Filler Diameter Research Articles

Improving Dissimilar Metal Joining Quality Through Shielded Metal Arc Welding: A Taguchi Optimization Strategy

The results of an experiment that used an orthogonal Taguchi method to improve shielded metal arc welding (SMAW) were given. The SMAW method was used to join dissimilar metal of SPHC and St. 30. SPHC material has a low carbon steel content, while St. 30C steels contain a medium amount of carbon steel, which is used for tractor shaft axles. Carbon percentages vary slightly between the two substances. This study aimed to achieve the highest possible quality of tensile strength by utilizing the specified SMAW parameters. SPHC material has a low carbon content, whereas St. 30 steel has a moderate carbon content. This study used the Taguchi experimental method with three input variables and three experimental levels. The SNR ratio is used to evaluate the most optimal SMAW performance. ANOVA analysis is used to evaluate the most crucial parameters in determining the response variable. This research has successfully provided input on the combination of SPHC and St. 30C for SMEs. It operates effectively with a welding current of 133 A, a welding voltage of 9 V, and a filler diameter of 2.0 mm. The S/N ratio analysis found that the welding current, voltage, and filler diameter all had a significant impact on the outcome.

A computational Finite Element Study for Optimizing the Biomedical Strength of MWCNT Reinforced Polymer Nanocomposites

Multi-walled carbon nanotubes (MWCNTs) are highly regarded for reinforcing polymeric nano biocomposites, like polymethylmethacrylate (PMMA), owing to their versatility across various biological applications such as such as dental crowns, artificial teeth and dentures. In this study micromechanical models were meticulously developed to evaluate PMMA matrices fortified with MWCNTs at varying weight percentages (0.1%, 0.5%, and 1.0%). The assessment was conducted using Finite Element Analysis (FEA) facilitated by ANSYS 2022 (Ansys, Inc., USA). Notably, the investigation focused on validating the tensile strength against experimental data, revealing the peak tensile strength at 0.5 wt% MWCNT. Moreover, models featuring isotropic filler orientations demonstrated remarkable alignment with experimental outcomes. Furthermore, the study delved into exploring the influence of diverse MWCNT filler diameters (ranging from 10 to 35 nm) on the tensile strength, indicating a direct correlation with increasing diameter. However, it was observed that the larger diameters tended to correlate with decreased compressive and flexural strength. These comprehensive findings underscore the promising potential of MWCNT reinforced PMMA nanocomposites in advancing biomedical research, where enhanced mechanical properties play a pivotal role.

Effect of structural support size and position on depressed tibial plateau fractures: A finite element analysis

ObjectiveStructural support for depressed tibial plateau fractures is receiving increasing attention. Currently, there has been little biomechanical evaluation of structural support. This work aimed to investigate the effect of structural support size and position on fracture fixation stability. MethodsA split-depressed tibial plateau fracture model was created according to the fracture map. Cortical screws combined with structural filler were used for fracture fixation. The filler diameter was set to small, medium and large, and the filler position was set to the center and offset by 1, 2 and 3 mm to study the effect of position and size on stability. ResultsThe maximum stress on the implant in all scenarios occurs at the lower contact surface between the anterior screw and the filler. Increased support size resulted in increased mean maximum screw stress, depressed fragment axial displacement and separated fragment transverse displacement (screw stress: 266.6 ± 37.7 MPa vs. 266.7 ± 51.0 MPa vs. 273.8 ± 41.5 MPa; depressed displacement: 0.123 ± 0.036 mm vs. 0.133 ± 0.049 mm vs. 0.158 ± 0.050 mm; separated displacement: 0.402 ± 0.031 mm VS 0.412 ± 0.047 mm VS 0.437 ± 0.049 mm). The larger the offset of the support position was, the larger the peak screw stress and the larger the reduction loss of depressed and separated fragment reduction, regardless of the support size. The medium support combined with the central position presented the minimum of peak stress and reduction loss. Cortical bone was below 2 % and trabecular strain was below 10 % for all scenarios. ConclusionCentral placement of structural support provides superior stability for the treatment of depressed tibial plateau fractures compared to the eccentric placement. When a support is placed centrally, optimal stability is achieved when the diameter matches the diameter of the depressed region. Thus, the utilization of equal-diameter fillers to provide central support appears to be an ideal selection for depressed tibial plateau fractures.

