Review of laser welding monitoring

Laser welding, as a highly efficient processing technology, has been widely applied to manufacturing industry. This paper makes an overview on real time monitoring of laser welding. It begins with a detailed introduction to six typical sensors (photodiode, visual, spectrometer, acoustical sensor, pyrometer, plasma charge sensor) in laser welding detection. Then it makes a review on multi-sensor fusion technology in both laser welding monitoring and adaptive control. Last, subjects for future research concerning welding monitoring and control have been proposed. The paper concludes that the real-time monitoring of laser welding can provide a great amount of valid information about welding status to help effectively identify weld defects and realize adaptive control.     

Development of novel two-interconnected fluidized bed system

Two-interconnected fluidized bed systems are widely used in various processes such as Fisher-Tropsch, hot gas desulfurization, CO₂ capture-regeneration with dry sorbent, chemical-looping combustion, sorption-enhanced steam methane reforming, chemical-looping hydrogen generation system, and so on. However, conventional two-interconnected fluidized bed systems are very complex, large, and difficult to operate because most of these systems require a riser and/or pneumatic transport line for solid conveying and loopseals or seal-pots for gas sealing, recirculation of solids to the riser, and maintaining of pressure balance. To solve these problems, a novel two-interconnected fluidized bed system has been developed. This system has two bubbling beds, solid injection nozzles, solid conveying lines, and downcomers. In this study, the effects of operating variables on solid circulation rate and gas leakage between two beds have been investigated in a cold mode two-interconnected fluidized bed system. The solid circulation rate increased as the hole diameter on the injection nozzle, the diameter of the injection nozzle, the solid height above the holes, and the number of holes on the injection nozzle increased. The gas leakage between the beds was negligible. Moreover, long-term operation of continuous solid circulation up to 60 hours was performed to check the feasibility of stable operation. The pressure drop profiles in the system loop were maintained steadily and solid circulation was smooth and stable.     

Pelletised fuel production from coal tailings and spent mushroom compost – Part II. Economic feasibility based on cost analysis

Due to the growing market for sustainable energy, in order to increase the quality of the fuels, pellets are being produced from various materials such as wood and other biomass energy crops, and municipal waste. This paper presents the results from an economic feasibility study for pellet production using blends of two residue materials: coal tailings from coal cleaning and spent mushroom compost (SMC) from mushroom production. Key variables such as the mixture composition, raw material haulage and plant scale were considered and the production costs were compared to coal and biomass energy prices. For both wet materials, the moisture content was the critical parameter that influenced the fuel energy costs. The haulage distance of the raw materials was another factor that can pose a high risk. The results showed that the pellet production from the above two materials can be viable when a less energy-intensive drying process is utilised. Potential market outlets and ways to lower the costs are also discussed in this paper.     

An Improvement of the Portmanteau Statistic

Abstract. The portmanteau statistic is based on the first m‐residual autocorrelations, and is used for diagnostic checks on the adequacy of fit of a model. In this article, we propose a modified portmanteau statistic with a correction term that allows for the use of small values of m for the chi‐squared test. For this modification, we take a different approach to that suggested by Ljung [Biometrika (1986), Vol. 73, pp. 725–30]. Their empirical behaviour is clarified using asymptotic theory.     

Isotropic carbon and graphite fibers from chemically modified coal-tar pitch

A precursor for a general purpose carbon fiber was prepared from coal tar pitch (CP) modified with 10 % p-benzoquinone (BQ) at 380 ?C for 3 hours. Such a modification raised the softening of the pitch from 85 ?C to 271 ?C at a yield of 43 %. The modified pitch was spun smoothly at a rate of 480 m/min into a fiber of 20 Μm diameter. The fiber was stepwise stabilized at 236 ?C (5 ?C/min) and 312 ?C (1 ?C/min) for 3 hours at each temperature. Successively,carbonization and graphitization were performed at 1,000 ?C and 2,400 ?C, respectively, for one hour. Both the carbonized and graphitized fibers exhibited tensile strength of 570 MPa. The structural parameters of carbon and graphite fibers were their orientation values of 56.2 and 58.1 %, relatively low Lc(002) of 11.24 and 25 å, and large interlayer spacing (d₀₀₂) of 3.86 and 3.49 å, respectively.     

