Further investigations and parametric analysis of microstructural alterations under rolling contact fatigue

Bearing elements under rolling contact fatigue (RCF) exhibit microstructural features, known as white etching bands (WEBs) and dark etching regions (DERs). The formation mechanism of these microstructural features has been questionable and therefore warranted this study to gain further understanding. Current research describes mechanistic investigations of standard AISI 52100 bearing steel balls subjected to RCF testing under tempering conditions. Subsurface analyses of RCF-tested samples at tempering conditions have indicated that the microstructural alterations are progressed with subsurface yielding and primarily dominated by thermal tempering. Furthermore, bearing balls are subjected to static load tests in order to evaluate the effect of lattice deformation. It is suggested from the comparative analyses that a complete rolling sequence with non-proportional stress history is essential for the initiation and progression of WEBs, supported by the combination of carbon flux, assisted by dislocation and thermally activated carbon diffusion. These novel findings will lead to developing a contemporary and new-fangled prognostic model applied to microstructural alterations

A multiscale overview of modelling rolling cyclic fatigue in bearing elements

During service, bearing components experience rolling cyclic fatigue (RCF), resulting in subsurface plasticity and decay of the parent microstructure. The accumulation of micro strains spans billions of rolling cycles, resulting in the continuous evolution of the bearing steel microstructure. The bearing steel composition, non-metallic inclusions, continuously evolving residual stresses, and substantial work hardening, followed by subsurface softening, create further complications in modelling bearing steel at different length scales. The current study presents a multiscale overview of modelling RCF in terms of plastic deformation and the corresponding microstructural alterations. This article investigates previous models to predict microstructural alterations and material hardening approaches widely adopted to mimic the cyclic hardening response of the evolved bearing steel microstructure. This review presents state-of-the-art, relevant reviews in terms of this subject and provides a robust academic critique to enhance the understanding of the elastoplastic response of bearing steel under non-proportional loadings, damage evolution, and the formation mechanics of microstructural alterations, leading to the increased fatigue life of bearing components. It is suggested that a multidisciplinary approach at various length scales is required to fully understand the micromechanical and metallurgical response of bearing steels widely used in industry. This review will make significant contributions to novel design methodologies and improved product design specifications to deliver the durability and reliability of bearing elements

Shell-and-tube based thermal energy system coupled with flat plate solar collector

To secure optimum utilisation of solar energy sources, a novel shell-and-tube heat exchanger with multi-tube passes and extended surfaces based latent heat storage (LHS) system was designed, developed and commissioned with an integration to flat plate solar collector in Organic Rankine Cycle (ORC). Paraffin, HFE-7000 and water were employed as thermal storage material and heat transfer fluids to sustain simultaneous generation of electricity and heat. It was noticed that the melting/solidification rates and charging/discharging powers were significantly augmented with an increase in Stefan number. However, an increase in Reynolds number had offered a moderate enhancement. The proposed design solution proficiently captured and released 14.35 MJ and 13.63 MJ while charging and discharging at constant inlet temperature for 3 h and 1.5 h, respectively. It was deduced that heat and electricity demands for domestic and industrial applications could be achieved and supplied by regulating inlet operating conditions of LHS system and/or by assembling LHS systems in series or parallel combinations

A holistic mathematical modelling and simulation for cathodic delamination mechanism – a novel and an efficient approach

This paper addresses a holistic mathematical design using a novel approach for understanding the mechanism of cathodic delamination. The approach employed a set of interdependent parallel processes with each process representing: cation formation, oxygen reduction and cation transport mechanism, respectively. Novel mathematical equations have been developed for each of the processes based on the observations recorded from experimentation. These equations are then solved using efficient time-iterated algorithms. Each process consists of distinct algorithms which communicate with each other using duplex channels carrying signals. Each signal represents a distinct delamination parameter. As a result of interdependency of various processes and their parallel behaviour, it is much easier to analyse the quantitative agreement between various delamination parameters. The developed modelling approach provides an efficient and reliable prediction method for the delamination failure. The results obtained are in good agreement with the previously reported experimental interpretations and numerical results. This model provides a foundation for the future research within the area of coating failure analysis and prediction

