INVESTIGATION INTO CURRENT EFFICIENCY FOR PULSE ELECTROCHEMICAL MACHINING OF NICKEL ALLOY

INVESTIGATION INTO CURRENT EFFICIENCY FOR PULSE ELECTROCHEMICAL MACHINING OF NICKEL ALLOY Yu Zhang, M.S. University of Nebraska, 2010 Adviser: Kamlakar P. Rajurkar Electrochemical machining (ECM) is a nontraditional manufacturing process that can machine difficult-to-cut materials. In ECM, material is removed by controlled electrochemical dissolution of an anodic workpiece in an electrochemical cell. ECM has extensive applications in automotive, petroleum, aerospace, textile, medical, and electronics industries. Improving current efficiency is a challenging task for any electro-physical or electrochemical machining processes. The current efficiency is defined as the ratio of the observed amount of metal dissolved to the theoretical amount predicted from Faraday’s law, for the same specified conditions of electrochemical equivalent, current, etc [1]. In macro ECM, electrolyte conductivity greatly influences the current efficiency of the process. Since there is a certain limit to enhance the conductivity of the electrolyte, a process innovation is needed for further improvement in current efficiency in ECM. Pulse electrochemical machining (PECM) is one such approach in which the electrolyte conductivity is improved by electrolyte flushing in pulse off-time. The aim of this research is to study the influence of major factors on current efficiency in a pulse electrochemical machining process in macro scale and to develop a linear regression model for predicting current efficiency of the process. An in-house designed electrochemical cell was used for machining nickel alloy (ASTM B435) by PECM. The effects of current density, type of electrolyte, and electrolyte flow rate, on current efficiency under different experimental conditions were studied. Results indicated that current efficiency is dependent on electrolyte, electrolyte flow rate, and current density. Linear regression models of current efficiency were compared with twenty new data points graphically and quantitatively. Models developed were close enough to the actual results to be reliable. In addition, an attempt has been made in this work to consider those factors in PECM that have not been investigated in earlier works. This was done by simulating the process by using COMSOL software. However, it was found that the results from this attempt were not substantially different from the earlier reported studies.

Screening, immobilization and utilization of whole cell biocatalysts to mediate the ethanolysis of babassu oil

The screening. biomass growth of lipase-producing fungus isolated from different sources and available at URM (University Recife Mycologia). as well as, the immobilization and utilization of the whole cells for the transesterification of babassu oil were investigated. Rhizopus oryzae (URM 3231, 4692), Mucor circinelloides (URM 4140, 4182) and Penicillium citrinum URM 4216 were considered to be good intracellular lipase producers whereas those from Mucor hiemalis URM 4144 and Mucor piriformis URM 4145 were weaker. Fungi biomass containing high lipase activities was immobilized on different biomass support particles (BSPs) and with the exception of Penicillium citrinum URM 4216 all the other fungi strains exhibited high lipase activity (20-50 Ug(-1)) when immobilized in situ using polyurethane foam particles. Transesterification activities of the immobilized whole cells were evaluated in the ethanolysis reaction with babassu oil and the highest performance was attained by M. circinelloides URM 4182 giving 83.22 +/- 3.68% ester yield in less than 96 h reaction. The biocatalyst operational stability was also assessed and an inactivation profile was found to follow the Arrhenius model, revealing values of 26 days and 2.6 x 10(-2)day(-1), for half-life and a deactivation coefficient, respectively. The purified product (biodiesel) exhibited viscosity (6.63 cSt) close to the value to attend specifications by the ASTM 06751 to be used as biofuel. Results are favorable compared with data already reported in the literature and demonstrated that M. circinelloides URM 4182 whole cells is a cheaper biocatalyst that can be used in the biodiesel synthesis. (C) 2012 Elsevier B.V. All rights reserved.