Coal combustion characteristics in a pressurized fluidized bed

The characteristics of emission and heat transfer coefficient in a pressurized fluidized bed combustor are investigated. The pressure of the combustor is fixed at 6 atm. and the combustion temperatures are set to 850, 900, and 950 °C. The gas velocities are 0.9, 1.1, and 1.3 m/s and the excess air ratios are 5, 10, and 20%. The desulfurization experiment is performed with limestone and dolomite and Ca/S mole ratios are 1,2, and 4. The coal used in the experiment is Cumnock coal from Australia. All experiments are executed at 2 m bed height. In this study, the combustion efficiency is higher than 99.8% through the experiments. The heat transfer coefficient affected by gas velocity, bed temperature and coal feed rate is between 550-800 W/m² °C, which is higher than those of AFBC and CFBC. CO concentration with increasing freeboard temperature decreases from 100 ppm to 20 ppm. NO_x concentration in flue gas is in the range of 5-130 ppm and increases with increasing excess air ratio. N₂O concentration in flue gas decreases from 90 to 10 ppm when the bed temperature increases from 850 to 950 °C.     

Application of Psf–PPSS–TPA composite membrane in the all-vanadium redox flow battery

The Psf–PPSS–TPA composite cation exchange membrane consist of Psf(polysulfone)–PPSS (polyphenylenesulfidesulfone) block copolymer with TPA (tungstophosphoric acid) is prepared to apply for a separator in the all-vanadium redox flow battery. The membrane properties such as membrane resistance and ion exchange capacity, and thermal stability are investigated. The prepared Psf–PPSS–TPA composite cation exchange membrane showed higher thermal stability than Nafion117. The lowest membrane resistance of the prepared Psf–PPSS–TPA composite cation exchange membrane measured in 1 M (mol/dm³) H₂SO₄ aqueous solution was 0.94 Ω cm² at 0.5 g of TPA solution. The performance properties of the all-vanadium redox flow battery (V-RFB) using the prepared cation exchange membrane are measured. The electromotive force, open circuit voltage at state of charge (SOC) of 100%, was 1.4 V. This value meets a theoretical electromotive force value of the V-RFB. The measuring cell resistance in charge and discharge at SOC 100% were 0.26 Ω and 0.31 Ω, respectively. The results of the present study suggest that the prepared Psf–PPSS–TPA composite cation exchange membrane is well suited for use in V-RFB as a separator.     

Aluminium alloy welding by CO2 laser using filler wire ‐AIN formation and aluminium alloy weldability

Based on literature sources and the author's own research, this article presents the current state of knowledge about composite coatings created by means of the plasma transfer method. The general characteristics of composite coatings and their strengthening mechanisms have been described. Methods of creating composite coatings by means of the plasma transfer method have also been discussed.     

Laser pressure welding of aluminium and galvannealed steel

Dissimilar metal joints of galvannealed steel and commercially available pure aluminium (A1050) sheets were produced by changing the laser power and the roller pressure by the laser pressure welding method. In this method, the YAG laser beam was irradiated into a flare groove made by these dissimilar metal sheets. In addition, the laser beam was scanned at various frequencies and patterns through the fθ lens using two-dimensional scanning mirrors. Then the sheets were pressed by the pressure rolls to be joined. The compound layers in the weld interface were observed by optical microscope, and the layer thicknesses were measured. The thicknesses were in the range of 7–20 μm. The mechanical properties of welded joints were evaluated by the tensile shear test and the peel test. In the tensile shear test, the strengths of the joints produced under the most welding conditions were so high that the fracture occurred through the base aluminium sheet. In the peel test of the specimens subjected to the laser beam of 1200–1400 W power under the roller pressure of 2.94 kN, the specimen fracture took place in the base aluminium sheet. Even if the compound layer was thick, high joint strength was obtained. In order to know the reason for such high strength of joints with thick compound layers and the joining mechanism, the compound layer was observed by the HR-TEM. The TEM observation results revealed that the main phase in the compound layer was the solid solution of Al + Zn. Moreover, the intermetallic compound was identified as FeAl, Fe₂Al₅, Fe₄Al₁₃, and Fe₂Al₅Zn_0.4 phase by electron diffraction. The Fe₃Zn₁₀ (Γ phase) of Fe–Zn intermetallic compound was confirmed on a Fe base material. It is assumed that the joining areas were heated in a range of 782°C more than 665°C, a melting point of Al, by laser irradiation because the δ_lk phase aspect was not confirmed. Because the surfaces of A1050 and Zn plated layer were melted thinly, the layer was over 10 μm thicker. The reason for the production of high strength joints with the relatively thick intermetallic compound layer was attributed to the formation of (Al + Zn) phase with finely dispersed intermetallic compounds.