CAD-CAM resin composites: Effective components for further development

ObjectiveThis paper summarizes the effective components of computer-aided design and computer-aided manufacturing (CAD-CAM) resin composites that contribute to achieving greater mechanical properties and further development. MethodsIn silico multi-scale analysis, in silico nonlinear dynamic finite element analysis (FEA), and artificial intelligence (AI) were used to explore the effective components of CAD-CAM resin composites. The effects of the filler diameter and silane coupling ratio on the mechanical properties of CAD-CAM resin composites have been clarified through multi-scale analysis. The effects of the filler contents, and filler and monomer compositions have been investigated by AI algorithms. The fracture behavior of CAD-CAM composite crown was analyzed using in silico non-linear dynamic FEA. The longevity of CAD-CAM composite crown was assessed through step-stress accelerating life testing (SSALT). ResultsAs the filler diameter decreases, there is an increase in elastic moduli and compressive strengths at the macroscale. At the nanoscale, a decrease in the filler diameter results in a decrease in the maximum value of the maximum principal strain. When the silane coupling ratio decreases, there is a decrease in the elastic modulus and compressive strength. According to the exhaustive search and feature importance analysis based on the AI algorithm, the combination of certain components was narrowed down to achieve a flexural strength of 269.5 MPa. The in silico non-linear FEA successfully detected the sign of the initial crack of the CAD-CAM composite molar crown. The SSALT revealed that CAD-CAM resin composite molar crowns containing nanofillers with a high fraction of resin matrix demonstrated great longevity. SignificanceThis paper summarized the effective components of CAD-CAM resin composites for their further development. The integration of in vitro and in silico approaches will expedite the advancement of CAD-CAM resin composites, offering benefits such as time efficiency and reduction of material waste for researchers and manufacturers.

Effect of Filler Wires on Welding Strength and Microstructural Changes of Inconel 718 and AISI 316L Dissimilar Weldments

In this research, the effect of fillers wires on weldability, welding strength and structural changes of dissimilar welds of Inconel 718 and AISI 316L are studied. Pulse arc mode in TIG welding with multiple passes were used to join V-groove configuration with 1.6 mm filler diameter. Constant welding parameters were used for both the weldments to study the effect of alloying elements of filler wires. Tensile properties were evaluated by conducting tensile test on universal testing machine as per ASTM E/8 standards. To reveal the structural changes at various zones of weldment, optical microscope was utilized. The dissimilar metals were joined successfully using two-filler wires without any internal defects. The highest tensile strength of 553 MPa was observed in Hastelloy filler weldment when compared with ERNiCrMo-4 filler weldment (530 MPa). Also, the better yield strength properties were observed in Hastelloy filler weldment. Well defined with clear grain boundaries were observed in both the filler weldments. Due to the pulsed arc mode, segregation of alloying elements was reduced.

TENSILE, IMPACT AND NON-DESTRUCTIVE ANALYSIS OF 316 L STAINLESS STEEL FOR MARINE APPLICATIONS

Welding is an age-old method used for joining the metals permanently. The marine industry is a major user of sheet metal components that benefit from custom welded blanks (TWBs). These advantages encompass weight, cost, and noise savings, as well as increases in crash safety, improved efficacy, and oxidation resistance. However, machinability issues are prevalent as a result of the welding process. These benefits and drawbacks are explored, as well as TWB forming techniques, welding procedures, and materials utilized in the marine sector. In this study two different thickness 316L stainless steel grade plate welded using manual and automatic TIG Welding process. The process parameters are chosen for this study is welding current, voltage, welding speed, shielding gas & filler diameter. The manual TIG welded specimen was than compared with automatic TIG welded specimen in terms of Liquid Penetration test, tensile and impact test. The result and discussion are briefly explored.

Dry-Contact Thermal Interface Material with the Desired Bond Line Thickness and Ultralow Applied Thermal Resistance.

