Study of dendrite growth in a rotational flow field

A numerical model to study the growth of dendrites in a pure metal solidification process with an imposed rotational flow field is presented. The micro-scale features of the solidification are modeled by the well-known enthalpy technique. The effect of flow changing the position of the dendrite is captured by the Volume of Fluid (VOF) method. An imposed rigid-body rotational flow is found to gradually transform the dendrite into a globular microstructure. A parametric study is carried out for various angular velocities and the time for merger of dendrite arms is compared with the order estimate obtained from scaling.

EVOLUTION OF DEFORMATION FIELDS IN PLOUGHING OF SAND

This paper reports on an experimental study on the ploughing or orthogonal cutting in sand. Plane strain cutting or ploughing experiments were carried out on model Ottawa sand while being imaged at high resolution. The images obtained were further processed using image analysis and the evolution of the velocity and deformation fields were obtained from these analysis. The deformation fields show the presence of a clear shear zone in which the sand accrues deformation. A net change in the direction of the velocity of the sand is also clearly visible. The effective depth of cut of the sand also increases with continuous cutting as the sand reposes on itself. This deformation mechanics at the incipient stages of cutting is similar to that observed in metal cutting.

Depuración de aguas residuales urbanas y concentración de metales en fangos digeridos

[ES] La progresiva implantación de plantas de tratamiento de aguas residuales urbanas ha ido estableciendo una experiencia en el conocimiento de la eficacia de tratamiento de los diversos parámetros en plazos largos de funcionamiento. El análisis y comparación de resultados y tecnologías debe pennitir conocer las características de fiabilidad en la operación y el comportamiento frente a los diversos aspectos de la nonnativa legal. Además, el análisis en diferentes épocas del año puede producir distintos resultados o conclusiones. En este trabajo se ha tomado para el análisis una planta de tratamiento convencional, estudiando inicialmente los porcentajes medios de eliminación de diferentes parámetros, en relación asimismo con las necesidades que debe satisfacer. En condiciones de alta carga orgánica, la concentración de nitrógeno y algún tóxico especial parecen plantear las mayores dificultades. Se ha deseado focalizar la atención en el proceso de concentración de metales que se. produce en las plantas con tratamiento anaerobío de fangos. Por este motivo se Uevó a cabo un estudio de la evolución de metales en la depuración y la concentración de fangos digeridos. El fenómeno resulta de interés para analizar la calidad de las aguas que se obtienen, aunque debe considerarse también la concentración de metales en el destino final que se dé a los fangos tratados.

Unnatural amino acids in the synthesis and semisynthesis of metalloprotein motifs

The design, synthesis, and characterization of two novel metalloprotein motifs is presented. The first project involved the design and construction of a protein motif which was programmed to form a tetradentate metal complex upon the addition of metal cations. The overall structure of the motif was based on a ββ super-secondary structure consisting of a flexible peptide sequence flanked by metal binding regions located at the carboxy and amino termini. The metal binding region near the amino terminus was constructed from a reverse turn motif with two metal ligating residues, (2R, 3R)-β-methyl-cysteine and histidine. Selection of the peptide sequence for this region was based on the conformational analysis of a series of tetrapeptides designed to form reverse turns in solution.

The stereospecific syntheses of a series of novel bipyridyl- and phenanthrolylsubstituted amino acids was carried out to provide ligands for the carboxy terminus metal binding region. These residues were incorporated into peptide sequences using solid phase peptide synthesis protocols, and metal binding studies indicated that the metal binding properties of these ligands was dictated by the specific regioisomer of the heteroaromatic ring and the peptide primary sequence.

Finally, a peptide containing optimized components for the metal binding regions was prepared to test the ability of the compound to form the desired intramolecular peptide:metal cation complexes. Metal binding studies demonstrated that the peptide formed monomeric complexes with very high metal cation binding affinities and that the two metal binding regions act cooperatively in the metal binding process. The use of these systems in the design of proteins capable of regulating naturally occurring proteins is discussed.

