The application of thermal sprayed coatings for pig iron ingot molds

Molds made of gray cast iron for casting pig iron ingots are subjected to severe temperature fluctuations. The main life- limiting factor for mold damage is the formation of surface cracks arising from thermal fa-tigue. Various flame and plasma sprayed coatings were investigated to extend the life of these molds. Coating materials studied include plasma sprayed ceramic coatings with bond coats as well as flame sprayed oxidation- resistant alloy powders. The results of cyclic furnace tests from room temperature to 1100 °C in air, simulating the thermal cycle in casting, indicated that failure occurred along the interface between the bond coat and the gray iron substrate because of iron oxidation, and not at the interface between the ceramic top coat-ing and the bond coating for a superalloy substrate. The field test results indicated that plasma sprayed alumina coatings with 200 μm top coating thickness are the most promising materials for pig iron casting.     

Thermal and thermomechanical properties of poly(ethylene oxide) networks produced with silica and organic crosslinking agents

The thermal and thermomechanical properties of two series of poly(ethylene oxide) networks (NPEOs) were investigated as a function of the chain length between crosslink sites (M_c) and the concentration of LiClO₄ (C_L) in the NPEOs. The two series of networks were produced with silica and organic crosslinking agents and, therefore, had crosslink sites of different natures: one was an inorganic silicate network (silica NPEO), and the other was an organic polar group (organic NPEO). The crosslink sites in both series of networks were commonly covalently bonded to the poly(ethylene oxide) (PEO) phase through a urethane group in the NPEOs. The glass‐transition temperatures (T_g's) of the PEO phases in the NPEOs, according to differential scanning calorimetry, increased with a decrease in M_c and were higher in the silica NPEOs than in the organic NPEOs under the same M_c conditions. The difference in T_g between the two series of networks with the same M_c values increased with decreasing M_c. These results suggested that the interaction of crosslink sites with the PEO phase was stronger in the silica NPEOs than in the organic NPEOs. The addition of LiClO₄ to the NPEOs resulted in T_g of the PEO phase in the NPEOs being elevated and increased according to the increase in C_L. The increase of T_g of the PEO phase according to the increase of C_L in the NPEOs was retarded or saturated at high values of C_L, and this indicated that the limit of solubility of the salt in the polymer was attained. The retardation or saturation of the increase of T_g was also observed in dynamic mechanical analyses. The curves of the loss factor tan δ and temperatures from the dynamic mechanical analyses for the NPEOs with high values of C_L showed shoulders or double peaks indicating the existence of the second phase in the polymer networks. In the curves of tan δ for salt‐complexed NPEOs with high values of C_L, silica NPEOs showed a shoulder of low intensity, but organic NPEOs showed a distinguished second peak becoming stronger with increasing C_L. The results of the T_g behavior and tan δ curves suggested that the salt solubility in the NPEOs was limited and that the salt solubility of PEO in the silica NPEOs was higher than that in the organic NPEOs. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 270–277, 2003     

Synthesis and physicochemical characterization of amphiphilic block copolymer self‐aggregates formed by poly(ethylene glycol)‐block‐poly(ϵ‐caprolactone)

Diblock copolymers with different poly(ε‐caprolactone) (PCL) block lengths were synthesized by ring‐opening polymerization of ε‐caprolactone in the presence of monomethoxy poly(ethylene glycol) (mPEG‐OH, MW 2000) as initiator. The self‐aggregation behaviors and microscopic characteristics of the diblock copolymer self‐aggregates, prepared by the diafiltration method, were investigated by using ¹H NMR, dynamic light scattering (DLS), and fluorescence spectroscopy. The PEG–PCL block copolymers formed the self‐aggregate in an aqueous environment by intra‐ and/or intermolecular association between hydrophobic PCL chains. The critical aggregation concentrations of the block copolymer self‐aggregate became lower with increasing hydrophobic PCL block length. On the other hand, reverse trends of mean hydrodynamic diameters were measured by DLS owing to the increasing bulkiness of the hydrophobic chains and hydrophobic interaction between the PCL microdomains. The partition equilibrium constants (K_v) of pyrene, measured by fluorescence spectroscopy, revealed that the inner core hydrophobicity of the nanoparticles increased with increasing PCL chain length. The aggregation number of PCL chain per one hydrophobic microdomain, investigated by the fluorescence quenching method using cetylpyridinium chloride as a quencher, revealed that 4–20 block copolymer chains were needed to form a hydrophobic microdomain, depending on PCL block length. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 99: 3520–3527, 2006     

