Modelling interacting phenomena during the solidification of metals in the casting process

A variety of interacting complex phenomena takes place during the casting of metallic components. Here molten metal is poured into a mould cavity where it flows, cools, solidifies and then deforms in its solid state. As the metal cools, thermal gradients will promote thermal convection which will redistribute the heat around the component (usually from feeders or risers) towards the solidification front and mushy zone. Also, as the evolving solid regions of the cast component deform they will form gap at the cast-mould interface. This gap may change the rate of solidification in certain parts the casting, hence affecting the manner in which the cast component solidifies. Interaction between a cast component and its surrounding mould will also govern stress magnitudes in both the cast and mould -these may lead to defects such as cracks. This paper presents a multiphysics modelling approach to this complex process. Emphasis will be placed on the interacting phenomena taking place during the process and the modelling strategy used. Comparisons with plant data are also be given.

Melhoria do processo de armazenagem do armazém de matérias-primas e de embalagem da Nestlé Portugal

O presente relatório de projeto de tese aborda o estudo da temática da gestão de armazéns, bem como o estudo de ferramentas de melhoria contínua. Nele, é apresentado um caso de estudo realizado na Nestlé Portugal – Fábrica de Avanca. Numa fase introdutória e preparatória ao projeto, foi realizado um trabalho de pesquisa e compreensão de conhecimentos base para definir quais os objetivos a alcançar e pontos de melhoria. Esta base serviu de pilar de conhecimento para o desenvolvimento do caso de estudo. O caso de estudo consistiu em analisar o sistema de armazenagem, tendo-se para isso simulado o desempenho atual do armazém de modo a otimizar os espaços de armazenagem. Para além disso, avaliou-se o layout do armazém em função da rotatividade dos materiais com recurso à análise ABC e ao estudo de tempos. As oportunidades de melhoria ao nível dos processos de armazenagem refletem-se no sistema de armazenagem em que o ideal seria uma reestruturação ao nível do sistema de armazenagem (estantes com racks convencionais) e ao nível do layout do armazém (segundo a classificação ABC).

Studies of turbulent flows in continuous casting of steel with and without magnetic field

This thesis develops and tests various transient and steady-state computational models such as direct numerical simulation (DNS), large eddy simulation (LES), filtered unsteady Reynolds-averaged Navier-Stokes (URANS) and steady Reynolds-averaged Navier-Stokes (RANS) with and without magnetic field to investigate turbulent flows in canonical as well as in the nozzle and mold geometries of the continuous casting process. The direct numerical simulations are first performed in channel, square and 2:1 aspect rectangular ducts to investigate the effect of magnetic field on turbulent flows. The rectangular duct is a more practical geometry for continuous casting nozzle and mold and has the option of applying magnetic field either perpendicular to broader side or shorter side. This work forms the part of a graphic processing unit (GPU) based CFD code (CU-FLOW) development for magnetohydrodynamic (MHD) turbulent flows. The DNS results revealed interesting effects of the magnetic field and its orientation on primary, secondary flows (instantaneous and mean), Reynolds stresses, turbulent kinetic energy (TKE) budgets, momentum budgets and frictional losses, besides providing DNS database for two-wall bounded square and rectangular duct MHD turbulent flows. Further, the low- and high-Reynolds number RANS models (k-ε and Reynolds stress models) are developed and tested with DNS databases for channel and square duct flows with and without magnetic field. The MHD sink terms in k- and ε-equations are implemented as proposed by Kenjereš and Hanjalić using a user defined function (UDF) in FLUENT. This work revealed varying accuracies of different RANS models at different levels. This work is useful for industry to understand the accuracies of these models, including continuous casting. After realizing the accuracy and computational cost of RANS models, the steady-state k-ε model is then combined with the particle image velocimetry (PIV) and impeller probe velocity measurements in a 1/3rd scale water model to study the flow quality coming out of the well- and mountain-bottom nozzles and the effect of stopper-rod misalignment on fluid flow. The mountain-bottom nozzle was found more prone to the longtime asymmetries and higher surface velocities. The left misalignment of stopper gave higher surface velocity on the right leading to significantly large number of vortices forming behind the nozzle on the left. Later, the transient and steady-state models such as LES, filtered URANS and steady RANS models are combined with ultrasonic Doppler velocimetry (UDV) measurements in a GaInSn model of typical continuous casting process. LES-CU-LOW is the fastest and the most accurate model owing to much finer mesh and a smaller timestep. This work provided a good understanding on the performance of these models. The behavior of instantaneous flows, Reynolds stresses and proper orthogonal decomposition (POD) analysis quantified the nozzle bottom swirl and its importance on the turbulent flow in the mold. Afterwards, the aforementioned work in GaInSn model is extended with electromagnetic braking (EMBr) to help optimize a ruler-type brake and its location for the continuous casting process. The magnetic field suppressed turbulence and promoted vortical structures with their axis aligned with the magnetic field suggesting tendency towards 2-d turbulence. The stronger magnetic field at the nozzle well and around the jet region created large scale and lower frequency flow behavior by suppressing nozzle bottom swirl and its front-back alternation. Based on this work, it is advised to avoid stronger magnetic field around jet and nozzle bottom to get more stable and less defect prone flow.

