Erosion-Corrosion Failure Analysis of a Mild Steel Nozzle Pipe in Water-Sand Flow.

Several leaks appeared in a mild steel (MS) pipe jet nozzle installed in a direct impact test rig after a few months of operation in erosive flow at the Centre for Erosion-Corrosion Research. The locations of perforation leaks were primarily upstream, but severe wall thinning was also noticed adjacent to the exit section. In this paper, a failure analysis was carried out on the leaking of a pipe jet nozzle, and the results are discussed in detail. The investigation carried out includes visual observation, scanning electron microscopy, 3D scanning, energy-dispersive spectroscopy, and laser profilometry measurements. In addition, numerical simulations based on computational fluid dynamics (CFD) and the discrete phase model (DPM) were conducted to investigate the root cause of the failure of leaks in the pipe jet nozzle. Further CFD-DPM simulations were performed on three different pipe jet designs for liquid-solid flow conditions, and were compared to find an alternative design to prevent the failure of the pipe jet nozzles. It was found that the increase in turbulence along with multiple impacts of particles on the wall generate leaks and cracks in the pipe jet nozzle. Moreover, the CFD-DPM showed a five-fold reduction in the maximum erosion rate; this was observed in the replacement of failed pipes with the proposed alternative nozzle pipe design featuring a chamfer reducer section. The CFD-DPM analysis of all geometric configurations showed that alteration of reducer section design has the greatest impact on erosive wear mitigation.

Investigation of the Mechanical and Tribological Behavior of Epoxy-Based Hybrid Composite.

The main target of this study is to evaluate the impact of hybrid reinforcement using Al2O3 nanoparticles and graphite on the epoxy nanocomposites' mechanical and tribological properties. Various weight fractions of the reinforcement materials, ranging from 0 to 0.5 wt.%, were incorporated into the epoxy. The aim is to enhance the characteristics and durability of the polymers for potential utilization in different mechanical applications. The addition of hybrid additives consisting of Al2O3 nanoparticles and graphite to the epoxy resin had a noticeable effect on the performance of the epoxy nanocomposites. The incorporation of these additives resulted in increased elasticity, strength, toughness, ductility, and hardness as the concentration of reinforcement increased. The enhancement in the stiffness, mechanical strength, toughness and ductility reached 33.9%, 25.97%, 25.3% and 16.7%, respectively. Furthermore, the frictional tests demonstrated a notable decrease in both the coefficient of friction and wear with the rise of the additives' weight fraction. This improvement in the structural integrity of the epoxy nanocomposites led to enhanced mechanical properties and wear resistance. The SEM was utilized to assess the surfaces of tested samples and provide insights into the wear mechanism.

Silica NPs in PLA-Based Electrospun Nanofibrous Non-Woven Protective Fabrics with Dual Hydrophilicity/Hydrophobicity, Breathability, and Thermal Insulation Characteristics for Individuals with Disabilities.

A perfect protective fabric for handicapped individuals must be lightweight, waterproof, breathable, and able to absorb water. We present a multifunctional protective fabric in which one side is hydrophobic based on the intrinsic hydrophobic biopolymer polylactic acid (PLA) to keep the disabled person from getting wet, while the other side is super-hydrophilic due to embedded silica nanoparticles (NPs) to keep the disabled person safe from a sudden spill of water or other beverage on their skin or clothes. The porosity of the electrospun nanofibrous structure allows the fabric to be breathable, and the silica NPs play an important role as a perfect infrared reflector to keep the person's clothing cool on warm days. Adding white NPs, such as silicon dioxide, onto or into the textile fibers is an effective method for producing thermally insulated materials. Due to their ability to efficiently block UV light, NPs in a network keep the body cool. Such a multifunctional fabric might be ideal for adult bibs and aprons, outdoor clothing, and other amenities for individuals with disabilities.

Unveiling the Potential of Rice Straw Nanofiber-Reinforced HDPE for Biomedical Applications: Investigating Mechanical and Tribological Characteristics.