Robust background maintenance by estimating global intensity level changes for dynamic scenes

The maintenance of relevant backgrounds under various scene changes is very crucial to detect foregrounds robustly. We propose a background maintenance method for dynamic scenes including global intensity level changes caused by changes of illumination conditions and camera settings. If the global level of the intensity changes abruptly, the conventional background models cannot discriminate true foreground pixels from the background. The proposed method adaptively modifies the background model by estimating the level changes. Because there are changes caused by moving objects as well as global intensity level changes, we estimate the dominant level change over the whole image regions by mean shift. Then, the problem caused by saturated pixels are handled by an additional scheme. In the experiments for dynamic scenes, our proposed method outperforms previous methods by adaptive background maintenance and handling of saturated pixels.     

Localization using GPS and VISION aided INS with an image database and a network of a ground-based reference station in outdoor environments

GPS/INS integrated systems do not guarantee robustness and accuracy of localization, because GPS has vulnerability to external disturbances. However, the overall performance and reliability of the system can be significantly improved by fusing multiple sensors with a different operating principle. In outdoor environments where GPS may be blocked, there are many features compared to the open space and these features can provide much information for UGV localization. Thus, this paper proposes an improved localization algorithm based on the hierarchical federation of three measurement layers, i.e., GPS, INS, and visual localization, to overcome the shortcomings of GPS/INS integrated systems. The proposed algorithm automatically switches the operation modes according to GPS status and a network of a ground-based reference station. A vocabulary tree with SURF is used in the visual localization method. In the data fusion of visual localization and INS, an asynchronous and time-delayed data fusion algorithm is presented because visual localization is always time-delayed compared with INS. By using DGPS to obtain the reference position under the dynamic conditions of the reference station, the restrictions of the conventional DGPS are overcome and all UGVs within WiBro communication range of the reference station can accurately estimate the position with a common GPS. The experiment results with a predefined path demonstrate enhancement of the robustness and accuracy of localization in outdoor environments.     

Concurrent consideration of evacuation safety and productivity in manufacturing facility planning using multi-paradigm simulations

Manufacturing facilities are expected to maintain a high level of production and at the same time, employ strict safety standards to ensure the safe evacuation of the people in the event of emergencies (fire is considered in this paper). These two goals are often conflicting. This paper presents a methodology to evaluate evacuation safety versus productivity concurrently for various, widely known manufacturing layouts. While the safety performance indicators such as evacuation times are inferred from the crowd (agent based) simulation, the productivity performance indicators (e.g. throughput) are analyzed using the discrete event simulation. To this end, this research focuses on creating innovative techniques for developing accurate crowd simulations, where Belief-Desire-Intention (BDI) agent framework is employed to build each person’s individual actions and the interactions between them. The data model and rule based action algorithms for each agent are reverse-engineered from the human-in-the-loop experiments in the immersive virtual reality environments. Finally, experiments are conducted using the constructed simulations to compare safety and productivity for different layouts. To demonstrate the proposed methodology, an automotive power-train (engine and transmission) manufacturing plant was used. Initial results look quite promising.     

Real-time transport of MPEG video with a statistically guaranteedloss ratio in ATM networks

Unlike deterministic real-time communication in which excessive resources may be required for “absolute” performance guarantees, statistical real-time communication seeks to achieve both probabilistic performance guarantees and efficient resource sharing. This paper presents a framework for statistical real-time communication in ATM networks, providing delay-guaranteed transport of MPEG-coded video traffic with a statistically-guaranteed cell-loss ratio. Delay-guaranteed communication is achieved with a modified version of Traffic-Controlled Rate-Monotonic Priority Scheduling (TCRM). A set of statistical real-time channels that share similar traffic characteristics are multiplexed into a common macrochannel. Those statistical real-time channels which are multiplexed together share the resources of a macrochannel, and individual statistical real-time channels are given timeliness and probabilistic cell-loss guarantees. A macrochannel is serviced by the modified TCRM which improves link utilization and makes channel management simpler. Based on the analysis of an M/D/1/N queueing system, we propose a procedure for determining the transmission capacity of a macrochannel necessary to statistically guarantee a cell-loss ratio bound. Our extensive trace-driven simulation has shown the superiority of the proposed framework to the other approaches. The overall cell-loss ratios for multihop statistical real-time channels are shown to be smaller than the predetermined bounds, thus verifying our analytical results     