Characterization of depolymerized residues from extremely low acid hydrolysis (ELA) of sugarcane bagasse cellulose: Effects of degree of polymerization, crystallinity and crystallite size on thermal decomposition

Sugarcane bagasse cellulose was subjected to the extremely low acid (ELA) hydrolysis in 0.07% H2SO4 at 190, 210 and 225 degrees C for various times. The cellulose residues from this process were characterized by TGA, XRD, GPC, FIR and SEM. A kinetic study of thermal decomposition of the residues was also carried out, using the ASTM and Kissinger methods. The thermal studies revealed that residues of cellulose hydrolyzed at 190, 210 and 225 degrees C for 80,40 and 8 min have initial decomposition temperature and activation energy for the main decomposition step similar to those of Avicel PH-101. XRD studies confirmed this finding by showing that these cellulose residues are similar to Avicel in crystallinity index and crystallite size in relation to the 110 and 200 planes. FTIR spectra revealed no significant changes in the cellulose chemical structure and analysis of SEM micrographs demonstrated that the particle size of the cellulose residues hydrolyzed at 190 and 210 degrees C were similar to that of Avicel. (C) 2011 Elsevier B.V. All rights reserved.

Influence of light, temperature and metallic ions on biodiesel degradation and corrosiveness to copper and brass

Corrosion is a relevant issue regarding the problem of biodiesel compatibility with polymers and metals. This work aims to evaluate the influence of the natural light incidence and temperature in the corrosion rate of brass and copper immersed in commercial biodiesel as well as biodiesel degradation after the contact with metallic ions. The characterization of corrosion behavior was performed by weight loss measurements according to ASTM G1 and ASTM G31. The experiments according to ASTM G1 were performed at room temperature in light presence and absence. Experiments were also conducted at 55 degrees C in order to compare with ASTM G31 that is also performed at that temperature. The biodiesel degradation was characterized by water content, oxidation stability, viscosity as well as XRF, IR and Raman spectroscopies. The results of ASTM G1 tests showed that the thickness loss for both metals determined at room temperature is slightly higher when there is light incidence and these values significantly decrease for the highest temperature. The results of ASTM G31 tests indicated that air bubbling along with higher temperature affects mostly immersed samples. Biodiesel in contact with metals shows significant degradation in its properties as evidenced by increasing water content, higher viscosity and lower oxidation stability. (C) 2012 Elsevier Ltd. All rights reserved.

Predicting Delta Ferrite Content in Stainless Steel Castings

The distribution of delta ferrite fraction was measured with the magnetic method in specimens of different stainless steel compositions cast by the investment casting (lost wax) process. Ferrite fraction measurements published in the literature for stainless steel cast samples were added to the present work data, enabling an extensive analysis about practical methods to calculate delta ferrite fractions in stainless steel castings. Nineteen different versions of practical methods were formed using Schaeffler, DeLong, and Siewert diagrams and the nickel and chromium equivalent indexes suggested by several authors. These methods were evaluated by a detailed statistical analysis, showing that the Siewert diagram, including its equivalent indexes and iso-ferrite lines, gives the lowest relative errors between calculated and measured delta ferrite fractions. Although originally created for stainless steel welds, this diagram gives relative errors lower than those for the current ASTM standard method (800/A 800M-01), developed to predict ferrite fractions in stainless steel castings. Practical methods originated from a combination of different chromium/nickel equivalent indexes and the iso-ferrite lines from Schaeffler diagram give the lowest relative errors when compared with combinations using other iso-ferrite line diagrams. For the samples cast in the present work, an increase in cooling rate from 0.78 to 2.7 K/s caused a decrease in the delta ferrite fraction, but a statistical hypothesis test revealed that this effect is significant in only 50% of the samples that have ferrite in their microstructures.

Evaluation of the propylene glycol association on some physical and chemical properties of mineral trioxide aggregate

