Analysis of Strain Rates and Microstructural Evaluation during Metal Forming: Role of Surface Texture and Friction

The surface texture of a die plays an important role in friction during metal forming. In the present study, unidirectional and random surface finishes were produced on hardened steel plate surfaces. To understand the influence of surface texture on friction, experiments were conducted using Al-Mg alloy pins that slid against steel plates of different surface textures. In the sliding experiments, a high coefficient of friction was observed when the pins slid perpendicular to the unidirectional grinding marks and low friction occurred when the pins slid on the random surfaces. Finite element simulations were performed using the measured friction values to understand the stress and strain evolutions in the deforming material using dies with various friction. The numerical results showed that the states of stress and strain rates are strongly influenced by the friction at the interface and hence would influence the final material microstructure. To substantiate the numerical results, laboratory compression tests were conducted. Different surface textures were obtained in order to experience different friction values at different locations. A large variation in the microstructure at these locations was observed during experiments, verifying that surface texture and die friction significantly influence fundamental material formation behavior.     

Influence of tilt angle of plate on friction and transfer layer—A study of aluminium pin sliding against steel plate

In the present investigation, unidirectional grinding marks were attained on the steel plates. Then aluminium (Al) pins were slid at 0.2°, 0.6°, 1.0°, 1.4°, 1.8°, 2.2° and 2.6° tilt angles of the plate with the grinding marks perpendicular and parallel to the sliding direction under both dry and lubricated conditions using a pin-on-plate inclined sliding tester to understand the influence of tilt angle and grinding marks direction of the plate on coefficient of friction and transfer layer formation. It was observed that the transfer layer formation and the coefficient of friction depend primarily on the grinding marks direction of the harder mating surface. Stick-slip phenomenon was observed only under lubricated conditions. For the case of pins slid perpendicular to the unidirectional grinding marks stick-slip phenomenon was observed for tilt angles exceeding 0.6°, the amplitude of which increases with increasing tilt angles. However, for the case of the pins slid parallel to the unidirectional grinding marks the stick-slip phenomena was observed for angles exceeding 2.2°, the amplitude of which also increases with increasing tilt angle. The presence of stick-slip phenomena under lubricated conditions could be attributed to the molecular deformation of the lubricant component confined between asperities.     

Friction Stir-Welded Dissimilar Aluminum Alloys: Microstructure, Mechanical Properties, and Physical State

A356 and 6061 aluminum alloys were joined by friction stir welding at constant tool rotational rate with different tool-traversing speeds. Thermomechanical data of welding showed that increment in tool speed reduced the pseudo heat index and temperature at weld nugget (WN). On the other hand, volume of material within extrusion zone, strain rate, and Zenner Hollomon parameter were reduced with decrease in tool speed. Optical microstructure of WN exhibited nearly uniform dispersion of Si-rich particles, fine grain size of 6061 Al alloy, and disappearance of second phase within 6061 Al alloy. With enhancement in welding speed, matrix grain size became finer, yet size of Si-rich particles did not reduce incessantly. Size of Si-rich particles was governed by interaction time between tool and substrate. Mechanical property of WN was evaluated. It has been found that the maximum joint efficiency of 116% with respect to that of 6061 alloy was obtained at an intermediate tool-traversing speed, where matrix grain size was significantly fine and those of Si-rich particles were substantially small.     

Pervaporation‐Assisted Esterification of Caproic Acid with Isobutanol in Conventional,In Situ,and Ex Situ Reactors

The factors that affect the pervaporation‐assisted esterification of caproic acid and isobutanol have been investigated in a batch reactor and compared with two different pervaporation reactors, in situ and ex situ reactors, with different configurations. The operating process parameters of the pervaporation modules can be adjusted to optimize the performance, which improves the conversion of reactants and reduces the operating costs. The performances of the reactors have been extensively studied and the membrane selectivity has been investigated in terms of the flux of individual reaction species. The mass transfer limitation of both pervaporation reactors was studied and suitably eliminated. In addition, the performance of the pervaporation reactors was investigated by evaluating the ratio of water removal rate to the water production rate.     

Immobilizing live bacteria for AFM imaging of cellular processes

Coccoid cells of the bacterial species Staphylococcus aureus have been mechanically trapped in lithographically patterned substrates and imaged under growth media using atomic force microscopy (AFM) in order to follow cellular processes. The cells are not perturbed as there is no chemical linkage to the surface. Confinement effects are minimized compared to trapping the cells in porous membranes or soft gels. S. aureus cells have been imaged undergoing cell division whilst trapped in the patterned substrates. Entrapment in lithographically patterned substrates provides a novel way for anchoring bacterial cells so that the AFM tip will not push the cells off during imaging, whilst allowing the bacteria to continue with cellular processes.     

