Friction Welding of Thixocast A356 Aluminium Alloy

In this paper, a numerical model for friction welding of thixo-cast materials is developed, which includes a coupling of thermal effect and plastic deformation using a finite element method (FEM). As the constitutive equations for flow behavior of materials for a thixo-cast material are expected to be different from those of conventionally cast material of the same alloy, the necessary material data are experimentally determined from isothermal hot compression tests of the A356 thixocast alloy. The Johnson-Cook model has been employed to represent the flow behavior of the thixocast A356 alloy. The purpose of this FEM analysis is to provide better understanding of the friction welding process of thixo-cast material, and to obtain optimized process parameters before an actual welding is carried out.

Rheological characterization of semi-solid A356 aluminium alloy

Rheological behavior of semi-solid slurries forms the backbone of semi-solid processing of metallic alloys. In particular, the effects of several process and metallurgical parameters such as shear rate, shear time, temperature, rest time and size, distribution and morphology of the primary phase on the viscosity of the slurry needs in-depth characterization. In the present work, rheological behaviour of the semisolid aluminium alloy (A356) slurry is investigated by using a high temperature Searle type Rheometer using concentric cylinders. Three different types of experiment are carried out: isothermal test, continuous cooling test and steady state test. Continuous decrease in viscosity is observed with increasing shear rate at a fixed temperature (isothermal test). It is also found that the viscosity increases with decreasing temperature for a particular shear rate due to increasing solid fraction (continuous cooling test). Thixotropic nature of the slurry is confirmed from the hysteresis loops obtained during experimentation. Time dependence of slurry viscosity has been evaluated from the steady state tests. After a longer shearing time under isothermal conditions the starting dendritic structure of the said alloy is transformed into globular grains due to abrasion, agglomeration, welding and ripening.

Studies on rheocasting using cooling slope

In the present work, a cooling channel is employed to produce semi-solid A356 alloy slurry. To understand the transport process involved, a 3D non-isothermal, multiphase volume averaging model has been developed for simulation of the semi-solid slurry generation process in the cooling channel. For simulation purpose, the three phases considered are the parent melt, the nearly spherical grains and air as separated but highly coupled interpenetrating continua. The conservation equations of mass, momentum, energy and species have been solved for each phase and the thermal and mechanical interactions (drag force) among the phases have been considered using appropriate model. The superheated liquid alloy is poured at the top of the cooling slope/channel, where specified velocity inlet boundary condition is used in the model, and allowed to flow along gravity through the channel. The melt loses its superheat and becomes semisolid up to the end of cooling channel due to the evolving -Al grains with decreasing temperature. The air phase forms a definable air/liquid melt interface, i.e. free surface, due its low density. The results obtained from the present model includes volume fractions of three different phases considered, grain evolution, grain growth rate, size and distribution of solid grains. The effect of key process variables such as pouring temperature, slope angle of the cooling channel and cooling channel wall temperature on temperature distribution, velocity distribution, grain formation and volume fraction of different phases are also studied. The results obtained from the simulations are validated by microstructure study using SEM and quantitative image analysis of the semi-solid slurry microstructure obtained from the experimental set-up.

Influence of anthropogenic contamination on groundwater chemistry in Mulbagal town, Kolar District, India

Geochemical studies are performed to examine the impact of leachate infiltration from on-site sewage disposal systems on the groundwater chemistry in Mulbagal town, Kolar District, Karnataka State, India. The leachate infiltration imposed nitrate concentrations ranging from 4 mg/L to 388 mg/L in the groundwater samples; it was observed that 79% of the samples exhibited nitrate concentrations in excess of drinking water permissible limit (45 mg/L). The average (of 43 measurements) E. coli levels in the groundwater samples corresponded to 189 MPN/100 mL and 55% of the samples tested exhibit pathogen contamination. Results also showed that the groundwater in the study area is characterized by acidic pH, large calcium + magnesium ion and Na/Cl ratios of < unity causing majority of the ground water samples to classify as Ca-Mg-Cl type and Na-Cl type. Saturation index (SI) computation using Visual MINTEQ program showed that the groundwater samples are under-saturated with respect to calcite. The theoretical SI values (of calcite) however suggested that the groundwater samples ought to be over-saturated with calcite. Under-saturation of the groundwater samples with calcite is attributed to increased dissolution of the mineral in the acidic environment of the groundwater.

Influence of anthropogenic contamination on fluoride concentration in groundwater: A study of Mulbagal town, Kolar district, Karnataka

Groundwater contamination is a serious concern in India. Major geogenic contaminants include fluoride, arsenic and iron, while common anthropogenic contaminants include nitrate, metals, organics and microbial contamination. Besides, known point and diffuse sources, groundwater c ontamination from inf iltration of pit to ilet leachate is an emerging concern. The study area of this paper is Kolar district in Karnataka that is hot spot of fluoride contamination. The absence of fluoride contamination in Mulbagal town and the alterations in groundwater chemistry from infiltration of pit toilet leachate motivated the author to examine the possible linkages between anthropogenic contamination and fluoride concentration in groundwater of Mulbagal town. Analysis of the groundwater chemistry revealed that the groundwater in Mulbagal town is under saturated with respect to calcite that suppresses the dissolution of fluorite and the fluoride concentration in the groundwater. The slightly acidic pH of the groundwater is considered responsible to facilitate calcite dissolution under saturation.