Nonaxisymmetric convection in stationary Gas Tungsten Arc Weld Pools

Observations of surface flow patterns of steel and aluminum GTAW pools have been made using a pulsed laser visualization system. The weld pool convection is found to be three-dimensional with the azimuthal circulation depending on the location of the clamp with respect to the torch. Oscillation of steel pools and undulating motion in aluminum weld pools are also observed even with steady process parameters. Current axisymmetric numerical models are unable to explain such phenomena. A three-dimensional computational study is carried out in this study to explain the rotational flow in aluminum weld pools.

Steady state three-dimensional mathematical model for cupola

A three-dimensional mathematical model has been developed to simulate the gas flow, composition, and temperature profiles inside a cupola. Comparison of the model with the reported experimental data shows the presence of a zone with low combustion rate at the tuyere level. For a 24 in (610 mm) cupola with four rows of tuyeres, the combustion zones from each tuyere overlap each other, forming an overall combustion zone of cylindrical shape of height similar to 0.2 m. Using the model, it is found that the spout temperature initially increases with increasing blast velocity and attains a maximum. Further increase in blast velocity does not change the spout temperature. This suggests that smaller size tuyeres and higher permeability of the bed can give superior cupola performance. (C) 1997 The Institute of Materials.

Low-power pipelined LMS adaptive filter architectures with minimal adaptation delay

The use of delayed coefficient adaptation in the least mean square (LMS) algorithm has enabled the design of pipelined architectures for real-time transversal adaptive filtering. However, the convergence speed of this delayed LMS (DLMS) algorithm, when compared with that of the standard LMS algorithm, is degraded and worsens with increase in the adaptation delay. Existing pipelined DLMS architectures have large adaptation delay and hence degraded convergence speed. We in this paper, first present a pipelined DLMS architecture with minimal adaptation delay for any given sampling rate. The architecture is synthesized by using a number of function preserving transformations on the signal flow graph representation of the DLMS algorithm. With the use of carry-save arithmetic, the pipelined architecture can support high sampling rates, limited only by the delay of a full adder and a 2-to-1 multiplexer. In the second part of this paper, we extend the synthesis methodology described in the first part, to synthesize pipelined DLMS architectures whose power dissipation meets a specified budget. This low-power architecture exploits the parallelism in the DLMS algorithm to meet the required computational throughput. The architecture exhibits a novel tradeoff between algorithmic performance (convergence speed) and power dissipation. (C) 1999 Elsevier Science B.V. All rights resented.

Tensile flow behaviour of 2.25Cr-1Mo ferritic steel base metal and simulated heat affected zone structures of 2.25Cr-1Mo weld joint

Tensile tests in the temperature range 298 to 873 K have been performed on 2.25Cr-1Mo base metal and simulated heat affected zone (HAZ) structures of its weld joint, namely coarse grain bainite, fine grain bainite and intercritical structure. Tensile flow behaviour of all the microstructural conditions could be adequately described by the Hollomon equation (sigma = K-1 epsilon(n1)) at higher (> 623 K) temperatures. Deviation from the Hollomon equation was observed at low strains and lower (< 623 K) temperatures. The Ludwigson modification of Hollomon's equation, sigma = K-1 epsilon(n1) + exp (K-2 + n(2) epsilon), was found to describe the flow curve. In general, the flow parameters n(1), K-1, n(2) and K-2 were found to decrease with increase in temperature except in the intermediate temperature range (423 to 623 K). Peaks/plateaus were observed in their variation with temperature in the intermediate temperature range coinciding with the occurrence of serrated flow in the load-elongation curve. The n(1) Value increased and the K-1 value decreased with the type of microstructure in the order: coarse grain bainite, fine grain bainite, base metal and intercritical structure. The variation of nl with microstructure has been rationalized on the basis of mean free path (MFP) of dislocations which is directly related to the inter-particle spacing. Larger MFP of dislocations lead to higher strain hardening exponents n(1).

