Process Parameters Research Articles

Numerical Simulation and Experimental Verification of Hot Roll Bonding of 7000 Series Aluminum Alloy Laminated Materials

In the present study, the hot roll bonding process of 7000 series aluminum alloy laminated materials was numerically simulated and investigated using the finite element method, and the process parameters were experimentally verified by properties testing and microstructure analysis after hot roll bonding. In the roll bonding process of aluminum alloy laminated materials, the effects of the intermediate layer, pass reduction ratio, rolling speed and thickness ratio of component layers were studied. The results of finite element simulations showed that the addition of a 701 intermediate layer in the hot roll bonding process could effectively coordinate the deformation of the 705 layer and 706 layer and prevented the warping of the laminated material during hot rolling. It is recommended to use a multi-pass rolling process with small deformation and high speed, and the recommended rolling reduction ratio is 20%~30%, the hot rolling speed is 1.5~2.5 m/s and the thickness ratio of the 705 layer and 706 layer is about 1:5. Based on the above numerical results, five-layer and seven-layer 7000 series aluminum alloy laminated materials were prepared by the hot roll bonding process. The results showed that metallurgical bonding was realized between each component layer, and no delamination was observed from the tensile fracture between the interfaces of component layers. The tensile strength of the prepared laminated materials decreased with the increase in the thickness ratio of the 705 layer, and the bonding strengths of the laminated materials were in the range of 88–99 MPa. The experimental results verified the rationality of the process parameters recommended by the numerical simulations in terms of warping and delamination prevention.

Heavy metal application of response surface optimized-lipopeptide biosurfactant produced by Pseudomonas aeruginosa strain CGA-02 in low-cost substrate

Cost-effective methods of biosurfactant production with minimal environmental impact are needed as global demand continues to increase. This study evaluated lipopeptide biosurfactant production in a Pseudomonas aeruginosa strain CGA-02 using a low-cost carbon substrate. The structural properties of the biosurfactant and applicability of the biosurfactant in heavy metal removal were evaluated. Response surface methodology (RSM) involving central composite design (CCD) was used to optimize process parameters to maximize biosurfactant production. The study identified sugar cane molasses and sodium nitrate as carbon and nitrogen sources of choice for bacterial growth and biosurfactant production, with a relatively 2.64-fold increase in biosurfactant yield under optimized conditions. Analysis of the biosurfactant measured a surface tension reduction of water from 72.2 ± 0.26 to 30.5 ± 0.2 mN/m at 40 mg/L critical micelle concentration. GC–MS and FTIR analysis revealed structural properties of the lipopeptide biosurfactant, with fatty acid components predominantly 9-octadecenoic acid (oleic acid), n-hexadecanoic acid, cyclotetrasiloxane and trimyristin, and infrared peaks belonging to amine, carboxyl, nitrile, alkanol, ether and carbonyl groups. Capture of heavy metals using the biosurfactant was evaluated in soil microcosms. Removal rates of 80.47, 100, 77.57, 100, and 97.57% were recorded for As, Pb, Hg, Cd and Cr respectively after 12 weeks of incubation. There was no significant difference (p < 0.05) in the removal efficiency of the biosurfactant and an analogous chemical surfactant, sodium dodecyl sulphate. First and second-order kinetic models described heavy metal removal rates by the biosurfactant. We demonstrate the production of a useful biosurfactant using low-cost waste carbon.

A Comprehensive Approach to Azo Dichlorotriazine Dye Treatment: Assessing the Impact of Physical, Chemical, and Biological Treatment Methods through Statistical Analysis of Experimental Data