The efficient utilization of rice waste has the potential to significantly contribute to environmental sustainability by minimizing the waste impact on the environment. Through repurposing such waste, novel materials can be developed for various biomedical applications. This approach not only mitigates waste, but it also promotes the adoption of sustainable materials within the industry. In this research, rice-straw-derived nanofibers (RSNFs) were utilized as a reinforcement material for high-density polyethylene (HDPE). The rice-straw-derived nanofibers were incorporated at different concentrations (1, 2, 3, and 4 wt.%) into the HDPE. The composites were fabricated using twin-screw extrusion (to ensure homogenous distribution) and the injection-molding process (to crease the test samples). Then, the mechanical strengths and frictional performances of the bio-composites were assessed. Different characterization techniques were utilized to investigate the morphology of the RSNFs. Thermal analyses (TGA/DTG/DSC), the contact angle, and XRD were utilized to study the performances of the HDPE/RSNF composites. The study findings demonstrated that the addition of RSNFs as a reinforcement to the HDPE improved the hydrophilicity, strength, hardness, and wear resistance of the proposed bio-composites.

Investigation on mechanical properties and corrosion resistance of Ti-modified AA5083 aluminum alloy for aerospace and automotive applications.

Casting of aluminum with different concentration of alloying elements such as Mg, Mn (similar to that in AA5083) with additional percentages of 0.1, 0.2 and 0.3% Ti, are carried out using graphite crucible. The as-cast microstructure is modified by hot rolling to a thickness of ~ 2 mm. Mechanical and metallurgical and characterization of heat-treated thin sheets are carried out using tensile testing, hardness measurement, metallography, image analysis and optical microscope. By increasing the Ti content, the results show grain refinement and increase in the formation of Al3Ti which reflected positively on the mechanical properties. Specifically, Ultimate tensile strength is increased from 260 MPa (0 wt% Ti) to 345 MPa (0.3 wt% Ti) when using water quenching, 32.6% improvement for air cooling, and 23.3% for furnace cooling. Electrochemical corrosion behavior of heat-treated water quenched, air cooled and furnace cooled samples were tested in 3.5% NaCl solution. The results show that the heat-treated alloys have very good resistance against corrosion, while by increasing the Ti content, the corrosion rate increases due to the grain refinement phenomena.

Service life assessment of yttria stabilized zirconia (YSZ) based thermal barrier coating through wear behaviour.

Countless research has suggested Yttria-stabilized Zirconia (YSZ) to be a top candidate for being implemented as thermal barrier coatings (TBC). However, when exposed to prolonged service, temperature and stress variations succeed in initiating a catastrophic phase transformation from tetragonal to monoclinic structure in Zirconia. Hence, the estimation of endurance for YSZ-based TBC is necessary to minimize failure in such situations. The main purpose of this research was to determine the relationship between tribological investigations and the estimated lifespan of YSZ coatings accurately. The study used various methods such as wear resistance testing, optical profilometry, specific wear rate, and coefficient of friction to estimate the maximum durability of TBCs. The research also provided insights into the composition and microstructure of the TBC system and found the optimized concentration of Yttrium doping to be 3.5 wt %. The study discovered that erosion was the main cause of roughness depreciation from SN to S1000. The estimation of the service life was primarily made based on optical profilometry, specific wear rate (SWR), coefficient of friction (COF) and wear resistance values which were further supported by the results of chemical characterization of the samples through electron dispersive spectroscopy (EDS), wavelength dispersive spectroscopy (WDS) and X-Ray Diffraction (XRD) analysis. The results were reliable and accurate and suggested future areas of investigation, such as 3D profilometry for surface roughness and thermal conductivity evaluation using laser-assisted infrared thermometers.

Developing PMMA/Coffee Husk Green Composites to Meet the Individual Requirements of People with Disabilities: Hip Spacer Case Study.

When replacing a damaged artificial hip joint, treatment involves using antibiotic-laced bone cement as a spacer. One of the most popular materials used for spacers is PMMA; however, it has limitations in terms of mechanical and tribological properties. To overcome such limitations, the current paper proposes utilizing a natural filler, coffee husk, as a reinforcement for PMMA. The coffee husk filler was first prepared using the ball-milling technique. PMMA composites with varying weight fractions of coffee husk (0, 2, 4, 6, and 8 wt.%) were prepared. The hardness was measured to estimate the mechanical properties of the produced composites, and the compression test was utilized to estimate the Young modulus and compressive yield strength. Furthermore, the tribological properties of the composites were evaluated by measuring the friction coefficient and wear by rubbing the composite samples against stainless steel and cow bone counterparts under different normal loads. The wear mechanisms were identified via scanning electron microscopy. Finally, a finite element model for the hip joint was built to investigate the load-carrying capacity of the composites under human loading conditions. The results show that incorporating coffee husk particles can enhance both the mechanical and tribological properties of the PMMA composites. The finite element results are consistent with the experimental findings, indicating the potential of the coffee husk as a promising filler material for enhancing the performance of PMMA-based biomaterials.