An energy-efficient distributed clustering algorithm for heterogeneous WSNs

Wireless sensor networks (WSNs) were envisaged to become the fabric of our environment and society. However, they are yet unable to surmount many operational challenges such as limited network lifetime, which strangle their widespread deployment. To prolong WSN lifetime, most of the existing clustering schemes are geared towards homogeneous WSN. This paper presents enhanced developed distributed energy-efficient clustering (EDDEEC) scheme for heterogeneous WSN. EDDEEC mainly consists of three constituents i.e., heterogeneous network model, energy consumption model, and clustering-based routing mechanism. Our heterogeneous network model is based on three energy levels of nodes. Unlike most works, our energy consumption model takes into account the impact of radio environment. Finally, the proposed clustering mechanism of EDDEEC changes the cluster head selection probability in an efficient and dynamic manner. Simulation results validate and confirm the performance supremacy of EDDEEC compared to existing schemes in terms of various metrics such as network life.Deanship of Scientific Research at King Saud University Research Group Project No. RG#1435-051.Scopu

Wear Performance Analysis of Ni-Al2O3 Nanocomposite Coatings under Nonconventional Lubrication

This article presents the wear study of Ni-Al2O3 nanocomposite coatings in comparison to uncoated steel contacts under reciprocating motion. A ball-on-flat type contact configuration has been used in this study in which a reciprocating flat steel sample has been used in coated and uncoated state against a stationary steel ball under refrigerant lubrication. The next generation of environmentally friendly refrigerant HFE-7000 has been used as lubricant in this study without the influence of any external lubricant. The thermodynamic applications and performance of HFE-7000 is being studied worldwide as it is replacing the previous generation of refrigerants. No work however has been performed to evaluate the wear performance of HFE-7000 using nanocomposite coatings. The wear scar developed on each of the flat and ball samples was studied under a Scanning Electron Microscope (SEM). The micrographs show that a combination of adhesive and abrasive wear occurs when using uncoated steel samples. Micro-delamination is observed in the case of Ni-Al2O3 nanocomposite coatings accompanied by adhesive and abrasive wear. Wear volume of the wear track was calculated using a White Light Interferometer. Energy-Dispersive X-ray Spectroscopic (EDS) Analysis of the samples reveal fluorine and oxygen on the rubbing parts when tested using coated as well as uncoated samples. The formation of these fluorinated and oxygenated tribo-films help reduce wear and their formation is accelerated by increasing the refrigerant temperature. Ni-Al2O3 nanocomposite coatings show good wear performance at low and high loads in comparison to uncoated contacts. At intermediate loads the coated contacts resulted in increased wear especially at low loads. This increase in wear is associated with the delamination of the coating and the slow formation of protective surface films under these testing conditions

Mathematical modelling and simulation of multiphase flow in a flat plate solar energy collector

Non-conventional collectors where organic fluid or refrigerant experience a phase change have many advantages over conventional collectors which have either air or relatively high temperature boiling liquid. Increase in heat transfer coefficient and system efficiency, corrosion prevention and freeze protection are the main benefits of the first type. In this study, a detailed numerical model of a flat plate collector is developed to investigate the fluid mean temperature, useful heat gain and heat transfer coefficient along the collector tube. The refrigerant HFC-134a was used in the simulation as the working fluid of the collector. The model can both predict the location where the fluid undergoes a phase change in the tube and the state at the exit under given inlet conditions. The effect of boiling on the heat transfer coefficient of the fluid is also investigated. Simulations were performed at three different mass flow rates (0.001, 0.005 and 0.01 kg/s) and three different operating pressures (4, 6 and 8 bar) to be able to see the effect of mass flow rate and pressure on plate temperature, heat loss coefficient, efficiency of the collector and the heat transfer coefficient of the fluid. The simulation results indicate that the heat transfer coefficient of the fluid increases from 153.54 W/m2K to 610.27 W/m2K in multiphase flow region. In the liquid single phase region, the collector efficiency rises from 60.2% to 68.8% and the heat transfer coefficient of the fluid increases from 39.24 W/m2K to 392.31 W/m2K with an increased flow rate whereas the collector efficiency decreases from 72.5% to 62.3% as the operating pressure increases from 4 bar to 8 bar. In order to validate the simulation model an experimental test rig was built and the experiments were performed with HFE 7000 as working thermo-fluid. A new simulation model utilizing HFE 7000 has been developed and the outlet temperature of the fluid was compared with the measured outlet temperature. Both measured and simulated results have shown close conformity