This exploration investigates integrated treatment systems combining advanced oxidation processes (Fenton and photo-Fenton) with biological methods for the effective elimination of stubborn organic compounds in simulated textile wastewater composed of azo Dichlorotriazine dye. A comprehensive optimization of key process factors including catalyst dosage, hydrogen peroxide quantity, irradiation duration, etc. was systematically conducted for both Fenton and photo-Fenton processes to realize maximum COD and color removal. Under ideal conditions (0.4 g/L photocatalyst, 1 mL/L H2O2, and 75-Watt UV intensity for 60 min), the photo-Fenton process realized 80% COD elimination and complete decolorization, meeting industrial discharge limits without needing extra biological treatment. Statistical models correlating process parameters to treatment efficiency were developed, giving important design insights. For Fenton, effluent COD exceeded discharge thresholds, so a post-biological treatment using activated sludge was essential to comply with regulations. This integrated Fenton–biological scheme utilizes synergism between chemical and biological processes for enhanced overall treatment. Notable economic benefits were achieved by photo-Fenton over conventional UV-only and UV/H2O2 methods regarding energy consumption and operating costs. Overall, this pioneering work successfully proves integrated advanced oxidation–biological systems as a superior, sustainable alternative to traditional techniques for economically removing obstinate pollutants, such as azo Dichlorotriazine dye, as it is a simulated textile wastewater treatment used to satisfy environmental standards.

Bioeconomic transformation of bio-oil production wastes: a novel adsorbent material for toxic dye adsorption and optimization of process parameters

In this study, for the first time, an adsorbent material was produced from the waste left behind after the bio-oil production process from Terebinth (Pistacia Terebinthus L.) seeds as part of bioconversion, and the adsorption of the hazardous dyestuff methylene blue from aquatic media was investigated. The characterization of the adsorbent was performed using FT-IR, SEM, and BET analysis. The characterization of methylene blue adsorption was conducted to fully understand its nature, including its kinetics, equilibrium, and thermodynamic works. The maximum adsorption capacity (q max) of the monolayer, as determined from the equilibrium data, was calculated to be 166.07 mg g−1. Additionally, the experimental design method was utilized to determine the optimum conditions of the methylene blue adsorption process under various conditions. This study revealed that activated carbons from Terebinth seeds can be used as an economical and environmentally friendly adsorbent, which is very suitable for the removal of highly toxic dyes.

In situ build surface topography determination in electron beam powder bed fusion

AbstractElectron optical imaging is the most promising process monitoring method in electron beam powder bed fusion. State of the art in modern machines is the installation of a single detector in the top center of the build chamber. Exemplary applications are the reconstruction of digital twins of manufactured parts to compare their dimensional accuracy or analysing the top surface of each layer to identify surface features like pores or material transport. Multi-detector systems are currently under research and have shown great potential in reconstructing the surface topography in situ. A recently developed ray tracing model, describing the image formation process, allows to formulate design guide lines for multi-detector systems and provides a method for the computation of the normal vector field of the build surface. This work utilizes the recent progress and presents a newly developed four-detector system and an updated computation chain, which enable build surface topography reconstruction in situ in every layer of a build process. The computation chain contains a normal integration algorithm, which employs Tikhonov regularization to cope with measurement irregularities. The integration method is validated with ex situ measured as-built surfaces. Additionally, first applications are demonstrated and connections to process parameter changes illustrated.

Dimensional accuracy of acrylonitrile butadiene styrene and polylactic acid samples printed in vacuum-assisted material extrusion system

This paper discusses the impact of integrating a vacuum system into a material extrusion 3D printing process for acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) materials. The study aimed to investigate the effect of a vacuum system on the dimensional accuracy of the printed samples. Upon completion of the printing process, the samples’ dimensions were carefully assessed using a Coordinate Measuring Machine (CMM). The geometrical dimensions measured are the diameter, corner radius, fillet, thickness, width, length and angle. Based on the result obtained, the material has yet to reach 100% of the desired geometry, which was identified due to the shrinkage of the material after the printing process. The results show that the vacuum system improved material flow and reduced dimensional deviations by reducing air molecules and minimizing convection. The results indicated a significant enhancement in dimensional accuracy for both ABS and PLA samples when using the vacuum system. ABS samples showed a 4% increase in accuracy, while PLA samples exhibited a 2% improvement compared to samples printed without vacuum assistance. These improvements were achieved by optimizing process parameters such as layer height (0.15 mm), infill percentage (10%), printing speed (45 mm s−1), and bed temperature (60 °C). These parameters were selected to ensure finer details, improved precision, structural support, stability, better adhesion, and reduced warping.