Efforts to directly utilize thixotropic polymer composites for out-of-plane thermal transport applications, known as thermal interface materials (TIMs), have been impeded by their mediocre applied thermal resistance (Reff) in a sandwiched structure. Different from traditional attempts at enhancing thermal conductivity, this study proposes a low-bond line thickness (BLT) path for mitigating the sandwiched thermal impedance. Taking the most common TIM, polydimethylsiloxane/aluminum oxide/zinc oxide (PDMS/Al2O3/ZnO), as an example, liquid metal is designed to on-demand localize at the Al2O3-polymer and Al2O3-filler interface regions, breaking rheological challenges for lowering the BLT. Specifically, during the sandwiched compression process, interfacial LM is just like the lubricant, dexterously promoting the relaxation of immobilized PDMS chains and helping fillers to flow through mitigating the internal friction between Al2O3 and adjacent filler. As a result, this TIM first time exhibits a boundary BLT (4.28 μm) that almost approaches the diameter of the maximum filler and performs an ultralow dry-contact Reff of 4.05 mm2 K/W at 40 psi, outperforming most reported and commercial dry-contact TIMs. This study of the low-BLT direction is believed to point to a new path for future research on high-performance TIMs.

Structure, physico-mechanical properties and piezoresponse of scaffolds based on polyhydroxybutyrate with composite magnetite/reduced graphene oxide filler

The influence of fiber diameter and addition of composite filler magnetite/reduced graphene oxide on the properties of electrospun scaffolds of poly(3-hydroxybutyrate) has been studied. The magnetic composite filler provides good magnetic properties and piezoresponse of the scaffolds, while changing the fiber diameter allows controlling the ductility, crystallinity, and surface electric potential.

Effect of nanoparticle on mechanical properties of activated tungsten gas welding of austenite stainless steel 316L and optimization of process parameters

Abstract Austenite stainless steel 316L was developed to improve corrosion resistance and is widely used in automobile components, thermal power plants, and pressure vessels due to their superior toughness and intergranular corrosion resistance. The austenite stainless steel 316L has a low carbon content of 0.03%, which helps in minimizing harmful carbide precipitation during welding. The joint strength of welded joints is poor unless proper care is taken. As a result, an attempt was made to use an activated Tungsten Inert Gas (A-TIG) welding procedure to improve the joint strength of butt welded joints of austenitic stainless steel 316L. The process parameters such as current, the volume of flow, and filler diameter were chosen in the study and generated an L 9 design matrix using MINI Tab software. The welded joints were prepared as per the design matrix using the activated flux of aluminum oxide nano powder as per the combination of process parameters. The mechanical tests such as tensile strength, hardness, and impact strength were evaluated and microstructural evaluation of welded joints was also assessed. The input parameters were optimized for better tensile strength of joints using Taguchi S/N analysis. It is found from the optimization that the highest ultimate tensile strength of 690.40 MPa was obtained at a current of 90 A, shielding gas flow of 13 l min–1, and filler material diameter of 2.5 mm. The model was also validated by conducting experiments.

High Dielectric Design of Polymer Composites by Using Artificial Neural Network

Polymer-based composites with a high dielectric property have shown great potential in electrical energy storage applications. It is important to predict the dielectric constant in designing polymer composites, but it is costly and time consuming. In this study, dielectric properties of various polymer composites have been predicted by using an artificial neural network (ANN) model trained with hundreds of experimentally measured data. Eight variables such as the dielectric constant of matrix, filler, and shell, the diameter of filler, the volume fraction of filler, the dimension of filler, the thickness of shell, and the frequency were considered. To improve the prediction accuracy, hyper parameters of the ANN model were optimized through the hyperband method. Using the ANN model, we demonstrated the correlation between the dielectric constant of polymer composites and the variables. The ANN model predicted the dielectric constant with a coefficient of determination (R2) of 0.97. Furthermore, the ANN model shows good performance to predict dielectric constant at various frequencies (spanning from 100 Hz to 100 kHz). Hence, we present that the AI-based prediction model using ANN method can be helpful in designing the polymer composites with desired properties.

