Mathematical modelling and numerical simulation of ordered porosity metal materials formation

Ordered porosity metal materials belong to a relatively new class of porous materials named gasars. This paper presents a mathematical model of the complex physical phenomena in the production of gasars. Analyses for heat transfer, solidification kinetics and gas diffusion were coupled to describe the formation of unique gasar structure. Several criterial functions were introduced to provide significant quantitative information about the relationship between the operating technological parameters and the final structure. The computational outcomes of the numerical simulation were compared with the characteristics of real gasar ingots. The model was applied to determine the boundary conditions that would provide approximately constant physical conditions on the solidification front. The structure sensitiveness of gasars with respect to the different technological parameters is discussed.     

SURFACE TENSION AND BUOYANCY DRIVEN INSTABILITIES IN A LAYER OF LIQUID TIN HEATED FROM BELOW

The linear theory of Pearson (1958) and Nield (1964) is modified here to study liquid tin and include the finite thermal resistances of the bounding layers of boron nitride, copper and air (∼10^-2 torr) in the experiments of Ginde et al. (1989). The magnitude of the ΔT_c across the layer of liquid tin required for the onset of convection depends on the ratios of the thermal conductivities and thicknesses of the supporting layers of boron nitride and copper to those of the tin.

According to our theory surface tension contributes more than buoyancy to the instability observed experimentally. The critical ΔT_c observed required for the onset of convection in the layer of tin, is up to 25% lower than that predicted, which shows the layer is less stable than the theory indicates. Thus the surface of the tin was uncontaminated, or a significantly larger observed critical ΔT_c would be expected.

The boundary condition on the thermal fluctuations at the base of the supporting layer of copper does not appear to be important in these experiments. However, the thermal resistance of the boron nitride would have to be assumed to be unrealistically large to obtain agreement within experimental error with the theory.     

Electrochemistry of polyaniline: Study of the pH effect and electrochromism

Polyaniline was electrochemically synthesized from an aqueous medium with various acid electrolytes via potentiodynamic and potentiostatic techniques. The electrochemical synthesis of polyaniline was studied over various substrates, including Pt, Ti, Ni, and SnO₂ coated glass, and in various acid electrolytes. Cyclic voltammograms of electrochemically synthesized polyaniline were studied in HCl in a pH range of 1–4. Probable electrochemistry and chemical changes were deduced that occurred when polyaniline film was electrochemically oxidized and reduced between ?0.2 and 1.0 V versus a Ag/AgCl reference electrode in an acidic electrolyte at pH 1, and three corresponding oxidation and reduction peaks were described instead of two redox peaks (as observed by W. S. Huang, B. D. Humphrey, and A. G. MacDiarmid, J Chem Soc Faraday Trans 1 1986, 82, 2385). The electrochromic property was studied with changes in the chemical states of polyaniline during electrochemical oxidation and reduction. A new viscous electrolyte, aqueous AlCl₃ (pH 2), saturated with AgCl was used for the construction of an electrochromic display device. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 378–385, 2002     

Rolling contact fatigue behavior of sintered and hardened steels

Powder-metal-processed bearings and gears are finding increasing application because of their economical and technical advantages. The residual pores from the sintering operatives act as lubricant pockets and dampen sound and vibration. However, porosity also decreases the mechanical strength and reduces the life of components fabricated by powder processing relative to similar wrought components. The rolling contact fatigue behavior of sintered and heat treated steel rollers was investigated using a fatigue test machine designed and fabricated for that purpose. The powder-metal-processed and the wrought steel rollers that were tested had similar composition and hardness and were mated against wrought steel rollers of high hardness. The contact stress versus number of cycles to failure data showed that the wrought steel had a very high endurance limit under rolling contact fatigue compared to the sintered steels investigated. Rolling contact fatigue behavior was found to depend on the porosity present in the material. Large surface peeling failures and pitting type fatigue failures were observed in the sintered and hardened steels, while only pitting type failures were observed in the wrought steels     

Effects of processing parameters in P/M steel forging on part properties: A review part I powder preparation,compaction, and sintering

In the last decade, powder metallurgy (P/M) technology has made marked advances in competitive manufacturing. P/M offers design opportunities that are not possible with other methods, as well as significant cost savings. In the automotive industry, P/M forgings are being developed for applications requiring good high- cycle fatigue properties. The processing parameters, material characteristics, individual stages of compaction and parts production, deformation and densification mechanics and tooling, and preform design influence the properties of the P/M part and related economics. Therefore, a review of the various parameters involved in the different stages of P/M steel forging in net-shape manufacturing and their implications on resulting properties of the P/M parts is presented in a three part review. Key parameters in steel powder preparation, compaction, and sintering of P/M forging and their effect on part properties are described in Part I. Part II discusses issues of forging the sintered compact, and Part III reviews currently available analysis methods for studying the powder forging process.     

Design development of a static sunshade using small scale modeling technique

The rising global demand for energy has triggered emphasis on conservation of energy. Buildings are one of the important energy consuming sectors. Passive solar architecture encompasses a wide range of strategies and options resulting in energy efficient building design and increased occupant's comfort. Passive solar design, aiming at increasing direct solar gains during winter period and to avoid overheating during summer period should make use of specific shading devices over energy efficient window. The static sunshades are most effective for solar control inside the buildings.Countries like India have composite climate, which can be classified under summer, winter and rainy season. Depending on the seasonal requirements, this paper introduces a new geometry of a static sunshade, designed by calculating the sun angles for the two dates. The static sun shading design methodology is validated with the help of small scale modeling experimentation technique, carried out in Pilani, Rajasthan (India). Although insulating materials can be used as a part of a building structure, its feasibility should be checked before particular application. In the present paper, the two small-scale experimental models of actual construction material with varying static sunshades, i.e. horizontal and the proposed one have been constructed and analyzed with the models of insulating material (Polyurethane Foam [PUF]). Depending upon the solar intersection over south facade wall, sunlit area and shaded area have been correlated with temperature inside the models to decide the effectiveness of the proposed sunshade.     

Particle distribution control in cast aluminium alloy-mica composites

A suspension of mica particles (40m diameter and 3.7 thick) obtained in a mechanically stirred Al-4 wt % Cu-1.5 wt % Mg melt was poured and solidified in a variety of moulds under different heat flow configurations. The resulting cast structure showed a non-uniform distribution of dispersed mica particles with mica-depleted and segregated zones due to their flotation before and during solidification. The experimentally observed profiles of mica-free regions deviate significantly from those computed on the basis of Stokes's law and freezing-time computations. In relatively thick castings, segregation of mica could be minimized by using low pouring temperatures and/or side as well as bottom chilling. It was found, however, that thin castings (12.5 mm) could easily be produced with a homogeneous distribution of mica particles.     

A summary of ring rolling technology—I. Recent trends in machines, processes and production lines

Ring rolling process is widely used in the production of seamless rings for automotive and aerospace industry. This paper presents a summary of the ring rolling technology: machine and process types; process considerations; and examples of ring rolling lines. In this technology survey, recent trends in ring rolling machines and processes are emphasized. This survey will be specially valuable for industry personnel engaged with the selection and implementation of ring rolling lines and process planning engineers working with ring rolling companies. It will also provide adequate background to researchers initiating research in the mechanics of the ring rolling process.