Effect of wire EDM on microstructure and fracture toughness of 7075-t6511 aluminum alloy

Abstract: This paper reports on an investigation conducted to establish the influence of Wire Electrical Discharge Machining (WEDM) on the fracture toughness of aluminum 7075-T6511. The main objective was to determine if WEDM can be used to introduce a pre-crack into a compact tension specimen instead of the ASTM E-1820-11 specified fatigue pre-crack method. Fracture tests were conducted on four specimens which were pre-cracked using the WEDM technique. The rest of the fracture toughness evaluation followed the ASTM E-1820-11 guidelines. Results obtained from the experimental data were found to be inconsistent with the theoretical expectations. The fracture toughness was found to be significantly dependent on the effect of the WEDM on the material. The WEDM introduced a Heat Affected Zone (HAZ) on the surface of the pre-crack which modifies the fracture behavior of the material. It was concluded that WEDM is not a viable alternative to create a pre-crack in a compact tension specimen to perform fracture toughness testing of aluminum 7075-T6511

Determining optimum parameters for manual compaction of loose biomass

Abstract: Significant amounts of loose biomass are produced annually through agricultural and forestry activities. It is common practice to burn these loose biomass deliberately after harvesting or in accidental veld fires in the case of forestry. This energy could be harnessed for cooking and heating. The challenge with the use of loose biomass lies in its low density and hence low energy content which can be improved through densification. The aim of this paper is to determine the optimum densification parameters that can be used to develop manual briquetting technologies to empower poor communities to harness the energy available in loose biomass that they dispose annually. This forms part of a larger project aimed at developing off grid biomass value chain technologies. Using loose grass and loose leaves, experimental data revealed an optimum density of 1250 kg/m3 and a corresponding densification pressure of 40 MPa. In addition, a comparison of the thermal profile of solid round and round hollow briquettes showed more superior performance of the round hollow briquette based on recorded maximum combustion temperatures. Briquettes with a hole in the middle are therefore preferred to solid briquettes

Effects of wire electrical discharge machining on fracture toughness of grade 5 titanium alloy

Grade 5 titanium (Ti6Al4V) is considered as the workhorse material when it comes to automotive and aerospace applications. It is widely referred to as an aerospace alloy and is relatively a new engineering material. The main attraction of this material is its high strength to weight ratio when compared to such common engineering materials such as steel and aluminum alloys. One of the major challenges in the use of this aerospace material is its machinability. Its high strength which is maintained at elevated temperatures, low thermal conductivity, low elastic modulus and high reactivity with oxygen is a perfect recipe for machining challenges. This leads to high tool wear and long production times. Such challenges are sometimes overcome by electrical discharge machining (EDM). Given that titanium is usually applied to mission critical components (gears, shafts, wing sections), it is important to understand the possible effect of wire EDM on their structural performance. One of the structural integrity indicators in such applications is fracture toughness. Fracture toughness is widely used for damage tolerance analysis of aerospace components in which critical crack sizes are computed for given loading conditions to arrive at safe inspection and maintenance intervals. It is therefore the purpose of this paper to conduct a study on the effect of wire EDM on the fracture toughness of this aerospace material. Standard test procedure using compact tension (CT) specimen is used to measure the fracture toughness. Four specimens are produced using wire EDM. This includes the pre-crack which is usually produced by fatigue cycling. Obtained results indicate a slight decrease in fracture toughness compared to that reported in literature. In addition, it can also be concluded that wire EDM can be used as an alternative to fatigue pre-cracking in fracture toughness testing of titanium alloys

Effect of HHO on four stroke petrol engine performance

Contemporary research into alternative sources of energy for transportation focuses mainly on electric/battery, hybrid and hydrogen powered vehicles. Such focus assumes that the current technology has to be discarded and cannot be improved. However, it is possible to introduce interim technology to alleviate the current challenges arising from continued reliance on fossil fuels. Such challenges include increased greenhouse gas (GHG) emissions with consequent global warming and climate change impacts. The purpose of this research work is to determine if the partial inclusion of hydrogen gas (HHO) in a petrol fuelled spark ignition (SI) internal combustion (IC) engine would improve engine performance. If this is possible, old SI technology can be modified to reduce GHG emissions and improve utilisation of fossil fuels which are expected to dominate the transport energy source for at least the next half century. An HHO generator was designed, constructed and mounted in the engine compartment of a 1989 Ford Laser vehicle. This system allowed partial inclusion of HHO gas on demand into the combustion process through the air supply stream. Detailed and comprehensive experimental investigations were conducted for engine speeds ranging from 1000 to 3500 rpm while parameters such as the power output, exhaust gas emissions and fuel consumption were monitored. Results obtained indicated a decrease in hydrocarbon emissions and an increase in power output with an increase in the HHO gas for certain engine operating conditions. However, performance improvement cannot be claimed for all operating conditions, especially under higher loads where the engine ran with a rich fuel mixture. Hence, further work is required, through HHO generator refinement alongside better engine management, to improve the experimental performance and hence further understanding of this technology