The effect of calcium carbonate content and particle size on the mechanical and morphological properties of a PVC foamed layer used for coated textiles

Due to recent developments in composite formulations and coating technology, polyvinyl chloride (PVC)-coated textiles are becoming increasingly popular in the textile industry. The most critical properties of PVC-coated textiles are their mechanical characteristics and morphological properties because they control their cost well. This study focuses on the impact of filler diameter and content on the mechanical properties of the PVC foam layer used for coated textiles stuffed with calcium carbonate (CaCO3). The mechanical properties of the PVC foamed layer (breaking load, tearing strength and elongation at break) were studied. The applied contents were found to significantly influence the mechanical properties of the PVC foamed layer. The addition of CaCO3 fillers improved their mechanical properties. The results also showed that mechanical properties were enhanced using calcium carbonate with different particle sizes; the smallest particle size gave the highest mechanical resistance. The morphology of the different samples showed that the employment of calcium carbonate increases foam formation. A higher CaCO3 content can deteriorate the PVC foam layer structure. Using a small filler particle diameter decreased pore sizes and ameliorated the regularity in pore size distribution.

Influence of Compound Spherical Trenched Holes on Film Cooling Performance at the end of Combustor Simulator

The major effects of cylindrical and spherical trenched cooling holes with distance between the hole surface and the combustion chamber panel and the filler diameter on the spherical hole contact surface and the panel surface H=0.3,R=D/2=0.1, H=0.3, R=D/2=0.2 and H=0.3, R=D/2=0.3 cm at BR=3.18 on the film cooling effectiveness near the combustor end wall surface is an important subject to study in details. In this research, a three-dimensional representation of a Pratt and Whitney gas turbine engine was simulated and analysed with a commercial finite volume package FLUENT 6.2.26. The analyses were done with RANS turbulence model on internal cooling passages. The combustor simulator was combined with the interaction of two rows of dilution jets, which were staggered in the streamwise direction and aligned in the spanwise direction. In comparison with the baseline case, the application of trenched holes increased the effectiveness of film cooling up to 47% near the wall surface and an average of 35% in depth of combustor simulator .

The Effect of Solution Casting Temperature and Ultrasound Treatment on PEBAX MH-1657/ZIF-8 Mixed Matrix Membranes Morphology and Performance.

Approximately two-thirds of anthropogenic emissions causing global warming are from carbon dioxide. Carbon capture is essential, with membranes proving to be a low cost and energy-efficient solution to alternative technologies. In particular, mixed matrix membranes (MMMs) can have higher permeability and selectivity than pure polymer membranes. The fabrication conditions affect the formation of defects within the membranes. In this work, MMMs were created using a PEBAX MH-1657 polymer and a ZIF-8 filler. The effect of casting plate temperature, varying from −5 °C to 50 °C, and the effect of ultrasound treatment time (80–400 min) and method (filler solution only, filler and polymer combined solution only and filler solution followed by combined solution) were investigated, aiming to reduce defect formations hence improving the performance of the MMMs. SEM images and permeation tests using pure CO2 and N2 gas, replicating flue gas for carbon capture, were used to investigate and compare the membranes morphology and performance. The results indicated that the MMMs maintained their permeabilities and selectivities at all tested casting temperatures. However, the neat PEBAX membranes demonstrated increased phase separation of the polyamide and polyether oxide phases at higher temperatures, causing a reduction in permeability due to the higher crystallinity degree, confirmed by DSC experiment. The MMMs fabricated at low ultrasound times displayed a large amount of aggregation with large particle size causing channeling. At high ultrasound times, a well-dispersed filler with small filler diameters was observed, providing a high membrane performance. Overall, defect-free membranes were successfully fabricated, leading to improved performance, with the best membrane resulting from the longest ultrasound time reaching the Robeson bound upper limits.

Parametric study of filler size and properties for a liquid-metal thermal energy storage

