Study of the Possibilities of Obtaining Powder Materials by Rotational Turning with Multi-Faceted Cutters

Composite materials obtained through powder metallurgy methods are increasingly applied in various industries, particularly in aviation and rocket and space equipment which use their high specific strength, resistance to high temperatures and other properties. Producers of composite materials use various metallic and non-metallic materials (fibres and powders) as fillers [1-2]. For example, the high plasticity (moldability) of aluminium powders allows utilizing them as a matrix material in moulding of composites using various methods of rolling, extrusion, and intense plastic deformation [3-5]. However, the widespread use of chip as a raw material for the production of composites is hampered by the complexities in obtaining powders with granules of the necessary shape and size.

Mapping of Beta Distribution for the Study of Dispersed Materials

In the study of polydisperse materials, most of the experimental particle size distributions were obtained on bounded intervals. In these cases, it is also desirable to use bounded models with different shapes to simulate the results of studying polydisperse and powder materials. The beta distribution is often used to approximate results due to the fact that this distribution contains many forms for displaying realizations on a limited interval. With the development of computer technology, there has been an increased interest in the use of beta distribution in the modern practice of analyzing results. Meanwhile, there remains a limitation in the use of the beta distribution that is associated with the choice of distribution shape. The possibilities of using known shape measures for mapping beta distribution in this paper is discusses. On the example of the space of shape measure of kurtosis and skewness, the limited use of only probabilistic measures of shapes is illustrated. It is proposed to use the entropy coefficients as an additional informational parameter of the beta distribution shape. On the base of a features comparison of the entropy coefficients for biased and unbiased beta distributions, recommendations for their application are given. By using the example of beta distributions mapping in the space of asymmetry and the entropy coefficient, it is shown that the synergistic combination of probabilistic and informational measures of the shape allows expanding the possibilities of estimating the shape parameters beta distributions. Two methods to display the positions of realizations of beta distributions is proposed. There are trajectories on a constant ratio of shape and realizations position curve on equal values of one parameter. In particular, the features of the choice of beta distributions with negative skewness are discussed.

Characterization of opportunity for upgrading of the system based on arc plasma torch for thermal spaying of ceramic materials, by means of use of fuel vortex intensifier. Part I: Thermodynamic modeling of the system efficiency parameters

One of the main trends in the field of improving the modern technologies of thermal spraying, including plasma one, for functional ceramic coatings formation is the reducing the energy consumption of the process. In this regard, one of the important directions for improving these technologies is the development of their new versions, using the principle of adding inexpensive fuel-oxidizer mixtures based on hydrocarbons with air. This type of plasma-fuel type of spraying will be promising for application at the present time, first of all, in order to obtain refractory functional coatings. For this purpose, we investigated the opportunity for upgrading an industrial unit/system for plasma spraying of ceramic powder materials with arc plasma torch of 25–40 kW power by the use of experimental variant of a fuel gas-vortex intensifier. The thermodynamic assessment of possible parameters of the generated mixed flow after the torch with this fuel intensifier was carried out to estimate the applicability of this system to optimize the spraying of oxide and carbide coatings (based on the examples of Al2O3, Cr3C2 and other powders). The analysis of possible parameters of the produced flow after the torch with intensifier was performed for the cases of main C–H–O–N–Ar–Me (Me = Al, Cr) systems and additional C–H–O–Al-system to assess the potential of this system to modify the technology of oxide and carbide ceramic coatings formation. New regimes, which were analyzed in our research as the simulants of Al2O3 spraying, surpass on calculated energy efficiency characteristics (by 10–20 %) one of the new prospective spraying methods with (СO2+СH4)-plasma, as well as the conventional method of powder heating during the spraying with N2-plasma. The case of our proposed fuel assisted process (FA-APS) with liquefied petroleum gas (LPG) fuel for the heating of ceramic powders (especially, Al2O3) demonstrates the advantage of the process (in particular, on the energy efficiencies and energy consumption) in a comparison with the conventional regimes of APS of the powders (in N2 plasma of the standard torch). For the variants of the FA-APS with Al2O3 and Cr3C2 feedstock powders it was established to be potentially possible to obtain (at the moderate values of total electric energy consumption for the torch and auxiliary equipment, – near 1.8 and 1.0 kWh/(kg of product)) such high level of the process productivity on the final product as approximately 17 and 28 kg/h, respectively; at the values of required power of the torch:  28.2 and  22.3 kW.

THE STUDY OF THE SORPTION PROPERTIES OF FILTERING MATERIALS BASED ON TITANIUM PHOSPHATE - POROUS TITANIUM COMPOSITION

Inorganic sorbents are more selective in comparison with commercial ion exchange resins towards of metal ions. However, inorganic sorbents characterized not high kinetic properties. One of the way to increase the kinetic rate of inorganic sorbents is to reduce the particle size of these materials, other way is synthesizing inorganic sorbents as porous products from powder materials. A sample of such inorganic sorbents is titanium phosphate of various compositions. Studying the properties of microfilters based on composition titanium phosphate - porous titanium has been developed. The sorbents based on acidic titanium phosphate Ti(HPO4)2∙H2O were used for filtering solution with Fe(II) content. It is found that the number of impregnations with inorganic sorbent modificator is important and influence filtration process. The obtained results demonstrated that after the first impregnation of porous material with a smaller pore size, it is possible to obtain such sorbent as a mass content of powder material. By varying the ionic form of titanium phosphate, the porosity of titanium, the amount of impregnation, it could be possible effect on the sorption Fe(II). The sorption properties of titanium-titanium phosphate microfilters were studied by potentiometric titration in the NaCl-NaOH system, as well as the sorption of Fe2+ ions. The degree of purification for Fe(II) from solution with a concentration of 10 mg/l is 64 %. Application an electric potential to the microfilter of porous titanium - phosphate titanium increases the degree of purification of Fe(II) to 88 %.

