Pub Date : 2023-06-01DOI: 10.5604/01.3001.0053.7662
L. M. Hasan, A. Ali
In this study, an environmentally friendly metal matrix was prepared, and the influence of eggshell powder and CaCO3 particles on the tensile strength and hardness of recycled aluminium were assessed.A matrix made of recycled aluminium was employed. Calcium carbonate and eggshells served as the study's reinforcing materials. Separately, weight percentages of 2, 4, and 8% of eggshell and calcium carbonate were used. The samples were made by sand-casting.The results showed that both eggshell and calcium carbonate positively affect the hardness, yield, and ultimate tensile strength of recycled aluminium. The hardness values were improved as the percentage of the eggshell increased. The maximum hardness was achieved at 2% calcium carbonate. Similarly, the highest improvement of yield strength was for 2% CaCO3 addition, while the highest tensile strength was obtained at 8% eggshell addition.To get better results, it would be desirable to use finer eggshells than those utilized in this study.Composites made with an aluminium matrix exhibit exceptional mechanical and physical characteristics. The most challenging obstacle to overcome is the cost of metal matrix composites. Eggshells are a by-product that could be employed as a lightweight, affordable form of reinforcement. One way to get rid of this by-product, improve composite characteristics, and lower the cost of aluminium composite is to use eggshells.A comparative investigation was carried out to determine the effects of adding agricultural by-product eggshell, and commercial CaCO3 reinforcement material on the characteristics of recycled aluminium matrix integrated 425 m sized eggshell and CaCO3 separately as a reinforcement material to create a metal matrix that is beneficial to the environment.
{"title":"Assessment of eggshell and CaCO3 reinforced recycled aluminium green metal matrix","authors":"L. M. Hasan, A. Ali","doi":"10.5604/01.3001.0053.7662","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7662","url":null,"abstract":"In this study, an environmentally friendly metal matrix was prepared, and the influence of eggshell powder and CaCO3 particles on the tensile strength and hardness of recycled aluminium were assessed.A matrix made of recycled aluminium was employed. Calcium carbonate and eggshells served as the study's reinforcing materials. Separately, weight percentages of 2, 4, and 8% of eggshell and calcium carbonate were used. The samples were made by sand-casting.The results showed that both eggshell and calcium carbonate positively affect the hardness, yield, and ultimate tensile strength of recycled aluminium. The hardness values were improved as the percentage of the eggshell increased. The maximum hardness was achieved at 2% calcium carbonate. Similarly, the highest improvement of yield strength was for 2% CaCO3 addition, while the highest tensile strength was obtained at 8% eggshell addition.To get better results, it would be desirable to use finer eggshells than those utilized in this study.Composites made with an aluminium matrix exhibit exceptional mechanical and physical characteristics. The most challenging obstacle to overcome is the cost of metal matrix composites. Eggshells are a by-product that could be employed as a lightweight, affordable form of reinforcement. One way to get rid of this by-product, improve composite characteristics, and lower the cost of aluminium composite is to use eggshells.A comparative investigation was carried out to determine the effects of adding agricultural by-product eggshell, and commercial CaCO3 reinforcement material on the characteristics of recycled aluminium matrix integrated 425 m sized eggshell and CaCO3 separately as a reinforcement material to create a metal matrix that is beneficial to the environment.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"30 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87982661","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-06-01DOI: 10.5604/01.3001.0053.7666
A. Kania, M. Polok-Rubiniec, A. Włodarczyk-Fligier
of this paper is to propose modernisation activities, including the improvement of machines and devices that will increase work safety during the epidemic state for the workplace of an injection moulding machine operator in a selected manufacturing company.In the work brief analyses of a production line and a workplace of an injection moulding machine operator were carried out. Then the threats that occur at the analysed workplace were identified. The risk assessment was done using three methods: matrix according to the PN-N-18002:2011 standard, Risk Score and PHA.The results of the occupational risk assessment obtained by the three assessment methods were similar and gave similar results. The greatest and unacceptable risk has occurred for the threat of SARS-CoV-2 virus infection. Therefore, the following modernisation solutions were proposed: the introduction of mandatory epidemiological questionnaires, online training for company employees, the use of a three-axis robot, replacement of traditional disinfection dispensers with automatic ones.The results of re-assessing the occupational risk after introducing the proposed improvements showed that the occupational risk was significantly reduced mainly to the low or very low levels.The proposed modernisation solutions at the workplace of an injection moulding machine operator can be used for each workplace and each epidemiological state.
