A. L. Mohd Tobi

Abrasive Wear Failure Analysis of Tungsten Carbide Hard facing on Carbon Steel Blade

This study investigate the abrasive wear failure of tungsten carbide hardfacing on continuous digester (CD) blade (carbon steel) in an environment of sulphuric acid and ilmenite ore mixture. Comparison being made on the hardness, thickness and microstructural of the hardfacing between unworn and 3 months old worn blade on few locations around the blade. The cross sections of the blade revealed non-uniform coverage of the hardfacing on the blade for both worn and unworn blade. The edge of the blade has the least amount of hardfacing thickness which with time acts as the point of failure during the wear process. The hardness obtained from both the unworn and worn samples are around 25% lower from the hardfacing electrode manufacturers hardness specification. Microstructural micrograph analysis of the hardfacing revealed non uniform size carbide with non-uniform distributed of carbide in the hardfacing layer.

Characterization of WC-10Ni HVOF Coating for Carbon Steel Blade

High Velocity Oxy-Fuel, HVOF is a depositing methods of a material layer over a base metal or substrate with characteristics of high flame velocity and moderate temperature. Where, tungsten carbide, WC cermet HVOF coatings is widely used to protect machine components from wear and corrosion. The main purpose of this present paper is to characterize the WC-10Ni coating deposited by HVOF thermal spray onto a carbon steel blade. The morphology and chemical composition of the coating were characterized by Scanning Electron Microstructure (SEM), electron dispersive spectrometer (EDS), and X-ray diffraction (XRD). The hardness test was carried out by using Vickers micro-hardness tester with loads of 490.3 mN (HV0.05). From XRD results, no sharp nickel peak was identified and has been replaced by a hump which indicate the amorphous Ni. The major crystalline phases were compounds WC, W2C and metallic phase of W. The WC-10Ni coating shows high hardness with low porosity distribution.

Cost viability of 3D printed house in UK

UK has been facing housing crisis due to the rising price of the property on sale. This paper will look into the viability of 3D printing technology as an alternative way for house construction on UK. The analysis will be carried out based on the data until the year of 2014 due to limited resources availability. Details cost breakdown on average size house construction cost in UK were analysed and relate to the cost viability of 3D printing technology in reducing the house price in UK. It is found that the 3D printing generates saving of up to around 35% out of total house price in UK. This cost saving comes from the 3D printed construction of walls and foundations for material and labour cost.

A Study on Wear Failure Analysis of Tungsten Carbide Hardfacing on Carbon Steel Blade in a Digester Tank

This paper addresses wear failure analysis of tungsten carbide (WC) hardfacing on a carbon steel blade known as the continuous digester blade (CD blade). The CD blade was placed in a digester tank to mix ilmenite ore with sulphuric acid as part of a production process. Tungsten carbide hardfacing was applied on the CD blade to improve its wear resistance while the CD blade was exposed to an abrasive and acidic environment. Failure analysis was carried out on the hardfaced CD blade in order to improve its wear resistance and lifetime. A thickness and hardness comparison study was conducted on worn and unworn specimens from the CD blades. The carbide distribution along with elemental composition analysis of the hardfaced CD blade specimens was examined using scanning electron microscopy and energy-dispersive spectroscopy. The investigation revealed that an inconsistent hardfacing thickness was welded around the CD blade. Minimum coating thickness was found at the edges of the blade surfaces causing failure to the blades as the bare carbon steel blades were exposed to the mixed environment. The wear resistance of the CD blade can be improved by distributing the carbide uniformly on the hardfaced coating. Applying extra coating coverage at the critical edge will prevent the exposure of bare carbon steel blade, thus increasing the CD blade lifetime.

Microstructure Analysis of Tungsten Carbide Hardfacing on Carbon Steel Blade

Tungsten carbide (WC) hardfacing coating is commonly used to enhance carbon steel blade performance which works in acidic and abrasive condition during production process. This paper deals with tungsten carbide (WC) hardfacing microstructure analysis on a carbon steel blade. Mixing of ilmenite ore with sulphuric acid is performed by the carbon steel blade as part of a production process. Tungsten carbide hardfacing is deposited on the carbon steel blade to enhance its wear resistance. The carbide distribution along with elemental composition analysis of the hardfaced carbon steel blade specimens is examined using Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS) and X-Ray Diffraction (XRD) respectively. Microstructure analysis revealed that different sizes of carbides with non-uniform distribution are found around the coating region. The carbide region is contains high percentage of tungsten (W) meanwhile, non-carbide region rich in tungsten (W) and iron (Fe).