The 2D Coulomb gas on a 1D lattice

The statistical mechanics of a two-dimensional Coulomb gas confined to one dimension is studied, wherein hard core particles move on a ring. Exact self-duality is shown for a version of the sine-Gordon model arising in this context, thereby locating the transition temperature exactly. We present asymptotically exact results for the correlations in the model and characterize the low- and high-temperature phases. Numerical simulations provide support to these renormalization group calculations. Connections with other interesting problems, such as the quantum Brownian motion of a panicle in a periodic potential and impurity problems, are pointed out.

The effect of boundaries on the plane Couette flow of granular materials: a bifurcation analysis

The tendency of granular materials in rapid shear flow to form non-uniform structures is well documented in the literature. Through a linear stability analysis of the solution of continuum equations for rapid shear flow of a uniform granular material, performed by Savage (1992) and others subsequently, it has been shown that an infinite plane shearing motion may be unstable in the Lyapunov sense, provided the mean volume fraction of particles is above a critical value. This instability leads to the formation of alternating layers of high and low particle concentrations oriented parallel to the plane of shear. Computer simulations, on the other hand, reveal that non-uniform structures are possible even when the mean volume fraction of particles is small. In the present study, we have examined the structure of fully developed layered solutions, by making use of numerical continuation techniques and bifurcation theory. It is shown that the continuum equations do predict the existence of layered solutions of high amplitude even when the uniform state is linearly stable. An analysis of the effect of bounding walls on the bifurcation structure reveals that the nature of the wall boundary conditions plays a pivotal role in selecting that branch of non-uniform solutions which emerges as the primary branch. This demonstrates unequivocally that the results on the stability of bounded shear how of granular materials presented previously by Wang et al. (1996) are, in general, based on erroneous base states.

Bubble size measurement in a gas-liquid ejector for a sodium chloride-air system

A high speed photographic technique has been employed to measure the Sauter mean diameter of bubbles experimentally in a gas liquid ejector using a sodium chloride-air system. The measured values are compared with the theoretically predicted maximum bubble size diameter using Sprow's correlation. Bubble size as a function of the liquid flow rate and also of its distance from the throat of the ejector has been reported in this paper. The results obtained for this non-reactive system are also compared with those obtained earlier for the air-water system.

Low-pressure MOCVD of Al2O3 films using aluminium acetylacetonate as precursor: nucleation and growth

A study of the deposition of aluminium oxide films by low-pressure metalorganic chemical vapour deposition from the complex aluminium acetylacetonate, in the absence of an oxidant gas, has been carried out. Depositions on to Si(100), stainless steel, and TiN-coated cemented carbide are found to be smooth, shiny, and blackish. SIMS, XPS and TEM analyses reveal that films deposited at temperatures as low as 600 degreesC contain small crystallites Of kappa-Al2O3, embedded in an amorphous matrix rich in graphitic carbon. Optical and scanning electron microscopy reveal a surface morphology made up of spherulites that suggests that film growth might involve a melting process. A nucleation and growth mechanism, involving the congruent melting clusters of precursor molecules on the hot substrate surface, is therefore invoked to explain these observations. An effort has been made experimentally to verify this proposed mechanism. (C) 2002 Elsevier Science B.V. All rights reserved.

Noise and outlier removal from jet engine health signals using weighted FIR median hybrid filters