{"title":"Modernisation of the workplace as a result of the outbreak of the pandemic","authors":"A. Kania, M. Polok-Rubiniec, A. Włodarczyk-Fligier","doi":"10.5604/01.3001.0053.7666","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7666","url":null,"abstract":"of this paper is to propose modernisation activities, including the improvement of machines and devices that will increase work safety during the epidemic state for the workplace of an injection moulding machine operator in a selected manufacturing company.In the work brief analyses of a production line and a workplace of an injection moulding machine operator were carried out. Then the threats that occur at the analysed workplace were identified. The risk assessment was done using three methods: matrix according to the PN-N-18002:2011 standard, Risk Score and PHA.The results of the occupational risk assessment obtained by the three assessment methods were similar and gave similar results. The greatest and unacceptable risk has occurred for the threat of SARS-CoV-2 virus infection. Therefore, the following modernisation solutions were proposed: the introduction of mandatory epidemiological questionnaires, online training for company employees, the use of a three-axis robot, replacement of traditional disinfection dispensers with automatic ones.The results of re-assessing the occupational risk after introducing the proposed improvements showed that the occupational risk was significantly reduced mainly to the low or very low levels.The proposed modernisation solutions at the workplace of an injection moulding machine operator can be used for each workplace and each epidemiological state.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"26 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75438989","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-06-01DOI: 10.5604/01.3001.0053.7661
Alaa Almansoori, R. Ghadban, M.H. Ali, M. Sabri
The present study aims to evaluate the effect of montmorillonite nanoclay (MMT) and waste glass powder (WGP) on the hardness and thermal conductivity of PMMA polymer composites. Thus, this study concentrates on the potential use of MMT and WGP as reinforcements, in different concentrations, in PMMA polymer matrix, with the expectation of improving the performance of PMMA polymer composites in various applications.There is a growing demand for PMMA with increased mechanical properties and thermal stability for applications where inorganic glass would fail. Montmorillonite (MMT) clay and Waste Glass Powder (WGP) have physical and chemical properties compatible with PMMA. Therefore, they could potentially enhance PMMAs hardness and thermal conductivity. Silicon dioxide in glass silica and MMT and octahedral aluminium hydroxide sheet in MMT can strengthen both covalent and hydrogen bonding architecture in PMMA composite for better mechanical strength and thermal conductivity. Thus, PMMA composites were designed by combining MMT powder and WGP powder in different ratios before being incorporated into the PMMA polymer matrix and tested for hardness and thermal conductivity.The present study measured Brinell Hardness (HB) and electrical conductivity values of four PMMA composites containing different proportions of MMT and WGP. MMT/WGP filler mix had optimal hardiness (HB number = 74) when glass content was 1% (3MMT1G) or better still (HB number = 63) when an equal mix ratio was used (1MMT1G). PMMA composite with 3MMT1G also had the highest thermal conductivity (0.01899W/m.K-1). However, the higher the glass content, the lower the thermal conductivity of the PMMA composite. Thus, the present study has demonstrated that 3MMT1G filler was the best for enhancing the thermal and mechanical properties of PMMA composite.The results of this study demonstrate the potential of this new composite material for a variety of applications. Further research is needed to explore the full potential of this material and to develop new and improved versions.Reusing waste glass as filler materials in composites requires minimal processing and therefore has lower environmental impacts than synthetic options.Experimental data from the present study has provided new insights into Glass/MMT mix design in PMMA composites. The PMMA composite containing 3MMT1G exhibited the best hardness and thermal conductivity characteristics. Thus, the present study has successfully optimised Glass/MMT mix design for PMMA composite for applications requiring these features.
{"title":"Studying the influence of waste glass and montmorillonite powders on the thermal conductivity and hardness of poly(methyl methacrylate) polymer matrix","authors":"Alaa Almansoori, R. Ghadban, M.H. Ali, M. Sabri","doi":"10.5604/01.3001.0053.7661","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7661","url":null,"abstract":"The present study aims to evaluate the effect of montmorillonite nanoclay (MMT) and waste glass powder (WGP) on the hardness and thermal conductivity of PMMA polymer composites. Thus, this study concentrates on the potential use of MMT and WGP as reinforcements, in different concentrations, in PMMA polymer matrix, with the expectation of improving the performance of PMMA polymer composites in various applications.There is a growing demand for PMMA with increased mechanical properties and thermal stability for applications where inorganic glass would fail. Montmorillonite (MMT) clay and Waste Glass Powder (WGP) have physical and chemical properties compatible with PMMA. Therefore, they could potentially enhance PMMAs hardness and thermal conductivity. Silicon dioxide in glass silica and MMT and octahedral aluminium hydroxide sheet in MMT can strengthen both covalent and hydrogen bonding architecture in PMMA composite for better mechanical strength and thermal conductivity. Thus, PMMA composites were designed by combining MMT powder and WGP powder in different ratios before being incorporated into the PMMA polymer matrix and tested for hardness and thermal conductivity.The present study measured Brinell Hardness (HB) and electrical conductivity values of four PMMA composites containing different proportions of MMT and WGP. MMT/WGP filler mix had optimal hardiness (HB number = 74) when glass content was 1% (3MMT1G) or better still (HB number = 63) when an equal mix ratio was used (1MMT1G). PMMA composite with 3MMT1G also had the highest thermal conductivity (0.01899W/m.K-1). However, the higher the glass content, the lower the thermal conductivity of the PMMA composite. Thus, the present study has demonstrated that 3MMT1G filler was the best for enhancing the thermal and mechanical properties of PMMA composite.The results of this study demonstrate the potential of this new composite material for a variety of applications. Further research is needed to explore the full potential of this material and to develop new and improved versions.Reusing waste glass as filler materials in composites requires minimal processing and therefore has lower environmental impacts than synthetic options.Experimental data from the present study has provided new insights into Glass/MMT mix design in PMMA composites. The PMMA composite containing 3MMT1G exhibited the best hardness and thermal conductivity characteristics. Thus, the present study has successfully optimised Glass/MMT mix design for PMMA composite for applications requiring these features.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"48 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75702039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-01DOI: 10.5604/01.3001.0053.7286