The second project involved the semisynthesis of two horse heart cytochrome c mutants incorporating the bipyridyl-amino acids at position 72 of the protein sequence. Structural studies on the proteins indicated that the bipyridyl amino acids had a neglible effect on the protein structure. One of the mutants was modified with Ru(bpy)_2^(+2) to form a redox-active protein, and the modified protein was found to have enhanced electron transfer properties between the heme and the introduced metal site.

Radially polarized and pulsed output from passively Q-switched Nd:YAG ceramic microchip laser

For the first time, to the best of our knowledge, a radially polarized laser pulse was produced from a passively Q-switched Nd:YAG ceramic microchip laser with a piece of Cr4+:YAG crystal as the saturable absorber and multilayer concentric subwavelength grating as the polarization-selective output coupler. The averaged laser power reached 450 mW with a slope efficiency of 30.2%. The laser pulse had a maximum peak power of 759 W, a minimum pulse duration of 86 ns, and a 6.7 kHz repetition rate at 3.7 W absorbed pump power. The polarization degree of the radially polarized pulse was measured to be as high as 97.4%. Such a radially polarized laser pulse with a high peak power and a short width is important to numerous applications such as metal cutting. (C) 2008 Optical Society of America

Nonlinear drillstring dynamics analysis

This paper studies the dynamical response of a rotary drilling system with a drag bit, using a lumped parameter model that takes into consideration the axial and torsional vibration modes of the bit. These vibrations are coupled through a bit-rock interaction law. At the bit-rock interface, the cutting process introduces a state-dependent delay, while the frictional process is responsible for discontinuous right-hand sides in the equations governing the motion of the bit. This complex system is characterized by a fast axial dynamics compared to the slow torsional dynamics. A dimensionless formulation exhibits a large parameter in the axial equation, enabling a two-time-scales analysis that uses a combination of averaging methods and a singular perturbation approach. An approximate model of the decoupled axial dynamics permits us to derive a pseudoanalytical expression of the solution of the axial equation. Its averaged behavior influences the slow torsional dynamics by generating an apparent velocity weakening friction law that has been proposed empirically in earlier work. The analytical expression of the solution of the axial dynamics is used to derive an approximate analytical expression of the velocity weakening friction law related to the physical parameters of the system. This expression can be used to provide recommendations on the operating parameters and the drillstring or the bit design in order to reduce the amplitude of the torsional vibrations. Moreover, it is an appropriate candidate model to replace empirical friction laws encountered in torsional models used for control. © 2009 Society for Industrial and Applied Mathematics.

Steel and aluminium in a low carbon future

Production of steel and aluminium creates 10% of global carbon emissions from energy and processes. Demand is likely to double by 2050, but climate scientists are recommending absolute reductions of at least 50% and these are Increasingly entering law. How can reductions of this order happen? Only 10-20% savings can be expected in liquid metal production, so the primary industry is pursuing carbon sequestration as the main solution. However, this Is as yet unproven at scale, and as well as carrying some risk, the capital and operating costs are likely to be high, but are as yet unknown. In parallel with these strategies we can also examine whether we can reduce demand for liquid metal. 'Material efficiency' may allow delivery of existing services with less requirement for metal, for instance through designing products that use less metal, reducing process scrap, diverting scrap for other use, re-using components or delaying end of life. Overall demand reduction could occur if goods were used more intensely, alternative means were used to deliver the same services, or total demand were constrained. The paper analyses all possible options, to define and evaluate scenarios that meet the 2050 target, and discuss the steps required to bring them about. The paper concludes with suggestions for key areas where future research In metal forming can support a future low carbon economy. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

Mobilization potential of heavy metals: A comparison between river and lake sediments

