Micromachining of glassy carbon toolsets for micro embossing applications

Laser micro machining is fast gaining popularity as a method of fabricating micro scale structures. Lasers have been utilised for micro structuring of metals, ceramics and glass composites and with advances in material science, new materials are being developed for micro/nano products used in medical, optical, and chemical industries. Due to its favourable strength to weight ratio and extreme resistance to chemical attack, glassy carbon is a new material that offers many unique properties for micro devices. The laser machining of SIGRADUR® G grade glassy carbon was characterised using a 1065 nm wavelength Ytterbium doped pulsed fiber laser. The laser system has a selection of 25 preset waveforms with optimised peak powers for different pulsing frequencies. The optics provide spot diameter of 40 μm at the focus. The effect of fluence, transverse overlap and pulsing frequency (as waveform) on glassy carbon was investigated. Depth of removal and surface roughness were measured as machining quality indicators. The damage threshold fluence was determined to be 0.29 J/cm2 using a pulsing frequency of 250 kHz and a pulse width of 18 ns (waveform 3). Ablation rates of 17 < V < 300 μm3/pulse were observed within a fluence range of 0.98 < F < 2.98 J/cm2. For the same fluence variation, 0.6 μm to 6.8 μm deep trenches were machined. Trench widths varied from 29 μm at lower fluence to 47 μm at the higher fluence. Square pockets, 1 mm wide, were machined to understand the surface machining or milling. The depth of removal using both waveform 3 and 5 showed positive correlation with fluence, with waveform 5 causing more removal than waveform 3 for the same fluence. Machined depths varied from less than 1 μm to nearly 40 μm. For transverse overlap variation using waveform 3, the best surface finish with Rz = 1.1 μm was obtained for fluence 0.792 J/cm2 for transverse overlap of 1 μm, 6 μm, and 9 μm at machined depths of 22.9 μm, 6.6 μm, and 4.6 μm respectively. For fluence of 1.426 J/cm2, the best surface finish with Rz = 1.2 μm was obtained for transverse overlap of 6 μm, and 9 μm at machined depths of 12.46 μm, and 8.6 μm respectively. The experimental data was compiled as machining charts and utilised for fabricating a micro-embossing glassy carbon master toolsets as a capability demonstration.

Drain groups in liquefiable soil

One of the major concerns for engineers in seismically active regions is the prevention of damage caused by earthquake-induced soil liquefaction. Vertical drains can aid dissipation of excess pore pressures both during and after earthquakes. Drain systems are designed using standard design charts based around the concept of a unit cell, assuming each drain is surrounded by more drains. It is unclear how predictable drain performance is outside that unit cell concept, for example, drains at the edge of a group. Centrifuge testing is a logical method of performing controlled experiments to establish the efficacy of vertical drains. Centrifuge testing is used to identify the effect of drains dealing with very different catchment areas. The importance of this is further highlighted by the results of a test where the same drains have been modified so that each should behave as a unit cell. It is shown that drains with large catchment areas perform more poorly than unit cells, and also have a knock-on detrimental effect on other drains. Copyright © 2011, IGI Global.

Stiffness and strength of tridimensional periodic lattices

This paper presents a method for the linear analysis of the stiffness and strength of open and closed cell lattices with arbitrary topology. The method hinges on a multiscale approach that separates the analysis of the lattice in two scales. At the macroscopic level, the lattice is considered as a uniform material; at the microscopic scale, on the other hand, the cell microstructure is modelled in detail by means of an in-house finite element solver. The method allows determine the macroscopic stiffness, the internal forces in the edges and walls of the lattice, as well as the global periodic buckling loads, along with their buckling modes. Four cube-based lattices and nine cell topologies derived by Archimedean polyhedra are studied. Several of them are characterized here for the first time with a particular attention on the role that the cell wall plays on the stiffness and strength properties. The method, automated in a computational routine, has been used to develop material property charts that help to gain insight into the performance of the lattices under investigation. © 2012 Elsevier B.V.

