Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)

Continuous research endeavors on hard turning (HT), both on machine tools and cutting tools, have made the previously reported daunting limits easily attainable in the modern scenario. This presents an opportunity for a systematic investigation on finding the current attainable limits of hard turning using a CNC turret lathe. Accordingly, this study aims to contribute to the existing literature by providing the latest experimental results of hard turning of AISI 4340 steel (69 HRC) using a CBN cutting tool. An orthogonal array was developed using a set of judiciously chosen cutting parameters. Subsequently, the longitudinal turning trials were carried out in accordance with a well-designed full factorial-based Taguchi matrix. The speculation indeed proved correct as a mirror finished optical quality machined surface (an average surface roughness value of 45 nm) was achieved by the conventional cutting method. Furthermore, Signal-to-noise (S/N) ratio analysis, Analysis of variance (ANOVA), and Multiple regression analysis were carried out on the experimental datasets to assert the dominance of each machining variable in dictating the machined surface roughness and to optimize the machining parameters. One of the key findings was that when feed rate during hard turning approaches very low (about 0.02mm/rev), it could alone be most significant (99.16%) parameter in influencing the machined surface roughness (Ra). This has, however also been shown that low feed rate results in high tool wear, so the selection of machining parameters for carrying out hard turning must be governed by a trade-off between the cost and quality considerations.

Properties of Super-Hydrophobic Copper and Stainless Steel Meshes: Applications in Controllable Water Permeation and Organic Solvents/Water Separation

The wettability and hydrophobicity of super-hydrophobic (SH) meshes is greatly influenced by their topographic structures, chemical composition and coating process. In this study, the properties of copper and stainless steel meshes, coated with super-hydrophobic electrolessly deposited silver were investigated. A new method to test the pressure resistance of super-hydrophobic mesh was applied to avoid any deformation of mesh. Results showed that SH copper mesh and SH stainless steel meshes with the same pore size have almost the same contact angle and the same hydrophobicity. SH copper mesh with a pore size of 122 μm can resist water pressure of 4900 Pa and a decrease of pore size of mesh can increase the pressure resistance of SH copper mesh. The SH copper mesh modified with 0.1 M HS(CH2)10COOH solution in ethanol has a controllable water permeation property by simply adjusting the pH of water solution. SH copper mesh shows super-oleophilicity with organic solvents and so with a water contact angle of 0° and it can be an effective tool for organic solvents/water separation. The separation efficiency of SH copper mesh for separating mixtures of organic solvent and water can be as high as 99.8%.

The Collapse Behaviour of Cold-formed Steel Portal Frames at Elevated Temperatures

This paper describes the results of non-linear elasto-plastic implicit dynamic finite element analyses that are used to predict the collapse behaviour of cold-formed steel portal frames at elevated temperatures. The collapse behaviour of a simple rigid-jointed beam idealisation and a more accurate semi-rigid jointed shell element idealisation are compared for two different fire scenarios. For the case of the shell element idealisation, the semi-rigidity of the cold-formed steel joints is explicitly taken into account through modelling of the bolt-hole elongation stiffness. In addition, the shell element idealisation is able to capture buckling of the cold-formed steel sections in the vicinity of the joints. The shell element idealisation is validated at ambient temperature against the results of full-scale tests reported in the literature. The behaviour at elevated temperatures is then considered for both the semi-rigid jointed shell and rigid-jointed beam idealisations. The inclusion of accurate joint rigidity and geometric non-linearity (second order analysis) are shown to affect the collapse behaviour at elevated temperatures. For each fire scenario considered, the importance of base fixity in preventing an undesirable outwards collapse mechanism is demonstrated. The results demonstrate that joint rigidity and varying fire scenarios should be considered in order to allow for conservative design.