F.E. Jabri, A. Ouballouch, L. Lasri, R. El alaiji
This review analyses different approaches used to study selective laser sintering (SLS) technology of polymer materials. These main approaches concern: thermal behaviour, fatigue and surface roughness.Regarding the first behaviour, researchers extensively studied the impact of process parameters, including scan speed, laser, power and laser energy density, on the thermal behaviour of 3D printed parts. Numerical and experimental analyses are used to conduct process parameter evaluations.Laser power and scan speed are the most significant parameters of the laser energy density. For the second, according to test protocols and quantitative analysis performed, the authors concluded that the combination of small and large laser energy density particles generates higher sintering and better fatigue resistance. Moreover, tensile analysis in different environments showed that testing in the water decreased the fatigue life of polymer samples. The influence of process parameters on the mechanical properties and surface roughness of 3D parts is also analysed. In addition, the investigators found that the additives increase the surface roughness of 3D printed parts.This review shows that researchers can focus on creating a combination of these approaches to expand the use of this process for industrial part production.All these investigations have made it possible to determine the optimal process conditions to ensure higher quality, optimal surface quality and better fatigue strength.
{"title":"A comprehensive review of polymer materials and selective laser sintering technology for 3D printing","authors":"F.E. Jabri, A. Ouballouch, L. Lasri, R. El alaiji","doi":"10.5604/01.3001.0053.7286","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7286","url":null,"abstract":"This review analyses different approaches used to study selective laser sintering (SLS) technology of polymer materials. These main approaches concern: thermal behaviour, fatigue and surface roughness.Regarding the first behaviour, researchers extensively studied the impact of process parameters, including scan speed, laser, power and laser energy density, on the thermal behaviour of 3D printed parts. Numerical and experimental analyses are used to conduct process parameter evaluations.Laser power and scan speed are the most significant parameters of the laser energy density. For the second, according to test protocols and quantitative analysis performed, the authors concluded that the combination of small and large laser energy density particles generates higher sintering and better fatigue resistance. Moreover, tensile analysis in different environments showed that testing in the water decreased the fatigue life of polymer samples. The influence of process parameters on the mechanical properties and surface roughness of 3D parts is also analysed. In addition, the investigators found that the additives increase the surface roughness of 3D printed parts.This review shows that researchers can focus on creating a combination of these approaches to expand the use of this process for industrial part production.All these investigations have made it possible to determine the optimal process conditions to ensure higher quality, optimal surface quality and better fatigue strength.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"26 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"88240012","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-01DOI: 10.5604/01.3001.0053.7288
V. Sebko, V. Zdorenko, N. Zashchepkina, S. Barylko
The necessity of developing new multi-parameter electromagnetic methods to obtain the information on controlled wastewater samples from fruit juice production has been proved. Based on the universal transformation functions G = f(x) and = f(x) obtained in the work, which relates the amplitude and phase components of the multi-parameter MFP signal with the parameters of wastewater samples, a three-parameter method for joint measurement control of the electrical conductivity , relative dielectric constant r and temperature t of wastewater samples from the production of apple juice. An algorithm for joint multi-parameter measurements of the parameters , r and t based on a transformer electromagnetic transducer (MFP) has been developed, the switching scheme provides for heating a wastewater sample during measurement control to simulate production conditions. Since the amplitude and phase components of the MFP multi-parameter signal depend on the temperature t, sample heating also makes it possible to create information redundancy and improve the accuracy of wastewater sample identification. The implementation of the proposed method makes it possible to indirectly determine the composition of wastewater samples, using only one transducer with known physical properties, all this leads to an increase in the accuracy of measuring the parameters of wastewater samples in comparison with reference methods and measuring instruments and ultimately allows choosing a promising method of wastewater treatment in accordance with the analysis of experimental data. The data obtained indicate the acidic composition of wastewater; therefore, it is proposed to neutralise industrial waste at the outlet of the finished product. The methodology of the above studies lies in the fact that, within the framework of a specific scientific approach, it is necessary to expand the functional and technical capabilities of the electromagnetic device by implementing a new multi-parameter electromagnetic method for joint measurements of the physicochemical parameters of wastewater samples.The essence of the proposed three-parameter method of joint measurement control of parameters t, r and t is based on the analysis of the interaction of an external homogeneous magnetic field with the magnetic field of eddy currents induced in a conductive electrolytic liquid (in a wastewater sample). Based on the input of special normalised parameters, as well as the obtained universal transformation functions G = f(x) and = f(x), which relate the physicochemical parameters , r and t of the electrolytic liquid medium (wastewater samples from apple juice production) with the amplitude and phase components of the multi-parameter signal MFP, at a constant frequency of the magnetic field f, the implementation of a three-parameter electromagnetic method of joint measurement control of the electrical conductivity , relative permittivity r and temperature t have been proposed. At the same time, using the th
