Erosion-fatigue of steam turbine blades

The premature failure of steam turbine rotor blades, manufactured in forged 12% Cr-NiMoV martensitic stainless steel, was investigated using visual inspection non-destructive testing, macro and microfractography, microstructural characterization, EDS microanalysis, chemical analysis, micro hardness and tensile testing. The blades belonged to the last stage of a thermoelectric plant steam turbine generator (140 MV A). The results indicated that the failure of the blades was promoted by foreign-particle erosion, which attacked preferentially the low-pressure side of the lower trailing edge of the blades. The resulting wear grooves acted as stress raisers and promoted the nucleation of fatigue cracks, which probably grew during the transition events of the steam turbine operation. Finally, water drop erosion was observed on the blade upper leading edge (low-pressure side). (C) 2009 Elsevier Ltd. All rights reserved.

Embrittlement of case hardened steel chain link

Various steel chain links presented cracking during their manufacturing process, which includes induction case hardening and electrogalvanizing steps. Fractographic examination of the exposed crack surfaces revealed intergranular cracking with some areas featuring a thin layer of iron oxide, indicating that the cracking took place after the electrogalvanizing step. The location of the cracks coincided with the position of the deepest case hardened layer, suggesting the occurrence of localized overheating during the induction case hardening step. Inductive heating finite element analysis (COSMOS Designstar Software) confirmed that during the case hardening the austenitising temperature reached in the crack region values of approximately 1050 degrees C. The results indicated that intergranular cracking was caused by hydrogen embrittlement. (C) 2009 Elsevier Ltd. All rights reserved.

Bending fatigue of stainless steel shear pins belonging to a hydroelectric plant

Coaracy Nunes was the first hydroelectric power plant in the Amazon region, being located in Araguari River, Amapa State, Brazil. The plant operates since 1976, presenting now a nominal capacity of 78 MW. The shear pins, which are installed in the turbine hydraulic arms to control the wicket gate and regulate the water flow into the turbine blades, suffered several breakdowns since 2004. These shear pins are made of an ASTM 410 stainless steel and were designed to break by a shear overload of 120 kN. Fractographic investigation of the pins, however, revealed two types of fracture topographies: a region of stable crack propagation area, with non-pronounced striation and secondary cracks; and a region of unstable propagation, featuring elongated dimples. These results indicated that the stable crack propagation occurred by fatigue (bidirectional bending), which was nucleated at machining marks under high nominal load. Finite element analysis was carried out using two loading conditions (pure shear and a combination of shear and bending) and the results indicated that the presence of a bending stress strongly increased the stress concentration factor (85% rise in the shear stress and 130% rise in the Von Mises stress). Misalignment during shear pins assembly associated with vibration might have promoted the premature failure of the shear by bending fatigue. (C) 2008 Elsevier Ltd. All rights reserved.

Cracking of 2.25Cr-1.0Mo steel tube/stationary tube-sheet weldment of a heat-exchanger

The premature failure of a horizontal heat-exchanger, which occurred after service exposure at 580 degrees C for 50,000 h, revealed the occurrence of extensive through-thickness cracking in approximately 40% of the tube/stationary tube-sheet welds. Additionally, the internal surface of the welded joint featured intensive secondary intergranular cracking (up to 250 mu m deep), preferential formation of a 150 mu m thick layer of (Fe, Cr)(3)O-4 and internal intergranular oxidation (40 mu m deep). The welded region also showed intense carbon pick-up and, as consequence, severe precipitation of intergranular M7C3 and M23C6 carbides. The fracture surface was composed of two distinct regions: a ""planar"" region of 250 mu m, formed due to the stable crack growth along by the intergranular oxidation; and a slant region with radial marks, formed by the fast crack growth along the network of intergranular carbides. The association of intergranular oxidation pre-cracks with microstructural embrittlement promoted the premature failure, which took place by an overload mechanism, probably due to the jamming of the floating tube-sheet during the maintenance halt (cooling operation). (C) 2007 Elsevier Ltd. All rights reserved.

