Undersökning av steady state och utvärdering av valskraft och friktion vid kallvalsning av aluminium

The purpose with this thesis was to examine the cold rolling mill located at Högskolan Dalarna and to stabilize the rolling process, to achieve steady state. Experiments with cold rolling of an aluminium strip have given results for rolling force, friction, reduction, strip tension and strain hardening. Results show that steady state has been found for the experiments with roll force and strain hardening, and not been found for the experiments with friction and reduction. Results show that increased strip tension gives lower roll forces. The roll force equation of Stone shows comparable results with reality for dry contact with reductions up to 30 %, but starts being incomparable with higher reductions. The roll force equation of Stone shows a bit higher roll forces than reality gave, but was comparable within reductions from 13 to 50 %. Experiments have shown that the aluminium strip has gone through strain hardening. Experiments show how the set roll gap did not yield the desired thickness reduction, there for the elastic spring constant for the rolling mill was examined and determined to be 417 N / mm for the specific alloy band. The influence of tension strip for roll force was examined and Results confirm the theory about how the roll force is decreased by increasing tension strip. The work rolls started to slip against the alumina strip as high tension strip; 70 N/mm2, gave low roll force; < 15kN.

Implementation of Video Monitoring In Aluminium Industry

The aim was to evaluate results and experiences from development of new technology, a training program and implementation of strategies for the use of a video exposure monitoring method, PIMEX. Starting point of this study is an increased incidence of asthma among workers in the aluminium industry. Exposure peaks of fumes are supposed to play an important role. PIMEX makes it possible to link used work practice, use of control technology, and so forth to peaks. Nine companies participated in the project, which was divided into three parts, development of PIMEX technology, production of training material, and training in use of equipment and related strategies. The use of the video exposure monitoring method PIMEX offers prerequisites supporting workers participation in safety activities. The experiences from the project reveal the importance of good timing of primary training, technology development, technical support, and follow up training. In spite of a delay of delivery of the new technology, representatives from the participating companies declared that the experiences showed that PIMEX gave an important contribution for effective control of hazards in the companies. Eight out of nine smelters used the PIMEX method as a part of a strategy for control of workers exposure to fumes in potrooms. Possibilities to conduct effective control measures were identified. This article describes experiences from implementation of a, for this branch, new method supporting workers participation for workplace improvements.

The generation of new high-angle boundaries in aluminium during hot torsion

The crystallographic rotation field for deformation in torsion is such that it is possible for orientations close to stable orientations to rotate away from the stable orientation. A Taylor type model was used to demonstrate that this phenomenon has the potential to transform randomly generated low-angle boundaries into high-angle boundaries. After imposing an equivalent strain of 1.2, up to 40% of the simulated boundaries displayed a disorientation in excess of 15°. These high-angle boundaries were characterised by a disorientation axis close to parallel with the sample radial direction. A series of hot torsion tests was carried out on 1050 aluminium to seek evidence for boundaries formed by this mechanism. A number of deformation-induced high-angle boundaries were identified. Many of these boundaries showed disorientation axes and rotation senses similar to those seen in the simulations. Between 10% and 25% of all the high-angle boundary present in samples twisted to equivalent strains between 2 and 7 could be attributed to the present mechanism.

Method for determining reaction rate of mild steel containers during melting of magnesium-aluminium alloys and effect of aluminium content on directionally solidified microstructures

A magnesium alloy of eutectic composition (33 wt-'%Al) was directionally solidified in mild steel tubes at two growth rates, 32 and 580 mum s(-1,) in a temperature gradient between 10 and 20 K mm(-1). After directional solidification, the composition of each specimen varied dramatically, from 32'%Al in the region that had remained solid to 18%Al (32 mum s(-1) specimen) and 13%Al (580 mum s(-1) specimen) at the plane that had been quenched from the eutectic temperature. As the aluminium content decreased, the microstructure contained an increasing volume fraction of primary magnesium dendrites and the eutectic morphology gradually changed from lamellar to partially divorced. The reduction in aluminium content was caused by the growth of an Al-Fe phase ahead of the Mg-Al growth front. Most of the growth of the Al-Fe phase occurred during the remelting period before directional solidification. The thickness of the Al-Fe phase increased with increased temperature and time of contact with the molten Mg-Al alloy. (C) 2003 Maney Publishing.

