Fracture behaviour and numerical study of resistance spot welded joints in high-strength steel sheet

Cross tension tests of resistance spot welded joints with varying nugget diameter were carried out using 980 MPa high strength steel sheet of 1.6 mm thickness. In proportion, as nugget diameter increased from 3√t to 5√t (where t is thickness), cross tension strength (CTS) increased while fracture morphology simultaneously transferred from interface fracture to full plug fracture. In cases of interface fracture, circumferential crack initiation due to separation of the corona bond arose at an early stage of loading. The crack opening process without propagation was recognized until just before fracture and then the crack propagated to the nugget immediately in a brittle manner around CTS. In full plug fracture, main ductile crack initiation from the notch-like part at the end of sheet separation occurred with the sub-crack initiated at an early stage. The ductile crack propagated toward the HAZ and base material to form full plug fracture. The mode I stress intensity factor was considered as a suitable fracture parameter because the circumferential crack behaved pre-crack for brittle fracture in the nugget region at the final stage. Based on the FE analysis, the mode I stress intensity factor was calculated as 116 MPa √m at CTS as fracture toughness for the nugget. With respect to full plug fracture, ductile crack initiation behaviour from the notch-like part was expressed by concentration of equivalent plastic strain. On the assumption that the ductile crack arose in critical value of equivalent plastic strain, the value was calculated as 0.34 by FE analysis. Reasonable interpretation for interface fracture and full plug fracture in the resistance spot welded joint was proposed due to first crack initiation by stress concentration, brittle fracture by using mode I stress intensity factor, and ductile crack initiation by using equivalent plastic strain.     

Crystallographic analysis for acicular ferrite formation in low carbon steel weld metals

Inclusions contributing to acicular ferrite nucleation were investigated from a crystallographic point of view in low carbon low alloy steelweld metals. The samples from electro slag welding (ESW) and submerged arc welding (SAW) deposits with various cooling rates were prepared in this study. In those samples, intragranular acicular ferrite formation was observed from inclusions. The inclusions contributing to acicular ferrite formation were of multi-phase type consisting of amorphous phase, spinel type and MnS. They were surrounded by a Ti-enriched layer. It was confirmed by selected area diffraction patterns and energy-dispersive X-ray spectrometer analyses that the Ti-enriched layer was TiO. The acicular ferrite had a Baker–Nutting orientation relationship with the TiO layer on the inclusion surface. The misfit was 3.0% at the interface between the acicular ferrite and TiO. Therefore, it is considered that TiO on the inclusion surface contributes to the heterogeneous nucleation of acicular ferrite by small lattice misfit. However, themorphologies of ferrite growth which nucleated from inclusions were different in both samples. Whereas the growth of ferrites nucleated from TiO was enough in ESW, the size of nucleated ferrite in SAW was a few hundred millimetres in size. In the early stage of nucleation from TiO, ferrite had small deviation from Kurdjumov–Sachs orientation relationship (K–S relationship) in both ESW and SAW. However, there was a difference in the growth stage of ferrite. The ferrite orientations were gradually changed to fit to the K–S relationship in ESW. On the other hand, the nucleated ferrite in SAW stopped growing and the newly nucleated ferrite which had K–S relationship prior to austenite was formed adjacently because of large super cooling due to small heat input.     

Effect of REM addition of wire on CO2 gas shielded arc phenomenon

Carbon dioxide (CO₂) gas shielded arc welding is the main arc welding method, but it generates a large amount of spatter during welding. The root cause of spatter lies in the fact that the droplet undergoes repeated irregular shaking. To solve this problem, spatter generation modes were clarified and the effects of polarity and rare earth metal (REM) addition of the wire on CO₂ gas shielded arc welding were investigated. As a result, when welding is performed with an electrode negative (DCEN) polarity using REM added wire, it was found that a conical arc plasma is formed, and the droplet which is transferred from the wire tip to the molten pool is fine and continuous, in what is termed ‘spray transfer’. Thus, spatter generation was reduced to 10% of amount of the conventional CO₂ gas shielded arc welding (from 0.058 to 0.005g/s).     