A study of the strain rate microstructural response and wear of metals

Titanium (Ti) and copper (Cu) pins were slid against alumina in a pin-on-disk machine at a load of 50 N and sliding speeds varying from 0.1 to 4 ms⁻¹. The evolution of the microstructure in the subsurface of the material and the wear rate was co-related to the strain rate microstructural response of the material in uniaxial compression, at different strain rates (0.1–100 s⁻¹) and temperatures (298–673 K). The strain rates and temperatures in the plastically deforming zone near the surface of the pins were determined using noniterative methods. The strain rates were found to be in the region of 100 s⁻¹ near the surface and decreases as one moves into the sub-surface of the pin. The temperatures increased as the speed increased. These estimated strain rates and temperatures were superimposed on the strain rate microstructural response maps of these materials. The uniaxial compression test results of Ti showed adiabatic shear banding as a microstructural mechanism that evolves at high strain rates (≥10 s⁻¹) and lower temperatures (<575 K). Adiabatic shear bands are sites of easy crack nucleation and propagation. When Ti is slid at low speeds the near surface region of the pins deform in the adiabatic shear banding regions in the strain rate microstructural response map. At such speeds the wear rate is found to be high and reduces as the sliding speed is increased, when the material undergoes a more homogeneous deformation. The microstructural response of Cu under uniaxial compression showed that the material undergoes flow banding at intermediate strain rates (1 s⁻¹) and temperatures of up to 473 K. The subsurface microstructure of the pins slid at low speeds showed subsurface cracking and sheet like debris formation. This happen at lower speeds because the flow banding and crack nucleation is expected in the subsurface where the strain rates and temperatures are lower. The present test results show a clear relation to exist between the strain rate response of the material in uniaxial compression and its subsurface microstructural evolution and wear rate.     

Internal defect and process parameter analysis during friction stir welding of Al 6061 sheets

Welding parameters like welding speed, rotation speed, plunge depth, shoulder diameter etc., influence the weld zone properties, microstructure of friction stir welds, and forming behavior of welded sheets in a synergistic fashion. The main aims of the present work are to (1) analyze the effect of welding speed, rotation speed, plunge depth, and shoulder diameter on the formation of internal defects during friction stir welding (FSW), (2) study the effect on axial force and torque during welding, (c) optimize the welding parameters for producing internal defect-free welds, and (d) propose and validate a simple criterion to identify defect-free weld formation. The base material used for FSW throughout the work is Al 6061T6 having a thickness value of 2.1 mm. Only butt welding of sheets is aimed in the present work. It is observed from the present analysis that higher welding speed, higher rotation speed, and higher plunge depth are preferred for producing a weld without internal defects. All the shoulder diameters used for FSW in the present work produced defect-free welds. The axial force and torque are not constant and a large variation is seen with respect to FSW parameters that produced defective welds. In the case of defect-free weld formation, the axial force and torque are relatively constant. A simple criterion, (?τ/?p)_defective?>?(?τ/?p)_{defect free} and (?F/?p)_defective?>?(?F/?p)_{defect free}, is proposed with this observation for identifying the onset of defect-free weld formation. Here F is axial force, τ is torque, and p is welding speed or tool rotation speed or plunge depth. The same criterion is validated with respect to Al 5xxx base material. Even in this case, the axial force and torque remained constant while producing defect-free welds.     

Rise in structural steel temperatures during ISO 9705 room fires

An experimental programme was undertaken to study the temperature rise of protected and unprotected structural steel during a fire within a small enclosure (an ISO 9705 room). The fuel (wood crib) was placed at two locations (front and back) within the ISO room. Each location had two fire scenarios present: the first fire scenario was for recording the temperatures of protected steel members within the enclosure, and the second fire scenario was to measure the temperatures of the directly exposed members. Six steel columns and two steel beams were strategically placed, and their temperatures were measured. Other data recorded were gas temperatures and heat release rates (HRRs). Thermocouples were kept in identical locations during the tests with protected and unprotected steel members to facilitate direct comparison. Despite the natural variability in fire development in identical situations, data up to ≈20 min were found suitable for direct comparison between protected and unprotected steel members. Comparison of these results with Fire Dynamics Simulator (FDS) version 5.3.1 modelling (with prescribed HRRs) results is presented to show the usefulness of the data collected.     

Determination of key sensor locations for non-point pollutant sources management in sewer network

As the importance of watershed management has emerged for water systems, non-point pollutant sources have been blamed as the main problem of water pollution. To control non-point pollutant sources, it is necessary to monitor sewers connected to the watershed and to analyze their effects on the sewer network. As the cost to monitor a sewer network depends on the number of sensors installed, the monitoring stations should be decided with proper guide of the installation location rule. In present paper, a new method to select the proper sensor location is proposed by combining monitoring information with data mining techniques. To estimate the amount of pollutants by wash-off and to find the sensor locations in a sewer network, three scenarios are considered based on rainfall intensity, influent concentrations and flow rate. The optimal locations of the sensor were selected based on the proposed method to facilitate the management of non-point pollutant source in sewer network. The presented approach can be extended to a complex sewer network system to design a minimum number of sensors and optimum locations for the sensors.