Facilitated heterogeneous photodegradation of dissolved organic matter by particulate iron

The photochemical degradation of dissolved organic matter (DOM) derived from the leaves of River Red Gum (Eucalyptus camaldulensis) was examined, with a particular focus on the photochemical generation of CO₂, consumption of O₂, and the effect of particulate iron minerals on these photochemical reactions. Solutions of leaf leachate were irradiated with ultraviolet and visible light in the presence and absence of amorphous iron oxides. Addition of fresh iron oxide was found to increase the rate of photodegradation of the organic matter by up to an order of magnitude compared to the reactions without added iron oxide. The ratio of CO₂ produced to O₂ consumed was ~1:1 in both the presence and absence of iron oxyhydroxide. The reactivity of the iron oxides was dependent on the preparation method and decreased with increased storage time. These results suggest that photochemical reactions on particle surfaces should be considered when examining carbon transformation in aquatic ecosystems, especially at sites with potential for the production of iron oxyhydroxides.

Surface analysis of aluminium by glow-discharge optical emission spectrometry

Surface engineering in solids has become an important field in materials science. Glow-discharge optical emission spectrometry (GD-OES) has proven to be a powerful tool for the rapid analysis of elements in the surface of solids. One may employ GD-OES to determine quantitatively the bulk concentration of elements in a sample, and elemental concentrations as a function of depth. Presented here is an overview of GD-OES analysis and an application to aluminium.

Stress analysis of compression of aluminium with rotating tools

Compression tests carried out on aluminium specimens showed that when the die was rotated the compression load dropped. A slab method is employed to examine this process. The load reduction is explained by the deviation of friction vector due to the relative circumferential movement between the die and the material. This mechanism is incorporated into a theoretical model and an expression is derived for compression pressure. Analytical solutions established compare favourably with experimental results. It is also shown that there is a limitation to the load reduction: the compressive load can never be lower than 70 percent of the yield limit.

Machine vision system for automatic inspection of surface defects in aluminium die casting

A machine vision system is presented for the automatic inspection of surface defects in aluminium die casting. The system uses a hybrid image processing algorithm based on mathematic morphology to detect defects with different sizes and shapes. The defect inspection algorithm consists of two parts. One is a parameter learning algorithm, in which a genetic algorithm is used to extract optimal structuring element parameters, and segmentation and noise removal thresholds. The second part is a defect detection algorithm, in which the parameters obtained by a genetic algorithm are used for morphological operations. The machine vision system has been applied in an industrial setting to detect two types of casting defects: parts mix-up and any defects on the surface of castings. The system performs with a 99% or higher accuracy for both part mix-up and defect detection and is currently used in industry as part of normal production.

Crushing simulation of foam-filled aluminium tubes

A numerical study is presented in this paper to investigate the energy absorption of foam-filled aluminium tubes during crushing. The post-buckling mode of the foam-tube structures has been successfully simulated. The predicted compressive load-displacement is in a good agreement with experimental results. The energy absorption ability of the composite structure due to plastic deformation in a crushing process is evaluated by comparison with the tube structure without foam. The results indicate that the energy absorption of a foam-filled tube structure is superior to the tube without foam. The influences of the friction and the geometric parameters of the structure on the energy absorption have also been investigated. Results from this study will assist automotive industry to design crashworthy components based on foam-filled tubes.