Utilização de resíduos de catalisador (ECAT) e cinzas da casca de arroz (CCA) na elaboração de vidros silicatos soda-cal destinados a embalagem

Dissertação (Mestrado em Tecnologia Nuclear)

Casa de embalagem de placas planas recicladas e tetra pak®: alternativa econômica e viável para a produção integrada de morango.

De acordo com Brasil (1997a, 1997b), as áreas de manipulação de alimento, como as Casas de embalagens de morango, devem atender a uma série de critérios. Os pisos devem ser de material resistente ao trânsito, impermeáveis, laváveis, antiderrapantes, não possuírem frestas e serem fáceis de limpar ou desinfetar. As superfícieis devem ser de material de fácil higienização. Atualmente, na região produtora de morango de Atibaia e Jarinu (SP), grande parte das Casas de embalagem convencionais são precárias, feitas somente de uma estrutura de madeira sem revestimento, coberta por folhas de Tetra Pak® e chão de terra-batida. Essas Casas não oferecem as condições mínimas de higiene previstas pelas Portarias mencionadas nem nas Normas Técnicas Específicas da Produção Integrada de Morango - NTE-PIMo (BRASIL, 2008), que estão sendo adotadas por um grupo de produtores da região. Devido ao fato do chão não ser lavável e as madeiras não receberem tratamento, as construções inadequadas podem se transformar em locais de propagação de patógenos, colocando em risco a segurança do morango embalado. No entanto, a falta de recursos financeiros dos pequenos produtores limita a compra de materiais ideais e de alto custo (aço inoxidável, por exemplo), a serem utilizados na construção. O objetivo deste trabalho é apresentar uma proposta de construção de uma Casa de embalagem simples, economicamente viável e que atenda minimamente às normas e portarias mencionadas, usando materiais de baixo custo e disponíveis na região.

Tratamentos de fibras de carnaúba [copernicia prunífera (miller) h. e. moore] para o desenvolvimento de compósito biodegradável com matriz de polihidroxibutirato

The use of raw materials from renewable sources for production of materials has been the subject of several studies and researches, because of its potential to substitute petrochemical-based materials. The addition of natural fibers to polymers represents an alternative in the partial or total replacement of glass fibers in composites. In this work, carnauba leaf fibers were used in the production of biodegradable composites with polyhydroxybutyrate (PHB) matrix. To improve the interfacial properties fiber / matrix were studied four chemical treatments to the fibers..The effect of the different chemical treatments on the morphological, physical, chemical and mechanical properties of the fibers and composites were investigated by scanning electron microscopy (SEM), infrared spectroscopy, X-ray diffraction, tensile and flexural tests, dynamic mechanical analysis (DMA), thermogravimetry (TGA) and diferential scanning calorimetry (DSC). The results of tensile tests indicated an increase in tensile strength of the composites after the chemical treatment of the fibers, with best results for the hydrogen peroxide treated fibers, even though the tensile strength of fibers was slightly reduced. This suggests a better interaction fiber/matrix which was also observed by SEM fractographs. The glass transition temperature (Tg) was reduced for all composites compared to the pure polymer which can be attributed to the absorption of solvents, moisture and other low molecular weight molecules by the fibers

Efeito da embalagem, periodo e local de armazenamento na qualidade de sementes do sorgo.

Sementes de sorgo (Sorghum bicolor (L.) Moench) cv. EA-955 foram condicionadas em latas de metal vedadas, sacos de pano e de polipropileno e armazenadas sob condicoes naturais, em quatro localidades do Estado do Ceara: Fortaleza, Quixada, Morada Nova e Ubajara, com o objetivo de determinar a influencia da embalagem do local e do periodo de armazenamento sobre a qua qualidade fisiologica. Mensalmente, foi determinado o teor de umidade das smentes, e a cada dois meses a qualidade das sementes era avaliada por meio de testes de germinacao, vigor (comprimento da raiz) e peso seco de plantulas. Utilizou-se um delineamento no esquema fatorial, no qual os fatores eram cinco periodos de armazenamento (0, 2, 4, 6 e 8 meses) e tres tipos de embalagem (lata, pano, polipropileno), com quatro repeticoes. Durante o periodo de armazenamento, observou-se ser a lata de metal a embalagem que melhor preserva a qualidade das sementes. No que se refere aos locais, constatou-se que as smentes armazenadas um Ubajara mostraram melhor qualidade do que as sementes estocadas nas outras localidades.