{"title":"Increasing the accuracy of measuring the physicochemical parameters of wastewater samples when implementing a new informative method","authors":"V. Sebko, V. Zdorenko, N. Zashchepkina, S. Barylko","doi":"10.5604/01.3001.0053.7288","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7288","url":null,"abstract":"The necessity of developing new multi-parameter electromagnetic methods to obtain the information on controlled wastewater samples from fruit juice production has been proved. Based on the universal transformation functions G = f(x) and = f(x) obtained in the work, which relates the amplitude and phase components of the multi-parameter MFP signal with the parameters of wastewater samples, a three-parameter method for joint measurement control of the electrical conductivity , relative dielectric constant r and temperature t of wastewater samples from the production of apple juice. An algorithm for joint multi-parameter measurements of the parameters , r and t based on a transformer electromagnetic transducer (MFP) has been developed, the switching scheme provides for heating a wastewater sample during measurement control to simulate production conditions. Since the amplitude and phase components of the MFP multi-parameter signal depend on the temperature t, sample heating also makes it possible to create information redundancy and improve the accuracy of wastewater sample identification. The implementation of the proposed method makes it possible to indirectly determine the composition of wastewater samples, using only one transducer with known physical properties, all this leads to an increase in the accuracy of measuring the parameters of wastewater samples in comparison with reference methods and measuring instruments and ultimately allows choosing a promising method of wastewater treatment in accordance with the analysis of experimental data. The data obtained indicate the acidic composition of wastewater; therefore, it is proposed to neutralise industrial waste at the outlet of the finished product. The methodology of the above studies lies in the fact that, within the framework of a specific scientific approach, it is necessary to expand the functional and technical capabilities of the electromagnetic device by implementing a new multi-parameter electromagnetic method for joint measurements of the physicochemical parameters of wastewater samples.The essence of the proposed three-parameter method of joint measurement control of parameters t, r and t is based on the analysis of the interaction of an external homogeneous magnetic field with the magnetic field of eddy currents induced in a conductive electrolytic liquid (in a wastewater sample). Based on the input of special normalised parameters, as well as the obtained universal transformation functions G = f(x) and = f(x), which relate the physicochemical parameters , r and t of the electrolytic liquid medium (wastewater samples from apple juice production) with the amplitude and phase components of the multi-parameter signal MFP, at a constant frequency of the magnetic field f, the implementation of a three-parameter electromagnetic method of joint measurement control of the electrical conductivity , relative permittivity r and temperature t have been proposed. At the same time, using the th","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"111 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75957918","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-01DOI: 10.5604/01.3001.0053.7287
A. Wieczorska, W. Labuda
This paper presents the issue of welding technology qualification using the example of structural steel S355JR with a plate thickness of 25 mm and 100 mm, bevelling V. The main objective of this work was to attempt to perform a full qualification of the submerged arc welding process in accordance with the requirements of PN EN ISO 15614. Particular attention was paid to the issue of the qualification of welding technology. The samples were subjected to non-destructive testing, i.e. visual and penetrant testing, as well as ultrasonic testing and heat treatment. This was followed by destructive testing, including macroscopic testing and hardness testing. According to the proposed procedure for the recognition of submerged arc welding technology, once the necessary tests had been carried out and the protocols with positive results had been obtained. The documentation had been completed, the analysis needed to obtain certificates of conformity for factory production control and welding quality was carried out.Submerged arc welding is often used for highly responsible butt joints, particularly when joining thick components. This has been achieved through the proper design of the preparation of the parts to be welded and the development of a welding technology that practically eliminates the pre-phase that occurs in traditional technology, thereby eliminating the risk of it affecting the quality of the welded joint.During the implementation of submerged arc welding, a number of technological problems were encountered. The first test joints contained many defects, i.e. sticking and slag inclusions inside the welds. In addition, obtaining welds with the correct profile and removing the slag from the weld groove was difficult. These obstacles were eliminated experimentally by carrying out successive tests using different parameters and welding groove geometries.The correct implementation of any welding process depends on its input parameters. These parameters include welding current, welding speed, welding current, wire diameter, welding voltage and many others. Submerged arc welding (SAW) is widely used in the industry for manufacturing as it is more reliable, provides deep penetration in the work, ensures a smooth finish on objects, and results in high productivity.The technology was developed for a company that manufactures control discs for steam turbines.