Duarte MAH, Alves de Aguiar K, Zeferino MA, Vivan RR, Ordinola-Zapata R, Tanomaru-Filho M, Weckwerth PH, Kuga MC. Evaluation of the propylene glycol association on some physical and chemical properties of mineral trioxide aggregate. International Endodontic Journal, 45, 565570, 2012. Abstract Aim To evaluate the influence of propylene glycol (PG) on the flowability, setting time, pH and calcium ion release of mineral trioxide aggregate (MTA). Methodology Mineral trioxide aggregate was mixed with different proportions of PG, as follows: group 1: MTA + 100% distilled water (DW); group 2: MTA + 80% DW and 20% PG; group 3: MTA + 50% DW and 50% PG; group 4: MTA + 20% DW and 80% PG; group 5: MTA + 100% PG. The ANSI/ADA No. 57 was followed for evaluating the flowability and the setting time was measured by using ASTM C266-08. For pH and calcium release analyses, 50 acrylic teeth with root-end cavities were filled with the materials (n = 10) and individually immersed in flasks containing 10 mL deionized water. After 3 h, 24 h, 72 h and 168 h, teeth were placed in new flasks and the water in which each specimen was immersed had its pH determined by a pH metre and the calcium release measured by an atomic absorption spectrophotometer with a calcium-specific hollow cathode lamp. Data were analysed by using one-way anova test for global comparison and by using Tukeys test for individual comparisons. Results The highest value of flowability was observed with MTA + 20% DW and 80% PG and the lowest values were found with MTA + 100% DW. They were significantly different compared to the other groups (P < 0.05). The presence of PG did not affect the pH and calcium release. The MTA + 100% PG favoured the highest (P < 0.05) pH and calcium release after 3 h. Increasing the PG proportion interfered (P < 0.05) with the setting time; when used at the volume of 100% setting did not occur. Conclusion The addition of PG to MTA-Angelus increased its setting time, improved flowability and increased the pH and calcium ion release during the initial post-mixing periods. The ratio of 80% DW 20% PG is recommended.

Ethnobotany of natural fibres - Bactris setosa (tucum) in a traditional rural community

This work aimed to study the characteristics of the fibres of the species Bactris setosa ('tucum') used by close-knit social groups, located in Sorocaba - Sao Paulo - Brazil, in basket-making techniques, for possible applications in textile activity. Optical microscopy (NBR 13 538:1995) and Tensile Properties (ASTM D 3 822-2001) were used to assess properties such as the fibre structre, linear density, breaking force, elongation at break and breaking tenacity of each species. Bactris setosa showed a longitudinal view similar to that of sisal; an average linear density of 41.2 tex, a tenacity average of 11.96 cN/tex, closer to fiberglass, and an elongation ranging between 1.35 and 3.87%. It is important to clarify the delicacy and detail of the tests, and from this we highlight the importance of carrying out these studies, based on which science and technology must be linked with socio-environmental aspects.

Effect of sample pre-cracking method and notch geometry in plane strain fracture toughness tests as applied to a PMMA resin

The influence of test method factors (notch shape, square or angular, and pre-cracking method, by tapping onto or pressing a razor blade) on the results obtained in plane strain fracture toughness test according to standard ASTM D5045 using SENB specimens made of a commercial PMMA resin were investigated. Results were analyzed quantitatively by comparing the obtained K-IC values and qualitatively by observing their effect on the Moire fringes observed using photoelasticity, showing that, at 95% significance level, the K-IC values are affected by the pre-cracking method, with the most conservative value being obtained when natural pre-cracks were introduced by tapping onto a razor blade (K-IC = 1.15 +/- 0.11 MPa.m(0.5)). This correlates with a perturbation in the stress field close to the pre-crack tip observed in the photoelasticity test sample when it was introduced by pressing the razor blade. Surprisingly, notch geometry only slightly affects the results. (C) 2012 Elsevier Ltd. All rights reserved.

Mass loss and wear mechanisms of HVOF-sprayed multi-component white cast iron coatings

In this work, multi-component white cast iron was applied by HVOF thermal spray process as alternative to other manufacture processes. Effects of substrate type, substrate pre-heating and heat treatment of coating on mass loss have been determined by rubber wheel apparatus in accordance with ASTM G-65. Furthermore, influence of heat treatment of coating on wear mechanisms was also determined by scanning electron microscopy analysis. Heat-treated coatings presented mass loss three times lower than as-sprayed coatings. Furthermore, wear mechanisms of as-sprayed coating are micro-cutting associated with cracks close to unmelted particles and pores. In heat-treated coating, lesser mass loss is due to sintering. (C) 2011 Elsevier B.V. All rights reserved.

