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Volume 1 Issue 2 July - September 2013

Research Paper

Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings - A Review

Sukhminderbir Singh Kalsi* , T.S. Sidhu, 0*

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India.

Shaheed Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India.

* Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

Kalsi, S. S., Sidhu, T. S., & Singh, H. (2013). Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings-A Review. i-manager's Journal on Material Science, 1(2), 1-12. https://doi.org/10.26634/jms.1.2.2451

Abstract

Fireside corrosion of boiler tubes in bio medical waste incinerator plants has been of great concern for plant operators, boiler designers, and boiler tube manufacturers since quite a few number of boiler tubes in these plants suffered from wall thinning due to hot corrosion. The corrosion problem at high temperature is more serious due to the highly aggressive environment in bio medical waste incinerator plants such as Cl , HCl, alkali metals and heavy metals. 2 Corrosion resistant coatings are the key technologies to reduce the maintenance in bio medical incinerator plants by reducing the hot corrosion problem. Different corrosion resistant coatings processes have been developed such as thermal spray, HVOF, HVSFS, PVD and cold spray. Employing the corrosion resistant coatings ensure the high corrosion and wear resistant of the boiler tubes. This paper highlights the hot corrosion in bio medical incinerator plants, its effects and its protection with corrosion resistant coatings. Cold spray coatings have been reviewed with the aim of summarizing their high temperature corrosion resistance properties.

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Research Paper

Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs using Fast Fourier Transforms

J. Kandasamy* , B. Ravikumar, M. Madhavi*

__ Department of Mechanical Engineering, M.V.S.R Engineering College, Nadergul, Hyderabad, Andhrapradesh, India.

Kandasamy, J., Ravikumar, B., & Madhav, M. (2013). Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs Using Fast Fourier Transforms. i-manager's Journal on Material Science, 1(2), 13-19. https://doi.org/10.26634/jms.1.2.2452

Abstract

The riding comfort of an automobile is greatly affected by the suspension system. Springs are crucial suspension elements, necessary to minimize the vertical vibrations, impacts and pumps due to road irregularities, vertical vibrations and impacts are buffered by variations is the spring deflection so that the potential energy is stored in spring as strain energy and then released slowly. Composite leaf spring made of Eglass/Epoxy is the best alternate to steel spring for having excellent higher strength-to-weight ratio, high energy spring capacity, excellent corrosion resistance and higher natural frequency.In the present paper, shape optimization of mono composite leaf spring was carried out with design constraints as stress and displacements. Through finite element technique, structural parameters are computed for both steel and optimized composite leaf springs. Experimental validations were done on steel and composite leaf spring for both static and dynamic conditions. The dynamic analysis is computed through Fast Fourier Transform (FFT) and MATLAB code is developed to determine the natural frequencies of the leaf springs. Composite leaf spring is found to have low deflections, less stress, weight, high natural frequency and high damping property compared to steel leaf springs. This results in fuel savings and better riding comfort in automobiles.

References

[1]. G. Siddaramanna shiva shankar, Sambagam Vijayarangan, Mono Composite Leaf Spring for Light Weight Vehicle – Design, End Joint Analysis and Testing, Materials Science , ISSN 1392–1320, Vol. 12, No. 3. 2006

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Research Paper

Characterization of NiCrAIY Coatings on Ni- And Fe-Based Superalloys by the ColdSpray Process

Sukhminderbir Singh Kalsi* , T.S. Sidhu, 0*

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India.

Principal, Shahedd Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India.

* Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

Kalsi, S. S., Sidhu, T. S., & Singh, H. (2013). Characterization of NicrAIY Coatings on Ni-and Fe-Based Superalloys By the Cold Spray Process. i-manager's Journal on Material Science, 1(2), 20-26. https://doi.org/10.26634/jms.1.2.2453

Abstract

Coatings are always considered to improve the thermal, chemical and mechanical properties of the materials. Cold spray is one of the upcoming technologies for coatings. In this study NiCrAlY coatings were successfully deposited on Superni 76, Superni 600 and Superfer 800H superalloys (Midhani grade) for hot corrosion protection. The characterization of the cold sprayed coatings have been studied using the combined techniques of, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDAX). The deposited coatings found were dense with a porosity less than 1% and micro hardness of the order of 582- 670 Hv. XRD and EDAX analysis show Ni as the major phase in as-sprayed coating. Coating was found free from oxides.

References

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[2]. Bala, N., Singh, H., & Prakash, S. (2010). Accelerated hot corrosion studies of cold spray Ni–50Cr coating on boiler steels. Materials and Design, 31, 244–253.