Oxygen Reduction Reaction on Metal-Terminated MnCr2O4 Nano-octahedron Catalyzing MnS Dissolution in an Austenitic Stainless Steel

To understand pitting corrosion in stainless steel is very important, and a recent work showed that the MnS dissolution catalyzed by MnCr2O4{111} is a starting point of pit g. This demonstrates the need to understand the oxygen reduction reaction (ORR) on MnCr2O4{111}, which is the other half-reaction to complete pitting corrosion. In this study, the adsorption behaviors of all oxygen-containing species on MnCr2O4{111}, which has several possible terminations, are explored via density functional theory calculations. It is found that O-2 adsorbs on MnCr2O4{111) surfaces very strongly. Many possible reactions are investigated and the favored reaction mechanism of ORR is determined. The interactions between O-2 and H2O on the two metal-terminated MriCr(2)O(4){111} are found to be different according to the atomic configurations of the two surfaces. All the calculated results suggest that ORR can readily occur on the MnCr2O4{111} surfaces.

Optimal design of cold-formed steel portal frames for stressed-skin action using genetic algorithm

This paper describes a stressed-skin diaphragm approach to the optimal design of the internal frame of a cold-formed steel portal framing system, in conjunction with the effect of semi-rigid joints. Both ultimate and serviceability limit states are considered. Wind load combinations are included. The designs are optimized using a real-coded niching genetic algorithm, in which both discrete and continuous decision variables are processed. For a building with two internal frames, it is shown that the material cost of the internal frame can be reduced by as much as 53%, compared with a design that ignores stressed-skin action.

Relationship between Laves phase and the impact brittleness of P92 steel reevaluated

Laves phase has been widely accepted to cause the impact brittleness of 9–12Cr martensitic heat-resistant steels after long time aging at elevated temperatures. However, in the present research, the impact toughness of the already brittle P92 steel aged at 600 °C for 2035 h could be restored to the original level by reheating at 700 °C for 1 h, with Laves phase barely changed. This interesting result strongly indicated that the presence of Laves phase might not be the real reason for the impact brittleness.

Topographical optimisation of single-storey non-domestic steel framed buildings using photovoltaic panels for net-zero carbon impact

A methodology is presented that combines a multi-objective evolutionary algorithm and artificial neural networks to optimise single-storey steel commercial buildings for net-zero carbon impact. Both symmetric and asymmetric geometries are considered in conjunction with regulated, unregulated and embodied carbon. Offsetting is achieved through photovoltaic (PV) panels integrated into the roof. Asymmetric geometries can increase the south facing surface area and consequently allow for improved PV energy production. An exemplar carbon and energy breakdown of a retail unit located in Belfast UK with a south facing PV roof is considered. It was found in most cases that regulated energy offsetting can be achieved with symmetric geometries. However, asymmetric geometries were necessary to account for the unregulated and embodied carbon. For buildings where the volume is large due to high eaves, carbon offsetting became increasingly more difficult, and not possible in certain cases. The use of asymmetric geometries was found to allow for lower embodied energy structures with similar carbon performance to symmetrical structures.

Optimal design of long-span steel portal frames using fabricated beams

This paper considers the optimal design of fabricated steel beams for long-span portal frames. The design optimisation takes into account ultimate as well as serviceability limit states, adopting deflection limits recommended by the Steel Construction Institute (SCI). Results for three benchmark frames demonstrate the efficiency of the optimisation methodology. A genetic algorithm (GA) was used to optimise the dimensions of the plates used for the columns, rafters and haunches. Discrete decision variables were adopted for the thickness of the steel plates and continuous variables for the breadth and depth of the plates. Strategies were developed to enhance the performance of the GA including solution space reduction and a hybrid initial population half of which is derived using Latin hypercube sampling. The results show that the proposed GA-based optimisation model generates optimal and near-optimal solutions consistently. A parametric study is then conducted on frames of different spans. A significant variation in weight between fabricated and conventional hot-rolled steel portal frames is shown; for a 50 m span frame, a 14–19% saving in weight was achieved. Furthermore, since Universal Beam sections in the UK come from a discrete section library, the results could also provide overall dimensions of other beams that could be more efficient for portal frames. Eurocode 3 was used for illustrative purposes; any alternative code of practice may be used.