Diesel exhaust particulate matter induces multinucleate cells and zinc transporter-dependent apoptosis in human airway cells

The cellular effects of biodiesel emissions particulate matter (BDEP) and petroleum diesel emissions particulate matter (PDEP) were compared using a human airway cell line, A549. At concentrations of 25 µg/ml, diesel particulate matter induced the formation of multinucleate cells. In cells treated with a mixture of 80% PDEP:20% BDEP, 52% of cells were multinucleate cells compared with only 16% of cells treated with 20% PDEP:80% BDEP with a background multinucleate rate of 7%. These results demonstrate a causal relation between the formation of multinucleate cells and exposure to exhaust particulate matter, in particular diesel exhaust. Exposure of A549 cells to PDEP induced apoptosis, seen by active caspase-3 expression and the presence of cleaved pancytokeratin. PDEP exhaust was a much stronger inducer of cellular death through apoptosis than BDEP. There was an eightfold increase in the expression of SLC30A3 (zinc transporter-3 or ZnT3) in cells exposed to 80% PDEP:20% BDEP compared to untreated cells. The increase in ZnT3 expression seen in apoptotic cells following PDEP suggests a role for this zinc transporter in the apoptotic pathway, possibly through controlling zinc fluxes. As exposure to diesel exhaust particles is associated with asthma and apoptosis in airway cells, diesel exhaust particles may directly contribute to asthma by inducing epithelial cell death through apoptotic pathway.

The effect of laser power density on the fatigue life of laser-shock-peened 7050 aluminium alloy

Laser shock peening (LSP) is an innovative surface treatment method that can result in significant improvement in the fatigue life of many metallic components. The process produces very little or no surface profile modification while producing a considerably deeper compressive residual stress layer than traditional shot peening operations. The work discussed here was designed to: (a) quantify the fatigue life improvement achieved by LSP in a typical high strength aircraft aluminium alloy and (b) identify any technological risks associated with its use. It is shown that when LSP conditions are optimal for the material and specimen configuration, a —three to four times increase in fatigue life over the as-machined specimens could be achieved for a representative fighter aircraft loading spectrum when applied at a representative load level. However, if the process parameters are not optimal for the material investigated here, fatigue lives of LSP treated specimens may be reduced instead of increased due to the occurrence of internal cracking. This paper details the effect of laser power density on fatigue life of 7050-T7451 aluminium alloy by experimental and numerical analysis.

Crushing modes of aluminium tubes under axial compression

A numerical study of the crushing of circular aluminium tubes with and without aluminium foam fillers has been carried out to investigate their buckling behaviours under axial compression. A crushing mode classification chart has been established for empty tubes. The influence of boundary conditions on crushing mode has also been investigated. The effect of foam filler on the crushing mode of tubes filled with foam was then examined. The predicted results would assist the design of crashworthy tube components with the preferred crushing mode with the maximum energy absorption.

The effect of artificial defects on the compressive properties of hollow sphere cellular aluminium (HSCA)

Hollow sphere cellular aluminium (HSCA) samples were fabricated by bonding together two kinds of single aluminium hollow spheres with the same outside diameter of 4 mm but different wall thicknesses of 0.1 mm and 0.3 mm, in which the hollow spheres with the thinner sphere wall thickness were used as artificial defects. Four types of HSCA samples with the same relative density but various distributions of artificial defects were prepared by simple cubic packing. For comparing, HSCA sample without defective hollow spheres inside was also prepared. The effects of the distribution of the artificial defects on the deformation behaviours and mechanical properties were investigated by compressive tests. Results indicated that the nominal stress - nominal strain curve and the deformation behavior of the HSCA samples varied with the distribution of the artificial defects in spite of the same relative density. It is therefore suggested that the deformation behavior and mechanical property of cellular materials were also significantly affected by the distribution of defects. In particular, the plateau stress of the HSCA samples increased with the decrease in number of contact points between the normal hollow spheres and the defective hollow spheres in the loading direction during deformation.

Energy absorption and crushing behaviour of foam-filled aluminium tubes

The crushing behaviour and energy absorption of foam filled aluminium tubular structures were investigated using the quasi-static compressive tests. The crushing behaviour of the tubular structures changed due to foam filling. The energy absorption of the foam filled tubular structures was improved significantly. Foam filling caused an interaction effect between the tube and the foam during progressive crushing, leading to an increase in the mean crushing load compared to that of the foam or tube itself. This interaction effect might be affected by several parameters such as the density of the foam, the properties of both the foam material and tube material, and the thickness and outer diameter of the tube. In particular, the interaction effect essentially depended on the ratio of the mean crushing force of the foam to that of the tube.