Design of chilled ceiling displacement ventilation for direct expansion HVAC system

Abstract: Displacement ventilation is a low cost ventilation technique used in distributing conditioned air in Heating, Ventilation and Air Conditioning (HVAC) systems. This is a ventilation strategy well suited to significantly reduce building energy consumption in this age of high energy costs, global warming and climate change. This is achieved through the leveraging of natural buoyancy driven flow in the conditioned space in a way that minimizes energy expenditure in supply and extraction fans. In addition, the conditioned air is supplied at higher temperature implying lower energy demand for cooling units. The global legislative move towards greener buildings demands the use of sustainable and energy efficient air conditioning systems of which displacement ventilation makes a major contribution. One of the challenges in using displacement ventilation is the stratified temperature distribution in the conditioned space. The temperature gradients between the ceiling and the floor can lead to decreased comfort conditions. One approach to overcome this problem is to use the chilled ceiling. How does one size the chilled ceiling system in such cases? The purpose of this paper is to present a detailed design analysis of a displacement ventilation chamber that includes chilled ceiling. The chamber utilizes an under floor air supply system into a conditioned space configured to represent typical office space. The construction and performance testing of the displacement ventilation testing chamber is then reported in a subsequent paper

Development of a validated numerical model of an unreinforced T-section pipe for large dams

Abstract: This paper reports on the development of a validated numerical model (using 3-D finite element method (FEM)) of an unreinforced T-section pipe. Pipe profiling severely compromises the localized performance of the T-section pipe. The main objective was to develop a less conservative tool to investigate the key factors that influence failure in T-section pipes. Strain gauges were mounted on the T-section to capture the induced strains as the pressure was gradually increased until the pipe burst. The executed FEM analysis provided comparable results to the experimental measurements which provided a cost effective tool to validate the numerical model. This result allows for better placement of branch piece reinforcements based on experimentally obtained results. The developed tool c be used to optimize the design and sizing of reinforcing crotch plates

Investigation of the parameters governing the performance of jet impingement quick food freezing and cooling systems – a review

Abstract: Jet Impingement Technology (JIT) is a heat transfer enhancement technique. Available literature soundly confirm its wide applications in the cooling of combustion chambers, critical parts of turbines, glass technology, electronic components, drying of paper and textile materials, drying of biomaterials and food preservation. The technology has interesting fluid dynamics and heat transfer properties. Its relative simplicity and low cost, abundance of air, generation of high heat transfer and faster freezing rates have made it a subject of extensive investigations. Several investigations on jet impingement quick food freezing and cooling systems which range from visualization, experimental, computational simulations and or numerical analysis, factorial and mathematical models have been studied. This paper reviews the governing parameters of the jet impingement quick food freezing and cooling systems

Emissions testing of loose biomass in Limpopo province of South Africa

Abstract: Southern Africa depends on wood for energy. This affects deforestation and global warming. Loose biomass briquettes can replace round wood and mitigate such problems. Loose biomass derived from agricultural and forestry waste has chemicals like pesticides which can cause unsafe emissions. This paper studies emissions resulting from combustion of such loose biomass collected from Limpopo, a province of South Africa. Twelve loose biomass samples were tested for gases emitted from domestic stove combustion. Exhaust gases were sampled and tested to determine composition and quantities of emitted elements. Both element identification and particulate analysis are reported

Repair of cracks in metals : a review

Abstract: Cracks are surface or subsurface fissures that develop in a material. Propagation energy derived from mechanical, thermal, chemical, and metallurgical effects, or a combination of these may influence crack initiation and growth. Various types of cracks exist in metals and can be categorised as cooling, solidification, centreline, crater, grinding, pickling, heat treatment, machining tears, plating, fatigue, creep, stress corrosion and hydrogen cracks. Cracks can grow and lead to complete fracture of the component posing significant threats to component life and may lead to serious injuries or loss of life. Brittle fracture in metals occurs with little or no visible warning. Discovery of any cracks warrants immediate interventions to arrest the cracks before they propagate to the point of fracture. Several crack detection and repair methods in metals have been developed, characterised and validated through research. This paper reviews the repair techniques of cracks in metals

Investigating thermal performance of PCM plates for free cooling applications in South Africa

Abstract: Free cooling involves using a thermal energy storage medium such as a phase change material (PCM) in order to store the ambient “cold” during the night when ambient air temperatures are lower compared to the indoor building temperatures and release this stored “cold” by using a heat transfer fluid (i.e. air) into the building during the day when higher ambient temperatures are experienced especially during the summer months. This paper assesses the free cooling potential in South Africa by using a set of Rubitherm RT25HC PCM plates. The performance of these PCM plates is assessed by benchmarking the ambient air cooled by the PCM plates during the day against the defined thermal comfort temperatures requirements. The influence of varying the air flow rate on the availability of thermal comfort temperatures at the PCM rig outlet is also studied. The results clearly show the potential of using PCM’s as a means of cooling higher ambient air temperature which is experienced in hot summer months to within thermal comfort temperatures for human occupancy in a building