Characterisation of galvanneal coatings on strip steel

Galvanneal is a form of zinc-coated sheet steel, where steel is dipped in molten zinc, and then heat treated in a furnace to produce a complex iron-zinc coating. Many industries, such as automotive, use galvanneal for components fabricated from sheet steel. The microstructural properties of galvanneal have a significant influence on how well the sheet metal changes shape on stamping. By means of optical microscopy, scanning electron microscopy, and glow-discharge optical emission spectrometry, we present a study of the microstructure of several galvanneal samples, both stamped and unformed, relating the phases and morphology of the coatings to performance in stamping operations. Samples of galvanneal were subjected to different heat-treatment temperatures. The frequency of defects in stamped components was found to be related to the average alloy content in the coatings, which varied with furnace temperature. An increased average iron content in the coatings was related to increased powdering defects in stamping operations that use galvanneal coated sheet steel.

Net energy analysis of solar and conventional domestic hot water systems in Melbourne, Australia

It is commonly assumed that solar hot water systems save energy and reduce greenhouse gas emissions. The net energy requirement of solar hot water systems has rarely been analysed, including their embodied energy. The extent to which solar hot water systems save energy compared to conventional systems in Melbourne, Australia, is shown through a comparative net energy analysis. It was shown that the embodied energy component of the net energy requirement of solar and conventional hot water systems was insignificant. The solar hot water systems provided a net energy saving compared to the conventional systems after 0.5–2 years, for electric- and gas-boosted systems respectively.

Effect of thermomechanical parameters on the critical strain for ultrafine ferrite formation through hot torsion testing

A C–Mn–V steel was used to study ultrafine ferrite formation (1–3 μm) through dynamic strain-induced transformation (DSIT) using hot torsion experiments. A systematic study determined the critical strain for the start of DSIT (C,DSIT), although this may not lead to a fully ultrafine microstructure. Therefore, the strain to produce an ultrafine ferrite (UFF) as final microstructure (C,UFF) during deformation was also determined. In addition, the effect of thermomechanical parameters such as deformation temperature, prior austenite grain size, strain rate and cooling rate on C,DSIT and C,UFF has been evaluated. DSIT ferrite nucleated on prior austenite grain boundaries at an early stage of straining followed by intragranular nucleation at higher strains. The prior austenite grain size affected the distribution of DSIT ferrite nucleation sites at an early stage of transformation and the subsequent coarsening behaviour of the grain boundary and intragranular ferrite grains during post-deformation cooling. Also, C,DSIT and C,UFF increased with an increase in the prior austenite grain size and deformation temperature. The post-deformation cooling had a strong effect not only on C,UFF but also the UFF microstructure (i.e. final ferrite grain size and second phase characteristics).

The influence of twinning on the hot working flow stress and microstructural evolution of magnesium alloy AZ31

The microstructural evolution during compression (at 350°C and a strain rate of 0.01s-1) was examined for magnesium alloy AZ31 received in the "as-cast" condition. It was revealed that at low strains, many twins are produced and dynamically recrystallized (DRX) grains form as a necklace along pre-existing grain boundaries. At higher strains, DRX stagnates, most likely due to the accommodation of deformation in the DRX fraction of the material. It was also observed that twin boundaries act as sites for the nucleation of DRX grains. The analysis was repeated for samples pre-compressed to a strain of 0.15 at room temperature prior to the hot deformation step. The idea of these additional tests was to increase the degree of twinning and therefore the density of sites for the nucleation of DRX. It was found that statically recrystallized (SRX) grains developed at the twins during heating to the test temperature. When these samples were deformed, the peak flow stress was reduced by approximately 20% and the development of DRX was enhanced. This can be attributed to the accelerated nucleation of DRX in the refined SRX structure.

Mapping the hot deformation microstructure of Ni-30Fe alloy

The evolution of structure during the hot working of an austenitic Ni-30%Fe alloy is studied using EBSD analysis of samples tested in torsion. A microstructural map in temperature-strain space that plots grain size, cell size, fracture and dynamic recrystallization is presented.

Mill specific prediction of worsted yarn performance

Different spinning mills use different raw materials, processing methodologies, and equipment, all of which influence the quality of the yarns produced. Because of many variables, there is a difficulty in developing a universal empirical/theoretical model. This work presents a multilayer perceptron algorithm (MLP) model for the purpose of building a mill specific worsted spinning performance prediction tool. Sixteen inputs are used to predict key yarn properties and spinning performance, including number of fibers in cross-section, unevenness (U%), thin places, neps, yarn tenacity, elongation at break, thick places, and spinning ends-down. Validation of the model on mill specific commercial data set shows that the general fit to the target values is good. Importantly, the performance of the MLP shows a certain degree of stability to different, random selections of independent test data. Subsequent comparison against the predicted outputs of Sirolan Yarnspec™ confirms the overall performance of the artificial neural network (ANN) method to be more accuratefor mill specific predictions.

Net energy analysis of solar and conventional domestic hot water systems in Melbourne, Australia

It is commonly assumed that solar hot water systems save energy and reduce greenhouse gas emissions. Very rarely has the life-cycle energy requirements of solar hot water systems been analysed, including their embodied energy. The extent to which solar hot water systems save energy compared to conventional systems in Melbourne, Australia, is shown through a comparative net energy analysis. The solar systems provided a net energy saving compared to the conventional systems after 0.5 to 2 years, for electricity and gas systems respectively.