Hot Corrosion Behavior and Microstructural Change of Al-Gradient CoNiCrAlYSi Coatings, Produced by LVPS and Diffusional Processes

Conventional and gradient CoNiCrAlYSi coatings were produced by using low vacuum plasma spray and an additional step of diffusional over aluminizing (pack cementation) techniques on an Inconel-738 substrate. Hot corrosion of these coatings was investigated using Na₂SO₄–20wt%NaVO₃ molten salt at 880?°C for 800?h. Hot corrosion rate was determined by measuring the weight gain of the specimens at regular intervals for a duration of 20?h. X-ray diffraction, field emission scanning electron microscopy and electron probe micro analysis techniques were used to determine the nature of phases, investigation of the thermally grown oxide, examination of the surface attack and determination of the elemental distribution. The gradient coating showed better performance by re-healing alumina scale due to its possession of more β phase as Al reservoir. Results indicated that pack cementation process caused an increase in amount of aluminum-rich β phase and better hot corrosion properties of gradient coatings owing to the Al enrichment in the outer layer and rapid formation of protective oxide on the surface.     

A linear model of elasto-plastic and adhesive contact deformation

Rigorous non-linear models of elasto-plastic contact deformation are time-consuming in numerical calculations for the distinct element method (DEM) and quite often unnecessary to represent the actual contact deformation of common particulate systems. In this work a simple linear elasto-plastic and adhesive contact model for spherical particles is proposed. Plastic deformation of contacts during loading and elastic unloading, accompanied by adhesion are considered, for which the pull-off force increases with plastic deformation. Considering the collision of a spherical cohesive body with a rigid flat target, the critical sticking velocity and coefficient of restitution in the proposed model are found to be very similar to those of Thornton and Ning’s model. Sensitivity analyses of the model parameters such as plastic, elastic, plastic-adhesive stiffnesses and pull-off force on work of compaction are carried out. It is found that by increasing the ratio of elastic to plastic stiffness, the plastic component of the total work increases and the elastic component decreases. By increasing the interface energy, the plastic work increases, but the elastic work does not change. The model can be used to efficiently represent the force-displacement of a wide range of particles, thus enabling fast numerical simulations of particle assemblies by the DEM.     

Zeolite filled polyimide membranes for dehydration of isopropanol through pervaporation process

Six mixed matrix membranes (MMMs) were prepared using zeolites of 4A and ZSM-5 incorporated in polyimide of Matrimid 5218. Effects of filler type on membrane morphology and pervaporation performance of MMMs were investigated using isopropanol dehydration. In addition, effects of operating temperature (30, 40, 50, and 60 °C), feed water concentration (10, 20, 30, and 40 wt.%) and permeate side pressure (0 and 15 torr) on pervaporation performance were studied. Scanning electron microscopy (SEM) analysis showed there were good adhesion between the fillers and the polymer matrix. Zeolite 4A has a better contact with the polymer phase and thereby nearly no void is formed in the MMM structure. Pervaporation were performed based on L16 array of Taguchi method for design of experiments. The results showed that the best separation condition is achieved at temperature, feed water concentration, and permeate pressure of 30 °C, 10 wt.% water and 0 torr, respectively. Selectivities of zeolites 4A and ZSM-5 filled MMMs were calculated as 8991 and 3904 compared with 1276 measured for the neat Matrimid 5218 membrane. Permeation rates of the zeolite 4A and ZSM-5 filled MMMs and the neat polymeric membrane were found to be 0.018, 0.016, and 0.013 kg/m² h, respectively.     

A probabilistic approach for video stabilisation in compressed domain

Machine vision systems, which are being extensively used for intelligent transportation applications, such as traffic monitoring and automatic navigation, suffer from image instability caused by environment unstable conditions. On the other hand, by increasing the use of home video cameras which sometimes need to remove unwanted camera movement, which is created by cameraman shaking hands, video stabilisation algorithms are being considered. The video stabilisation process consists of three essential phases: global motion estimation, intentional motion estimation and motion compensation. Motion estimation process is the main time consuming part of global motion estimation phase. Using motion vectors extracted directly from MPEG compressed video, instead of any other special feature, can increase the algorithm generality. In addition, it provides the facility for integrating video stabilisation and video compression subsystems and removing the block matching phase from video stabilisation procedure. Elimination of any iterative outlier removal preprocessing and adaptive selection of motion vectors has increased speed of the algorithm. Although deterministic approaches are faster than the related probabilistic methods, they have essential problems in escaping from local optima. For this purpose, particle filters, the ability of which is considerable when submitted to non-linear systems with non-Gaussian noises, are utilised. Setting the parameters of the particle filter using a fuzzy control system reduces the incorrect intentional camera motion removal. The proposed method is simulated and applied to video stabilisation problem and its high performance on various video sequences is demonstrated.     