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[6]. Goyal, T., Walia, R.S., & Sidhu, T.S. (2012). Study of Coating Thickness of Cold Spray Process Using Taguchi Method. Materials and Manufacturing Processes, 27(2), 185–192.

[7]. Gurrappa, I. (2000). Hot corrosion of protective coatings. Materials and Manufacturing Processes, 15(5), 761–773.

[8]. Kalsi, S.S., Sidhu, T.S., & Singh H. (2013). Chlorine based hot corrosion study of cold sprayed NiCrAlY coating. Surface Engineering, DOI 10.1179/1743294413Y. 0000000233.

[9]. Kalsi, S.S., Sidhu, T.S., & Singh H. (2014). Performance of cold spray coatings on Fe-based superalloy in Na2SO4- NaCl environment at 900oC, Surface and Coating Technology, DOI 10.1016/j.surfcoat.2014.01.001.

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[15]. Rapp, R.A., & Zhang, Y.S. (1994). Hot corrosion of materials: Fundamental studies. JOM, 46(12), 47–55.

[16]. Richer, P., Yandouzi, M., Beauvais, L., & Jodoin, B. (2010). Oxidation behaviour of CoNiCrAlY bond coats produced by plasma HVOF and cold gas dynamic spraying. Surface and Coatings Technology, 204, 3962–3974.

[17]. Sidhu, B.S., & Prakash, S. (2006). Erosion-corrosion of plasma as sprayed and laser remelted Stellite-6 coatings in a coal fired boiler. Wear, 260, 1035–1044.

[18]. Sidhu, T.S., (2006). PhD thesis, Met. & Mat. Eng. Dept., IITR, Roorkee, India.

[19]. Sidhu, T.S., Agrawal, R.D., & Prakash, S. (2005). Hot corrosion of some superalloys and role of high-velocity oxyfuel spray coatings—a review. Surface and Coatings Technology, 198, 441– 446.

[20]. Singh, H., Sidhu, T.S., & Kalsi, S.B.S. (2012). Cold spray Technology future of coating deposition process. Frattura ed Integrità Strutturale, 22, 69–84.

[21]. Singh, H., Sidhu, T.S., Kalsi, S.B.S., & Karthikeyan, J. (2013). Development of cold spray from innovation to emerging future coating technology. Journal of Brazilin Society Mechanical Science and Engineering, DOI 10.1007/s40430-013-0030-1.

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Research Paper

Parametric Optimization of Friction Stir Welded AA5083 Using Response SurfaceMethodology

Neeraj Sharma* , Rajat Gupta, Sumit Jain*

- Assistant Professor, Department of Mechanical Engineering, R.P. Inderaprastha Institute of Technology, Karnal, Haryana

Assistant Professor, Department of Mechanical Engineering, Delhi Institute of Technology & Management (Ganaur), Sonepat, Haryana

Sharma, N., Gupta, R., & Jain, S. (2013). Parametric Optimization Of Friction Stir Welded AA 5083 Using Response Surface Methodology. i-manager's Journal on Material Science, 1(2), 27-33. https://doi.org/10.26634/jms.1.2.2454

Abstract

Response surface methodology is used to model Friction Stir Welding (FSW) for the prediction of % elongation of AA 5083.The applications of friction stir welding are in aerospace, railways and space craft. The control factors of the process are tool rotational speed, welding speed, shoulder diameter and tool pin profile. Planning of experiments was carried using central composite design. The Analysis Of Variance (ANOVA) is used for the prediction of significant control factors along with their percentage contribution. The predicted optimized (minimum % elongation) setting of FSW control factors are tool rotational speed of 3966.23 rpm, a welding speed of 34.91 mm/min, and 19.89 mm shoulder diameter with trapezoidal pin profile. From this research it is found that the trapezoidal pin profile tool has the best effect on percentage elongation as compared to other pin profiles.

References

[1]. Fukuda, T. (2001). Friction stir welding process, Welding International, 15, 611-615.

[2]. Aval, H.J., Serajzadeh,S. & Kokabi, A.H. (2012). Experimental and theoretical evaluations of thermal histories and residual stresses in dissimilar friction stir welding of AA5086-AA6061, Int J Adv Manuf Technol, 61, 149–160.

[3]. Ericsson, M., & Sandstrom, R. (2003). Influence of welding speed on the fatigue of friction stir welds, and comparison with MIG and TIG, International Journal of Fatigue, 25, 1379–1387.

