The processing of nanopowders by thermal plasma technology

The thermal plasma synthesis of nanopowders is a relatively new technology with great potential for future industrial applications. This article introduces research carried out in the plasma processing laboratory at the University of Alabama in Tuscaloosa, Alabama. Ceramic nanopowders and nanofibers (SiC, TiC, and B₄C) and nanocomposite powders (TiC−Al(Ti), TiC−Fe(Ti), and TiN−Fe (Ti)) were successfully synthesized by thermal plasma technology.     

Characterization of rust phases formed on low carbon steel exposed to natural marine environment of Chennai harbour – South India

The corrosion behaviour of low carbon steel exposed to marine atmospheric, splash and immersion zones has been systematically studied by exposing steel specimens for a period of 12 months at the boat basin corrosion station of Chennai harbour, Chennai, Tamil Nadu, South India. The literature on similar work has been thoroughly reviewed which led to the initiation of this study for the first time at this harbour. The corrosion product (rust) on the specimens at 1, 2, 3 and 12 months was obtained and characterized by Fourier transform infrared spectroscopy (FT‐IR) and X‐ray diffraction (XRD) analysis. Acaganeite was the rust phase identified in the splash zone as revealed by the FT‐IR and XRD analysis. The other dominant phases were lepidocrocite, goethite and ferroxyhite. Small amounts of magnetite were also found to be present. The transformation of phases was observed in this investigation and discussed. A remarkable difference in the FT‐IR and XRD patterns of the corrosion products at the splash and immersion zones were noticed and the corresponding phases formed were reported in this paper. The rate of corrosion in all the three zones was compared.     

Electronic absorption spectrum of Cu2 ions doped in lithium ammonium sulphate crystal

Single crystals of Lithium Ammonium Sulphate doped with Cu²⁺ ions were grown by slow evaporation technique. Electronic absorption spectra have been recorded at room and liquid nitrogen temperatures on Cary-2390 spectrophotometer. The spectrum is characteristic of a Cu²⁺ ion in octahedral symmetry. From the magnitude and and relative position of the bands a successful interpretation of all the observed bands has been made. The crystal field and tetragonal field parameters are derived. The observed and calculated energies are in good agreement.     

Design of optimal process parameters for non-isothermal forging

This paper presents a state space model and an optimal design scheme for non-isothermal metal forming processes. By selecting nodal velocity and temperature as the state variables, a non-isothermal state equation with coupled deformation and thermal terms is established. Based on this state space model, a control design scheme is developed to obtain the optimal die velocity and initial die temperature which will ensure that the effective strain-rate and temperature satisfy the design requirements. A titanium alloy engine disk forging is used to demonstrate two design examples. The results show that the proposed model and design scheme behave well for different design requirements.     

Optimum design of plano-milling machine structure using finite element analysis

The problem of optimum design of plano-milling machine structure is formulated as a nonlinear mathematical programming problem with the objective of minimizing the structural weight. The plano-milling machine structure is idealized with triangular plate elements and three dimensional frame elements based on finite element displacement method. Constraints are placed on static deflections and principal stresses in the problem formulation. The optimization problem is solved by using an interior penalty function method in which the Davidon-Fletcher-Powell variable metric unconstrained minimization technique and cubic interpolation method of one dimensional search are employed. A numerical example is presented for demonstrating the effectiveness of the procedure outlined. The results of sensitivity analysis conducted with respect to design variables and fixed parameters about the optimum point are also reported.     

Direct Pyrolysis of Raw Rice Husks for Maximization of Silicon Carbide Whisker Formation

A new alternate route for the production of SiC from rice husks has been described. The proposed single-stage process has the advantage of reduced time of production and a much higher yield of SiC whiskers than the conventional two-stage process. Direct pyrolysis of raw rice husks was carried out in a graphite furnace under vacuum and the reaction products were analyzed through macroscopic examination, XRD, SEM, and chemical analysis. Effects of time and temperature on the relative yields of the various reaction products have been determined over a wide range. The pyrolysis of raw rice husks has been found to be accompanied by four different competitive processes, viz., formation of SiC whiskers, formation of SiC polycrystals, crystallization of amorphous silica, and graphitization of amorphous carbon. Crystallization of silica and formation of SiC( w ) are dominant processes at 1150° to 1310°C. At higher temperatures formation of SiC polycrystals and graphitization of carbon are more favored. A multistep pyrolysis to 1310°C was found to yield a still higher amount of SiC( w ) than direct pyrolysis.     

Particle motion in the fountain flow region during filling of a tube with a viscoelastic fluid

We present the results of an investigation of particle motion behind the advancing free surface during the filling of an initially empty tube with a viscoelastic fluid. Particle motion in the vicinity of an advancing free surface (the fountain flow region) is of significance in a number of processes used to form composite materials, notably injection and compression molding. This motion determines, to a large extent, the distribution of the reinforcing phase in the molded part. We show experimentally that an isolated spherical particle moves behind the interface in characteristic orbits, remaining in close proximity to the advancing free surface. This is in stark contrast to what happens in a Newtonian fluid. In that case, the particle is deposited on the tube walls by the fountain flow and never again reaches the faster moving free surface. The particle motion behind the interface is modeled with a combination of equations that describe the advection of the particle due to convective/fountain flow and its lateral migration due to viscoelasticity. This model neglects the finite size of the particle and is thus unable to capture the full details of the observed motion. However, the qualitative agreement between the experimental results and the modeling predictions suggests that the observed particle motion is the result of the combined effect of viscoelasticity and fountain flow.     

State-space representation and optimal control of non-linear material deformation using the finite element method

A state-space model for representing the non-linear material deformation and an optimal control scheme for obtaining desired process conditions in the deforming material are presented in this paper. The formulation is general for various metal-forming processes including forging and extrusion operations. The state variables selected in the formulation are the die/billet contact nodal velocities and the nodal velocities of the critical finite elements of the billet. The control input is the ram velocity, which is determined by using the linear quadratic regulator (LQR) theory to maintain desired strain rates within the selected finite elements. The influence of an optimally designed ram velocity on the deforming material is studied using performance measures. This paper includes the development of the state-space model from non-linear finite element formulation, optimal control strategy and numerical example cases with discussions.