Liquid metals are promising heat transfer fluids since they remain liquid in a wide temperature range and can transfer heat efficiently due to their high thermal conductivity. A first-of-its-kind lab-scale thermal energy storage system with filler material and with lead-bismuth as heat transfer fluid is currently tested at the Karlsruhe Institute of Technology, while a 100-kWh storage system is under construction. This numerical study aims to analyse the influence of the filler parameters on the system’s efficiency when the fluid used is a liquid metal. The filler should store part of the thermal energy, be efficiently discharged during the cyclic process and buffer the degradation of the thermocline during standby. For each of these purposes different particle diameters and values of some thermophysical properties of the filler, such as thermal conductivity, specific heat capacity and density, may be advantageous. Their influence on the thermocline extension is numerically investigated using a one-dimensional concentric dispersion model.The results of the parameter study show that for an efficient discharge process in a liquid metal dual-media storage, a small filler particle size is beneficial (d< 10 mm for the reference case chosen in this work). In contrast, the standby phase is favoured by larger diameters, here an order of 10–20 mm. Furthermore, a high thermal conductivity of the filler material improves the discharge performance, due to the enhanced heat transfer, but leads to an accelerated growth of the thermocline during standby. For this case, the optimum value is 5–10W/mK. Moreover, using a filler material with a high volumetric heat capacity leads to the best overall performance.A full factorial analysis shows that the filler diameter has the strongest effect on the discharge behaviour, while, during standby, the volumetric heat capacity has the largest influence.

Optimization of gas tungsten arc welding parameters on mechanical properties of dissimilar AA2024 and AA6061 Aluminium alloys using Taguchi’s grey relational analysis

Due to the high strength to weight ratio and structural strength, aluminum alloys have potential applications in the aerospace, defense, and automobile industries. However, fusion welding of dissimilar aluminum alloys remains challenging for the manufacturers. This paper solely deals with the effects of welding current, gas flow rate, and filler diameter on three mechanical properties of two dissimilar AA2024 and AA6061 gas tungsten arc welded joints. A multi-response optimization was carried out using grey relational analysis. For designing the experiments, Taguchi L9 orthogonal array was employed, and the Tungsten Inert Gas (TIG) butt welding was carried out. Then, the samples were tested for mechanical properties such as hardness, tensile and flexural strength. The optimal process parameters from grey relational grade obtained were welding current 140A, gas flow rate 15 lpm, and electrode diameter 3.2 mm. Electrode diameter has more influence on mechanical properties when compared to the other two variables.

Analytical Approach of Wave Transmission Coefficient through on Composite Hanging Breakwater

Conventional breakwater like a rubble mount is require large infestation, especially when that structure construct in deep water. Currently, innovations are needed to solve financial problems in building breakwaters. Composite hanging breakwater is proposed as a new solution in marine structure. Composite hanging breakwater made by both of stone and concrete or steel material consist of two-part are structural part and filler. Structural parts are piles, beams, and brackets made of concrete or steel. Filler material using of stone or other material. This structure has the advantage are cheaper than conventional breakwater, precast material, and the diameter of stone filler is relatively small. Until now, the performance of composite hanging breakwater is unknown. Commonly, the key performance indicator of breakwaters is wave transmission and represent by the waves transmission coefficient. Therefore, in this study, an analytical equation of wave transmission coefficient was developed using the conservation of energy concept. Based on this equation shows that the wave transmission coefficient is influenced by both structure and wave parameter. After the equation has been obtained, then it is compared with previous research. Research that has been used as a comparison includes research by Weigel (1960), Abul-Azm (1993), Liu and Abbaspour (1982), Abu-Azm (1993), Heikal (1997), Koraim (2005), Rage and Koraim (2010), and Koraim (2014). Wave parameter represents by waves steepness implicitly, and structure parameter is represented by the permeability of structure, relative length, and relative depth. The greater the value both of relative depth and length, the smaller value of wave transmission coefficient. The greater the value of structure permeability, the smaller the value of wave transmission coefficient. When the D/h is zero, the wave transmission coefficient is equal to one and when the D/h is equal to one, the transmission coefficient is close to or equal to zero. When the D/h value is less than 0.5, the Kt value in this present study is lower than the Kt value in previous studies for the same D/h value, and when the D/h value is greater or equal to 0.5 then the Kt value is close or the same with the previous study.

