Characterization of in situ synthesized TiC particle reinforced Fe-based composite coatings produced by multi-pass overlapping GTAW melting process

In this paper, in situ synthesized TiC particles reinforced Fe-based surface composite coatings by multi-pass overlapping gas tungsten arc welding (GTAW) melting process employing a proper amount of graphite and ferrotitanium (FeTi) on AISI 1020 steel substrate was produced. The microstructure and wear properties of the composite coatings were investigated by means of an electron microprobe microanalysis (EPMA), X-ray diffractometer and wear tester. The results showed that the multi-pass overlapping GTAW melting surface composite coatings can be obtained under suitable welding parameters, and no crack and porosity are found in the tracks. The X-ray and EPMA results confirm that TiC particles can be formed via reaction of FeTi and graphite during multi-pass overlapping GTAW melting process. TiC particles present cubic and dendrite shape in the non-overlapping zone. It is found that there occurred TiC particles coarsening at the overlap regions, which can lead to detrimental effects on the hardness and wear performance. Composite coatings give a high hardness and excellent wear resistance; and the wear friction coefficient of the coating is less than that of the 1020 steel. As a result, multi-pass overlapping GTAW melting process can be used effectively for producing surface composite coatings with a pre-placed powder to improve wear resistance of the AISI 1020 steel.     

Weld seam profile detection and feature point extraction for multi-pass route planning based on visual attention model

Automatic multi-pass route planning is one of key technologies for thick plate in robotic metal active gas (MAG) arc welding. In this research, a scheme for the extracting feature points of the weld seam profile to implement automatic multi-pass route planning, and guidance of the initial welding position in each layer during MAG arc welding, is presented. It consists of two steps: first a vision sensor based on structured light is employed to capture laser stripes and molten pools simultaneously within the same frame, and the laser stripe, forming the weld seam profile is detected by a visual attention model based on saliency. Then a methodology of polynomial fitting plus derivatives for feature point extraction of the weld seam profile is suggested. With respect to the effectiveness of highlighting the laser stripe, the proposed model is much better than the classic ones in this field, whereas the feature point extraction methodology in this paper outperforms typical template matching. Finally, the performance of the proposed scheme is demonstrated on different weld seam images captured in different layers and different welding experiments.     

Grain refinement of HAZ in multi-pass welding

A technique named Impacting Trailed Welding (ITW) was proposed, aimed at refining the grain size of the HAZ in multi-pass welding. The key idea of ITW is to obtain a large deformation in the HAZ during one weld pass, and get it recrystallized during the next weld pass. Theoretical analysis suggests that the deformed HAZ can get completely recrystallized and the degree of the successive grain growth is lower than the normal grain growth, so that the grains can be dramatically refined. The average grain size was reduced by a factor 2 through the application of the ITW technique, and remained close to the grain size of the base material. The results are consistent with the theoretical analysis.     

Multi-pass serpentine flow-fields to enhance under-rib convection in polymer electrolyte membrane fuel cells: Design and geometrical characterization

The flow-field for reactant distribution is an important design factor that influences the performance of polymer electrolyte membrane fuel cells (PEMFCs). Under-rib convection between neighboring channels has been recognized to enhance the performance of PEMFCs with serpentine flow-fields. This study presents a simple design method to generate multi-pass serpentine flow-fields (MPSFFs) that can maximize under-rib convection in a given cell area. Geometrical characterization indicates that MPSFFs lead to significantly higher under-rib convection intensities and more uniform conditions, such as reactant concentrations, temperature, and liquid water saturation, compared with conventional serpentine flow-fields. The implications of the enhanced under-rib convection due to MPSFFs on the performance of PEMFCs are discussed.     

THE INFLUENCE OF RECYCLE ON MULTI-PASS LAMINAR COUNTERFLOW HEATERS OR COOLERS

A multi-pass laminar counterflow cooler or heater is an open duct divided into four subchannels with uniform wall temperature by inserting three impermeable sheets. Only the temperature of the flow stream varies along the subchannels. Improvements in heat transfer efficiency were investigated analytically with the use of eigenfunction expansions in the power series. The enhancement results in heat-transfer efficiency for two multi-pass devices (flow pattern A and flow pattern B) are represented graphically and compared with those in a single-pass device (without three impermeable sheets inserted) and those in a double-pass device (only one impermeable sheet inserted). Analytical results show that suitable impermeable-sheet position adjustments can effectively enhance heat transfer efficiencies for two multi-pass devices (flow pattern A and flow pattern B) compared with the efficiencies of single and double-pass devices.     

A note on ‘optimization of multi-pass turning operations using ant colony system’

An article by Vijayakumar et al. [Optimization of multi-pass turning operations using ant colony system, International Journal of Machine Tools and Manufacture 43(15) (2003) 1633–1639] proposed an ant colony optimization methodology for determining the machining parameters in a multi-pass turning operation model. By using the problem of Chen and Tsai [A simulated annealing approach for optimization of multi-pass turning operations, International Journal of Production Research 34(10) (1996) 2803–2825], they concluded that their ant colony approach outperformed the other optimization techniques proposed by other researchers. This note discusses an illustrative multi-pass turning problem, which was used in several literatures and demonstrates that the optimal solution as found by Vijayakumar et al. [1] is not valid.     

