Formation and retention of local melted films in AZ91 friction stir spot welds

The formation of local melted films during friction stir spot welding of as-cast AZ91D and thixomolded AZ91 material is investigated. The average temperatures close to the tip of the rotating pin vary from 438 to 454 °C during the dwell period in friction stir spot welding. These measured temperature values are higher than the melting temperature of α-Mg + Mg₁₇Al₁₂ eutectic (437 °C). It is suggested that the temperature in the stir zone during the dwell period is determined by the relative proportions of α-Mg and (α-Mg + Mg₁₇Al₁₂) eutectic material, which are incorporated during friction stir spot welding. Based on the stir zone temperature measurements and a detailed examination of material located at the root of the pin thread it is suggested that material is moved downwards via the pin thread and into the stir zone during the dwell period in friction stir spot welding. Evidence of local melted film formation is observed in the stir zone of AZ91 spot welds. It is suggested that melted films are retained since their dissolution rate is much slower in the high temperature stir zone than it is when melted films is formed in the stir zone during Al 7075-T6 friction stir spot welding. The spontaneous melting temperature, solute diffusion rate and the thermodynamic driving force for droplet dissolution are much higher during Al 7075-T6 friction stir spot welding.     

Small thermophotovoltaic prototype systems

In an earlier paper we reported on a small grid-connected thermophotovoltaic (TPV) system consisting of an ytterbia mantle emitter and silicon solar cells with 16% efficiency (under solar irradiance in standard test conditions, STCs). The emitter was heated up using a butane burner with a rated thermal power of 1.35 kW (referring to the lower heating value). This system produced an electrical output of 15 W, which corresponds to a thermal to electric (direct current) conversion efficiency of 1.1%. In the interim, further progress has been made, and significantly higher efficiencies have been achieved. The most important development steps are: (1) the infrared radiation-absorbing water filter between emitter and silicon cells (to protect the cells against overheating and against contact with flue gasses) has been replaced by a suitable glass tube. By doing this, it has been possible to prevent losses of convertible radiation in water. (2) Cell cooling has been significantly improved, in order to reduce cell temperature, and therefore increase conversion efficiency. (3) The shape of the emitter has been changed from spherical to a quasi-cylindrical geometry, in order to obtain a more homogeneous irradiation of the cells. (4) The metallic burner tube, on which the ytterbia emitter was fixed in the initial prototypes, has been replaced by a heat-resistant metallic rod, carrying ceramic discs as emitter holders. This has prevented the oxidation and clogging of the perforated burner tube. (5) Larger reflectors have been used to reduce losses in useful infrared radiation. (6) Smaller cells have been used, to reduce electrical series resistance losses. Applying all these improvements to the basic 1.35 kW prototype, we attained a system efficiency of 1.5%. By using preheated air for combustion (at approximately 370 °C), 1.8% was achieved. In a subsequent step, a photocell generator was constructed, consisting of high-efficiency silicon cells (21% STC efficiency). In this generator, the spaces between the cells were minimized, in order to achieve as high an active cell area as possible, while simultaneously reducing radiation losses. This new system has produced an electrical output of 48 W, corresponding to a system efficiency of 2.4%. This is the highest-ever-reported value in a silicon-cell-based TPV system using ytterbia mantle emitters. An efficiency of 2.8% was achieved by using preheated air (at approximately 500 °C). An electronic control unit (fabricated of components with low power consumption, and including a battery store) was developed, in order to make the TPV system self-powered. This unit controls the magnetic gas supply valve between gas supply cylinder and burner as well as the high-voltage ignition electrodes. Both the control unit’s own power consumption and the battery-charging power are supplied directly by the TPV generator. A small commercial inverter is used to transfer excess power to the 230 V grid.     

Fluctuations of Turbulent Bed Shear Stress

With the assumption that the bed shear stress fluctuates in a lognormal fashion, the probability density function (PDF) of the standardized bed shear stress is derived as a function of the relative shear stress intensity. The PDF is more skewed with larger relative intensities, but approaches a Gaussian function when the relative intensity is small. The computed PDF agrees well with the reported experimental data for flows over a smooth boundary. The higher-order moments of the bed shear stress, skewness, and kurtosis, are shown analytically to be also dependent on the relative intensity. The theoretical dependencies are then compared to a number of measurements available in the literature. The Reynolds number effect on the relative intensity is also discussed.     