本文以钢板厚度为25mm和100mm，坡口v的S355JR结构钢为例，提出了焊接技术鉴定的问题。本工作的主要目的是根据PN EN ISO 15614的要求，尝试对埋弧焊工艺进行全面鉴定。对焊接技术的鉴定问题给予了特别的关注。样品进行了无损检测，即目测和渗透检测，以及超声波检测和热处理。其次是破坏性测试，包括宏观测试和硬度测试。根据拟议的埋弧焊技术识别程序，一旦进行了必要的试验，并取得了积极的结果。文件已完成，为工厂生产控制和焊接质量获得合格证书所需的分析已进行。埋弧焊通常用于高度可靠的对接接头，特别是在连接厚构件时。这是通过正确设计待焊部件的准备和开发焊接技术实现的，该技术实际上消除了传统技术中出现的预阶段，从而消除了其影响焊接接头质量的风险。埋弧焊在实施过程中，遇到了许多技术问题。第一次试验的接头存在很多缺陷，如粘接和夹渣。此外，获得具有正确轮廓的焊缝和从焊缝坡口清除渣是困难的。通过使用不同的参数和焊接坡口几何形状进行连续试验，消除了这些障碍。任何焊接工艺的正确实施都取决于其输入参数。这些参数包括焊接电流、焊接速度、焊接电流、丝径、焊接电压等。埋弧焊(SAW)在制造业中被广泛应用，因为它更可靠，在工作中提供深度渗透，确保物体表面光滑，并导致高生产率。这项技术是为一家生产汽轮机控制盘的公司开发的。
{"title":"Analysis of the process of qualifying the welding technology of S355JR structural steel using the submerged arc welding method","authors":"A. Wieczorska, W. Labuda","doi":"10.5604/01.3001.0053.7287","DOIUrl":"https://doi.org/10.5604/01.3001.0053.7287","url":null,"abstract":"This paper presents the issue of welding technology qualification using the example of structural steel S355JR with a plate thickness of 25 mm and 100 mm, bevelling V. The main objective of this work was to attempt to perform a full qualification of the submerged arc welding process in accordance with the requirements of PN EN ISO 15614. Particular attention was paid to the issue of the qualification of welding technology. The samples were subjected to non-destructive testing, i.e. visual and penetrant testing, as well as ultrasonic testing and heat treatment. This was followed by destructive testing, including macroscopic testing and hardness testing. According to the proposed procedure for the recognition of submerged arc welding technology, once the necessary tests had been carried out and the protocols with positive results had been obtained. The documentation had been completed, the analysis needed to obtain certificates of conformity for factory production control and welding quality was carried out.Submerged arc welding is often used for highly responsible butt joints, particularly when joining thick components. This has been achieved through the proper design of the preparation of the parts to be welded and the development of a welding technology that practically eliminates the pre-phase that occurs in traditional technology, thereby eliminating the risk of it affecting the quality of the welded joint.During the implementation of submerged arc welding, a number of technological problems were encountered. The first test joints contained many defects, i.e. sticking and slag inclusions inside the welds. In addition, obtaining welds with the correct profile and removing the slag from the weld groove was difficult. These obstacles were eliminated experimentally by carrying out successive tests using different parameters and welding groove geometries.The correct implementation of any welding process depends on its input parameters. These parameters include welding current, welding speed, welding current, wire diameter, welding voltage and many others. Submerged arc welding (SAW) is widely used in the industry for manufacturing as it is more reliable, provides deep penetration in the work, ensures a smooth finish on objects, and results in high productivity.The technology was developed for a company that manufactures control discs for steam turbines.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"220 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79075035","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-04-01DOI: 10.5604/01.3001.0053.6707
S. Abbas, M. Alali, M. Abass, W. Abbas
This paper investigates the possibility of successfully welding a Low Alloy Steel (LAS) stud to Galvanized Steel (GS) plate.Arc Stud Welding (ASW) was performed on joining LAS studs to GS plates. Welding parameters were selected based on weld trails. The first tests of the welded joints were based on visual inspection for welding defects such as lack of fusion and undercut welding defects. The good quality should be free of these defects and have full weld reinforcement. Other weld qualifications included torque strength test, microhardness test, and microstructure examination.The LAS studs have been successfully welded to a galvanized steel plate using the arc stud welding process. Higher welding current with adjusted welding time (800 A, 0.3 s) gave full weld reinforcement, the best joint appearance, and strength. Martensite phase was detected in the weld area and heat affected zone (HAZ), affecting the joint mechanical properties. Hardness property varied across the welded joint, and maximum hardness was recorded at the HAZ at the stud side. Hardness increased with the increasing welding current. At 800 A, welding current hardness was 10% higher than at 400 and 600 A. Torque strength was affected by weld reinforcement, and 800 A gave the best weld reinforcement that produced the highest torque strength.The main research limitation is the difficulty of welding LAS studs and GS plates. In conventional welding methods, such as gas metal arc welding, it is hard to get full weld penetration due to the geometry restrictions of the joint, which results in partial weld penetration between the studs and the plates. Furthermore, the issue of zinc evaporation during welding can be reduced by the advantage of the very high welding speed (in milliseconds) of ASW that overcomes the problem of continuous welding that usually results in the formation of harmful porosities and poor weldability.In this research, galvanized steel plates were successfully welded to LAS studs using the ASW process. The welding parameters for this dissimilar welding joint were carefully selected. Microstructure changing due to the welding process was investigated. The joint mechanical properties were evaluated.