Effect of Synthesized Titanium Dioxide Nanofibers Weight Fraction on the Tribological Characteristics of Magnesium Nanocomposites Used in Biomedical Applications.

Biomedical applications, such as artificial implants, are very significant for the disabled due to their usage in orthopedics. Nevertheless, available materials in such applications have insufficient mechanical and tribological properties. The current study investigated the mechanical and tribological properties of a biomedical metallic material, magnesium (Mg), after incorporating titanium dioxide nanofibers (TiO2) with different loading fractions. The TiO2 nanofibers were synthesized using the electrospinning technique. The ball-milling technique was utilized to ensure the homogenous distribution of TiO2 nanofibers inside the Mg matrix. Then, samples of the mixed powder with different loading fractions of TiO2 nanofibers, 0, 1, 3, 5, and 10 wt.%, were fabricated using a high-frequency induction heat sintering technique. The physicomechanical and tribological properties of the produced Mg/TiO2 nanocomposites were evaluated experimentally. Results showed an enhancement in mechanical properties and wear resistance accompanied by an increase in the weight fraction of TiO2 nanofibers up to 5%. A finite element model was built to assess the load-carrying capacity of the Mg/TiO2 composite to estimate different contact stresses during the frictional process. The finite element results showed an agreement with the experimental results.

Evaluating the Mechanical and Tribological Properties of 3D Printed Polylactic-Acid (PLA) Green-Composite for Artificial Implant: Hip Joint Case Study.

Artificial implants are very essential for the disabled as they are utilized for bone and joint function in orthopedics. However, materials used in such implants suffer from restricted mechanical and tribological properties besides the difficulty of using such materials with complex structures. The current study works on developing a new polymer green composite that can be used for artificial implants and allow design flexibility through its usage with 3D printing technology. Therefore, a natural filler extracted from corn cob (CC) was prepared, mixed homogeneously with the Polylactic-acid (PLA), and passed through a complete process to produce a green composite filament suit 3D printer. The corn cob particles were incorporated with PLA with different weight fractions zero, 5%, 10%, 15%, and 20%. The physical, mechanical, and tribological properties of the PLA-CC composites were evaluated. 3D finite element models were constructed to evaluate the PLA-CC composites performance on a real condition implant, hip joints, and through the frictional process. Incorporating corn cob inside PLA revealed an enhancement in the hardness (10%), stiffness (6%), compression ultimate strength (12%), and wear resistance (150%) of the proposed PLA-CC composite. The finite element results of both models proved an enhancement in the load-carrying capacity of the composite. The finite element results came in line with the experimental results.

Influence of Tantalum Addition on the Corrosion Passivation of Titanium-Zirconium Alloy in Simulated Body Fluid.

Ti-15%Zr alloy and Ti-15%Zr-2%Ta alloy were fabricated to be used in biomedical applications. The corrosion of these two alloys after being immersed in simulated body fluid for 1 h and 72 h was investigated. Different electrochemical methods, including polarization, impedance, and chronoamperometric current with time at 400 mV were employed. Also, the surface morphology and the compositions of its formed film were reported by the use of scanning electron microscope and energy dispersive X-ray. Based on the collected results, the presence of 2%Ta in the Ti-Zr alloy passivated its corrosion by minimizing its corrosion rate. The polarization curves revealed that adding Ta within the alloy increases the corrosion resistance as was confirmed by the impedance spectroscopy and current time data. The change of current versus time proved that the addition of Ta reduces the absolute current even at high anodic potential, 400 mV. The results of both electrochemical and spectroscopic methods indicated that pitting corrosion does not occur for both Ti-Zr and Ti-Zr-Ta alloys, even after their immersion in SBF solutions for 72 h.

Evaluating the Performance of 3D-Printed PLA Reinforced with Date Pit Particles for Its Suitability as an Acetabular Liner in Artificial Hip Joints.