Stress intensity factors and interaction of two parallel surface cracks on cylinder under tension

This paper presents three-dimensional (3D) finite element solution on multiple surface cracks. The cracks on solid cylinder are similar in sizes, parallel each other, assumed to grow in semi-elliptical shape and subjected to remotely tension loading (mode I). A wide range of parametric study involving crack depth ratios ( 0.1<a/D<0.4), crack aspect ratios (0.2<a/b<1.2), normalized coordinates on crack front (0.0<x/h<0.93) and inter-crack distance ratios (0.005<c/l<0.32) are considered for numerical estimation of stress intensity factors (SIFs) along crack front. For multiple surface cracks under axial loading, the stress intensity factors along crack front decreased when c/l decreased. When multiple cracks approach one another, the stress intensity changes due to interaction of the stress field. The results show that it produces a stress shielding effects.

Wave velocity characteristic for Kenaf natural fibre under impact damage

This paper aims to determining the wave velocity characteristics for kenaf fibre reinforced composite (KFC) and it includes both experimental and simulation results. Lead zirconate titanate (PZT) sensor were proposed to be positioned to corresponding locations on the panel. In order to demonstrate the wave velocity, an impacts was introduced onto the panel. It is based on a classical sensor triangulation methodology, combines with experimental strain wave velocity analysis. Then the simulation was designed to replicate panel used in the experimental impacts test. This simulation was carried out using ABAQUS. It was shown that the wave velocity propagates faster in the finite element simulation. Although the experimental strain wave velocity and finite element simulation results do not match exactly, the shape of both waves is similar.

Fracture toughness of woven kenaf fibre reinforced composites

This paper presents the role of fibre orientations on the woven-type kenaf fibre reinforced composites. According to literature survey, lack of information regarding to the fracture toughness of woven kenaf fibre reinforced composites. Fracture toughness tests were performed using ASTM D5045. Four fibre orientations were used such as 0/15/0/-15/0, 0/30/0/-30/0, 0/45/0/-45/0 and 0/90/0/-90/0 and on the other hand virgin polyester and unidirectional fibre reinforced composites were also used for comparisons. Based on the experimental works, woven-typed composites produced lower fracture toughness compared with the unidirectional fiber composite. Fracture toughness obtained from different fibre orientations composites are almost identical however 0/30/0/-30/0 and 0/90/0/-90/0 produced higher toughness relative with others. Fracture mechanisms revealed that as expected the fibres aligned along the stress direction capable to sustain better mechanical deformation and therefore producing higher fracture toughness.

Development in Geared Turbofan Aeroengine

This paper looks into the implementation of epicyclic gear system to the aeroengine in order to increase the efficiency of the engine. The improvement made is in the direction of improving fuel consumption, reduction in pollutant gasses and perceived noise. Introduction of epicyclic gear system is capable to achieve bypass ratio of up to 15:1 with the benefits of weight and noise reduction. Radical new aircraft designs and engine installation are being studied to overcome some of the challenges associated with the future geared turbofan and open-rotor engine.

Effect of hybridized fiber wrapped around the aluminum tubes on the crushing performances

Nowadays, synthetic fibres for an example glass fibres is frequently used to wrap the metallic tubes in order to increase their load-bearing capacity. Due to environmental considerations and non-biodegradable behaviour, natural fibres or materials are increasingly used to replace synthetic fibres. The use of synthetic fibres can be minimized by combining them with natural fibres. Based on the literature survey, combining both fibres (synthetic and natural) for crushing applications are relatively new and therefore the main work of this paper is to present the crushing performances of hybridized fibres wrapped around the aluminium tubes when subjected to quasi-static crushing forces. Glass fibres are then combined with yarn kenaf fibres according to these volume fractions: 0, 25, 50, 75 and 100%. The hybridized fibres are wrapped around the tubes twice using different orientations [0o/0o], [15°/-15°], [30o/-30o] and [45o/-45o] included empty tubes before they are immersed into polyester resin bath. The composite tubes are then quasi-statically compressed using a constant cross-head displacement of 10mm/min. The force-displacement curves for each tube conditions are recorded automatically and analysed. The relation between hybridized fibbers and fibre orientations with crashworthiness parameters are investigated and discussed associating with their crushing mechanisms.