Development of novel temperature-stable Al2O3–TiO2-based dielectric ceramics featuring superior thermal conductivity for LTCC applications

A new composition was developed using sintering to improve the dielectric properties of low-temperature co-fired alumina (LTCA) containing CuO–TiO₂–Nb₂O₅–Ag₂O. By substituting some alumina with rutile TiO₂, the second-phase compound could be changed from AgNbO₃ to the rutile phase. Further, low-temperature sintering at temperatures below 960 °C was possible, suppressing Al₂TiO₅ formation during firing. The dielectric characteristics, particularly the temperature coefficient of the resonant frequency (τ_f) and Q × f values, were improved without significantly reducing the sinterability and thermal conductivity. The dielectric properties of the developed 88Al₂O₃–12TiO₂-based ceramic were ε_r: 14.7, τ_f: +0.8 ppm/K, and Q × f: 13,383 GHz (at ～10 GHz) at a firing temperature of 940 °C. The thermal conductivity was 18.5 W/mK, which is the highest value for reported temperature-stable low-temperature co-fired ceramics (LTCCs). These results provide one of the key technologies for the practical application of LTCCs with superior thermal conductivities.     

A PHYSICAL CHEMICAL EXPLANATION FOR DETERIORATION IN THE HOT WATER PROCESSABILITY OF ATHABASCA OIL SAND DUE TO AGING

ABSTRACT

The oxidation of sulphide minerals during storage of Athabasca oil sands causes solubilization of inorganic salts which affect recovery of bitumen during hot water extraction. DLVO and Ionizable Surface Group Model theories accurately predict that the level of soluble salts produced is sufficient to cause coagulation of the fine particles during the process which leads to a deterioration in froth quality and loss of bitumen recovery. The rate of aging is specific to each oil sand but storage of oil sands under an inert atmosphere in air-tight container at sub-zero temperatures will minimize oxidation.     

Subcooled Flow Boiling in a Minichannel

It has been considered that dry-out occurs easily in boiling heat transfer for a small channel, a mini- or microchannel, because the channel was easily filled with coalescing vapor bubbles. In the present study, the experiments of subcooled flow boiling of water were performed under atmospheric conditions for a horizontal rectangular channel for which the size is 1 mm height and 1 mm width, with a flat heating surface of 10 mm length and 1 mm width placed on the bottom of the channel. The heating surface has a top of copper heating block and is heated by ceramic heaters. In the high heat flux region of nucleate boiling, about 70–80% of the heating surface was covered with a large coalescing bubble and the boiling reached critical heat flux as observed by high-speed video. In the beginning of transition boiling, coalescing bubbles were collapsed to many fine bubbles and microbubble emission boiling was observed at liquid subcooling higher than 30 K. The maximum heat flux obtained was 8 MW/m² (800 W/cm²) at liquid subcooling of higher than 40 K and a liquid velocity of 0.5 m/s. However, the surface temperature was very much higher than that of a centimeter-scale channel. The high-speed video photographs indicated that microbubble emission boiling occurs in the deep transition boiling region.     

Effect of treatment of activated carbon fiber cloth electrodes with cold plasma upon performance of electric double-layer capacitors

Charge/discharge behavior of electric double-layer capacitors composed of activated carbon fiber cloth (ACFC) electrodes and an organic electrolyte was investigated. The modification of the ACFC electrodes was performed using cold plasma generated in argon-oxygen atmosphere. The effect of the cold plasma treatment of the ACPC electrodes on the capacitor performance was discussed on the basis of the physical and chemical properties of the ACFC surface such as pore radius distribution and surface atom concentration.     

