Parameter studies of fibre laser micro-welding of AISI 316L using Taguchi method

This paper discusses the application of the Taguchi experimental design approach in optimizing the key process parameters for micro-welding of thin AISI 316L foil using the 100W CW fibre laser. A L16 Taguchi experiment was conducted to systematically understand how the power, scanning velocity, focus position, gas flow rate and type of shielding gas affect the bead dimensions. The welds produced in the L16 Taguchi experiment was mainly of austenite cellular-dendrite structure with an average grain size of 5µm. An exact penetration weld with the largest penetration to fusion width ratio was obtained. Among those process parameters, the interaction between power and scanning velocity presented the strongest effect to the penetration to fusion width ratio and the power was found to be the predominantly important factor that drives the interaction with other factors to appreciably affect the bead dimensions.

Day-Ahead Optimal Charging/Discharging Scheduling for Electric Vehicles in Micro-Grids

A micro-grid is an autonomous system which can be operated and connected to an external system or isolated with the help of energy storage systems (ESSs). While the daily output of distributed generators (DGs) strongly depends on the temporal distribution of natural resources such as wind and solar, unregulated electric vehicle (EV) charging demand will deteriorate the imbalance between the daily load and generation curves. In this paper, a statistical model is presented to describe daily EV charging/discharging behaviour. An optimisation problem is proposed to obtain economic operation for the micro-grid based on this model. In day-ahead scheduling, with estimated information of power generation and load demand, optimal charging/discharging of EVs during 24 hours is obtained. A series of numerical optimization solutions in different scenarios is achieved by serial quadratic programming. The results show that optimal charging/discharging of EVs, a daily load curve can better track the generation curve and the network loss and required ESS capacity are both decreased. The paper also demonstrates cost benefits for EVs and operators.

Micro-mechanical analysis of bonding failure in a particle-filled composite

Composites with a weak interface between the filler and matrix which are susceptible to interfacial crack formation are studied. A finite-element model is developed to predict the stres/strain behavior of particulate composites with an interfacial crack. This condition can be distinguished as a partially bonded inclusion. Another case arises when there is no bonding between the inclusion and the matrix. In this latter case the slip boundary condition is imposed on the section of the interface which remains closed. The states of stress and displacement fields are obtained for both cases. The location of any further deformation through crazing or shear band formation is identified as the crack tip. A completely unbonded inclusion with partial slip at a section of the interface reduces the concentration of the stress at the crack tip. Whereas this might lead to slightly higher strength, it decreases the load-transfer efficiency and stiffness of this type of composite. © 2002 Elsevier Science Ltd. All rights reserved.

Design of a radio frequency heated isothermal micro-trickle bed reactor

A near-isothermal micro-trickle bed reactor operated under radio frequency heating was developed. The reactor bed was packed with nickel ferrite micro-particles of 110. μm diameter, generating heat by the application of RF field at 180. kHz. Hydrodynamics in a co-current configuration was analysed and heat transfer rates were determined at temperature ranging from 55 to 100. °C. A multi-zone reactor bed of several heating and catalytic zones was proposed in order to achieve near-isothermal operations. Exact positioning, number of the heating zones and length of the heating zones composed of a mixture of nickel ferrite and a catalyst were determined by solving a one dimensional model of heat transfer by conduction and convection. The conductive losses contributed up to 30% in the total thermal losses from the reactor. Three heating zones were required to obtain an isothermal length of 50. mm with a temperature non-uniformity of 2. K. A good agreement between the modelling and experimental results was obtained for temperature profiles of the reactor. © 2013 Elsevier B.V.

Study of localized damage in composite laminates using micro-macro approach

A robust multiscale scheme referred to as micro–macro method has been developed for the prediction of localized damage in fiber reinforced composites and implemented in a finite element framework. The micro–macro method is based on the idea of partial homogenization of a structure. In this method, the microstructural details are included in a small region of interest in the structure and the rest is modeled as a homogeneous continuum. The solution to the microstructural fields is then obtained on solving the two different domains, simultaneously. This method accurately predicts local stress fields in stress concentration regions and is computationally efficient as compared with the solution of a full scale microstructural model. This scheme has been applied to obtain localized damage at high and low stress zones of a V-notched rail shear specimen. The prominent damage mechanisms under shear loading, namely, matrix cracking and interfacial debonding, have been modeled using Mohr–Coulomb plasticity and traction separation law, respectively. The average stress at the notch has been found to be 44% higher than the average stresses away from the notch for a 90 N shear load. This stress rise is a direct outcome of the geometry of the notch.

Micro-abrasion mechanisms of cast CoCrMo in simulated body fluids

The abrasion seen on some of the retrieved CoCrMo hip joints has been reported to be caused by entrained hard particles in vivo. However, little work has been reported on the abrasion mechanisms of CoCrMo alloy in simulated body environments. Therefore. this study covers the mapping of micro-abrasion wear mechanisms of cast CoCrMo induced by third body hard particles under a wide range of abrasive test conditions. This study has a specific focus on covering the possible in vivo wear modes seen on metal-on-metal (MoM) surfaces. Nano-indentation and nano-scratch tests were also employed to further investigate the secondary wear mechanisms-nano-scale material deformation that involved in micro-abrasion processes. This work addresses the potential detrimental effects of third body hard particles in vivo such as increased wear rates (debris generation) and corrosion (metal-ion release). The abrasive wear mechanisms of cast CoCrMo have been investigated under various wear-corrosion conditions employing two abrasives, SiC (similar to 4 mu m) and Al(2)O(3) (similar to 1 mu m), in two test solutions, 0.9% NaCl and 25% bovine serum. The specific wear rates, wear mechanisms and transitions between mechanisms are discussed in terms of the abrasive size, volume fraction and the test solutions deployed. The work shows that at high abrasive volume fractions, the presence of protein enhanced the wear loss due to the enhanced particle entrainment, whereas at much lower abrasive volume fractions, protein reduced the wear loss by acting as a boundary lubricant or rolling elements which reduced the abrasivity (load per particle) of the abrasive particles. The abrasive wear rate and wear mechanisms of the CoCrMo are dependent on the nature of the third body abrasives, their entrainment into the contact and the presence of the proteins. (C) 2009 Elsevier B.V. All rights reserved.