Performance and mechanism of organic solid-phase sediment composite plugging agent

The surface pipeline sediments of the Yingmai and Hade oil fields mainly contain substances such as asphalt and paraffin. The formation of sediment can increase the backpressure during pipeline transportation, and in severe cases, it can also lead to pipeline blockage. In order to solve this on-site situation, indoor experiments were conducted in the early stage, and an efficient organic unblocking system LXW was optimized and formulated. Based on this system, this article selects the wire mesh filtration method to evaluate the unblocking performance of LXW and on-site unblocking agents in the study and comparison of three evaluation methods. At the same time, based on the analysis of the chemical composition, microstructure, and melting point of organic sediments, from the perspectives of safety, environmental protection, and economic factors, further compares the performance and universality of the three unblocking systems, optimizes the process parameters of the LXW unblocking system, explores its stability and impact on the demulsification and dehydration of crude oil emulsions, and evaluates its safety performance. The LXW unblocking system has a more efficient unblocking effect and better universality, which can solve the problem of multiple block blockages on site. In addition, compared with existing unblocking agents, it has better economic benefits and is in line with the characteristics of low cost on site. On this basis, the dissolution and dispersion mechanism of the blockage system on sediment was studied through laser scattering system and fluorescence microscope, and its microscopic mechanism was further verified. At the same time, the oil-water interfacial tension under the action of the unblocking system was studied, and it was found that adding the agent can significantly reduce the equilibrium interfacial tension, which is of great significance for increasing production and injection.

Welding residual stress analysis of the X80 pipeline: simulation and validation

Abstract. In this work, a finite-element welding model of the X80 pipeline is established, and the residual stress is calculated using a direct thermal–mechanical coupling method through the User Material (UMAT) subroutine of the double-ellipsoid moving heat source. The effects of process parameters on the welding residual stress of the X80 pipelines are discussed. The ultrasonic longitudinal critical refraction (LCR) wave-detecting method is adopted to verify the simulation results. The results show that the residual stress at the inner surface is higher than that at the outer surface, and the peak Mises stress at the welding seam approaches the yield stress. With the increase in welding groove angle and heat input, the peak Mises stress increases at the inner surface and decreases at the outer surface, but the high-stress zone at the outer surface broadens. The residual stresses at the outer surface are more sensitive to the welding parameters. The comparison between the simulated results and ultrasonic LCR detection indicates that the finite-element method is feasible, and the simulation results are credible.

Development of sustainable alkali-activated slag bricks with high content of carbonated recycled concrete fines: Strength, microstructure and environmental benefit

This research presents a novel method of recycling construction waste while capturing CO2 through the formation of mineral carbon. The technology uses carbonated recycled concrete fines (CRCF) as the primary raw material to produce sustainable, high-performance alkali bricks with high replacement rates. Firstly, a general assessment of the physical and chemical properties of CRCF was carried out, which revealed the formation of silica gel encapsulating the surface of CRCF during carbonation. Subsequently, alkali bricks were prepared utilizing CRCF. The study investigated the impact of various mix proportions, water-to-cement ratios, and manufacturing process parameters on brick strength. Additionally, an in-depth analysis of reaction products and brick microstructures was carried out. The results showed that the bricks produced from CRCF were stronger than those from RCF, indicating enhanced reactivity after carbonation. Finally, an analysis demonstrated that utilizing RCF from construction waste can significantly reduce carbon dioxide emissions, thereby mitigating the environmental impact associated with cement production.

Near Dry Powder Mixed Electric Discharge Machining of AA7050 Hybrid Composites Utilizing Composite Tool Materials