Off-the-shelf hip joints are considered essential parts in rehabilitation medicine that can help the disabled. However, the failure of the materials used in such joints can cause individual discomfort. In support of the various motor conditions of the influenced individuals, the aim of the current research is to develop a new composite that can be used as an acetabular liner inside the hip joint. Polylactic acid (PLA) can provide the advantage of design flexibility owing to its well-known applicability as a 3D printed material. However, using PLA as an acetabular liner is subject to limitations concerning mechanical properties. We developed a complete production process of a natural filler, i.e., date pits. Then, the PLA and date pit particles were extruded for homogenous mixing, producing a composite filament that can be used in 3D printing. Date pit particles with loading fractions of 0, 2, 4, 6, 8, and 10 wt.% are dispersed in the PLA. The thermal, physical, and mechanical properties of the PLA-date pit composites were estimated experimentally. The incorporation of date pit particles into PLA enhanced the compressive strength and stiffness but resulted in a reduction in the elongation and toughness. A finite element model (FEM) for hip joints was constructed, and the contact stresses on the surface of the acetabular liner were evaluated. The FEM results showed an enhancement in the composite load carrying capacity, in agreement with the experimental results.

A Closer Look at Precision Hard Turning of AISI4340: Multi-Objective Optimization for Simultaneous Low Surface Roughness and High Productivity.

This article reports an extended investigation into the precision hard turning of AISI 4340 alloy steel when machined by two different types of inserts: wiper nose and conventional round nose. It provides a closer look at previously published work and aims at determining the optimal process parameters for simultaneously minimizing surface roughness and maximizing productivity. In the mathematical models developed by the authors, surface roughness at different cutting speeds, depths of cut and feed rates is treated as the objective function. Three robust multi-objective techniques, (1) multi-objective genetic algorithm (MOGA), (2) multi-objective Pareto search algorithm (MOPSA) and (3) multi-objective emperor penguin colony algorithm (MOEPCA), were used to determine the optimal turning parameters when either the wiper or the conventional insert is used, and the results were experimentally validated. To investigate the practicality of the optimization algorithms, two turning scenarios were used. These were the machining of the combustion chamber of a gun barrel, first with an average roughness (Ra) of 0.4 µm and then with 0.8 µm, under conditions of high productivity. In terms of the simultaneous achievement of both high surface quality and productivity in precision hard turning of AISI 4340 alloy steel, this work illustrates that MOPSA provides the best optimal solution for the wiper insert case, and MOEPCA results are the best for the conventional insert. Furthermore, the results extracted from Pareto front plots show that the wiper insert is capable of successfully meeting both the requirements of Ra values of 0.4 µm and 0.8 µm and high productivity. However, the conventional insert could not meet the 0.4 µm Ra requirement; the recorded global minimum was Ra = 0.454 µm, which reveals the superiority of the wiper compared to the conventional insert.

Evaluation of Mechanical and Tribological Properties of Corn Cob-Reinforced Epoxy-Based Composites-Theoretical and Experimental Study.

Epoxy is considered to be the most popular polymer and is widely used in various engineering applications. However, environmental considerations require natural materials-based epoxy. This necessity results in further utilization of natural materials as a natural reinforcement for different types of composites. Corn cob is an example of a natural material that can be considered as an agricultural waste. The objective of the present work is to improve the economic feasibility of corn cob by converting the original corn cob material into powder to be utilized in reinforcing epoxy-based composites. In the experiment, the corn cob was crushed and ground using a grain miller before it was characterized by scanning electron microscopy (SEM). The corn cob powder was added to the epoxy with different weight fractions (2, 4, 6, 8, 10 wt%). In order to prevent corn cob powder agglomeration and ensure homogeneous distribution of the reinforcement inside the epoxy, the ultrasonic technique and a mechanical stirrer were used. Then, the composite's chemical compositions were evaluated using X-ray diffraction (XRD). The mechanical experiments showed an improvement in the Young's modulus and compressive yield strength of the epoxy composites, increasing corn cob up to 8 wt% by 21.26% and 22.22%, respectively. Furthermore, tribological tests revealed that reinforcing epoxy with 8 wt% corn cob can decrease the coefficient of friction by 35% and increase wear resistance by 4.8%. A finite element model for the frictional process was constructed to identify different contact stresses and evaluate the load-carrying capacity of the epoxy composites. The finite element model showed agreement with the experimental results. An epoxy containing 8 wt% corn cob demonstrated the optimal mechanical and tribological properties. The rubbed surfaces were investigated by SEM to identify the wear mechanism of different composites.