[4]. Hu Uzun, H., Donne, C.D., Argagnotto,A., Ghidini,T., & Gambaro,C. (2005). Friction stir welding of dissimilar Al 6013-T4 To X5CrNi18-10 stainless steel, Materials and Design, 26, 41–46.

[5]. Zhang, H., Lin,S.B., Wu,L., Feng, J.C.,& Ma, S.L. (2006). Defects formation procedure and mathematic model for defect free friction stir welding of magnesium alloy, Materials and Design, 27, 805–809.

[6]. Kulekci, M.K., Sik, A., & Kaluç, E. (2008). Effects of tool rotation and pin diameter on fatigue properties of friction stir welded lap joints, Int J Adv Manuf Technol, 36, 877–882.

[7]. Borino, G., Fratini, L., & Parrinello, F. (2009). Mode I failure modeling of friction stir welding joints, Int J Adv Manuf Technol, 41,498–503.

[8]. Arora, A., Mehta, M., & DebRoy A.D.T. (2012). Load bearing capacity of tool pin during friction stir welding, Int J Adv Manuf Technol, 61,911–920.

[9]. Jonckheere, C., Meester,B.D., Cassiers,C., Delhaye.,M., & Simar,A. (2012). Fracture and mechanical properties of friction stir spot welds in 6063-T6 aluminum alloy, Int J Adv Manuf Technol, 62,569–575.

[10]. Cole,E.G., Fehrenbacher,A., Shultz,E.F., Smith,C.B., Ferrier,N.J., Zinn, M.R., et al. (2012). Stability of the friction stir welding process in presence of work piece mating variations, Int J Adv Manuf Technol, 63, 583–593.

[11]. Das, H., Basak,S., Das,G., & Pal,T.K. (2012). Influence of energy induced from processing parameters on the mechanical properties of friction stir welded lap joint of aluminum to coated steel sheet, Int J Adv Manuf Technol.

[12]. Sakthivel,T., Sengar, G. S.,& Mukhopadhyay, J. (2009). Effect of welding speed on microstructure and mechanical properties of friction-stir-welded aluminum, Int J Adv Manuf Technol, 43,468–473.

[13]. Montgomery DC (2001). Design and analysis of experiments. Wiley, New York

[14]. ASTM Handbook

[15]. Sharma, N., Khanna, R., Gupta, R.D. & Gupta, P. (2012), Effect of Process Parameters on Cutting Rate in WEDM Using Response Surface Methodology, i-manager's Journal on Mechanical Engineering, 2(1), 28-34.

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Research Paper

Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet by Ultrasonic Thickness Gauge

Sheetal Kumar Dewangan* , K. Ganpati Shrinivas**

* Assistant Professor, Department of Mechanical Engineering, CCET Bhilai, Chattisgarh, India.

** Assistant Professor, Department of Applied Elec.& Instrumentation Engineering, BIT Raipur, Chattisgarh, India.

Dewangan, S. K., & Shrinivas, K. G. (2013). Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet By Ultrasonic Thickness Gauge. i-manager's Journal on Material Science, 1(2), 34-40. https://doi.org/10.26634/jms.1.2.2455

Abstract

This paper summarizes some of the major aspects of precision ultrasonic thickness gauging. Ultrasonic NonDestructive Testing (NDT) characterizing material thickness, integrity, or other physical properties by means of high-frequency sound waves has become a widely used technique for quality control. In thickness gauging, ultrasonic techniques permit quick and reliable measurement of thickness without requiring access to both sides of a part. During the thickness measurement of any corroded plate, the reading of ultrasonic equipment gives many different readings for each time of inspection at same position due to their non uniform surfaces. Due to corrosion of metal piece, a material whose thickness is lower than the low limit of the probe causes measurement errors. Sometimes the displayed reading is twice as big as the actual thickness. To prevent these errors, the critical thin materials should be measured repeatedly for verification. This paper looks at the review causes of poor performance with ultrasonic techniques and suggests some methods to improve the situation.

References

[1]. BS EN ISO 17640:2010, “Non-destructive testing of welds – Ultrasonic testing Techniques, testing levels, and assessment.”

[2]. J.C. Drury Ultrasonic Flaw Detection for Technicians

[3]. R. Porter, Lloyds (1996). Thickness Measurement of Hull Structures (Paper presented at BINDT Seminar 13 March 1996)

[4]. TSCF, (1997). Guidance manual for tanker structures,

[5]. IACS Unified Requirements Z10.1 (Rev.12), Z10.3 (Rev.7) and Z10.4 (Rev.2)

[6]. Guidelines for corrosion protection of sea water ballast tanks and hold spaces, BV, 1995

[7]. Mdshakir ASNT Level II (UT thickness measurement)

[8]. P.C. Charlton, Evaluating Current Options for NDT

[9]. J Blitz and G Simpson, (1996). 'Ultrasonic methods of non-destructive testing', Chapman & Hall.