Analysis on the thermal and electrical characteristics of impregnating materials for the bifilar winding-type superconducting fault current limiter

The resistive type high temperature superconducting fault current limiter (HTSFCL) limits the fault current with the resistance that generated by fault current. The generated resistance by fault current makes large pulse power which makes the operation of HTSFCL unstable. So, the cryogenic cooling system of the resistive type HTSFCL must diffuse and eliminate the pulse energy very quickly. Although the best way is to make wide direct contact area between HTS winding and coolant as much as possible, HTS winding also need the impregnation layer which fixes and protects it from electromagnetic force. This paper deals with thermal conductivity and dielectric strength of some epoxy compounds for the impregnation of high temperature superconducting (HTS) winding at 77 K. The measured data can be used in the optimal design of impregnation for HTS winding. Aluminar filling increased the thermal conductivity of epoxy compounds. Hardener also affected the thermal conductivity and the dielectric strength of epoxy compounds.     

Numerical analysis on electroosmotic flows in a microchannel with rectangle-waved surface roughness using the Poisson–Nernst–Planck model

The present study has numerically investigated two-dimensional electroosmotic flows in a microchannel with dielectric walls of rectangle-waved surface roughness to understand the roughness effect. For the study, numerical simulations are performed by employing the Nernst–Planck equation for the ionic species and the Poisson equation for the electric potential, together with the traditional Navier–Stokes equation. Results show that the steady electroosmotic flow and ionic-species transport in a microscale channel are well predicted by the Poisson–Nernst–Planck model and depend significantly on the shape of surface roughness such as the amplitude and periodic length of wall wave. It is found that the fluid flows along the surface of waved wall without involving any flow separation because of the very strong normal component of EDL (electric double layer) electric field. The flow rate decreases exponentially with the amplitude of wall wave, whereas it increases linearly with the periodic length. It is mainly due to the fact that the external electric-potential distribution plays a crucial role in driving the electroosmotic flow through a microscale channel with surface roughness. Finally, the present results using the Poisson–Nernst–Planck model are compared with those using the traditional Poisson–Boltzmann model which may be valid in these scales.     

Influence of the duty cycle on structural and mechanical properties of oxide layers on Al-1050 by a plasma electrolytic oxidation process

Oxide layers were prepared on Al-1050 substrates by an environmentally friendly plasma electrolytic oxidation process using an alkaline solution of Na₂SiO₃ (8 g/L) and NaOH (3 g/L) as the electrolyte. The effects of three different duty cycles (20%, 40%, and 60%) on the structure and hardness of the oxides were investigated. XRD analysis revealed that the oxides were mainly composed of α-Al₂O₃, γ-Al₂O₃, and mullite. The proportion of each phase depended on various electrical parameters, such as the duty cycle and frequency. The morphology, thickness, and the elemental distribution of the oxides were examined by scanning electron microscopy and energy dispersive spectroscopy. The thicknesses of the oxides were found to vary from 20 μm to more than 60 μm for various duty cycles, when identical treatment durations were used. The oxidation treatment also resulted in good adhesion between the oxide layer and the substrate. SEM images indicated that the oxide layers formed at the 60% duty cycle exhibited relatively coarser surfaces with larger pore sizes and sintering particles, and slower growth rates than did those formed at the 20% duty cycle, under identical treatment durations. The oxides prepared at the 20% duty cycle showed smooth surfaces. The oxides layers were found to improve the micro-hardness of Al-1050. In particular, the oxide layers formed at the 40% duty cycle exhibited relatively better micro-hardness owing to their compact microstructures.