Electric Discharge Machining (EDM) is a prominent technique for producing components with complex geometry and intricate shapes. However, productivity depends on the selection of optimal input variables. This research investigates EDM and Near-Dry EDM (NDEDM) on AA7050 hybrid composites, exploring the impact of tool materials, Al2O3 powder concentration, and dielectric fluids on Material Removal Rate (MRR) and Surface Roughness (Ra). NDEDM offers a higher MRR due to localized heating and energy concentration, while hydrocarbon oil EDM provides lower Ra due to cooling and lubrication. Tool material properties, thermal conductivity and bonding strength, affect MRR and TWR. Aluminum composite tools via stir casting display a strong bonding interface, leading to efficient energy transfer and higher MRR, while copper composite tools via friction stir processing exhibit weaker bonding, potentially reducing MRR. Hydrocarbon oil significantly lowers TWR due to effective lubrication and cooling, while near dry EDM results in slightly higher TWR. Al2O3 powder enhances MRR, with an optimal concentration of 1 g/l, while higher concentrations hinder MRR. The presence of Al2O3 powder enhanced the surface quality by reducing the size of the recast layers and producing a smoother surface. Globules, craters, microcracks, pock marks and re-casted layers are the noticeable features spotted on the surface. The results were optimized using the TOPSIS optimization technique and process parameters 32 A current, 30 µs Ton, 3 mm gap distance machined under 3 g/l Al2O3 incorporated hydrocarbon oil dielectric medium using copper composites tool proffers optimal machining performance.

Surface morphology of API 5L X65 pipeline steel processed by ultrasonic impact peening: An integrated experimental and computational study

Ultrasonic impact peening (UIP) is a highly effective surface engineering technique to improve material durability through peening-induced surface plastic deformation. These improvements are determined by not only the generation of surface compressive residual stresses but also the alteration of surface morphological features. In literature, researchers have focused primarily on the average roughness (Sa) to understand the morphology changes induced by UIP. From the surface engineering perspective, in addition to Sa, other surface morphological characteristics play key roles in determining material durability, particularly surface skewness (Ssk) and surface kurtosis (Sku), which describe the asymmetrical distribution of surface profiles and the sharpness of peak features, respectively. In this study, surface morphological characteristics of API 5L X65 pipeline steel processed by UIP are investigated with a focus on the effects of processing parameters on Sa, Ssk, and Sku. The results indicate that the optimized UIP conditions lead to the preparation of surfaces with valley structures as the dominant feature accompanied by blunt peaks, resulting in the elimination of stress concentration sites towards enhanced material durability. In addition, surface hardness, residual stresses, and peening-induced deformation depth are measured. Furthermore, to gain a comprehensive understanding of the material response and the underlying mechanisms driving surface morphological alterations by UIP, a finite element method (FEM)-based model is developed. By investigating the effect of process parameters (peening amplitude, peening cycles, and pin size) on the surface deformation depth and stress/strain distribution, a correlation between these process variables with surface characteristics is established.

Response Surface Methodology Optimization of Resistance Welding Process for Unidirectional Carbon Fiber/PPS Composites

The use of thermoplastic composites (TPCs) as one of the lightweight solutions will inevitably encounter problems in connection. Resistance welding has the characteristics of high strength, simplicity, and high reliability, and is considered a very potential hot-melt connection technology. The resistance welding technology of unidirectional carbon fiber-reinforced polyphenylene sulfide composites (UCF/PPS) was systematically studied. The experimental results show that the 100-mesh brass mesh has the best resin wetting effect and heating efficiency, and the PPS/oxidized 100-mesh brass mesh composite resistance element (Ox-RE/PPS) has the highest welding strength. The welding failure mode changes from interface failure and RE failure to interlayer structure damage and fiber fracture. The single-factor experimental results show that the maximum welding strength is reached at 310 °C, 1.15 MPa, and 120 kW/m2. According to the conclusion of the single-factor experiment, the Box–Behnken method was further used to design a three-factor, three-level experiment, and a quadratic regression model was established according to the test results. The results of variance analysis, fitting curve analysis, and perturbation plot analysis proved that the model had high fitting and prediction abilities. From the 3D surface diagram analysis, the influence of power density is the largest, and the interaction between welding temperature and power density is the most significant. Combined with the analysis of Design Expert 13 software, the optimal range of process parameters was obtained as follows: welding temperature 313–314 °C, welding pressure 1.04–1.2 MPa, and power density 124–128 kW/m2. The average strength of resistance welding joints prepared in the optimal range of process parameters was 13.58 MPa.