Interpretation of electrochemical measurements made during micro-scale abrasion-corrosion

This paper brings together and analyzes recent work based on the interpretation of the electrochemical measurements made on a modified micro-abrasion-corrosion tester used in several research programmes. These programmes investigated the role of abradant size, test solution pH in abrasion-corrosion of biomaterials, the abrasion-corrosion performance of sintered and thermally sprayed tungsten carbide surfaces under downhole drilling environments and the abrasion-corrosion of UNS S32205 duplex stainless steel. Various abrasion tests were conducted under two-body grooving, three-body rolling and mixed grooving-rolling abrasion conditions, with and without abrasives, on cast F75 cobalt-chromium-molybdenum (CoCrMo) alloy in simulated body fluids, 2205 in chloride containing solutions as well as sprayed and sintered tungsten carbide surfaces in simulated downhole fluids. Pre- and post-test inspections based on optical and scanning electron microscopy analysis are used to help interpret the electrochemical response and current noise measurements made in situ during micro-abrasion-corrosion tests. The complex wear and corrosion mechanisms and their dependence on the microstructure and surface composition as a function of the pH, abrasive concentration, size and type are detailed and linked to the electrochemical signals. The electrochemical versus mechanical processes are plotted for different test parameters and this new approach is used to interpret tribo-corrosion test data to give greater insights into different tribo-corrosion systems. Thus new approaches to interpreting in-situ electrochemical responses to surfaces under different abrasive wear rates, different abrasives and liquid environments (pH and NaCl levels) are made. This representation is directly related to the mechano-electrochemical processes on the surface and avoids quantification of numerous synergistic, antagonistic and additive terms associated with repeat experiments. (C) 2010 Elsevier Ltd. All rights reserved.

Micro- and Nano-scale Tribo-Corrosion of Cast CoCrMo

Previous studies have established that some of the wear damage seen on cast CoCrMo joint surface is caused by entrained third-body hard particles. In this study, wet-cell micro-indentation and nano-scratch tests have been carried out with the direct aim of simulating wear damage induced by single abrasive particles entrained between the surfaces of cast CoCrMo hip implants. In situ electrochemical current noise measurements were uniquely performed to detect and study the wear-induced corrosion as well as the repassivation kinetics under the micro-/nano-scale tribological process. A mathematical model has been explored for the CoCrMo repassivation kinetics after surface oxide film rupture. Greater insights into the nature of the CoCrMo micro-/nano-scale wear-corrosion mechanisms and deformation processes are determined, including the identification of slip band formation, matrix/carbide deformation, nanocrystalline structure formation and strain-induced phase transformation. The electrochemical current noise provides evidence of instantaneous transient corrosion activity at the wearing surface resulting from partial oxide rupturing and stripping, concurrent with the indent/scratch.

Micro-abrasion-corrosion of cast CoCrMo-Effects of micron and sub-micron sized abrasives

The abrasion damage on retrieved CoCrMo based hip joints is reported to be influenced by the entrainment of micron and sub-micron sized debris/hard particles. This paper represents the first attempt to look into the effects of relatively soft abrasives with micron and sub-micron dimensions on the abrasion mechanisms and the abrasion-corrosion performance of the cast CoCrMo in simulated hip joint environments. A modified micro-abrasion tester incorporating a liquid tank and a three-electrode electrochemical cell was used. Al O (300 nm and 1 μm) and sub-micron sized BaSO abrasives were chosen as being comparable in the size and hardness to the wear particles found in vivo. Results show that the specific wear rates of cast CoCrMo are dependent on the abrasive particle size, hardness and volume concentration. Larger particle size, higher hardness and greater abrasive volume fractions gave greater wear rates. The wear-induced corrosion current generally increases with increasing wear rates, and the presence of proteins seems to suppress the wear-induced corrosion current especially when abrasive volume fractions were high. This study shows that the nature of abrasives and the test solutions are both important in determining the wear mechanisms and the abrasion-corrosion response of cast CoCrMo. These findings provide new and important insights into the in vivo wear mechanisms of CoCrMo. © 2009 Elsevier B.V. All rights reserved.

Evaluation of an in situ spatial resolution instrument for fixed beds through the assessment of the invasiveness of probes and a comparison with a micro-kinetic model

This paper reports the detailed description and validation of a fully automated, computer controlled analytical method to spatially probe the gas composition and thermal characteristics in packed bed systems. This method has been designed to limit the invasiveness of the probe, a characteristic assessed using CFD. The thermocouple is aligned with the sampling holes to enable simultaneous recording of the gas composition and temperature profiles. This analysis technique has been validated by studying CO oxidation over a 1% Pt/Al2O3 catalyst. The resultant profiles have been compared with a micro-kinetic model, to further assess the strength of the technique.