本文研究了低合金钢(LAS)螺柱成功焊接到镀锌钢板(GS)的可能性。采用电弧螺柱焊(ASW)将LAS螺柱与GS板连接。根据焊缝轨迹选择焊接参数。焊接接头的第一次试验是基于目视检查焊接缺陷，如缺乏熔合和下切焊接缺陷。良好的质量应该没有这些缺陷，并有充分的焊接加固。其他焊接资格包括扭矩强度测试、显微硬度测试和显微结构检查。采用电弧螺柱焊工艺成功地将LAS螺柱焊接到镀锌钢板上。较大的焊接电流，调整焊接时间(800 A, 0.3 s)，焊缝增强充分，接头外观和强度最佳。焊缝区和热影响区存在马氏体相，影响了接头的力学性能。焊接接头的硬度性能各不相同，最大硬度记录在螺柱侧的热影响区。硬度随焊接电流的增大而增大。在800 A时，焊接电流硬度比400和600 A时高10%。转矩强度受焊缝补强的影响，800a的焊缝补强效果最好，产生的转矩强度最高。研究的主要局限是LAS螺柱与GS板的焊接困难。在传统的焊接方法中，如气体保护金属电弧焊，由于接头的几何形状的限制，很难得到完全的焊透，导致螺柱与板之间的部分焊透。此外，由于ASW的焊接速度非常快(毫秒级)，克服了连续焊接通常会导致有害孔隙形成和可焊性差的问题，因此可以减少焊接过程中锌的蒸发问题。在本研究中，采用ASW工艺成功地将镀锌钢板焊接到LAS螺柱上。对这种异种焊接接头的焊接参数进行了精心选择。研究了焊接过程中组织的变化。对接头力学性能进行了评价。
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Pub Date : 2023-04-01DOI: 10.5604/01.3001.0053.6702
S. Drewing, N. Abramczyk, D. Żuk, T. Dyl
The article presents a statistical analysis of strength parameters of newly developed epoxy-glass composite materials modified with the addition of rubber recyclate.Three variants of materials with a percentage of recyclate content in the composite matrix of 3%, 5%, 7% and a reference variant without the addition of recyclate were used for the study. The samples were subjected to an impact test on a ZWICK RKP 450IR-GE impact hammer. Resilience measurement values were subjected to statistical analyses at the significance level = 95%, such as: testing the normality of distributions with the Shapiro-Wilk test, testing differences between pairs with the Student's t-test for dependent groups, and testing ANOVA differences for independent groups.The Shapiro-Wilk test confirmed that the resilience variables for all tested samples were in normal distributions; therefore the highest power parametric tests were used to test the differences. Using the Student's t-test, it was confirmed that between pairs of variables in configurations: standard sample with the modified sample, there were significant statistical differences in the distribution of resilience values for all samples. ANOVA confirmed significant changes in impact strength in 10 comparison variants.The obtained test results showed that in 9 compared cases, there were significant statistical differences, and in one case, there were no significant differences.The performed statistical analyses confirmed their significant usefulness in the process of qualification of strength parameters for materials with high anisotropy, such as composites.The manufactured products are innovative in terms of the method of using the addition of rubber recyclate as a filler for epoxy-glass composites. The use of static methods for their study also has practical value. It optimizes the analysis methods of the results of measurements of strength parameters of new composite materials.