Grain refinement and superplasticity of pipes processed by high-pressure sliding

ABSTRACT

The high-pressure sliding (HPS) process was applied for grain refinement of a pipe form of an Al-3wt%Mg-0.2wt%Sc alloy by developing two types of straining techniques (called in this study anvil sliding and mandrel sliding). To achieve a homogeneous microstructure throughout the cross-section of the pipe, the sample is rotated around the longitudinal axis every after sliding operation by introducing multi-pass technique, named multi-pass HPS (MP-HPS) as developed earlier for rods. The MP-HPS-processed sample shows ultrafine-grained structures with an average grain size of ～260 and ～300?nm after the HPS processing using anvil sliding and mandrel sliding. The samples also exhibit superplasticity with total elongations well more than 400%, respectively. A finite-element method is used to simulate the evolution of strain in the HPS processing and demonstrates that the simulation well represents the experimental results.     

Characteristic of a multi-pass membrane separator for hydrogen separation through self-supported PdAg membranes

Dense PdAg membranes have shown immense potential to achieve high hydrogen purity required for proton exchange membrane (PEM) fuel cell. However, high hydrogen recovery and flux at lower transmembrane partial pressure is still a concern. In current study self-supported dense PdAg membranes were used to study the hydrogen recovery in a multi-pass membrane separator. Performance of a single and four collective membranes are tested in a single (without baffle) and multi-pass (with longitudinal baffles) membrane separator. Further, array of membrane configurations were tested experimentally by using longitudinal baffles and placing membranes at different locations. The hydrogen recovery for each configuration was measured experimentally. Experiments were performed using binary gas mixture 50H₂:50N₂ (v/v) at 3 bar pressure, 673 K temperature and gas-hourly space velocity (GHSV) 43 h^?1. The best assembly was further tested with typical methanol reformate gas composition by using simulated gas mixture of 50H₂:30N₂:18CO₂:2CO (v/v) at same operating condition. Numerical simulations were performed by using commercial software ANSYS 14.5 to understand the flow dynamics inside the separator with and without baffle. The results demonstrate that a multi-pass membrane separator enables to control hydrogen partial pressure radially along the length of reactor. This resulted in 33% enhancement in hydrogen recovery with multi-pass in comparison to single pass membrane separator.     

Comparative Evaluation of Hot-Air and Superheated-Steam Impinging Stream Drying as Novel Alternatives for Paddy Drying

An investigation was conducted on impinging stream drying of moist paddy using hot air and superheated steam as the drying media. Drying experiments were divided into two parts: namely, one-pass and two-pass drying. The volumetric water evaporation rate, volumetric heat transfer coefficient, and specific energy consumption of the drying system at various conditions were assessed; in the case of superheated-steam drying, the effect of steam recycle was also assessed. The quality of dried paddy was evaluated in terms of color, head rice yield, and degree of starch gelatinization. In the case of one-pass drying, an increase in the drying temperature led to a significant increase in the volumetric water evaporation rate and volumetric heat transfer coefficient. On the other hand, in the case of two-pass drying, an increase in the drying temperature led to a significant decrease in the volumetric heat transfer coefficient; the volumetric water evaporation rate was not significantly affected, however. The specific energy consumption decreased with an increase in the drying temperature. At the same temperature, using superheated steam as the drying medium led to lower specific energy consumption; higher level of steam recycle also led to more energy conservation. The color of the dried paddy was not affected by the change in the drying temperature; superheated-steam-dried paddy was redder and more yellow than the hot-air-dried paddy. An increase in the drying temperature led to decreased percentage of head rice yield. Superheated-steam drying helped enhance the level of starch gelatinization in comparison with hot-air drying at the same temperature. Nevertheless, drying at the highest tested temperature led to a lower level of starch gelatinization.     

Investigations on welding residual stresses in penetration nozzles by means of 3D thermal elastic plastic FEM and experiment

Recent discoveries of stress corrosion cracking (SCC) in weldments including penetration nozzles at pressurized water reactors (PWRs) and boiling water reactors (BWRs) have raised concerns about safety and integrity of plant components. It is well known that welding residual stress is an important factor resulting in SCC in weldments. In the present work, both experimental method and numerical simulation technology are used to investigate the characteristics of welding residual stress distribution in penetration nozzles welded by multi-pass J-groove joint. An experimental mock-up is fabricated to measure welding residual stress at first. In the experiment, each weld pass is performed using a semi-circle balanced welding procedure. Then, a corresponding finite element models with considering moving heat source, deposition sequence, inter-pass temperature, temperature-dependent thermal and mechanical properties, strain hardening and annealing effect is developed to simulate welding temperature and residual stress fields. The simulation results predicted by the 3D model are generally in good agreement with the measurements. Meanwhile, to clarify the influence of deposition sequence on the welding residual stress, the welding residual stress field in the same geometrical model induced by a continuous welding procedure is also calculated. Finally, the influence of a joint oblique angle on welding residual stress is investigated numerically. The numerical results suggest that both deposition sequence and oblique angles have effect on welding residual stress distribution.