Effect of torch angle on arc properties and weld pool shape in stationary GTAW

In this paper, a three dimensional numerical simulation is performed on a stationary arc to study the effect of torch angle in gas tungsten arc welding (GTAW) of SS304 stainless steel. A comparison has been made to investigate 90o and 70o torch angles and analyze the effect on arc and weld pool shape. Current density, heat flux and gas shear stress are calculated in the arc region and are used as input to the workpiece to determine the weld pool. Buoyancy and Marangoni shear also affect the weld pool shape and are taken into account. The computed and experimental results are observed symmetric for 90o torch angle. For 70o torch angle, current density and hence the heat flux due to electron contribution is found the maximum behind and heat flux due to conduction and convection is found the maximum ahead of the electrode tip in the welding direction. This makes the maximum of total heat flux symmetric along the arc center. Heat flux due to conduction and convection decreases as the torch angle decreases resulting in a shallow weld pool. The nonsymmetric “w” shaped weld pool is developed by the combined effect of the gas shear and Marangoni convection. It is found that for 70o torch angle, the weld pool becomes non-symmetric, shallow and wide ahead of the electrode tip in the welding direction. The numerical weld pool shapes are verified through experiments

Physiological Evidence for Isopotential Tunneling in the Electron Transport Chain of Methane-Producing Archaea

Many, but not all, organisms use quinones to conserve energy in their electron transport chains. Fermentative bacteria and methane-producing archaea (methanogens) do not produce quinones but have devised other ways to generate ATP. Methanophenazine (MPh) is a unique membrane electron carrier found in Methanosarcina species that plays the same role as quinones in the electron transport chain. To extend the analogy between quinones and MPh, we compared the MPh pool sizes between two well-studied Methanosarcina species, Methanosarcina acetivorans C2A and Methanosarcina barkeri Fusaro, to the quinone pool size in the bacterium Escherichia coli. We found the quantity of MPh per cell increases as cultures transition from exponential growth to stationary phase, and absolute quantities of MPh were 3-fold higher in M. acetivorans than in M. barkeri. The concentration of MPh suggests the cell membrane of M. acetivorans, but not of M. barkeri, is electrically quantized as if it were a single conductive metal sheet and near optimal for rate of electron transport. Similarly, stationary (but not exponentially growing) E. coli cells also have electrically quantized membranes on the basis of quinone content. Consistent with our hypothesis, we demonstrated that the exogenous addition of phenazine increases the growth rate of M. barkeri three times that of M. acetivorans. Our work suggests electron flux through MPh is naturally higher in M. acetivorans than in M. barkeri and that hydrogen cycling is less efficient at conserving energy than scalar proton translocation using MPh

Transient Physical Effects in Electron Beam Sintering

The extensive use of the electron beam in manufacturing processes like welding or perforating revealed the high potentials for also using it for solid freeform fabrication. First approaches like feeding wire into a melt pool have successfully shown the technical feasibility. Among other features, the electron beam exhibits high scanning speed, high power output, and beam density. While in laser-based machines the fabrication is working in a stable way, transient physical effects in the electron beam process can be observed, which still restrict process stability. For instance, a high power input of the electron beam can result in sudden scattering of the metal powder. The authors have developed an electron beam freeform fabrication system and examined the above mentioned effects. Thus, the paper provides methods in order to identify, isolate and avoid these effects, and to finally realize a reproducible process.Mechanical Engineerin

Effect of a Distributed Heat Source on Melt Pool Geometry and Microstructure in Beam-Based Solid Freeform Fabrication