A critical view on biaxial and short-beam uniaxial flexural strength tests applied to resin composites using Weibull, fractographic and finite element analyses

Objective. To evaluate the biaxial and short-beam uniaxial strength tests applied to resin composites based upon their Weibull parameters, fractographic features and stress distribution. Methods. Disk- (15 mm x 1 mm) and beam-shaped specimens (10 mm x 2 mm x 1 mm) of three commercial composites (Concept/Vigodent, CA; Heliomolar/Ivoclar-Vivadent, HE; Z250/3M ESPE, FZ) were prepared. After 48h dry storage at 37 degrees C, disks and beams were submitted to piston-on-three-balls (BI) and three-point bending (UNI) tests, respectively. Data were analyzed by Weibull statistics. Fractured surfaces were observed under stereomicroscope and scanning electron microscope. Maximum principal stress (sigma(1)) distribution was determined by finite element analysis (FEA). Maximum sigma(1-BI) and sigma(1-UNI) were compared to FZ strengths calculated by applying the average failure loads to the analytical equations (sigma(a-BI) and sigma(a-UNI)). Results. For BI, characteristic strengths were: 169.9a (FZ), 122.4b (CA) and 104.8c (HE), and for UNI were: 160.3a (FZ), 98.2b (CA) and 91.6b (HE). Weibull moduli ( m) were similar within the same test. CA and HE presented statistically higher m for BI. Surface pores ( BI) and edge flaws ( UNI) were the most frequent fracture origins. sigma(1-BI) was 14% lower than sigma(a-BI.) sigma(1-UNI) was 43% higher than sigma(a-UNI). Significance. Compared to the short-beam uniaxial test, the biaxial test detected more differences among composites and displayed less data scattering for two of the tested materials. Also, biaxial strength was closer to the material`s strength estimated by FEA. (C) 2009 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Strength improvement of adhesively-bonded joints using a reverse-bent geometry

Adhesive bonding of components has become more efficient in recent years due to the developments in adhesive technology, which has resulted in higher peel and shear strengths, and also in allowable ductility up to failure. As a result, fastening and riveting methods are being progressively replaced by adhesive bonding, allowing a big step towards stronger and lighter unions. However, single-lap bonded joints still generate substantial peel and shear stress concentrations at the overlap edges that can be harmful to the structure, especially when using brittle adhesives that do not allow plasticization in these regions. In this work, a numerical and experimental study is performed to evaluate the feasibility of bending the adherends at the ends of the overlap for the strength improvement of single-lap aluminium joints bonded with a brittle and a ductile adhesive. Different combinations of joint eccentricity were tested, including absence of eccentricity, allowing the optimization of the joint. A Finite Element stress and failure analysis in ABAQUS® was also carried out to provide a better understanding of the bent configuration. Results showed a major advantage of using the proposed modification for the brittle adhesive, but the joints with the ductile adhesive were not much affected by the bending technique.

Otimização de consumo energético de equipamento de grande potência

Um dos princípios da Gestão é: “If you cannot measure it, you cannot improve it.” In The Economist – 26.Dez.2008, idea of 19th century English physicist Lord Kelvin. Embora seja uma afirmação aplicável à gestão económica, também pode ser utilizada no domínio da gestão da energia. Este trabalho surge da necessidade sentida pela empresa Continental - Industria Têxtil do Ave, S.A. em efetuar uma atualização dos seus standards de produção, minimizando os seus consumos de eletricidade e gás natural. Foi necessário efetuar o levantamento dos consumos em diversas máquinas e equipamentos industriais, caracterizando e analisando os consumos ao longo de todo o processo produtivo. Para o tratamento de dados recolhidos foi desenvolvida uma folha de cálculo em MS Office ExcelTM com metodologia adequada ao equipamento em análise, que dará apoio ao decisor para a identificação dos aspetos que melhorem o processo produtivo e garantam uma elevada eficiência energética. Porém, não se enquadra no âmbito do Plano Nacional de Racionalização de Energia, sendo uma “auditoria energética” ao processo produtivo. Recentemente, a empresa, tem vindo a utilizar equipamentos eletrónicos que permitem otimizar o funcionamento mecânico dos equipamentos e das potências instaladas dos transformadores, na tentativa de racionalizar o consumo da energia elétrica. Outros equipamentos como, conversores de frequência para controlo de motores, balastros eletrónicos que substituem os convencionais balastros ferromagnéticos das lâmpadas de descarga fluorescente, têm sido incluídos ao nível das instalações elétricas, sendo gradualmente substituída a eletromecânica pela eletrónica. Este tipo de soluções vem deteriorar as formas de onda da corrente e da tensão do sistema pela introdução de distorções harmónicas. Faz ainda parte deste trabalho, um estudo de uma solução que melhore, simultaneamente o fator de potência e reduza as harmónicas presentes num posto de transformação localizado no seio da fábrica. Esta solução, permite melhorar a qualidade da energia elétrica e as condições de continuidade de serviço, garantindo melhores condições de exploração e incrementando a produtividade da empresa.