The removal of noise and outliers from measurement signals is a major problem in jet engine health monitoring. Topical measurement signals found in most jet engines include low rotor speed, high rotor speed. fuel flow and exhaust gas temperature. Deviations in these measurements from a baseline 'good' engine are often called measurement deltas and the health signals used for fault detection, isolation, trending and data mining. Linear filters such as the FIR moving average filter and IIR exponential average filter are used in the industry to remove noise and outliers from the jet engine measurement deltas. However, the use of linear filters can lead to loss of critical features in the signal that can contain information about maintenance and repair events that could be used by fault isolation algorithms to determine engine condition or by data mining algorithms to learn valuable patterns in the data, Non-linear filters such as the median and weighted median hybrid filters offer the opportunity to remove noise and gross outliers from signals while preserving features. In this study. a comparison of traditional linear filters popular in the jet engine industry is made with the median filter and the subfilter weighted FIR median hybrid (SWFMH) filter. Results using simulated data with implanted faults shows that the SWFMH filter results in a noise reduction of over 60 per cent compared to only 20 per cent for FIR filters and 30 per cent for IIR filters. Preprocessing jet engine health signals using the SWFMH filter would greatly improve the accuracy of diagnostic systems. (C) 2002 Published by Elsevier Science Ltd.

Studies on a new high-intensity low-emission burner

This paper presents computational and experimental results on a new burner configuration with a mild combustion concept with heat release rates up to 10 MW/m(3). The burner configuration is shown to achieve mild combustion by using air at ambient temperature at high recirculation rates (similar to250%-290%) both experimentally and computationally. The principal features of the configuration are: (1) a burner with forward exit for exhaust gases; (2) injection of gaseous fuel and air as multiple, alternate, peripheral highspeed jets at the bottom at ambient temperature, thus creating high enough recirculation rates of the hot combustion products into fresh incoming reactants; and (3) use of a suitable geometric artifice-a frustum of a cone to help recirculation. The computational studies have been used to reveal the details of the flow and to optimize the combustor geometry based on recirculation rates. Measures, involving root mean square temperature fluctuations, distribution of temperature and oxidizer concentration inside the proposed burner, and a classical turbulent diffusion jet flame, are used to distinguish between them quantitatively. The system, operated at heat release rates of 2 to 10 MW/m(3) (compared to 0.02 to 0.32 MW/m(3) in the earlier studies), shows a 10-15 dB reduction in noise in the mild combustion mode compared to a simple open-top burner and exhaust NOx emission below 10 ppm for a 3 kW burner with 10% excess air. The peak temperature is measured around 1750 K, approximately 300 K lower than the peak temperature in a conventional burner.

Influence of temperature and strain rate on the flow stress of an FeAl alloy

The deformation behavior of an FeAl alloy processed by hot extrusion of water atomized powder has been investigated. Compression tests are performed in the temperature range 1073–1423 K and in the strain rate range 0.001–100 s−1 up to a true plastic strain of 0.5. The flow stress has been found to be strongly dependent on temperature as well as strain rate. The stress exponent in the power law rate equation is estimated to be in the range 7.0–4.0, decreasing with temperature. The activation energy for plastic flow in the range 1073–1373 K varies from 430 kJ mol−1 at low stresses to 340 kJ mol−1 at high stresses. However, it is fairly independent of strain rate and strain. The activation area has similarly shown a stress dependence and lies in the range 160–45b2. At 1423 K and at strain rates lower than 0.1 s−1 a strain rate sensitivity of 0.3 is observed with an associated activation energy of 375 kJ mol−1. The plastic flow in the entire range of temperature and strain rate investigated appears to be controlled by a diffusion mechanism. The results have revealed that it is possible to process the alloy by superplastic forming in the range 1373–1423 K at strain rates lower than 0.1 s−1.

A dynamical instability due to fluid–wall coupling lowers the transition Reynolds number in the flow through a flexible tube