Implementação e qualificação de uma área de embalagem de formas farmacêuticas sólidas

Poster apresentado no Congresso Nacional dos Farmacêuticos’2015. Centro de Congressos de Lisboa, 29-31 Outubro 2015

Il ruolo del casting nella riabilitazione del soggetto neurologico: una scoping review

Background:i soggetti con esiti di una lesione del SNC sono caratterizzati da un quadro clinico comprensivo di segni negativi e segni positivi come la spasticità e possono andare incontro a molteplici problematiche,come le contracture,che limitano il recupero motorio del paziente favorendo l’immobilità e l’aumento della spasticità,contribuendo alla persistenza della condizione stessa.Il casting si inserisce in questo contesto come trattamento conservativo sui fattori non neurali delle contracture e della spasticità e sembra portare beneficio anche ad alcuni meccanismi neurali della spasticità.Obiettivo:l’obiettivo di questa Scoping review è una mappatura della letteratura esistente sul ruolo del casting all’interno della riabilitazione dei soggetti neurologici,fornendo una descrizione dei protocolli nei vari studi e identificando evidenze e lacune per aiutare la ricerca futura.Metodi:sono state interrogate le banche dati PEDro,PubMed,Cochrane Library ponendo come limiti la lingua inglese,italiana e l’età dei partecipanti maggiore di 19 aa.Gli articoli ottenuti sono stati selezionati con i criteri di eleggibilità e sono stati inclusi SR,RCT,case report,case series e studi osservazionali.Risultati:la Review ha incluso 10 fonti di evidenza.Gli articoli fanno riferimento a diversi tipi di interventi di casting:unito alla tossina botulinica,allo splinting, allo stretching,al motor training o da solo.Conclusioni:dall’analisi delle fonti di evidenza emerge il potenziale degli interventi di casting in un contesto multidisciplinare.Si evidenzia la necessità di condurre ulteriori studi che descrivano i particolari del trattamento riabilitativo con casting,che si concentrino su una selezione di outcome e di scale di valutazione in linea con l'ICF e che approfondiscano il contributo del casting alla riabilitazione del soggetto neurologico,per guidare i clinici e i fisioterapisti nella scelta ed erogazione di tale intervento e fornire prove di efficacia ulteriori a suo supporto.

Silk Fibroin And Sodium Alginate Blend: Miscibility And Physical Characteristics.

Films of silk fibroin (SF) and sodium alginate (SA) blends were prepared by solution casting technique. The miscibility of SF and SA in those blends was evaluated and scanning electron microscopy (SEM) revealed that SF/SA 25/75 wt.% blends underwent microscopic phase separation, resulting in globular structures composed mainly of SF. X-ray diffraction indicated the amorphous nature of these blends, even after a treatment with ethanol that turned them insoluble in water. Thermal analyses of blends showed the peaks of degradation of pristine SF and SA shifted to intermediate temperatures. Water vapor permeability, swelling capacity and tensile strength of SF films could be enhanced by blending with SA. Cell viability remained between 90 and 100%, as indicated by in vitro cytotoxicity test. The SF/SA blend with self-assembled SF globules can be used to modulate structural and mechanical properties of the final material and may be used in designing high performance wound dressing.

Nitric Oxide-releasing Poly(vinyl Alcohol) Film For Increasing Dermal Vasodilation.

Pathological conditions associated with the impairment of nitric oxide (NO) production in the vasculature, such as Raynaud's syndrome and diabetic angiopathy, have stimulated the development of new biomaterials capable of delivering NO topically. With this purpose, we modified poly(vinyl-alcohol) (PVA) by chemically crosslinking it via esterification with mercaptosuccinic acid. This reaction allowed the casting of sulfhydrylated PVA (PVA-SH) films. Differential scanning calorimetry and X-ray diffractometry showed that the crosslinking reaction completely suppressed the crystallization of PVA, leading to a non-porous film with a homogeneous distribution of -SH groups. The remaining free hydroxyl groups in the PVA-SH network conferred partial hydrophylicity to the material, which was responsible for a swelling degree of ca. 110%. The PVA-SH films were subjected to an S-nitrosation reaction of the -SH groups, yielding a PVA containing S-nitrosothiol groups (PVA-SNO). Amperometric and chemiluminescence measurements showed that the PVA-SNO films were capable of releasing NO spontaneously after immersion in physiological medium. Laser Doppler-flowmetry, used to assess the blood flow in the dermal microcirculation, showed that the topical application of hydrated PVA-SNO films on the health skin led to a dose- and time-dependent increase of more than 5-fold in the dermal baseline blood flow in less than 10min, with a prolonged action of more than 4h during continuous application. These results show that PVA-SNO films might emerge as a new material with potential for the topical treatment of microvascular skin disorders.