Condition-Based Diagnosis of Mechatronic Systems Using a Fractional Calculus Approach

While fractional calculus (FC) is as old as integer calculus, its application has been mainly restricted to mathematics. However, many real systems are better described using FC equations than with integer models. FC is a suitable tool for describing systems characterised by their fractal nature, long-term memory and chaotic behaviour. It is a promising methodology for failure analysis and modelling, since the behaviour of a failing system depends on factors that increase the model’s complexity. This paper explores the proficiency of FC in modelling complex behaviour by tuning only a few parameters. This work proposes a novel two-step strategy for diagnosis, first modelling common failure conditions and, second, by comparing these models with real machine signals and using the difference to feed a computational classifier. Our proposal is validated using an electrical motor coupled with a mechanical gear reducer.

Hard real-time multiprocessor scheduling resilient to core failures

Presented at 21st IEEE International Conference on Embedded and Real-Time Computing Systems and Applications (RTCSA 2015). 19 to 21, Aug, 2015, pp 122-131. Hong Kong, China.

Impacto da influência de um Sistema de Gestão Técnica Centralizada na redução dos custos de exploração de um edifício

É de conhecimento do meio, que os Sistemas de Gestão Técnica Centralizada (SGTC) são uma mais-valia para a redução de utilização de energia associados principalmente aos sistemas de Aquecimento, Ventilação e Ar Condicionado (AVAC) apesar das potencialidades serem abrangentes a outras áreas. No entanto, existe alguma lacuna quanto à quantificação dessa mais-valia, facto importante sobretudo para a alteração de mentalidades dos promotores e proprietários dos edifícios, que por falta de prova, normalmente apenas associam o SGTC a um investimento num serviço desnecessário. As potencialidades dos SGTC são muitas, a título de exemplo, redução na utilização de fontes de energia, gestão da manutenção de sistemas e equipamentos, análise de eficiências de equipamentos, entre muitas outras, sendo nesta dissertação estudado com mais profundidade a questão associada à diferença dos custos de exploração resultantes da utilização de energia num edifício por parte dos sistemas de AVAC, isto é, quais serão os ganhos na utilização da energia, associados ao sistema AVAC, que podem ser obtidos com a implementação de um SGTC. Para o efeito, utilizou-se os sistemas e equipamentos existentes no edifício ECOTERMOLAB, pertencente ao Instituto de Soldadura e Qualidade (ISQ), com o objetivo de verificar as diferenças de utilização de energia resultantes do funcionamento do edifício em normal atividade, isto é, o edifício com todos os seus sistemas operacionais, incluindo o SGTC, e o edifício em funcionamento sem o auxílio do SGTC, ou seja, todos os sistemas associados ao sistema AVAC em funcionamento em modo manual e sem recurso a variação de caudal na rede aeráulica e hidráulica. Em termos anuais, o ECOTERMOLAB consome, aproximadamente, cerca de 38,1 MWh de energia elétrica e 39,2 MWh de gás natural, o que representa uma utilização de energia primária de 14,4 tep/ano. Esta energia, representa um encargo financeiro anual de, aproximadamente, 9500€/ano, correspondente a 7000€/ano de energia elétrica e 2500€/ano de gás natural. Após a análise desenvolvida neste trabalho, conclui-se que o funcionamento do edifício sem controlo do sistema de AVAC por SGTC representaria em termos anuais a um aumento de, aproximadamente, 25,2 MWh e 6,2 MWh de energia elétrica e de gás natural, respetivamente. Em termos de energia primária, a diferença entre soluções origina um acréscimo na utilização de energia de 7,8 tep/ano o que representa um aumento de emissão de CO2 na ordem das 9,4 ton/ano. A avaliação económica, recaiu sobre a determinação de indicadores para avaliação da viabilidade de implementação de um SGTC, nomeadamente, o período de retorno simples, o valor atual líquido e a taxa interna de rentabilidade. Todos estes indicadores se revelaram positivos, apresentando um período de retorno ligeiramente superior a oito anos, um valor atual líquido positivo (8864,1€) e uma taxa interna de rentabilidade superior à taxa de custo de capital (11,2%).