Influence of Alloying Elements Upon the Solidification Interval of CA6NM Cast Martensitic Stainless Steel

The influence of different Cr and C contents upon the solidification interval of ASTM A352M-06 Grade CA6NM cast martensitic stainless steel has been investigated using computational thermodynamics, and checked against DTA measurements in samples taken from 13 large cast parts, in order to identify potential sources for improvement on the part castability. Calculation results suggest, indeed, that this would be the case for C: when its content increases from 0.018 to 0.044 wt.% C (within the allowed range in the alloy specification), the solidification intervals increases from 25 to 43 K, which suggests improved castability with decreasing C contents. DTA results, however, do not support this prediction, showing a fairly constant solidification interval around 23 K for all investigated samples. The results are discussed both regarding the impact in alloy processing and the fitness of the existing databases to reproduce experimental results in these limiting cases.

Effect of light sources and curing mode techniques on sorption, solubility and biaxial flexural strength of a composite resin

Adequate polymerization plays an important role on the longevity of the composite resin restorations. Objectives: The aim of this study was to evaluate the effect of light-curing units, curing mode techniques and storage media on sorption, solubility and biaxial flexural strength (BFS) of a composite resin. Material and Methods: Two hundred and forty specimens were made of one composite resin (Esthet-X) in a stainless steel mold (2 mm x 8 mm 0), and divided into 24 groups (n=10) established according to the 4 study factors: light-curing units: quartz tungsten halogen (QTH) lamp and light-emitting diodes (LED); energy densities: 16 J/cm(2) and 20 J/cm(2); curing modes: conventional (CM) and pulse-delay (PD); and permeants: deionized water and 75% ethanol for 28 days. Sorption and solubility tests were performed according to ISO 4049:2000 specifications. All specimens were then tested for BFS according to ASTM F394-78 specification. Data were analyzed by three-way ANOVA followed by Tukey, Kruskal-Wallis and Mann-Whitney tests (alpha=0.05). Results: In general, no significant differences were found regarding sorption, solubility or BFS means for the light-curing units and curing modes (p>0.05). Only LED unit using 16 J/cm(2) and PD using 10 s produced higher sorption and solubility values than QTH. Otherwise, using CM (16 J/cm(2)), LED produced lower values of BFS than QTH (p<0.05). 75% ethanol permeant produced higher values of sorption and solubility and lower values of BFS than water (p<0.05). Conclusion: Ethanol storage media produced more damage on composite resin than water. In general the LED and QTH curing units using 16 and 20 J/cm(2) by CM and PD curing modes produced no influence on the sorption, solubility or BFS of the tested resin.

Biocompatibility and setting time of CPM-MTA and white Portland cement clinker with or without calcium sulfate

To evaluate the biocompatibility and the setting time of Portland cement clinker with or without 2% or 5% calcium sulfate and MTA-CPM. Twenty-four mice (Rattus norvegicus) received subcutaneously polyethylene tubes filled with Portland cement clinker with or without 2% or 5% calcium sulfate and MTA. After 15, 30 and 60 days of implantation, the animals were killed and specimens were prepared for microscopic analysis. For evaluation of the setting time, each material was analyzed using Gilmore needles weighing 113.5 g and 456.5 g, according to the ASTM specification Number C266-08 guideline. Data were analyzed by ANOVA and Tukey's test for setting time and Kruskal-Wallis and Dunn test for biocompatibility at 5% significance level. Histologic observation showed no statistically significant difference of biocompatibility (p>0.05) among the materials in the subcutaneous tissues. For the setting time, clinker without calcium sulfate showed the shortest initial and final setting times (6.18 s/21.48 s), followed by clinker with 2% calcium sulfate (9.22 s/25.33 s), clinker with 5% calcium sulfate (10.06 s/42.46 s) and MTA (15.01 s/42.46 s). All the tested materials showed biocompatibility and the calcium sulfate absence shortened the initial and final setting times of the white Portland cement clinker

Prove di ozonolisi sui fanghi biologici prodotti da impianti di depurazione delle acque reflue urbane

La tecnica di ozonolisi viene applicata ai fanghi biologici derivanti da impianti di depurazione acque reflue urbane, e consiste nell'ottenere, grazie all'ozono, una minor massa fangosa da smaltire e una miglior trattabilità del fango residue. In questo elaborato si prendono in esame le sperimentazioni effettuate a Marina di Ravenna e si estraggono le prime conclusioni gestionali, economiche e ambientali sull'applicabilità del metodo a questo tipo di fango.