Caracterização físico-química de filmes comestíveis de amido adicionado de acerola (Malphigia emarginata D.C.)

Edibles films are an alternative to synthetic materials used for packing food products. Barbados cherry is rich in vitamin C and carotenoids. The aim of this study was to characterize and develop films by casting from cassava starch, lyophilized Barbados cherry pulp and glycerol. The films were characterized with respect to thickness, water vapor permeability (WVP), water solubility, vitamin C, carotene and mechanical properties. The interaction of pulp and glycerol reduced film thickness. An increase in pulp concentration up to 60% increased WVP but beyond this concentration reduced both WVP and solubility leading to an increased level of vitamin C and β carotene in the films.

Rigidez do papelão ondulado: comparação entre resultados experimentais e os obtidos por cálculo analítico

Cardboard packing for horticultural products has as main function to protect them. The design of a cardboard packing request the knowledge of the bending stiffens which is depending on the modulus of elasticity. The objective of this work was to calculate the cardboard modulus of elasticity from data obtained in laboratory using physical characterization test, with different methods, and comparing the results with the values obtained experimentally. Ten samples of each cardboard selected for this study were tested in the paper fabrication direction and in its transverse direction. The papers liner and medium resistance to the traction, used to calculate the bending stiffness, was determined in a universal machine test. To obtaining of the bending stiffens the four points test was accomplished. Expressive variations among the methods from which the modulus of elasticity is obtained were observed and that influence the bending stiffness of the structure. The stiffness values obtained experimentally were always greater than the values obtained from analytical method. This difference can be attributed to two factors, the production processes that assurance a larger rigidity than the components separately and the addition of the adhesive layer that is not taken in consideration in the analytic calculations.

Caracterização sensorial de amêndoas de castanha-de-caju fritas e salgadas

Shelled, roasted and salted cashew nut kernels were packaged in three different flexible materials (PP/PE= polypropylene / polyethylene; PETmet/PE= metallized polyethylene terephthalate / polyethylene; PET/Al/LDPE= polyethylene terephthalate / aluminum foil / low density polyethylene ), with different barrier properties. Kernels were stored for one year at 30° C and 80% relative humidity. Quantitative descriptive sensory analysis (QDA) were performed at the end of storage time. Descriptive terms obtained for kernels characterization were brown color, color uniformity and rugosity for appearance; toasted kernel, sweet, old and rancidity for odor; toasted kernel, sweet, old rancidity, salt and bitter for taste, crispness for texture. QDA showed that factors responsible for sensory quality decrease, after one year storage, were increase in old aroma and taste, increase in rancidity aroma and taste, decrease in roasted kernel aroma and taste, and decrease of crispness. Sensory quality decrease was higher in kernels packaged in PP/PE.

Effect of phosphate-bonded investments on titanium reaction layer and crown fit

This study analyzed the reaction layer and measured the marginal crown fit of cast titanium applied to different phosphate-bonded investments, prepared under the following conditions (liquid concentration/casting temperature): Rema Exakt (RE) - 100%/237°C, 75%/287°C, Castorit Super C (CS)-100%/70°C, 75%/141°C and Rematitan Plus (RP)- 100%/430°C (special to titanium cast, as the control group). The reaction layer was studied using the Vickers hardness test, and analyzed by two way ANOVA and Tukey's HSD tests (α = 0.05). Digital photographs were taken of the crowns seated on the die, the misfit was measured using an image analysis system and One-way ANOVA, and Tukey's test was applied (α = 0.05). The hardness decreased from the surface (601.17 VHN) to 150 μm (204.03 VHN). The group CS 75%/141°C presented higher hardness than the other groups, revealing higher surface contamination, but there were no differences among the groups at measurements deeper than 150 μm. The castings made with CS - 100%/70°C presented the lowest levels of marginal misfit, followed by RE -100%/237°C. The conventional investments CS (100%) and RE (100%) showed better marginal fit than RP, but the CS (75%) had higher surface contamination.