scholarly journals Pulsed Waterjet Roughening of Cast Iron and Aluminum Alloy for Automotive Engine Remanufacturing with Plasma Transferred Wire Arc Coating

Coatings ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 864
Author(s):  
Nicholas O’Neil ◽  
Abu Syed Kabir
Keyword(s):  
Cast Iron ◽  
Adhesion Strength ◽  
Steel Wire ◽  
Surface Profile ◽  
Cast Aluminum ◽  
Automotive Engine ◽  
Roughness Profile ◽  
Wide Range ◽  
Roughened Surface ◽  
Pulsed Waterjet

This study utilized the high-pressure pulsed waterjet process and paired it with the plasma transferred wire arc technology to develop a novel technique to remanufacture damaged engine cylinder bores. The objective of this research was to eliminate the need for expensive bond-coats such as Ni-Al by optimizing the surface roughness profile of the substrate to provide acceptable mechanical bonding between the coating and the substrate. In this study, a high chrome stainless steel wire (Metcoloy #2) was plasma spray coated on a wide range of pulsed waterjet roughened surface profiles generated on grey cast iron and cast aluminum A380 alloy, the two most common engine materials. The pulsed waterjet greatly increased the adhesion strength between the substrates and the Metcoloy #2 coating. The increase in adhesion strength is a result of the formation of favorable mechanical anchoring points. Optimal pulsed waterjet parameters were determined to avoid the production of a copious roughness profile which resulted in a coating that mirrored the roughened surface profile. Additionally, if the roughness profile produced by the pulsed waterjet was insignificant the coating was removed in its entirety during detachment-based failure.

The Surface Wavelength Composition of Thin Wall Iron Castings and Its Influence on CMM Measurements

2004 ◽  
Author(s):  
Edward P. Morse ◽  
Krishnakumar Gopal ◽  
Jayaraman Raja
Keyword(s):  
Cast Iron ◽  
Surface Profile ◽  
Coordinate Measuring Machine ◽  
Morphological Filter ◽  
Thin Wall ◽  
Iron Castings ◽  
Roughness Profile ◽  
Surface Data ◽  
Measuring Machine ◽  
Thickness Measurements

When measuring any mechanical artifact, thickness measurements obtained using a coordinate measuring machine (CMM) are affected by geometric variations having different wavelengths, leading to uncertainty in the reported thickness. These effects can be very pronounced in cast iron products, as the surfaces can be quite rough. This paper presents a methodology for reducing the uncertainty in the thickness measurements by comparing the measurements obtained using profilometry with CMM measurements. The surface data obtained from a profilometer are filtered using standard ISO filter and also using a morphological filter. The different wavelength components — such as the waviness profile and roughness profile — are separated and the thickness values are obtained from the filtered and unfiltered surface profile. The efficacy of different filtering methods is examined, and a procedure for reducing the uncertainty of the reported thicknesses is proposed.

AMPCOLOY 570

Alloy Digest ◽  
1980 ◽  
Vol 29 (3) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Cast Iron ◽  
Iron Alloy ◽  
Heat Treating ◽  
Nickel Aluminum ◽  
High Quality ◽  
Glass Making ◽  
Temperature Performance ◽  
Wide Range ◽  
Cobalt Iron

Abstract AMPCOLOY 570 is a cast copper-nickel-aluminum-cobalt-iron alloy specially developed for applications involving severe stresses and high temperatures, such as glass-making molds and plate-glass rolls. It is significantly superior to cast iron which has been commonly used for glass-making molds. Good foundry techniques will yield high-quality castings of Ampcoloy 570 in a wide range of section sizes. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on high temperature performance and corrosion resistance as well as casting, heat treating, machining, and joining. Filing Code: Cu-392. Producer or source: Ampco Metal Inc..

The Possibility of Manufacturing Long-Length Metal Products with Ultra-Fine Grain Structure by Combination of Strain Effects

2016 ◽  
Vol 685 ◽  
pp. 487-491 ◽  
Author(s):  
Mikhail Chukin ◽  
Marina Polyakova ◽  
Alexandr Gulin ◽  
Olga Nikitenko
Keyword(s):  
Steel Wire ◽  
Continuous Method ◽  
Grain Structure ◽  
Strain Effect ◽  
Strain Effects ◽  
Fine Grain ◽  
Wide Range ◽  
Processing Modes ◽  
Efficiency Estimation ◽  
Metal Products