A flow-induced instability in a tube with flexible walls is studied experimentally. Tubes of diameter 0.8 and 1.2 mm are cast in polydimethylsiloxane (PDMS) polymer gels, and the catalyst concentration in these gels is varied to obtain shear modulus in the range 17–550 kPa. A pressure drop between the inlet and outlet of the tube is used to drive fluid flow, and the friction factor $f$ is measured as a function of the Reynolds number $Re$. From these measurements, it is found that the laminar flow becomes unstable, and there is a transition to a more complicated flow profile, for Reynolds numbers as low as 500 for the softest gels used here. The nature of the $f$–$Re$ curves is also qualitatively different from that in the flow past rigid tubes; in contrast to the discontinuous increase in the friction factor at transition in a rigid tube, it is found that there is a continuous increase in the friction factor from the laminar value of $16\ensuremath{/} Re$ in a flexible tube. The onset of transition is also detected by a dye-stream method, where a stream of dye is injected into the centre of the tube. It is found that there is a continuous increase of the amplitude of perturbations at the onset of transition in a flexible tube, in contrast to the abrupt disruption of the dye stream at transition in a rigid tube. There are oscillations in the wall of the tube at the onset of transition, which is detected from the laser scattering off the walls of the tube. This indicates that the coupling between the fluid stresses and the elastic stresses in the wall results in an instability of the laminar flow.

Epitaxial Growth of Co3O4 Films by Low Temperature, Low Pressure Chemical Vapor Deposition

The growth of strongly oriented or epitaxial thin films of metal oxides generally requires relatively high growth temperatures or infusion of energy to the growth surface through means such as ion bombardment. We have grown high quality epitaxial thin films of Co3O4 on different substrates at a temperature as low as 450°C by low-pressure metal-organic chemical vapor deposition (MOCVD) using cobalt(II) acetylacetonate as the precursor. With oxygen as the reactant gas, polycrystalline Co3O4 films are formed on glass and Si(100) in the temperature range 350-550°C. Under similar conditions of growth, highly oriented films of Co3O4 are formed on SrTiO3(100) and LaAlO3(100). The film on LaAlO3(100) grown at 450°C show a rocking curve FWHM of 1.61°, which reduces to 1.32° when it is annealed in oxygen at 725°C. The film on SrTiO3(100) has a FWHM of 0.330 (as deposited) and 0.29° (after annealing at 725°C). The ø-scan analysis shows cube-on-cube epitaxy on both these substrates. The quality of epitaxy on SrTiO3(100) is comparable to the best of the pervoskite-based oxide thin films grown at significantly higher temperatures.

The effect of boundaries on the plane Couette flow of granular materials: a bifurcation analysis

The tendency of granular materials in rapid shear ow to form non-uniform structures is well documented in the literature. Through a linear stability analysis of the solution of continuum equations for rapid shear flow of a uniform granular material, performed by Savage (1992) and others subsequently, it has been shown that an infinite plane shearing motion may be unstable in the Lyapunov sense, provided the mean volume fraction of particles is above a critical value. This instability leads to the formation of alternating layers of high and low particle concentrations oriented parallel to the plane of shear. Computer simulations, on the other hand, reveal that non-uniform structures are possible even when the mean volume fraction of particles is small. In the present study, we have examined the structure of fully developed layered solutions, by making use of numerical continuation techniques and bifurcation theory. It is shown that the continuum equations do predict the existence of layered solutions of high amplitude even when the uniform state is linearly stable. An analysis of the effect of bounding walls on the bifurcation structure reveals that the nature of the wall boundary conditions plays a pivotal role in selecting that branch of non-uniform solutions which emerges as the primary branch. This demonstrates unequivocally that the results on the stability of bounded shear flow of granular materials presented previously by Wang et al. (1996) are, in general, based on erroneous base states.

Study of gas-fines in decreasing gas velocity in a packed bed

It has been well recognized now that the blast furnace aerodynamics can be represented more accurately under the decreasing gas velocity condition. Therefore, gas-fines study has been carried out in a packed bed under the decreasing gas velocity condition. Gas and fines flow equations have been developed and solved, for two-dimensional case using finite volume method. To take into account the turbulence, k-e turbulent flow model has also been developed in two-dimension. The model's predictions have been validated against the published experimental data for the increasing gas velocity case, as no experimental data are available in open literature for the decreasing gas velocity. This study shows the difference in the results for increasing and decreasing gas velocity cases under various conditions which have been reported here. Implication of the results to the blast furnace condition has also been discussed.