Mechanical properties of hierarchical lattices

This paper focuses on the stiffness and strength of lattices with multiple hierarchical levels. We examine two-dimensional and three-dimensional lattices with up to three levels of structural hierarchy. At each level, the topology and the orientation of the lattice are prescribed, while the relative density is varied over a defined range. The properties of selected hierarchical lattices are obtained via a multiscale approach applied iteratively at each hierarchical level. The results help to quantify the effect that multiple orders of structural hierarchy produces on stretching and bending dominated lattices. Material charts for the macroscopic stiffness and strength illustrate how the property range of the lattices can expand as subsequent levels of hierarchy are added. The charts help to gain insight into the structural benefit that multiple hierarchies can impart to the macroscopic performance of a lattice. © 2013 Elsevier Ltd. All rights reserved.

Cement-fly ash stabilisation/solidification of contaminated soil: Performance properties and initiation of operating envelopes

This study was aimed at evaluating the mechanical and pH-dependent leaching performance of a mixed contaminated soil treated with a mixture of Portland cement (CEMI) and pulverised fuel ash (PFA). It also sought to develop operating envelopes, which define the range(s) of operating variables that result in acceptable performance. A real site soil with low contaminant concentrations, spiked with 3000mg/kg each of Cd, Cu, Pb, Ni and Zn, and 10,000mg/kg of diesel, was treated with one part CEMI and four parts PFA (CEMI:PFA=1:4) using different binder and water contents. The performance was assessed over time using unconfined compressive strength (UCS), hydraulic conductivity, acid neutralisation capacity (ANC) and pH-dependent leachability of contaminants. With binder dosages ranging from 5% to 20% and water contents ranging from 14% to 21% dry weight, the 28-day UCS was up to 500kPa and hydraulic conductivity was around 10-8m/s. With leachant pH extremes of 7.2 and 0.85, leachability of the contaminants was in the range: 0.02-3500mg/kg for Cd, 0.35-1550mg/kg for Cu, 0.03-92mg/kg for Pb, 0.01-3300mg/kg for Ni, 0.02-4010mg/kg for Zn, and 7-4884mg/kg for total petroleum hydrocarbons (TPHs), over time. Design charts were produced from the results of the study, which show the water and/or binder proportions that could be used to achieve relevant performance criteria. The charts would be useful for the scale-up and design of stabilisation/solidification (S/S) treatment of similar soil types impacted with the same types of contaminants. © 2013 Elsevier Ltd.

Probabilistic soil identification based on cone penetration tests

In geotechnical engineering, soil classification is an essential component in the design process. Field methods such as the cone penetration test (CPT) can be used as less expensive and faster alternatives to sample retrieval and testing. Unfortunately, current soil classification charts based on CPT data and laboratory measurements are too generic, and may not provide an accurate prediction of the soil type. A probabilistic approach is proposed here to update and modify soil identification charts based on site-specific CPT data. The probability that a soil is correctly classified is also estimated. The updated identification chart can be used for a more accurate prediction of the classification of the soil, and can account for prior information available before conducting the tests, site-specific data, and measurement errors. As an illustration, the proposed approach is implemented using CPT data from the Treporti Test Site (TTS) near Venice (Italy) and the National Geotechnical Experimentation Sites (NGES) at Texas A&M University. The applicability of the site-specific chart for other sites in Venice Lagoon is assessed using data from the Malamocco test site, approximately 20 km from TTS.

Stiffness of clays and silts: Normalizing shear modulus and shear strain

An analysis is presented of a database of 67 tests on 21 clays and silts of undrained shear stress-strain data of fine-grained soils. Normalizations of secant G in terms of initial mean effective stress p9 (i.e., G=p9 versus log g) or undrained shear strength cu (i.e., G=cu versus log g) are shown to be much less successful in reducing the scatter between different clays than the approach that uses the maximum shear modulus,Gmax, a technique still not universally adopted by geotechnical researchers and constitutive modelers. Analysis of semiempirical expressions forGmax is presented and a simple expression that uses only a void-ratio function and a confining-stress function is proposed. This is shown to be superior to a Hardin-style equation, and the void ratio function is demonstrated as an alternative to an overconsolidation ratio (OCR) function. To derive correlations that offer reliable estimates of secant stiffness at any required magnitude of working strain, secant shear modulus G is normalized with respect to its small-strain value Gmax, and shear strain g is normalized with respect to a reference strain gref at which this stiffness has halved. The data are corrected to two standard strain rates to reduce the discrepancy between data obtained from static and cyclic testing. The reference strain gref is approximated as a function of the plasticity index.Aunique normalized shear modulus reduction curve in the shape of a modified hyperbola is fitted to all the available data up to shear strains of the order of 1%. As a result, good estimates can be made of the modulus reduction G/Gmax ±30% across all strain levels in approximately 90% of the cases studied. New design charts are proposed to update the commonly used design curves. © 2013 American Society of Civil Engineers.