{"title":"Statistical methods in the analysis of strength parameters of epoxy-glass composites modified with rubber recyclate","authors":"S. Drewing, N. Abramczyk, D. Żuk, T. Dyl","doi":"10.5604/01.3001.0053.6702","DOIUrl":"https://doi.org/10.5604/01.3001.0053.6702","url":null,"abstract":"The article presents a statistical analysis of strength parameters of newly developed epoxy-glass composite materials modified with the addition of rubber recyclate.Three variants of materials with a percentage of recyclate content in the composite matrix of 3%, 5%, 7% and a reference variant without the addition of recyclate were used for the study. The samples were subjected to an impact test on a ZWICK RKP 450IR-GE impact hammer. Resilience measurement values were subjected to statistical analyses at the significance level = 95%, such as: testing the normality of distributions with the Shapiro-Wilk test, testing differences between pairs with the Student's t-test for dependent groups, and testing ANOVA differences for independent groups.The Shapiro-Wilk test confirmed that the resilience variables for all tested samples were in normal distributions; therefore the highest power parametric tests were used to test the differences. Using the Student's t-test, it was confirmed that between pairs of variables in configurations: standard sample with the modified sample, there were significant statistical differences in the distribution of resilience values for all samples. ANOVA confirmed significant changes in impact strength in 10 comparison variants.The obtained test results showed that in 9 compared cases, there were significant statistical differences, and in one case, there were no significant differences.The performed statistical analyses confirmed their significant usefulness in the process of qualification of strength parameters for materials with high anisotropy, such as composites.The manufactured products are innovative in terms of the method of using the addition of rubber recyclate as a filler for epoxy-glass composites. The use of static methods for their study also has practical value. It optimizes the analysis methods of the results of measurements of strength parameters of new composite materials.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"77174114","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-04-01DOI: 10.5604/01.3001.0053.6699
R. Sazali, K. Sorbie, L. Boak, A. Z. Azman, Ismail Mohd Saaid, Aqilah Dollah, N. K. Kassim Shaari, K. Ismail
Silica/silicate scale is a significant problem, especially in oilfield production during Alkaline Surfactant Polymer (ASP) flooding, where chemical inhibitors are the preferred method to prevent them. In this study, the effect of inhibitor vinyl sulfonated copolymer (VS-Co) on silica/silicate scale formation was analysed using X-Ray Diffraction (XRD) and Fourier-transform infrared spectroscopy (FTIR).The functional group type of VS-Co are sulfonate ions, SO3-, and these interact in the scaling process. Bulk-inhibited scaling brine tests were conducted at 60C and pH 8.5. During these tests, the silicon brine (with VS-Co) representing the inhibited ASP leachate was mixed with a magnesium brine representing the connate water to replicate reservoir conditions during ASP flooding. The samples tested in this study were non-inhibited Si/Mg mixed brine of 60 ppm Mg2+ and 940 ppm Si4+ (60Mg:940Si) as a blank, and inhibited 60Mg:940Si mixture with various VS-Co concentrations of 20 ppm, 50 ppm, and 100 ppm. The inhibition efficiency of the VS-Co was determined, followed by the characterisation study of the silica/silicate scale deposited from both test conditions.The IR spectra of all 60Mg:940Si samples show a similar peak at 1050 cm-1 to 1080 cm-1, attributed to a Si-O covalent bond and a band at 790 cm-1 to 800 cm-1 showing the presence of Si-O-Si stretching. XRD patterns produced a broad scattering peak for all samples at 2 of 24 showing that the samples are amorphous silica. For tests of high Mg2+ in the brine mix, 900Mg:940Si, a mix of crystalline silica and crystalline magnesium silicate was produced. Based on these results, it can be concluded that the scale formed even with 100 ppm of VS-Co present. Further studies are required to address how to mitigate scale formation effectively in the future.Based on the research conducted, we can conclude that the VS-Co alone could not significantly inhibit the formation of silica/silicate scale even at the highest concentration (100 ppm) of VS-Co. However, having VS-Co present caused an alteration in IR spectra frequency which requires further investigation to assess how best to develop the inhibiting properties of the VS-Co product. The application of nanoparticles and their successful stories spark the interest of authors in searching for an efficient method of managing the silica/silicate scale where the modification of potential scale inhibitor (SI) with nanoparticles may be able to improve the inhibition efficiency towards the silicate/silicate scale.The presence of VS-Co in the scaling brine only slightly inhibits the Mg2+ ion (initially comes from connate water) from reacting. It is worth further investigation on how this VS-Co can make it happen. Hence, the functional groups responsible for this may be altered by adding other functional groups to provide a synergistic effect in preventing this silica/silicate scale; or by modifying the VS-Co with nanoparticles to improve their adsorption/desorption ca
{"title":"The characterization study of inhibited silica/silicate scale using vinyl sulfonated copolymer (VS-Co)","authors":"R. Sazali, K. Sorbie, L. Boak, A. Z. Azman, Ismail Mohd Saaid, Aqilah Dollah, N. K. Kassim Shaari, K. Ismail","doi":"10.5604/01.3001.0053.6699","DOIUrl":"https://doi.org/10.5604/01.3001.0053.6699","url":null,"abstract":"Silica/silicate scale is a significant problem, especially in oilfield production during Alkaline Surfactant Polymer (ASP) flooding, where chemical inhibitors are the preferred method to prevent them. In this study, the effect of inhibitor vinyl sulfonated copolymer (VS-Co) on silica/silicate scale formation was analysed using X-Ray Diffraction (XRD) and Fourier-transform infrared spectroscopy (FTIR).The functional group type of VS-Co are sulfonate ions, SO3-, and these interact in the scaling process. Bulk-inhibited scaling brine tests were conducted at 60C and pH 8.5. During these tests, the silicon brine (with VS-Co) representing the inhibited ASP leachate was mixed with a magnesium brine representing the connate water to replicate reservoir conditions during ASP flooding. The samples tested in this study were non-inhibited Si/Mg mixed brine of 60 ppm Mg2+ and 940 ppm Si4+ (60Mg:940Si) as a blank, and inhibited 60Mg:940Si mixture with various VS-Co