Strength improvement of adhesively-bonded scarf repairs in aluminium structures with external reinforcements

Adhesively bonded techniques are an attractive option to repair aluminium structures, compared to more traditional methods. Actually, as a result of the improvement in the mechanical characteristics of adhesives, adhesive bonding has progressively replaced the traditional joining methods. There are several bonded repair configurations, as single-strap, double-strap and scarf. Compared with strap repairs, scarf repairs have the advantages of a higher efficiency and the absence of aerodynamic disturbance. The higher efficiency is caused by the elimination of the significant joint eccentricities of strap repairs. Moreover, stress distributions along the bond length are more uniform, due to tapering of the scarf edges. The main disadvantages of this technique are the difficult machining of the surfaces, associated costs and requirement of specialised labour. This work reports on an experimental and numerical study of the tensile behaviour of two-dimensional (2D) scarf repairs of aluminium structures bonded with the ductile epoxy adhesive Araldite® 2015. The numerical analysis, by Finite Elements (FE), was performed in Abaqus® and used cohesive zone models (CZM) for the simulation of damage onset and growth in the adhesive layer, thus enabling the strength prediction of the repairs. A parametric study was performed on the scarf angle (α) and different configurations of external reinforcement (applied on one or two sides of the repair, and also different reinforcement lengths). The obtained results allowed the establishment of design guidelines for repairing, showing that the use of external reinforcements enables increasing α for equal strength recovery, which makes the repair procedure easier. The numerical technique was accurate in predicting the repairs’ strength, enabling its use for design and optimisation purposes.

In Situ Breakage of Implanon® - Two Cases of a Rare Occurrence

BACKGROUND: In situ breakage of Implanon® is a rare occurrence with unknown clinical significance. Authors report two different cases of broken Implanon® of women attended at our Family Planning Clinic. DISCUSSION: In situ implants may spontaneously and asymptomatically break, although some uncertainty relies on whether that situation has a real impact on the contraceptive effectiveness or on bleeding patterns. Even more, it can be argued if, as a result of an occurrence of that nature, the implant shall or shall not be removed before the envisaged 3-year period of effectiveness. CONCLUSION: Currently, the clinical significance of implant breakage remains unknown. The decision to remove a broken or bent implant should be based on clinical judgements considering patients' wishes.

Safety management of cranes on construction sites in Portugal: Critical factors of safety

The evolution of the construction caused a need to use more effective equipments, capable of meeting the increasingly demanding deadlines for the completion of works. In this context, the safety and efficiency of equipment have become key aspects in order to optimize the execution time of the works, as well as reducing labor costs and loss of materials. With the evolution of construction and construction processes, cranes have come to represent a signal of the construction of buildings, revealing to be, in most of the cases, the main equipment of construction sites. Currently, some engineers revels some apprehension regarding the use and handling of cranes which is natural and acceptable, since an equipment failure can lead to serious or fatal accidents. The factors affecting safety management of the cranes in construction sites were investigated, identified, classified and evaluated according to their degree of importance, through interviews with representatives of the general contractors of a set of selected construction sites.

Late migration of percutaneous bio-absorbable devices--a word of caution.

BACKGROUND: Closures of atrial septal defects or a patent foramen ovale (PFO) are increasingly performed percutaneously. The experience of late migration of a new bio-absorbable device is presented here, followed by conceptual discussion. METHODS: Six months post PFO closure with a BioSTAR® device a patient presented with chest pain. Echocardiography showed a hyperechogenic structure perforating the aortic wall. RESULTS: Surgical exploration showed a perforation of the ascending aorta by one metallic, non absorbable arm. This is the second case of late (>6 months) dislocation of the residual framework of the occluder. CONCLUSIONS: The overall incidence of perforation of cardiac structures due to secondary dislocation is low. However this complication exists and should kept in mind in symptomatic patients with new onset of chest pain, after percutaneous procedures. The concept of biodegradation, with residual, non absorbable metal braiding, should be reviewed, analyzing in particular long term results and incidence of secondary dislocation.