Effect of MIG Welding Speed Butt-Joint on Physical and Mechanical Properties of Materials AA 5083

Aluminium is a non-ferrous metal known as a light metal that has good corrosion resistance properties. Aluminium materials can be classified according to their alloying elements. Aluminium alloys are widely applied in the manufacture of marine structure, especially 5083 series aluminium. Parameters in a welding process, especially aluminium, are very important things to consider. The high and low welding speed is a parameter that can affect the mechanical and physical properties of the welded material. The purpose of this study was to determine the mechanical and physical properties of the 5083-aluminium connection. The welding process was carried out on the Butt-Joint connection using 5083 aluminium alloy materials, with plate dimensions of 300 mm × 150 mm × 3 mm. The speed variations used were 10 mm/s, 12 mm/s, and 14 mm/s with a voltage of 20 V, a filler diameter of 0.8 mm, a protective gas flow of 25 L/minute and a torch distance of 5 mm. The results showed that the welding speed variation of 10 mm/s had the largest distortion with a value of 6.89 mm and the highest tensile strength of 194.83 MPa. There were incomplete penetration and linear porosity defects in every variation of welding speed. Micro-porosity observations showed an increase in the welding speed results in more porosity.

Pengaruh Variasi Diameter Filler Dan Kuat Arus Terhadap Kekuatan Tarik Hasil Pengelasan SMAW Material Stainless Steel 304

One of the railway facilities uses stainless steel as the main construction material. The method of joining stainless steel materials, especially the most widely used is the SMAW welding technique. The purpose of this study was to determine the tensile strength of SMAW welding joints on stainless steel 304 material with variations in diameter of rod filler as filler material an d variations in current from DC inverter electric welding machine. The diameter of rod filler as filler material is 1 mm, 2 mm and 3 mm. The variation of the current of the DC inverter of the electric welding machine is 70 A, 100 A and 120 A. The results show the highest tensile strength of the 304 stainless steel welded connection with an average tensile stress of 34.48 MPa on the current electric welding inverter. 120 A is used and the diameter of the rod filler is 2 mm. And the tensile strength of the welding connection of the 304 stainless steel material is the lowest with an average tensile stress of 17.01 MPa at the electric welding inverter current used is 70 A and the diameter of the rod filler is 3 mm.Keyword: SMAW welding, filler, current and stainless steel

Fabrication of natto-structured oxides using metal-EDTA solution

We fabricated unique ceramics matrix composites (CMCs) called natto-structured oxides using metal-ethylenediaminetetraacetic acid (EDTA) solution. The natto-structured oxide in this study is a combination of micron-sized oxide particles and oxide with nanoscale fibrous microstructures. The natto-structures were fabricated on Si substrates by spin-coating Er-EDTA solutions with hollow (Y2O3:Eu3+, SiO2) particles followed by atmospheric sintering. We investigated the effects of filler concentrations, rotation speeds, and filler diameters on the formation of natto-structured oxides. The results indicate that the rotating centrifugal force in the spin coating process is the dominant factor affecting the formation of natto-structured oxides.

The impact of model rigid fillers in acid-induced sodium caseinate/xanthan gum cooperative protein gels

This work evaluates the impact of model rigid fillers on the deformation and fracture behavior of acid-set sodium caseinate/xanthan gum (NaCas/XG) mixed biopolymer gels. Glass microspheres of varying size ranges were used as idealized filler particles. The large deformation elastic modulus showed a power law scaling behavior with increasing filler volume fraction (φf) for all fillers. The magnitude of this response was strongly dependent on filler size, as decreasing filler diameter produced a higher scaling exponent. For the smallest fillers tested (8 μm), the presence of amino functional groups on the filler surface produced a further increase in the scaling behavior. The stark increase in elastic modulus indicates the microspheres behaved as active fillers which bound to the electrostatically-induced cooperative gel network. The fracture strain (εr*) of both the neat and amino-coated 8 μm microspheres showed an abrupt decrease at low φf, which roughly followed the theoretically expected response proposed by Nielsen. In contrast, the larger fillers (90 μm and 180 μm) produced a roughly linear decrease in εr* with increasing filler loading. Above a threshold values of φf ~0.15, the fracture stress (σr*) displayed a power law scaling behavior, with the effect of filler size and surface chemistry analogous to that seen for the elastic modulus. Water loss results correlated well with the increase in mechanical strength, and T2 relaxometry suggested the hydrophilic fillers reduce water mobility within the gel network. These results indicate that the effect of filler size and surface chemistry can be used to modulate the large deformation and fracture mechanics of particle-filled food gels. This work adds to the growing body of literature on developing a more fundamental understanding of foods as composite soft materials.