Excess estrogen sulfoconjugation as the possible cause for a poor sign of parturition in pregnant cows carrying somatic cell clone fetuses

We conducted this study to elucidate a factor causing a poor sign of parturition and prolonged gestation, which is frequently observed in cows carrying somatic clone fetuses. Pre-partum rises in concentrations of plasma estrone and estradiol-17beta in the recipient cows pregnant with clones were subtle. By contrast, the plasma concentration of estrone sulfate in clone pregnancies increased gradually from pre-initiation of parturition induction whereas control cows that received in vivo-derived embryos showed a significant increase at parturition. Therefore, in clone pregnancies, the ratio of estrone/estrone sulfate was low during the pre-partum period compared with control. Messenger RNA expression of estrogen sulfotransferase (SULT1E1) in the placenta at parturition was significantly higher in clone pregnancies than control pregnancies and was localized in binucleate cells (BNC). SULT1E1 mRNA abundance was negatively and positively correlated with concentrations of maternal estrone and estrone sulfate at parturition respectively. Messenger RNA expressions of estrogen sulfatase (STS) and aromatase (CYP19) were similar between clone and control pregnancies and were localized in BNC and caruncular epithelial cells. STS and CYP19 mRNA abundances showed positive correlations with maternal estradiol-17beta concentration. The population of BNC in the placenta did not differ between clone and control pregnancies. Plasma cortisol concentration of vaginally delivered newborn clone calves was comparable with those of control, although cesarean section delivered clone calves showed a low concentration. These results suggest that excess estrogen sulfoconjugation is the reason for the perturbed low ratio of active to inactive estrogens and the resulting hormonal imbalance contributes to the lack of overt signs of readiness for parturition in cows pregnant with clones.     

A study of the volume and bounce decrease in hair with ageing using bending elasticity measurements

Hair diameters and bending stresses were measured for chemically untreated regions of hair close to the scalp, collected from 38 Japanese female (age range: 26–51) and 35 Caucasian female (age range: 20–40) volunteers. For the bending stress measurements, a new methodology to obtain averaged Young's modulus has been developed in which 50 fibres are measured together to give reproducible data, overcoming the individual differences in each hair fibre. By comparing the resulting data of the fibres collected from the panelists younger than 40 years of age, no significant difference in Young's modulus between Japanese and Caucasian hair was recognized, and the modulus was c. 10 GPa, regardless of the hair diameter. On the other hand, there existed cases in which fibres showed lower Young's moduli, and these fibres were from senior panelists who were conscious of the decrease in hair volume and bounce with ageing. This result indicates that the decrease in volume and bounce in hair with ageing is not only caused by a decrease in hair diameter and fewer hairs per square centimetre of scalp but also by some internal change in the hair.     

Newly Developed Thyristor Chopper Equipment for Electric Railcars

In the chopper control system for electric railcars, it is effective to adopt high operational frequency of the chopper for achievement of the following: 1) decrease of higher harmonic current induced in the trolley wire, 2) reduction of weight for reactors and capacitors in the traction circuit, and 3) improvement of control response. Through development of reverse-conducting thyristors with very short turn-off time and a repulsion type two-phase chopper, we finally realized production of a new standard high-frequency chopper equipment with regenerative braking for 1500-V dc railcars. Technical achievements mentioned previously were completely realized as a result of adoption of high frequency, 660 Hz, in the equipment. The newly developed standard high-frequency chopper equipment for 30 cars were delivered to the Chiyoda Line of Teito Rapid Transit Authority in Tokyo, and they have been operated satisfactorily in revenue service since March 1971. This paper also describes: 1) the chopper circuit using fast-switching reverse-conducting thyristors and series saturable reactors, 2) analysis of commutation circuit and methods of suppressing reapplied forward voltage increasing rate (dv/dt) and shortening commutation period, 3) the composition of the traction circuit including the protection system, such as protection for overvoltage at the regenerative braking, and 4) test results on the Chiyoda Line of Teito Rapid Transit Authority.