Toxic metals introduced into aquatic environments by human activities accumulation in sediments. A common notion is that the association of metals with acid volatile sulfides (AVS) affords a mechanism for partitioning metals from water to solid phase, thereby reducing biological availability. However, variation in environmental conditions can mobilize the sediment-bound metal and result in adverse environmental impacts. The AVS levels and the effect of AVS on the fate of Cu, Cd, Zn, Ni in sediments in the the Changjiang River, a suboxic river with sandy bottom sediment and the Donghu Lake, a anoxic lake with muddy sediment in China, were compared through aeration, static adsorption and release experiments in laboratory. Sips isotherm equation, kinetic equation and grade ion exchange theory were used to describe the heavy metal adsorb and release process. The results showed that AVS level in the lake sediment are higher than that of the river. Heavy metals in the overlying water can transfer to sediments incessantly as long as the sediment remains undisturbed. The metal release process is mainly related to AVS oxidation in lake sediment while also related to Org-C and Fe-Mn oxyhydroxide oxidation in river sediment. The effect of sulfides on Zn and Ni is high, followed by Cd, and Cu is easy bound to Org-C. AVS plays a major role in controlling metals activity in lake sediment and its presence increase the adsorption capacity both of the lake and river sediments.

Domain decomposition methods for welding problems

This paper, a 2-D non-linear electric arc-welding problem is considered. It is assumed that the moving arc generates an unknown quantity of energy which makes the problem an inverse problem with an unknown source. Robust algorithms to solve such problems e#ciently, and in certain circumstances in real-time, are of great technological and industrial interest. There are other types of inverse problems which involve inverse determination of heat conductivity or material properties [CDJ63][TE98], inverse problems in material cutting [ILPP98], and retrieval of parameters containing discontinuities [IK90]. As in the metal cutting problem, the temperature of a very hot surface is required and it relies on the use of thermocouples. Here, the solution scheme requires temperature measurements lied in the neighbourhood of the weld line in order to retrieve the unknown heat source. The size of this neighbourhood is not considered in this paper, but rather a domain decomposition concept is presented and an examination of the accuracy of the retrieved source are presented. This paper is organised as follows. The inverse problem is formulated and a method for the source retrieval is presented in the second section. The source retrieval method is based on an extension of the 1-D source retrieval method as proposed in [ILP].

Insight Extraction for Semiconductor Manufacturing Processes

In the semiconductor manufacturing environment it is very important to understand which factors have the most impact on process outcomes and to control them accordingly. This is usually achieved through design of experiments at process start-up and long term observation of production. As such it relies heavily on the expertise of the process engineer. In this work, we present an automatic approach to extracting useful insights about production processes and equipment based on state-of-the-art Machine Learning techniques. The main goal of this activity is to provide tools to process engineers to accelerate the learning-by-observation phase of process analysis. Using a Metal Deposition process as an example, we highlight various ways in which the extracted information can be employed.

A linear optimization approach to the combined production planning model

Two fundamental processes usually arise in the production planning of many industries. The first one consists of deciding how many final products of each type have to be produced in each period of a planning horizon, the well-known lot sizing problem. The other process consists of cutting raw materials in stock in order to produce smaller parts used in the assembly of final products, the well-studied cutting stock problem. In this paper the decision variables of these two problems are dependent of each other in order to obtain a global optimum solution. Setups that are typically present in lot sizing problems are relaxed together with integer frequencies of cutting patterns in the cutting problem. Therefore, a large scale linear optimizations problem arises, which is exactly solved by a column generated technique. It is worth noting that this new combined problem still takes the trade-off between storage costs (for final products and the parts) and trim losses (in the cutting process). We present some sets of computational tests, analyzed over three different scenarios. These results show that, by combining the problems and using an exact method, it is possible to obtain significant gains when compared to the usual industrial practice, which solve them in sequence. (C) 2010 The Franklin Institute. Published by Elsevier Ltd. All rights reserved.

