei hydromagnetischer Strömung über eine impulsartig gestartete Platte

Zusammenfassung Für das Problem der Hall-Effekte bei der hydromagnetischen Strömung, durch den impulsartigen Start einer porösen, ebenen Platte, wurde eine exakte Lösung erhalten. Es wird beobachtet, daß im Anfangszustand keine Trägheitsschwingung auftritt, wogegen nach längerer Zeit der stationäre Zustand durch Trägheitsschwingungen erreicht wird. Die Zeit um den stationären Zustand zu erreichen, wächst mit dem Anwachsen der Hall-Parameter an.

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With 2 Figures     

Faraday rotation in a stratified medium

The effect on Faraday rotation caused by stratification in an ionized medium and in semiconductor samples is examined. Expressions for rotation are derived in closed form for linear, exponential, and parabolic electron density profiles, including the effects of reflection at the boundaries. An expression in the form of a series is also derived for a general polynomial type of electron concentration variation. The change in rotation due to the deviation from the equivalent homogeneous carrier distribution is then examined for some experimental conditions in semiconductors and in the ionosphere.     

Long term oxidation resistance and thermal stability of Ni-aluminide/Fe-aluminide duplex diffusion coatings formed on ferritic steels at low temperatures

A coating with a duplex structure consisting of an outer Ni₂Al₃ layer and an inner Fe₂Al₅ layer was formed on a commercial type of ferritic steel P92 using a two step process of electroless Ni/B plating followed by pack aluminising at 650 °C. Nearly 11,000 h oxidation test in air and more than 13,000 h isothermal annealing test in argon atmosphere were carried out to assess the long term oxidation resistance and thermal stability at 650 °C. The amount of oxidation was only about 0.66 mg/cm² for the coating as compared to 10.3 mg/cm² for the uncoated steel after nearly 11,000 h oxidation test. Inward Al diffusion took place during oxidation test, which led to the transformation of the outer Ni₂Al₃ layer to NiAl and increase in the Al diffusion depth. However, once the outer Ni₂Al₃ layer was completely transformed to NiAl, it stayed stable during the remaining period of oxidation test, providing long term oxidation resistance. Kirkendall voids formed and grew and then finally disappeared in the coating layers due to interdiffusion processes taking place at the oxidizing temperature at the interfaces between different layers of the duplex coating. No spallation was observed in the coating during the entire period of the oxidation or isothermal annealing tests.     

Optimization of bead geometry in electron beam welding using a Genetic Algorithm

Bead-on-plate welds were carried out on austenitic stainless steel plates using an electron beam welding machine. Experimental data were collected as per central composite design and regression analysis was conducted to establish input–output relationships of the process. An attempt was made to minimize the weldment area, after satisfying the condition of maximum bead penetration. Thus, it was posed as a constrained optimization problem and solved utilizing a Genetic Algorithm with a penalty function approach. The Genetic Algorithm was able to determine optimal weld-bead geometry and recommend the necessary process parameters for the same.     

Decentralized indirect adaptive control of interconnected systems

Continuous time decentralized indirect adaptive controllers are proposed for a large-scale system composed of N interconnected linear subsystems with unknown parameters. Each local adaptive law utilizes a normalizing signal which is generated using the local input and the outputs of all the subsystems. This requires the exchange of output signals between the different subsystems, so that the scheme is no longer totally decentralized. Nevertheless, the degree of computational complexity is about the same as that of a totally decentralized scheme and this makes the scheme very attractive.     

Influence of surface texturization on the light trapping andspectral response of silicon solar cells

A quantitative model that explains the spectral response, internal quantum efficiency, total short-circuit current, open-circuit voltage, and efficiency of high-efficiency solar cells with textured front surface and Lambertian back-surface reflectors is presented. A comparison of the textured cell characteristics is made with those of planar cells, and the separate roles of the front surface reflection coefficient and internal quantum efficiency in enhancing the short-circuit current have been investigated. It is shown that, in the case of large diffusion lengths, almost all the contribution to the increase of spectral response on texturization is due to the reduced reflection coefficient whereas, for small diffusion lengths, there is a significant increase in internal quantum efficiency on texturization, especially in the region of higher wavelengths. However, there is a small decrease in open-circuit voltage for large diffusion lengths, whereas no significant change is observed for small diffusion lengths on texturization. Nevertheless, there is a net gain in power conversion efficiency which is larger for smaller diffusion lengths