It is shown that combination of strain effects leads to possessing the ultra-fine grain structure in carbon wire. The continuous method of wire deformation nanostructuring was developed on the basis of simultaneous applying of tension deformation by drawing, bending deformation when going through the system of rolls and torsional deformation on a continuously moving wire. One of the main advantages of the developed method is that various hardware devices and tools already applied for steel wire production can be used to implement this method thus simplifying its introduction to the current industrial equipment. The efficiency estimation of the developed continuous method of deformation nanostructuring was carried out using carbon wire with different carbon content. It is shown that the mechanical properties of the wire after combination of different kinds of strain can vary over a wide range. This method makes it possible to choose such modes of strain effect, which can provide the necessary combination of strength and ductile properties of carbon wire depending on its further processing modes and application.

Rolling/Sliding Wear Behavior of High Carbon Steel Wire Rod (HSWR) of Traction Machine

2008 ◽  
Author(s):  
Beom-Taek Jang ◽  
Seock-Sam Kim
Keyword(s):  
Wear Behavior ◽  
Steel Wire ◽  
High Carbon Steel ◽  
Wire Rope ◽  
Wear Volume ◽  
Steel Wires ◽  
Volume Curve ◽  
Wide Range ◽  
Lubrication Condition ◽  
Worn Surface

Steel wires are critical load-bearing components in a wide range of applications such as elevator, cranes, mine haulage etc. The traction machine of elevator which transmits power to wire rope causes micro-slip between wire rope and sheave during reciprocating action. The lubrication condition of wire rope is also changed due to the lack of grease. This study focuses on the wear behavior of steel wire and effect of both dry and grease conditions by using the rolling/sliding contact wear tester done under various slip ratios and rolling speeds. The experimental results of the wear volume curve against the number of revolutions under the grease condition are compared with the results under dry condition. The worn surface of steel wire and the size of wear particles were observed by SEM. In order to quantify the wear amount of steel wire we established an equation and finally obtained the wear coefficient.

Bearing profile of sliding tribological systems

2021 ◽  
pp. 53-56
Author(s):  
Keyword(s):  
Hydrodynamic Lubrication ◽  
Surface Profile ◽  
Experimental Methods ◽  
Hydrodynamic Characteristics ◽  
Bearing Surface ◽  
Tabular Data ◽  
Sliding Bearing ◽  
Friction Process ◽  
Operational Characteristics ◽  
Wide Range

The main contours of the bearing surfaces of friction pairs with hydrodynamic lubrication are considered. Analysis of tabular data and graphs obtained by experimental methods made it possible to establish additional parameters of influence on the hydrodynamic characteristics of the friction process and the operational characteristics of tribological systems, in a wide range of load-speed modes. Keywords: sliding bearing, hydrodynamics, bushing, bearing surface, profile, circle, ellipse, wavy contour, wear. [email protected]

scholarly journals A reduced-complexity model for river delta formation – Part 1: Modeling deltas with channel dynamics

2015 ◽  
Vol 3 (1) ◽  
pp. 67-86 ◽  
Author(s):  
M. Liang ◽  
V. R. Voller ◽  
C. Paola
Keyword(s):  
Sediment Transport ◽  
Flow Field ◽  
Water Surface ◽  
Surface Profile ◽  
River Delta ◽  
Suspended Sediment Transport ◽  
Channel Dynamics ◽  
Wide Range ◽  
Delta Formation ◽  
Reduced Complexity

Abstract. In this work we develop a reduced-complexity model (RCM) for river delta formation (referred to as DeltaRCM in the following). It is a rule-based cellular morphodynamic model, in contrast to reductionist models based on detailed computational fluid dynamics. The basic framework of this model (DeltaRCM) consists of stochastic parcel-based cellular routing schemes for water and sediment and a set of phenomenological rules for sediment deposition and erosion. The outputs of the model include a depth-averaged flow field, water surface elevation and bed topography that evolve in time. Results show that DeltaRCM is able (1) to resolve a wide range of channel dynamics – including elongation, bifurcation, avulsion and migration – and (2) to produce a variety of deltas such as alluvial fan deltas and deltas with multiple orders of bifurcations. We also demonstrate a simple stratigraphy recording component which tracks the distribution of coarse and fine materials and the age of the deposits. Essential processes that must be included in reduced-complexity delta models include a depth-averaged flow field that guides sediment transport a nontrivial water surface profile that accounts for backwater effects at least in the main channels, both bedload and suspended sediment transport, and topographic steering of sediment transport.