Ultra-strong and conductive graphene fiber via sacrificial layer technology

Microfluidic spinning technology (MST) is an emerging method specialized in the construction of multi-component and multi-structure fibers. In this study, we designed an ultra-strong coaxial graphene oxide (GO) fiber by employing sodium alginate (SA) as sheath flow via MST. The diameter of the fiber and the arrangement of GO molecules could be controlled by adjusting process parameters. More importantly, the outer SA layer could be removed during a subsequent reduction process of GO, which served as a sacrificial layer to GO fiber formation and enhanced the fiber strength. Ultimately, this could achieve a conductive graphene fiber with a maximum strength of 365.2 MPa and electrical conductivity of 52 Ω/cm via a common wet spinning mechanism.

Characterization of Freezing Processes in Drug Substance Bottles by Ice Core Sampling

Freezing of biological drug substance (DS) is a critical unit operation that may impact product quality, potentially leading to protein aggregation and sub-visible particle formation. Cryo-concentration has been identified as a critical parameter to impact protein stability during freezing and should therefore be minimized. The macroscopic cryo-concentration, in the following only referred to as cryo-concentration, is majorly influenced by the freezing rate, which is in turn impacted by product independent process parameters such as the DS container, its size and fill level, and the freezing equipment. (At-scale) process characterization studies are crucial to understand and optimize freezing processes. However, evaluating cryo-concentration requires sampling of the frozen bulk, which is typically performed by cutting the ice block into pieces for subsequent analysis. Also, the large amount of product requirement for these studies is a major limitation. In this study, we report the development of a simple methodology for experimental characterization of frozen DS in bottles at relevant scale using a surrogate solution. The novel ice core sampling technique identifies the axial ice core in the center to be indicative for cryo-concentration, which was measured by osmolality, and concentrations of histidine and polysorbate 80 (PS80), whereas osmolality revealed to be a sensitive read-out. Finally, we exemplify the suitability of the method to study cryo-concentration in DS bottles by comparing cryo-concentrations from different freezing protocols (-80°C vs -40°C). Prolonged stress times during freezing correlated to a higher extent of cryo-concentration quantified by osmolality in the axial center of a 2 L DS bottle.Graphical

Uncertainty Quantification of Process- Property-Structure Linkage for Fused Filament Fabrication Parts

Uncertainty Quantification of Process- Property-Structure Linkage for Fused Filament Fabrication Parts

Prediction of the penetration depth of particle-loaded inks in binder jetting

Prediction of the penetration depth of particle-loaded inks in binder jetting

Size matters: Exploring part size effects on microstructure, defects, and mechanical property in optimized laser powder bed fusion (L-PBF) additive manufacturing

In laser-based metal additive manufacturing (MAM), effective process optimization requires a thorough analysis of variations across the process window. Despite the common practice of utilizing small-sized coupons to optimize process parameters in laser-based MAM, this study challenges this convention. Through an analysis of microstructure and defect differences in Fe-Ni material parts produced via laser-powder bed fusion (L-PBF), the study reveals significant discrepancies in microstructure, defect and mechanical property based on part size. As part size increases, lack-of-fusion defects and cracks become more pronounced, resulting in a decrease in density from 8.11 g/cm3 to 8.02 g/cm3, leading to constrained grain growth with a decrease of grain size from 41.88 μm to 23.07 μm in the scanning plane. Each defect and microstructural difference was traced back to variations in thermal history based on part size. Finite element method simulations, highlighting differences in thermal history from scanning a single layer to the entire part, showed that an increase in scan length with a widened scan area enlarged the period of the thermal history cycle, leading to considerable cooling. This study underscores crucial considerations for future researchers engaged in process optimization for novel alloy systems using laser-based MAM processes.

Machining Performance Analysis of Ti6-Al-4V in Powder-Mixed EDM Using Green Dielectric Oil