High-Temperature Corrosion of APS- and HVOF-Coated Nickel-Based Super Alloy under Air Oxidation and Melted Salt Domains.

Various thermal spraying approaches, such as air/atmospheric plasma spraying (APS) and high-velocity oxy-fuel (HVOF) spraying, are widely employed by plants owing to their flexibility, low costs and the high surface quality of the manufactured product. This study focuses on the corrosion behavior of a Ni superalloy coated with powder Cr3C2-25NiCr through APS and HVOF at 950 °C under air oxidation and Na2SO4 + 0.6V2O5 molten salt environments (MSE). The results show that HVOF-deposited Ni superalloys have higher hardness and bond strength than the respective APS coating. The thermo-gravimetric probe reveals that the Ni superalloys exposed to an oxidizing air environment has a minor mass gain compared to those under the MSE domain for both non-coated and coated samples, in line with the parabola curvature rate oxidizing law. The Ni superalloys show good corrosion resistance but poor oxidation resistance in APS-deposited Ni superalloys under the MSE. HVOF-coated Ni superalloys in both environments exhibit better corrosion resistance and lower mass gain than APS-coated superalloys. The excellent coating characteristics of HVOF-coated Ni superalloys lead to their better high-temperature corrosion performance than APS.

Stress Distribution and Fracture Toughness of Underground Reinforced Plastic Pipe Composite.

Reinforced composite materials have many applications in the aerospace, marine, and petroleum industries. Glass fiber-reinforced pipes are of considerable importance as pressurized vessels, infrastructure materials, and petroleum wastewater pipelines. The stress intensity factor due to through-thickness discontinuities is a major parameter in fracture mechanics to understand the failure mechanisms in glass fiber-composite pipes. The stress intensity factor is calculated for a composite cylinder subjected to internal pressure using the linear extended finite element method based on the law of energy release evaluation of surface damage. The analytical model needs two material properties; they are the tensile strength and the fracture toughness; therefore, a standard tensile test was carried out on a standard specimen taken from the pipe's wall thickness. Moreover, the compact tension test specimen was manufactured from the pipe's wall thickness to obtain the fracture toughness. The average tensile strength was measured as 21.5 MPa with a standard deviation of 5.59 MPa, moreover, the average Young's modulus was measured as 32.75 GPa with a standard deviation of 6.64 GPa. The fracture toughness was measured as 2322 (MPa √m) with a standard deviation of 142.5 (MPa √m), whereas the average surface release energy (GIC) was 153.6 kJ/m2 with a standard deviation of 22.53 kJ/m2. A valuable design equation was extracted from the finite element model to measure the effect of cracks on the hoop stress of the cylinder wall thickness based on a nonlinear model. Moreover, an acceptable equation was used to calculate the correction and shape factor of a cylinder with movable and unmovable through-thickness cracks. This study provides useful tools and guidance for the design and analysis of composite cylinders.

Multiresponse Optimization of Linkage Parameters of a Compliant Mechanism Using Hybrid Genetic Algorithm-Based Swarm Intelligence.

This research focuses on the synthesis of linkage parameters for a bistable compliant system (BSCS) to be widely implemented within space applications. Initially, BSCS was theoretically modeled as a crank-slider mechanism, utilizing pseudo-rigid-body model (PRBM) on stiffness coefficient (v), with a maximum vertical footprint (b max) for enhancing vibration characteristics. Correlations for mechanism linkage parameters (MLPs) and responses (v and b max) were set up by utilizing analysis of variance for response surface (RSM) technique. RSM evaluated the impact of MLPs at individual/interacting levels on responses. Consequently, a hybrid genetic algorithm-based particle swarm/flock optimization (GA-PSO) technique was employed and optimized at multiple levels for assessing ideal MLP combinations, in order to minimize characteristics (10% v + 90% of b max). Finally, GA-PSO estimated the most appropriate Pareto-frontal optimum solutions (PFOS) from nondominance set and crowd/flocking space approaches. The resulting PFOS from validation trials demonstrated significant improvement in responses. The adapted GA-PSO algorithm was executed with ease, extending the convergence period (through GA) and exhibiting a good diversity of objectives, allowing the development of large-scale statistics for all MLP permutations as optimal solutions. A vast set of optimal solutions can be used as a reference manual for mechanism developers.