Scanning laser wave recorder with registration of “instantaneous” sea surface profiles

2021 ◽  
Author(s):  
V.V. Sterlyadkin ◽  
K.V. Kulikovsky ◽  
A.V. Kuzmin ◽  
E.A. Sharkov ◽  
M.V. Likhacheva
Keyword(s):  
Spatial Scales ◽  
Wind Waves ◽  
Single Point ◽  
Video Recording ◽  
Surface Profile ◽  
Weather Conditions ◽  
Sea Surface ◽  
Sea Waves ◽  
Wide Range ◽  
Wave Recorder

AbstractA direct optical method for measuring the “instantaneous” profile of the sea surface with an accuracy of 1 mm and a spatial resolution of 3 mm is described. Surface profile measurements can be carried out on spatial scales from units of millimeters to units of meters with an averaging time of 10−4 s. The method is based on the synchronization of the beginning of scanning a laser beam over the sea surface and the beginning of recording the radiation scattered on the surface onto the video camera matrix. The heights of all points of the profile are brought to a single point in time, which makes it possible to obtain “instantaneous” profiles of the sea surface with the frequency of video recording. The measurement technique and data processing algorithm are described. The errors of the method are substantiated. The results of field measurements of the parameters of sea waves are presented: amplitude spectra, distribution of slopes at various spatial averaging scales. The applied version of the wave recorder did not allow recording capillary oscillations, but with some modernization it will be possible. The method is completely remote, does not distort the properties of the surface, is not affected by wind, waves and sea currents, it allows you to measure the proportion of foam on the surface. The possibility of applying the proposed method at any time of the day and in a wide range of weather conditions has been experimentally proved.

Possibilities Reducing of Energy Consumption by Cast Iron Production in Foundry

2020 ◽  
Vol 998 ◽  
pp. 36-41
Author(s):  
Peter Futaš ◽  
Alena Pribulová ◽  
Marcela Pokusova
Keyword(s):  
Cast Iron ◽  
Energy Consumption ◽  
Iron Production ◽  
Hot Metal ◽  
Metal Production ◽  
Material Efficiency ◽  
Electric Induction ◽  
Wide Range ◽  
The Cost ◽  
Metal Melting

Modern metal melting includes of cast iron production in different types furnaces with specific characteristics. Furnaces usually adopted are cupola and induction furnaces. Casting cast iron is a manufacturing process characterized by its energy-intensive nature (ie, the use of large amounts of energy per unit of product for main activities) and a long tradition. An example of the energy balance in a foundry is the design of procedures to reduce energy consumption. The most important is the consumption of energy in the production of hot metals (52%), therefore reducing the cost of preparing hot metal is especially important by reducing the energy consumption of metal melting. The most important energy cost practices are the consumption of hot metal to produce 1mt of high quality castings (often 1700 kg) and reduce the energy consumption of hot metal production that varies over a wide range (from 500 to 1300 kWh/mt). Although scientific and technological aspects are now well established, new studies seem to be needed to describe "foundry of the future", where energy and material efficiency is of great importance to ensure competitiveness alongside environmental protection. The paper presents specific procedures for reducing both economically important indicators in cupola and electric induction furnaces.

scholarly journals Additive Manufacturing with Superduplex Stainless Steel Wire by CMT Process

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 272 ◽  
Author(s):  
Malin Lervåg ◽  
Camilla Sørensen ◽  
Andreas Robertstad ◽  
Bård M. Brønstad ◽  
Bård Nyhus ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Volume Fraction ◽  
Steel Wire ◽  
Oil And Gas Industry ◽  
Secondary Phases ◽  
Crack Tip Opening Displacement ◽  
Opening Displacement ◽  
Σ Phase ◽  
Wide Range ◽  
Wire Arc Additive Manufacturing

For many years, the oil and gas industry has utilized superduplex stainless steels due to their high strength and excellent corrosion resistance. Wire arc additive manufacturing (WAAM) was used with superduplex filler wire to create walls with different heat input. Due to the multiple heating and cooling cycles during layer deposition, brittle secondary phases may form such as intermetallic sigma (σ) phase. By inspecting deposited walls within wide range of heat inputs (0.40–0.87 kJ/mm), no intermetallic phases formed due to low inter-pass temperatures used, together with the high Ni content in the applied wire. Lower mechanical properties were observed with high heat inputs due to low ferrite volume fraction, precipitation of Cr nitrides and formation of secondary austenite. The walls showed good toughness values based on both Charpy V-notch and CTOD (crack tip opening displacement) testing.

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