The ability to control geometric and mechanical properties of parts fabricated using laser-based manufacturing processes requires an understanding and control of melt pool geometry and microstructure. With the development of electron beam manufacturing or future beam-based deposition processes, the user may have more control over the distribution of incident energy, so that beam width becomes a potential process variable. As such, the focus of this work is the effect of a distributed heat source on melt pool geometry (length and depth) and the thermal conditions controlling microstructure (cooling rates and thermal gradients) in beam-based solid freeform fabrication. Previous work by the authors has employed the Rosenthal solution for a moving point heat source to determine the effects of process variables (laser power and velocity) on solidification cooling rates and thermal gradients controlling microstructure (grain size and morphology) in laser-deposited materials. Through numerical superposition of the Rosenthal solution, the current work extends the approach to include the effects of a distributed heat source for both 2-D thinwall and bulky 3-D geometries. Results suggest that intentional variations in beam width could potentially enable significant changes in melt pool geometry without affecting microstructure.Mechanical Engineerin

Height Control and Deposition Measurement for the Electron Beam Free Form Fabrication (EBF3) Process

A method of controlling a height of an electron beam gun and wire feeder during an electron freeform fabrication process includes utilizing a camera to generate an image of the molten pool of material. The image generated by the camera is utilized to determine a measured height of the electron beam gun relative to the surface of the molten pool. The method further includes ensuring that the measured height is within the range of acceptable heights of the electron beam gun relative to the surface of the molten pool. The present invention also provides for measuring a height of a solid metal deposit formed upon cooling of a molten pool. The height of a single point can be measured, or a plurality of points can be measured to provide 2D or 3D surface height measurements

Use of beam deflection to control an electron beam wire deposition process

A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool

Queuing models for abstracting interactions in Bacterial communities

Microbial communities play a significant role in bioremediation,plant growth,human and animal digestion,global elemental cycles including the carbon-cycle,and water treatment.They are also posed to be the engines of renewable energy via microbial fuel cells which can reverse the process of electrosynthesis.Microbial communication regulates many virulence mechanisms used by bacteria.Thus,it is of fundamental importance to understand interactions in microbial communities and to develop predictive tools that help control them,in order to aid the design of systems exploiting bacterial capabilities.This position paper explores how abstractions from communications,networking and information theory can play a role in understanding and modeling bacterial interactions.In particular,two forms of interactions in bacterial systems will be examined:electron transfer and quorum sensing.While the diffusion of chemical signals has been heavily studied,electron transfer occurring in living cells and its role in cell-cell interaction is less understood.Recent experimental observations open up new frontiers in the design of microbial systems based on electron transfer,which may coexist with the more well-known interaction strategies based on molecular diffusion.In quorum sensing,the concentration of certain signature chemical compounds emitted by the bacteria is used to estimate the bacterial population size,so as to activate collective behaviors.In this position paper,queuing models for electron transfer are summarized and adapted to provide new models for quorum sensing.These models are stochastic,and thus capture the inherent randomness exhibited by cell colonies in nature.It is shown that queuing models allow the characterization of the state of a single cell as a function of interactions with other cells and the environment,while being amenable to complexity reduction.Comment: IEEE Journal on Selected Areas in Communications (Bonus Issue on Emerging Technologies -- invited

Improved estimate of electron capture rates on nuclei during stellar core collapse

Electron captures on nuclei play an important role in the dynamics of the collapsing core of a massive star that leads to a supernova explosion. Recent calculations of these capture rates were based on microscopic models which account for relevant degrees of freedom. Due to computational restrictions such calculations were limited to a modest number of nuclei, mainly in the mass range A=45-110. Recent supernova simulations show that this pool of nuclei, however, omits the very neutron-rich and heavy nuclei which dominate the nuclear composition during the last phase of the collapse before neutrino trapping. Assuming that the composition is given by Nuclear Statistical Equilibrium we present here electron capture rates for collapse conditions derived from individual rates for roughly 2700 individual nuclei. For those nuclei which dominate in the early stage of the collapse, the individual rates are derived within the framework of microscopic models, while for the nuclei which dominate at high densities we have derived the rates based on the Random Phase Approximation with a global parametrization of the single particle occupation numbers. In addition, we have improved previous rate evaluations by properly including screening corrections to the reaction rates into account.Comment: 32 pages, 13 figures, 1 table; elsart; to appear in Nuclear Physics