concentrations of 20 ppm, 50 ppm, and 100 ppm. The inhibition efficiency of the VS-Co was determined, followed by the characterisation study of the silica/silicate scale deposited from both test conditions.The IR spectra of all 60Mg:940Si samples show a similar peak at 1050 cm-1 to 1080 cm-1, attributed to a Si-O covalent bond and a band at 790 cm-1 to 800 cm-1 showing the presence of Si-O-Si stretching. XRD patterns produced a broad scattering peak for all samples at 2 of 24 showing that the samples are amorphous silica. For tests of high Mg2+ in the brine mix, 900Mg:940Si, a mix of crystalline silica and crystalline magnesium silicate was produced. Based on these results, it can be concluded that the scale formed even with 100 ppm of VS-Co present. Further studies are required to address how to mitigate scale formation effectively in the future.Based on the research conducted, we can conclude that the VS-Co alone could not significantly inhibit the formation of silica/silicate scale even at the highest concentration (100 ppm) of VS-Co. However, having VS-Co present caused an alteration in IR spectra frequency which requires further investigation to assess how best to develop the inhibiting properties of the VS-Co product. The application of nanoparticles and their successful stories spark the interest of authors in searching for an efficient method of managing the silica/silicate scale where the modification of potential scale inhibitor (SI) with nanoparticles may be able to improve the inhibition efficiency towards the silicate/silicate scale.The presence of VS-Co in the scaling brine only slightly inhibits the Mg2+ ion (initially comes from connate water) from reacting. It is worth further investigation on how this VS-Co can make it happen. Hence, the functional groups responsible for this may be altered by adding other functional groups to provide a synergistic effect in preventing this silica/silicate scale; or by modifying the VS-Co with nanoparticles to improve their adsorption/desorption ca","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"85 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"84055477","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-04-01DOI: 10.5604/01.3001.0053.6696
K. Korniejenko, K. Pławecka, A. Bulut, B. Şahin, G. Azizağaoğlu, B. Figiela
The aim of this work was to prepare and characterise geopolymer composites containing lightweight aggregates - perlite and vermiculite.The geopolymer matrix was prepared on the basis of fly ash, sand and a 6M sodium hydroxide solution with sodium silicate. The properties of the materials were tested 28 days after the preparation of the samples. The following research methods were used to characterise the composites: compressive and flexural strength tests, microstructural tests using a scanning electron microscope, and thermal conductivity were measured.The results obtained showed a slight effect of the additives on the strength properties. Lightweight aggregates are characterised by good coherence with the matrix material. Their addition allowed to reduce the density and lowered the thermal conductivity of the materials. The results obtained indicate that the proposed additives can improve the properties of the geopolymer composite for use in the construction industry.Further research should focus on geopolymer composites with perlite and involve fire-resistant and water-absorption tests.The production of lightweight building materials brings a number of benefits, such as reducing the density of building elements and, at the same time, the entire structure, which results in a reduction in their weight, as well as lower transport costs. Such elements have better thermal and acoustic insulation, reflected in the parameters of buildings. An additional advantage is the reduced environmental impact through better insulation properties, lower fuel consumption during transport, etc.The density of the material can be reduced by using lightweight aggregates or obtaining porous material in the foamed process. In the case of geopolymer composites, a number of studies related to foamed materials have been provided, but there is only a few previous research connected with lightweight aggregates such as perlite and vermiculite.
{"title":"Development of lightweight geopolymer composites containing perlite and vermiculite","authors":"K. Korniejenko, K. Pławecka, A. Bulut, B. Şahin, G. Azizağaoğlu, B. Figiela","doi":"10.5604/01.3001.0053.6696","DOIUrl":"https://doi.org/10.5604/01.3001.0053.6696","url":null,"abstract":"The aim of this work was to prepare and characterise geopolymer composites containing lightweight aggregates - perlite and vermiculite.The geopolymer matrix was prepared on the basis of fly ash, sand and a 6M sodium hydroxide solution with sodium silicate. The properties of the materials were tested 28 days after the preparation of the samples. The following research methods were used to characterise the composites: compressive and flexural strength tests, microstructural tests using a scanning electron microscope, and thermal conductivity were measured.The results obtained showed a slight effect of the additives on the strength properties. Lightweight aggregates are characterised by good coherence with the matrix material. Their addition allowed to reduce the density and lowered the thermal conductivity of the materials. The results obtained indicate that the proposed additives can improve the properties of the geopolymer composite for use in the construction industry.Further research should focus on geopolymer composites with perlite and involve fire-resistant and water-absorption tests.The production of lightweight building materials brings a number of benefits, such as reducing the density of building elements and, at the same time, the entire structure, which results in a reduction in their weight, as well as lower transport costs. Such elements have better thermal and acoustic insulation, reflected in the parameters of buildings. An additional advantage is the reduced environmental impact through better insulation properties, lower fuel consumption during transport, etc.The density of the material can be reduced by using lightweight aggregates or obtaining porous material in the foamed process. In the case of geopolymer composites, a number of studies related to foamed materials have been provided, but there is only a few previous research connected with lightweight aggregates such as perlite and vermiculite.","PeriodicalId":14825,"journal":{"name":"Journal of Achievements in Materials and Manufacturing Engineering","volume":"32 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89681370","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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