Analisi sperimentale degli effetti di temperature elevate sul comportamento strutturale dei rinforzi in FRP

In questa tesi si è voluta porre l’attenzione sulla suscettibilità alle alte temperature delle resine che li compongono. Lo studio del comportamento alle alte temperature delle resine utilizzate per l’applicazione dei materiali compositi è risultato un campo di studio ancora non completamente sviluppato, nel quale c’è ancora necessità di ricerche per meglio chiarire alcuni aspetti del comportamento. L’analisi di questi materiali si sviluppa partendo dal contesto storico, e procedendo successivamente ad una accurata classificazione delle varie tipologie di materiali compositi soffermandosi sull’ utilizzo nel campo civile degli FRP (Fiber Reinforced Polymer) e mettendone in risalto le proprietà meccaniche. Considerata l’influenza che il comportamento delle resine riveste nel comportamento alle alte temperature dei materiali compositi si è, per questi elementi, eseguita una classificazione in base alle loro proprietà fisico-chimiche e ne sono state esaminate le principali proprietà meccaniche e termiche quali il modulo elastico, la tensione di rottura, la temperatura di transizione vetrosa e il fenomeno del creep. Sono state successivamente eseguite delle prove sperimentali, effettuate presso il Laboratorio Resistenza Materiali e presso il Laboratorio del Dipartimento di Chimica Applicata e Scienza dei Materiali, su dei provini confezionati con otto differenti resine epossidiche. Per valutarne il comportamento alle alte temperature, le indagini sperimentali hanno valutato dapprima le temperature di transizione vetrosa delle resine in questione e, in seguito, le loro caratteristiche meccaniche. Dalla correlazione dei dati rilevati si sono cercati possibili legami tra le caratteristiche meccaniche e le proprietà termiche delle resine. Si sono infine valutati gli aspetti dell’applicazione degli FRP che possano influire sul comportamento del materiale composito soggetto alle alte temperature valutando delle possibili precauzioni che possano essere considerate in fase progettuale.

Caratterizzazione meccanica di calcestruzzi fibrorinforzati con fibre d'acciaio

L’utilizzo di materiali compositi come i calcestruzzi fibrorinforzati sta diventando sempre più frequente e diffuso. Tuttavia la scelta di nuovi materiali richiede una approfondita analisi delle loro caratteristiche e dei loro comportamenti. I vantaggi forniti dall’aggiunta di fibre d’acciaio ad un materiale fragile, quale il calcestruzzo, sono legati al miglioramento della duttilità e all'aumento di assorbimento di energia. L’aggiunta di fibre permette quindi di migliorare il comportamento strutturale del composito, dando vita ad un nuovo materiale capace di lavorare non solo a compressione ma anche in piccola parte a trazione, ma soprattutto caratterizzato da una discreta duttilità ed una buona capacità plastica. Questa tesi ha avuto come fine l’analisi delle caratteristiche di questi compositi cementizi fibrorinforzati. Partendo da prove sperimentali classiche quali prove di trazione e compressione, si è arrivati alla caratterizzazione di questi materiali avvalendosi di una campagna sperimentale basata sull’applicazione della norma UNI 11039/2003. L’obiettivo principale di questo lavoro consiste nell’analizzare e nel confrontare calcestruzzi rinforzati con fibre di due diverse lunghezze e in diversi dosaggi. Studiando questi calcestruzzi si è cercato di comprendere meglio questi materiali e trovare un riscontro pratico ai comportamenti descritti in teorie ormai diffuse e consolidate. La comparazione dei risultati dei test condotti ha permesso di mettere in luce differenze tra i materiali rinforzati con l’aggiunta di fibre corte rispetto a quelli con fibre lunghe, ma ha anche permesso di mostrare e sottolineare le analogie che caratterizzano questi materiali fibrorinforzati. Sono stati affrontati inoltre gli aspetti legati alle fasi della costituzione di questi materiali sia da un punto di vista teorico sia da un punto di vista pratico. Infine è stato sviluppato un modello analitico basato sulla definizione di specifici diagrammi tensione-deformazione; i risultati di questo modello sono quindi stati confrontati con i dati sperimentali ottenuti in laboratorio.