Crystallization of Polymer-Derived Silicon Carbonitride at 1873 K under Nitrogen Overpressure

The chemical stability of an amorphous silicon carbonitride ceramic, having the composition 0.57SiC·0.43Si₃N₄·0.49C is studied as a function of nitrogen overpressure at 1873 K. The ceramic suffers a weight loss at p _N2 < 3.5 bar (1 bar = 100 kPa), does not show a weight change from 3.5 to 11 bar, and gains weight above 11 bar. The structure of the ceramic changes with pressure: it is crystalline from 1 to 6 bar, amorphous at ∼10 bar, and is crystalline above ∼10 bar. The weight-loss transition, at 3.5 bar, is in excellent agreement with the prediction from thermodynamic analysis when the activities of carbon, SiC, and Si₃N₄ are set equal to those of the crystalline forms; this implies that the material crystallizes before decomposition. The amorphous to crystalline transition that occurs at ∼10 bar, and which is accompanied by weight gain, is likely to have taken place by a different mechanism. A nucleation and growth reaction with the atmospheric nitrogen is proposed as the likely mechanism. The supersaturation required to nucleate α-Si₃N₄ crystals is calculated to be 30 kJ/mol.     

Pretreatment and physical activation of acetylene cokes

Pretreatment of acetylene cokes at 450 °C with a mixture of nitrogen, oxygen and water vapour creates a relatively large surface area and some initial microporosity, further developed by water activation at 800 °C. For the same degree of burn-off, but without pretreatment, large micropores (L > 2–3 nm) are obtained and the external surface area remains small.     

Gelling of alginate fibres

Equipment was developed to measure the time for complete gelling of sodium alginate fibres in calcium chloride solution, taken as the time to achieve maximum tensile strength. The effects of fibre diameter, alginate concentration, alginate composition and calcium chloride concentration on gelling time were investigated. A diffusional model, developed to predict the gelling time, agreed with experimental results except for the effect of calcium ion concentration which was modelled empirically.     

Location of Aluminum in Substituted Calcium Silicate Hydrate (C-S-H) Gels as Determined by 29Si and 27Al NMR and EELS

Solid-state ²⁷Al and ²⁹Si magic angle spinning NMR spectroscopy has been combined with electron energy loss spectroscopy carried out in the transmission electron microscope to determine the location of Al substituting in a semicrystalline C-S-H gel present in a hydrated synthetic slag glass. The gel is found to contain mainly pentameric silicate chains in which the central silicon is substituted by aluminum.     

Initial Stages in the Metal-dusting Process on Alloy 800

The initial stages of the metal-dusting process on Alloy 800 at 620 °C were investigated by light optical microscopy, RAMAN spectroscopy, atomic-force microscopy, Auger electron spectroscopy, transmission-electron microscopy and electron back-scatter diffraction. As it turned out the incubation period for metal-dusting is characterized by simultaneous formation of a heterogeneously growing oxide scale and deposition of carbon. The material surface shows different tarnish colors depending on the substrate-grain orientation with different susceptibility to the beginning of metal-dusting attack. “Low-index” grains were not attacked within the times investigated while the other grain orientations showed pitting. Carbon is evidently incorporated into the oxide scale from the very beginning of exposure with different intensities depending on the underlying substrate-grain orientation leading to differences in the tarnish colors. As a consequence carbides are formed even underneath “dense” oxide layers. Evidently metal-dusting attack starts at positions of the oxide scale where “higher carbon concentrations” are present.     

Novel aspects of the microstructure of PP/PA blends prepared by reactive compounding as studied by microhardness

The microhardness of injection-moulded i-polypropylene/polyamide (iPP/PA) blends prepared by reactive compounding was determined. The formulation rules and processing technology for the preparation of these alloys was reported previously. iPP/PA compositions between 100/0 and 50/50 using functionalized PP with various degrees of mainchain grafting, were investigated. It is shown that the deviation of microhardness from the additivity law of the single components is mainly due to a decrease in the crystallinity of the iPP phase. The results are discussed in the light of the microstructural variations as revealed by X-ray diffraction methods.