Preparation and Characterization of NiCr/NiCr-Al2O3/Al2O3 Multilayer Gradient Coatings by Gas Detonation Spraying

This paper investigates the influence of the technological parameters of detonation spraying on the phase composition of NiCr- and Al2O3-based coatings. It was determined that the phase composition of Al2O3 coatings during detonation spraying strongly depends on the barrel filling volume with the gas mixture. The acetylene–oxygen mixture, which is the most frequently used fuel in the detonation spraying of powder materials, was used as a fuel gas. To obtain a ceramic layer based on Al2O3, spraying was performed at an acetylene–oxygen O2/C2H2 mixture ratio of 1.856; the volume of filling of the detonation gun barrel with an explosive gas mixture was 63%. To obtain a NiCr-based metallic layer, spraying was performed at the O2/C2H2 ratio of 1.063; the volume of filling of the detonation gun barrel with an explosive gas mixture was 54%. Based on a study of the effect of the detonation spraying mode on the phase composition of NiCr and Al2O3 coatings, NiCr/NiCr-Al2O3/Al2O3-based multilayer coatings were obtained. Mixtures of NiCr/Al2O3 powders with different component ratios were used to obtain multilayer gradient coatings. The structural-phase composition, mechanical and tribological properties of multilayer gradient metal–ceramic coatings in which the content of the ceramic phase changes smoothly along the depth were experimentally investigated. Three-, five- and six-layer gradient coatings were obtained by alternating metallic (NiCr) and ceramic (Al2O3) layers. The phase composition of all coatings was found to correspond to the removal of information from a depth of 20–30 μm. It was determined that the five-layer gradient coating, consisting of the lower metal layer (NiCr), the upper ceramic layer (Al2O3) and the transition layer of the mechanical mixture of metal and ceramics, is characterized by significantly higher hardness (15.9 GPa), wear resistance and adhesion strength.

Evaluation and Multi-Objective Optimization of Lightweight Mortars Parameters at Elevated Temperature via Box–Behnken Optimization Approach

In this research, the mechanical properties of lightweight mortars containing different percentages of additional powder materials has been investigated using response surface methodology (RSM). Box–Behnken design, one of the RSM techniques, was used to study the effects of silica fume content (5, 10, and 15%), vermiculite/cement (V/C) ratio (4, 6, and 8), and temperature (300, 600, and 900 °C) on the ultrasonic pulse velocity (UPV), bending strength, and compressive strength of lightweight mortars. Design expert statistical software was accustomed to determining and evaluating the mix-design of materials in mortar mixtures and temperature effect on mortars. After preliminary experimental research of the relationships between independent and response variables, regression models were built. During the selection of the model parameters, F value, p-value, and R2 values of the statistical models were taken into account by using the backward elimination technique. The results showed a high correlation between the variables and responses. Multi-objective optimization results showed that the critical temperatures for different levels of silica fume (5–10–15%) were obtained as 371.6 °C, 306.3 °C, and 436 °C, respectively, when the V/C ratio kept constant as 4. According to the results obtained at high desirability levels, it is found that the UPS values varied in the range of 2480–2737 m/s, flexural strength of 3.13–3.81 MPa, and compressive strength of 9.9–11.5 MPa at these critical temperatures. As a result of this research, RSM is highly recommended to evaluate mechanical properties where concrete includes some additional powder materials and was exposed to high temperature.

Simulation of Thermoplastic Powder Cold Spraying

The work is devoted to the deposition of composite powder materials by cold spray method. As a spraying material, a thermoplastic compound «WAY» for marking the roadway was used. An asphalt concrete was used as a substrate. As a result of experimental studies, the dependence of the deposition efficiency on the stagnation temperature of the working air in the ejector nozzle was obtained. The ANSYS Fluent package was used for evaluative modeling of the cold spraying process. Gas flow patterns were obtained in the computational domain without particles and taking into account the interaction of the flow with particles. The trajectory of the particles was calculated for various spraying parameters

Influence of alloying components on diffusion and bonding processes in powder materials

At present, powder materials are used in practically all branches of industry, from medicine to aerospace technology. This is a wide range of materials ranging from constructional and instrumental materials and ending with special-purpose materials and medical implants. Powder metallurgy methods are most often used where the manufacture of products with desired properties is impossible using traditional methods: casting, stamping, etc. The production of all these materials is based on such basic operations as: obtaining starting materials, molding from these materials blanks of a given shape, size and strength, and sintering, intended for the final formation of the required properties and dimensions. The peculiarity of powder metallurgy technology allows creating a huge variety of developed technological schemes, which puts these technologies to a new level and allows for the rapid development of many industries. Alloying powder steels, in contrast to cast steels, has a number of characteristic features due to the specificity of their production. The structure of powder alloy steels and their properties depend on the methods of obtaining steels and technological features of their production. The following main methods of obtaining powder alloyed steels can be named: preparation of multicomponent mixtures of powders of iron and alloying elements and their subsequent processing; the use of alloyed iron powders, to which, if necessary, add carbon or other alloying elements; impregnation with liquid alloying metals or diffusion saturation of frameworks sintered from iron powders.