[10]. S Dixon, C Edwards and S B Palmer 'High accuracy non-contact ultrasonic thickness.

[11]. Gauging of aluminum sheet using electromagnetic acoustic transducers', Ultrasonic, Vol 39, pp 445-453, 2001.

i-manager's Journal on Material Science (JMS)

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Volume 1 Issue 2 July - September 2013

Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings - A Review

Sukhminderbir Singh Kalsi* , T.S. Sidhu**, 0***

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India. ** Shaheed Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India. *** Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

Kalsi, S. S., Sidhu, T. S., & Singh, H. (2013). Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings-A Review. i-manager's Journal on Material Science, 1(2), 1-12. https://doi.org/10.26634/jms.1.2.2451

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Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs using Fast Fourier Transforms

J. Kandasamy* , B. Ravikumar**, M. Madhavi***

*_**_*** Department of Mechanical Engineering, M.V.S.R Engineering College, Nadergul, Hyderabad, Andhrapradesh, India.

Kandasamy, J., Ravikumar, B., & Madhav, M. (2013). Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs Using Fast Fourier Transforms. i-manager's Journal on Material Science, 1(2), 13-19. https://doi.org/10.26634/jms.1.2.2452

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Characterization of NiCrAIY Coatings on Ni- And Fe-Based Superalloys by the ColdSpray Process

Sukhminderbir Singh Kalsi* , T.S. Sidhu**, 0***

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India. ** Principal, Shahedd Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India. *** Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

Kalsi, S. S., Sidhu, T. S., & Singh, H. (2013). Characterization of NicrAIY Coatings on Ni-and Fe-Based Superalloys By the Cold Spray Process. i-manager's Journal on Material Science, 1(2), 20-26. https://doi.org/10.26634/jms.1.2.2453

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Parametric Optimization of Friction Stir Welded AA5083 Using Response SurfaceMethodology

Neeraj Sharma* , Rajat Gupta**, Sumit Jain***

*-** Assistant Professor, Department of Mechanical Engineering, R.P. Inderaprastha Institute of Technology, Karnal, Haryana *** Assistant Professor, Department of Mechanical Engineering, Delhi Institute of Technology & Management (Ganaur), Sonepat, Haryana

Sharma, N., Gupta, R., & Jain, S. (2013). Parametric Optimization Of Friction Stir Welded AA 5083 Using Response Surface Methodology. i-manager's Journal on Material Science, 1(2), 27-33. https://doi.org/10.26634/jms.1.2.2454

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Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet by Ultrasonic Thickness Gauge

Sheetal Kumar Dewangan* , K. Ganpati Shrinivas**

* Assistant Professor, Department of Mechanical Engineering, CCET Bhilai, Chattisgarh, India. ** Assistant Professor, Department of Applied Elec.& Instrumentation Engineering, BIT Raipur, Chattisgarh, India.

Dewangan, S. K., & Shrinivas, K. G. (2013). Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet By Ultrasonic Thickness Gauge. i-manager's Journal on Material Science, 1(2), 34-40. https://doi.org/10.26634/jms.1.2.2455

Abstract

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Sukhminderbir Singh Kalsi* , T.S. Sidhu, 0*

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India.

Shaheed Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India.

* Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

J. Kandasamy* , B. Ravikumar, M. Madhavi*

__ Department of Mechanical Engineering, M.V.S.R Engineering College, Nadergul, Hyderabad, Andhrapradesh, India.

Sukhminderbir Singh Kalsi* , T.S. Sidhu, 0*

* Research Scholar, Punjab Technical University, Kapurthala, Punjab, India.

Principal, Shahedd Bhagat Singh College of Engineering & Technology, Ferozpur, Punjab, India.

* Guru Nanak Dev University, Regional Campus, Jalandhar, Punjab, India.

Neeraj Sharma* , Rajat Gupta, Sumit Jain*

- Assistant Professor, Department of Mechanical Engineering, R.P. Inderaprastha Institute of Technology, Karnal, Haryana

Assistant Professor, Department of Mechanical Engineering, Delhi Institute of Technology & Management (Ganaur), Sonepat, Haryana

* Assistant Professor, Department of Mechanical Engineering, CCET Bhilai, Chattisgarh, India.

** Assistant Professor, Department of Applied Elec.& Instrumentation Engineering, BIT Raipur, Chattisgarh, India.