An efficient genetic algorithm for the design optimization of cold-formed steel portal frame buildings

The design optimization of a cold-formed steel portal frame building is considered in this paper. The proposed genetic algorithm (GA) optimizer considers both topology (i.e., frame spacing and pitch) and cross-sectional sizes of the main structural members as the decision variables. Previous GAs in the literature were characterized by poor convergence, including slow progress, that usually results in excessive computation times and/or frequent failure to achieve an optimal or near-optimal solution. This is the main issue addressed in this paper. In an effort to improve the performance of the conventional GA, a niching strategy is presented that is shown to be an effective means of enhancing the dissimilarity of the solutions in each generation of the GA. Thus, population diversity is maintained and premature convergence is reduced significantly. Through benchmark examples, it is shown that the efficient GA proposed generates optimal solutions more consistently. A parametric study was carried out, and the results included. They show significant variation in the optimal topology in terms of pitch and frame spacing for a range of typical column heights. They also show that the optimized design achieved large savings based on the cost of the main structural elements; the inclusion of knee braces at the eaves yield further savings in cost, that are significant.

Tensile and impact properties of low nickel maraging steel

This short communication presents a research update of a new low nickel maraging steel, Fe–12.94%Ni–1.61%Al–1.01%Mo–0.23%Nb (wt%). Its yield stress and the tensile strength are 1080 MPa and 1180 MPa, respectively, after ageing treatment. Tensile specimens show ductile fracture. Fractography demonstrated deep dimples. Impact energy is 22 J on half-size specimens.

Evolution of microstructure and changes of mechanical properties of CLAM steel after long-term aging

The China Low Activation Martensitic (CLAM) steel has been developed as a candidate structural material for future fusion reactors. It is essential to investigate the evolution of microstructure and changes of mechanical properties of CLAM steel during thermal exposure. In this study, the long-term thermal aging of the CLAM steel has been carried out in air at 600 °C and 650 °C for 1100 h, 3000 h and 5000 h. The microstructural evolution with aging time was studied, including characteristics of the growth of M23C6 carbides and the formation of Laves-phase precipitates as well as the evolved subgrains. The microstructural evolution leads to the changes of mechanical properties of the CLAM steel. The Ductile–Brittle Transition Temperature (DBTT) increases significantly during the thermal aging, which is related to the formation of Laves-phase in the steel matrix. The possible mechanism of stabilizing microstructure during the thermal exposure has been analyzed based on the interaction between M23C6 carbides and subgrain boundaries.

Low cycle fatigue properties of CLAM steel at room temperature

The low cycle fatigue (LCF) properties and the fracture behavior of China Low Activation Martensitic (CLAM) steel have been studied over a range of total strain amplitudes from 0.2 to 2.0%. The specimens were cycled using tension-compression loading under total strain amplitude control. The CLAM steel displayed initial hardening followed by continuous softening to failure at room temperature in air. The relationship between strain and fatigue life was predicted using the parameters obtained from fatigue test. The factors effecting on low cycle fatigue of CLAM steel consisted of initial state of matrix dislocation arrangement, magnitude of cyclic stress, magnitude of total strain amplitude and microstructure. The potential mechanisms controlling the stress response, cyclic strain resistance and low cycle fatigue life have been evaluated.

Microstructure and Mechanical Propertiesof a Nitride-Strengthened Reduced ActivationFerritic/Martensitic Steel

Nitride-strengthened reduced activation ferritic/martensitic (RAFM) steels are developed taking advantage of the high thermal stability of nitrides. In the current study, the microstructure and mechanical properties of a nitride-strengthened RAFM steel with improved composition were investigated. Fully martensitic microstructure with fine nitrides dispersion was achieved in the steel. In all, 1.4 pct Mn is sufficient to suppress delta ferrite and assure the steel of the full martensitic microstructure. Compared to Eurofer97, the steel showed similar strength at room temperature but higher strength at 873 K (600 °C). The steel exhibited very high impact toughness and a low ductile-to-brittle transition temperature (DBTT) of 243 K (–30 °C), which could be further reduced by purification.