Dynamic models of piled foundations

The vibration behavior of piled foundations is an important consideration in fields such as earthquake engineering, construction, machine-foundation design, offshore structures, nuclear energy, and road and rail development. This paper presents a review of the past 40 years' literature on modeling the frequency-dependent behavior of pile foundations. Beginning with the earliest model of a single pile, adapted from those for embedded footings, it charts the development of the four pile-modeling techniques: the "dynamic Winkler-foundation" approach that uses springs to represent the effect of the soil; elasticcontinuum-type formulations involving the analytical solutions for displacements due to a subsurface disk, cylinder, or other element; boundary element methods; and dynamic finite-element formulations with special nonreflecting boundaries. The modeling of pile groups involves accounting for pile-soil-pile interactions, and four such methods exist: interaction factors; complete pile models; the equivalent pier method; and periodic structure theory. Approaches for validating pile models are also explored. Copyright © 2013 by ASME.

Stack ventilation in multi-storey atrium buildings: A dimensionless design approach

Using a simplified mathematical model, a preliminary design strategy for steady stack ventilation in multi-storey atrium buildings is developed. By non-dimensionalising the governing equations of flow, two key dimensionless parameters are identified - a ventilation performance indicator, λ, and atrium enhancement parameter, E - which quantify the performance of the ventilation system and the effectiveness of the atrium in assisting flows. Analytical expressions are determined to inform the vent sizes needed to provide the desired balance between indoor air temperature, ventilation flow rate and heat inputs for any distribution of occupants within the building, and also to ensure unidirectional flow. Dimensionless charts for determining the required combination of design variables are presented with a view to informing first-order design guidance for naturally ventilated buildings. © 2013 Elsevier Ltd.

Comparisons of operating envelopes for contaminated soil stabilised/solidified with different cementitious binders

This work initiated the development of operating envelopes for stabilised/solidified contaminated soils. The operating envelopes define the range of operating variables for acceptable performance of the treated soils. The study employed a soil spiked with 3,000 mg/kg each of Cd, Cu, Pb, Ni and Zn, and 10,000 mg/kg of diesel. The binders used for treatment involved Portland cement (CEMI), pulverised fuel ash (PFA), ground granulated blast furnace slag (GGBS) and hydrated lime (hlime). The specific binder formulations were CEMI, CEMI/PFA = 1:4, CEMI/GGBS = 1:9 and hlime/GGBS = 1:4. The water contents employed ranged from 13 % to 21 % (dry weight), while binder dosages ranged from 5 % to 20 % (w/w). We monitored the stabilised/solidified soils for up to 84 days using different performance tests. The tests include unconfined compressive strength (UCS), hydraulic conductivity, acid neutralisation capacity (ANC) and pH-dependent leachability of contaminants. The water content range resulted in adequate workability of the mixes but had no significant effect on leachability of contaminants. We produced design charts, representing operating envelopes, from the results generated. The charts establish relationships between water content, binder dosage and UCS; and binder dosage, leachant pH and leachability of contaminants. The work also highlights the strengths and weaknesses of the different binder formulations. © 2013 Springer-Verlag Berlin Heidelberg.

New approaches to materials education

A novel approach to the teaching of material to engineering students is outlined. It starts from the overview of the "world" of materials made possible by material property charts, and develops both an understanding of material properties and skills in selecting materials and processes to meet design specifications. It is supported by extensive computerbased methods and tools, and is well adapted both for elementary and for advanced courses. © 2003 by Granta Design Limited. Published by the American Institute of Aeronautics and Astronautics, Inc.