Control and chaos for vibro-impact and non-ideal oscillators

In the paper, we discuss dynamics of two kinds of mechanical systems. Initially, we consider vibro-impact systems which have many implementations in applied mechanics, ranging from drilling machinery and metal cutting processes to gear boxes. Moreover, from the point of view of dynamical systems, vibro-impact systems exhibit a rich variety of phenomena, particularly chaotic motion. In this paper, we review recent works on the dynamics of vibro-impact systems, focusing on chaotic motion and its control. The considered systems are a gear-rattling model and a smart damper to suppress chaotic motion. Furthermore, we investigate systems with non-ideal energy source, represented by a limited power supply. As an example of a non-ideal system, we analyse chaotic dynamics of the damped Duffing oscillator coupled to a rotor. Then, we show how to use a tuned liquid damper to control the attractors of this non-ideal oscillator.

Ex Situ Scanning Electrochemical Microscopy (SECM) Investigation of Bismuth- and Bismuth/Lead Alloy Film-Modified Gold Electrodes in Alkaline Medium

Scanning electrochemical microscopy (SECM) in feedback mode was employed to characterise the reactivity and microscopic peculiarities of bismuth and bismuth/lead alloys plated onto gold disk substrates in 0.1 molL(-1) NaOH solutions. Methyl viologen was used as redox mediator, while a platinum microelectrode was employed as the SECM tip. The metal films were electrodeposited ex situ from NaOH solutions containing either bismuth ions only or both bismuth and lead ions. Approach curves and SECM images indicated that the metal films were conductive and locally reactive with oxygen to provide Bi(3+) and Pb(2+) ions. The occurrence of the latter chemical reactions was verified by local anodic stripping voltammetry (ASV) at the substrate solution interface by using a mercury-coated platinum SECM tip. The latter types of measurements allowed also verifying that lead was not uniformly distributed onto the bismuth film electrode substrate. These findings were confirmed by scanning electron microscopy images. The surface heterogeneity produced during the metal deposition process, however, did not affect the analytical performance of the bismuth coated gold electrode in anodic stripping voltammetry for the determination of lead in alkaline media, even in aerated aqueous solutions. Under the latter conditions, stripping peak currents proportional to lead concentration with a satisfactory reproducibility (within 5% RSD) were obtained.

Production and Delivery (Optimization of production system and reliability)

This thesis is done to solve two issues for Sayid Paper Mill Ltd Pakistan. Section one deals with a practical problem arise in SPM that is cutting a given set of raw paper rolls of known length and width, and a set of product paper rolls of known length (equal to the length of raw paper rolls) and width, practical cutting constraints on a single cutting machine, according to demand orders for all customers. To solve this problem requires to determine an optimal cutting schedule to maximize the overall cutting process profitability while satisfying all demands and cutting constraints. The aim of this part of thesis is to develop a mathematical model which solves this problem.Second section deals with a problem of delivering final product from warehouse to different destinations by finding shortest paths. It is an operational routing problem to decide the daily routes for sending trucks to different destination to deliver their final product. This industrial problem is difficult and includes aspect such as delivery to a single destination and multiple destinations with limited resources. The aim of this part of thesis is to develop a process which helps finding shortest path.

Numerical simulation of heat and mass transfer in fluidised bed heat treatment furnaces

In this paper, a novel combined theoretical and computational model is developed to simulate the heat and mass transfer between a fluidised bed and a workpiece surface, and within the workpiece by considering the fluidised bed as a medium consisting of a double-particle layer and an even porous layer. The heat and mass-transfer flux from the fluidised bed to the workpiece surface is contributed by dense and bubble phases, respectively. The convective heat and mass transfer is simulated by analysing the gas dynamics in the fluidised bed, while radiative heat transfer is modelled by simulating photon emission in a three-dimensional particle array. The simulation shows that convection is approximately constant, while radiation contributes significantly to the heat transfer. The heat-transfer coefficient on an immersed surface near particles is about 6–10 times that on other areas. The transient heat and mass-transfer coefficient, heat and mass-transfer flux on any surface of the workpiece, transient temperature and carbon distributions at any position of the workpiece during the metal carburising process are studied with the simulation.