In this investigation, the factors were oil type ([Formula: see text]), powder type ([Formula: see text]), and powder concentration ([Formula: see text]) level, and the machining parameters were the voltage (V), capacitance (pf), pulse-on time ([Formula: see text]), and pulse-off time ([Formula: see text]). The output parameters were the material removal rate (MRR), and tool wear rate (TWR). Three types of oils and powders, along with their respective particle concentrations, were selected for this experiment. Neem, Karanja, and sesame oils were mixed with aluminum oxide (Al2O3), chromium (Cr), and nickel (Ni) powder at 4, 6, and 8[Formula: see text]gm/l, respectively, using an overhead stirrer to investigate the conditions under which the green oil powder mixed mixture yielded a higher MRR and lower TWR during the micro-EDM process of titanium alloy (Ti-6Al-4V) using a 0.8[Formula: see text]mm tungsten carbide (WC) tool with fixed machining parameters (240[Formula: see text]V, 100[Formula: see text]pf, 20[Formula: see text][Formula: see text]s [Formula: see text], and 5[Formula: see text][Formula: see text]s [Formula: see text]). All the powders used in this experiment had a 32-micron (450 mesh) size. The Taguchi L[Formula: see text] orthogonal array and grey relational analysis methods were used to design and optimize the input process parameters for both responses. SEM, optical microscopic analysis, and EDS analysis were performed to examine the surface morphology, characteristics of the WC tool, and elemental composition of both the tool and the workpiece material. The optimum conditions for Karanja oil with a Cr powder mixture concentration of 4[Formula: see text]g/l resulted in higher MRR and lower TWR. However, machining with neem and sesame oils resulted in higher TWR and lower MRR.

Multi-objective optimization of a hydrogen production process for polymer membrane coupled with electrochemical hydrogen pump from hydrogen-doped natural gas by NSGA-II

In this work, a novel process of polymer membrane coupled with electrochemical hydrogen pump (EHP) was proposed to achieve efficient hydrogen production from hydrogen-doped natural gas (HDNG), and was simulated by UniSim Design. A hydrogen separation unit of two-stage polymer membrane was used for achieving hydrogen enrichment from low H2 concentration HDNG. Due to the hydrogen upgrade, EHP was operated at a H2 concentration much higher than HDNG, resulting in low energy consumption. Benefiting from the synergy between hydrogen upgrade and purification, the coupling process brought substantial effect while improving the hydrogen purity and recovery rate and reducing the hydrogen separation cost. The real natural gas components were considered into HDNG to ensure the effectiveness of process simulation. An optimization strategy considering both product yield and production cost was proposed to achieve the trade-off between hydrogen recovery rate and separation cost. However, the impact of process parameters on the objectives is nonlinear and difficult to describe with mathematical expressions. Therefore, an agent model of the proposed process was established based on back propagation neural network (BPNN), and multi-objective optimization of H2 recovery rate and total annual cost (TAC) of hydrogen separation unit was achieved using non-dominated sorting genetic algorithm-II (NSGA-II). Investigations with HDNG under various operating conditions (feed pressure of 8–40 bar and feed H2 concentration of 5–25 mol%) were performed, which proved that 90 % overall H2 recovery rate and 99.99 mol% H2 purity of hydrogen product can be achieved at low cost, with the lowest hydrogen separation cost of 1.00 $/kg H2 achievable at 40 bar feed pressure and 25 mol% feed H2 concentration. In summary, this coupling process can provide engineering solutions for efficient hydrogen production from HDNG and promote the development of green hydrogen.

Calculating the acoustic radiation force on spherical particles in a standing ultrasound wave field considering single and multiple scattering

Ultrasound directed self-assembly (DSA) utilizes the acoustic radiation force (ARF) associated with a standing ultrasound wave to organize particles dispersed in a fluid medium into specific patterns. The ARF is a superposition of the primary acoustic radiation force, which results from the incident standing ultrasound wave, and the acoustic interaction force, which originates from single and multiple scattering between neighboring particles. In contrast with most reports in the literature that neglect multiple scattering when calculating the ARF, we demonstrate that the deviation between considering single or multiple scattering may reach up to 100%, depending on the ultrasound DSA process parameters and material properties. We evaluate a theoretical case with three spherical particles in a viscous medium and derive operating maps that quantify the deviation between both scattering approaches as a function of the ultrasound DSA process parameters. Then, we study a realistic system with hundreds of particles dispersed in a viscous medium, and show that the deviation between the ARF resulting from single and multiple scattering increases with decreasing particle size and increasing medium viscosity, density ratio, compressibility ratio, and particle volume fraction. This work provides a quantitative basis for determining whether to consider single or multiple scattering in ultrasound DSA simulations.