The effect of substrate surface integrity on the surface properties of TiCrN coating applied via the CAE-PVD method

This study aims to investigate how the predeposition machining processes such as magnetic grinding, turning machining, and wire electrical discharge machining can influence the surface properties including electrochemical and tribological behavior of TiCrN nanostructured coating applied on Mo40 steel substrate. A physical vapor deposition technique using cathodic arc evaporation was used to apply the coating. The crystallographic phases and the microstructure of the coating were studied by X-ray diffraction and scanning electron microscope, respectively. Rockwell-C, electrochemical impedance spectroscopy and potentiodynamic polarization, and pin-on-disk wear tests were employed to evaluate the adhesion strength, corrosion behavior, and tribological property of specimens, respectively. The electrochemical results after 24 h of exposure to 3.5 wt% NaCl solution showed that TiCrN coating pretreated with a turning process with polarization resistance of about 3525.32 Ω.cm² had the best corrosion resistance among all specimens. This was because of the improvement of the smoothness, surface quality, and adhesion after the turning process. On the other, the friction coefficient of the grounded sample is less than that of other ones. This is probably due to its higher adhesion strength and higher surface smoothness.     

Fault diagnosis of an automobile cylinder head using low frequency vibrational data

This paper proposes a vibration-based fault-diagnosis method for mechanical parts. This method, after algorithm development, only requires a single inexpensive test to inspect the part which could take as short as half a second. The algorithm is developed in three major stages, (i) exciting specimens without or with known faults using a controlled force and recording acceleration of a single point for a short time (ii) finding a signature for each faulty specimen, using Fourier transform and statistical analysis. (iii) Developing a multi-layer perceptron, as a mathematical model, using the results of stage (ii). The elements of a part signature are the inputs to the model. The location (and possibly size and shape factor) of the fault is model output. Stage (i) can be performed experimentally or alternatively with a validated FEM, one experiment or simulation per specimen. The proposed technique was examined to locate (isolate) a fault on an automobile cylinder head. The presented accuracy is considerable, and the data collected at fairly low frequency range (below 1200 Hz) were found to be sufficient for this technique. In the case study of this paper, possible fault locations are on a line; as a result, fault location has one dimension. It is shown that the technique can be extended to higher dimensions.     

Ternary gas permeation through synthesized pdms membranes: Experimental and CFD simulation basedon sorption‐dependent system using neural network model

In this study, a predictive model for the separation of gases via a polydimethylsiloxane (PDMS) membrane has been developed. This model takes into account the effects of gas composition and pressure at the membrane surfaces on the gas sorption and diffusion coefficients in the membrane. Computational fluid dynamics (CFD) modeling has been employed in order to predict the behavior of a gas mixture containing C₃H₈, CH₄, and H₂ at various operating conditions and three zones (upstream, downstream, and membrane body). Artificial neural network (ANN) modeling has been applied to predict sorption and diffusion coefficients of each component of the gas mixture in the membrane. A procedure of calculation has been applied to combine the CFD modeling and the ANN modeling in order to predict sorption, diffusion, and composition of each component at various sites of the membrane. The results determined using the developed prediction model have been found to be in agreement with those determined using experimental investigations with an average error of 10.21%. POLYM. ENG. SCI., 54:215–226, 2014. © 2013 Society of Plastics Engineers     

Mechanochemical sulfidization of a mixed oxide-sulphide copper ore by co-grinding with sulfur and its effect on the flotation efficiency

Mechanochemical sulfidization of a mixed sulfide/oxide copper ore by co-grinding with sulfur and additives including Mg(NO₃)₂ and Fe(NO₃)₃ salts and iron, aluminum and magnesium powders was investigated for the first time. Also, the influence of sulfidization during the wet-milling process was examined on the separation efficiency and recovery of copper in detail. The results demonstrated that co-grinding with sulfur solely had the best flotation performance at the value of 0.5 wt.% and it was attributed to the possible existence of S-O bonding on copper oxides surfaces. In addition, adding magnesium nitrate salt, magnesium powder, iron nitrate salt and aluminum powder as additive associated with 0.5 wt% sulfur into ball milling caused the flotation improvement at the amounts of 0.2 wt%, 0.2 wt%, 0.5 wt% and 0.5 wt%, respectively. Also, the effect of grinding time and sulfidization pH with 0.5 wt% sulfur solely was determined and pHs of 7.5 to 8.5 gave the best results. The highest recovery (75.76%) and separation efficiency (63.44%) were achieved at pH of 7.5 and 8.5, respectively.