Many municipal facilities, such as pools and drinking water treatment facilities, are subject to ongoing maintenance due to the corrosion of their metallic materials caused by chlorine, leading to ...high costs and a possible risk to public health. A proper study of the employed product's effect could lead to the use of better materials, which significantly increase the lifetime of metallic equipment more attacked by corrosion, through studies evaluating their cost-effectiveness. This paper was carried out with the objective of studying the degradation of some metallic materials (AISI 316L, AISI 321 and Duplex 14462) used in the referred facilities in order to select the one that possessed a better behavior. It was observed that the introduction of some more adequate materials can drastically reduce maintenance operations, with Duplex 14462 showing the best results, ideal for greater chlorine concentrations, followed by AISI 321, which may be employed for components in less contact with chlorine, since it is more easily affordable.
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The use of disinfection and cleaning chemicals in several municipal facilities, such as swimming pools and drinking water treatment plants, causes the degradation of various types of wood, which ...leads to failures in equipment and the corresponding need for maintenance. This degradation creates added costs for municipalities, as well as the closure of certain facilities due to curative or preventive maintenance and, in many cases, public health issues, due to the water being contaminated with deteriorating products. Through a thorough study of the degradation effect on the products, more resistant materials can be found which are able to withstand these adversities and increase the lifespan of wood in regular contact with chemical agents. This is achievable by the determination of the cost-effectiveness of the substitute material to replace these components with alternative ones, with properties that better resist the deterioration effects promoted by aggressive environments. No studies have been found so far strictly focused on this matter. The objective of this study is to evaluate the degradation presented by two types of wood, beech and oak, which are exposed to the action of chlorine in municipal facilities. This degradation varies according to the chlorine content and the materials' time of contact with the chemical agent, allowing the selection of new materials which will provide an extended lifetime of the components, reducing maintenance drastically, as well as costs for the facilities and the risk to public health. The performed experimental tests have shown that the oak wood has the best results regarding chlorine degradation resistance.
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Coatings usually play an important role in terms of machining tool behaviour and lifespan. TiAlN is a well-known PVD coating but, the permanent need for improved performance is inducing new ...compositions around this coating. In this work, the wear behaviour of different PVD coated tools with different geometries was analysed, in the milling of pre-hardened tool steel. The selected tools had two different geometries, namely ball nose end mill and end mill tools. Additionally, these were coated with two different PVD coatings, TiAlSiN and TiAlN. These tools were employed in milling operations of W 1.2711 pre-hardened tool steel. The cutting parameters were defined in a way to enable a valid comparison between the milling tools, varying only feed and cutting length, to analyse the influence of these parameters on the tool's wear mechanisms. Cutting force data was collected during the milling tests using a dynamometer in order to identify the different wear stages of the tool, and surface roughness was measured after each test. Furthermore, after the milling tests the tools were submitted to a SEM analysis, in order to analyse the wear mechanisms of each coated tool. The main wear mechanisms that were identified in both coatings are adhesion and abrasion, followed by coating delamination. Moreover, the analysed wear was less significant in the TiAlSiN PVD coated tools used, mainly in the ball-nose tools, providing as well very good surface roughness of the machined surface. The surface morphology of the tool and the direction of the grooves left on the tool surface after grinding operations of the uncoated tool showed a significant influence on the coating wear mode. The best machining conditions have been established, taking into account the lowest surface roughness obtained on the machined surface and the lowest wear rate of the tool.
•TiAlSIN coating presented better results in pre-hardened tool steel milling than TiAlN coated tools (end-mill and ball-nose tools’ geometry).•Wear mechanisms follow this sequence: adhesion, abrasion, and delamination. The cycle is repeating itself, increasing systematically.•For the conservative set of parameters used, low machining forces were registered, and no significant variations were observed.•The first signals of tool failure happened after 2 m cutting length.•TiAlSiN coated tools provided lower roughness of the machined surfaces, showing a better suitability for finishing operations.•Best cutting conditions: 80 m/min cutting speed, 0.0147 mm/edge feed rate, 3 mm depth of cut under dry machining conditions.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
Microscale abrasion has been intensively used to study the wear behavior o several hard coatings, enabling the observation of different wear mechanisms. Recently, a study arguing whether the surface ...texture of the ball could influence the dynamics of abrasive particles throughout the contact was presented. In this work, the influence of the abrasive particles concentration able to change the texture of the ball was studied to understand its influence on the wear modes-rolling or grooving. Thus, tests were carried out using samples with a thin coating of TiN, deposited using the Physical Vapor Deposition (PVD) technique, and AISI 52100 steel balls etched over 60 s to induce a change in their texture and roughness were used. Three abrasive slurries were prepared with black silicon carbide (SiC) particles (average particle size of 4 μm) with different concentrations, 0.25, 0.35, and 0.45 g/cm
. The rotation speed used in the tests was 80 rpm and the normal loads applied in the study were 0.2 N and 0.5 N, and 1 N. After the wear tests, the coated samples and tracks on the surface of the balls were observed by SEM and 3D microscopy to understand the abrasive particle dynamics, evaluating the wear mode transition as well as the function of both applied load and slurry concentration. The tracks in the balls showed particles embedded on their surface. A lower concentration of abrasion was conducted to higher specific wear rate. Moreover, a predominant two-body wear mechanism was induced when the abrasive concentration was increased. There was an increase in the roughness of the scar and the surface of the balls with an increase in the abrasive particles' concentration.
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The milling process is one of the most used processes in the manufacturing industry. Milling, as a process, as evolved, with new machines and methods being employed, in order to obtain the best ...results consistently. Milling tools have also seen quite an evolution, from the uncoated high-speed steel tool, to the now vastly used, coated tools. Information on the use of these coated tools in recent scientific researches was collected. The coatings that are currently being researched are going to be presented, highlighting some novel advances in the nanocomposite and diamond coatings area, as these coatings are seeing a growing use in the industry, with very satisfactory results, with performance and tool-life increase. Wear mechanism of various types of coatings are also a popular topic on recent research, as the cutting behavior of these coated tools provides valuable information on the tool’s-life. Furthermore, analysis of these mechanisms enables for the selection of the best coating type for the correct application. Recently, the employment of coated tools paired with sustainable lubrication methods as seen some use. As this presents the opportunity to enhance the coated tool’s and the process’s performance, obtaining better results, in terms of better tool-life and better surface finish quality, in a more sustainable fashion.
Turning continues to be the largest segment of the machining industry, which highlights the continued demand for turned parts and the overall improvement of the process. The turning process has seen ...quite an evolution, from basic lathes using solid tools, to complex CNC (Computer Numerical Control) multi-process machines, using, for the most part, coated inserts and coated tools. These coatings have proven to be a significant step in the production of high-quality parts and a higher tool life that have captivated the industry. Continuous improvement to turning coated tools has been made, with many researches focusing on the optimization of turning processes that use coated tools. In the present paper, a presentation of various recently published papers on this subject is going to be made, mentioning the various types of coatings that have recently been used in the turning process, the turning of hard to machine materials, such as titanium alloys and Inconel, as well as the interaction of these coatings with the turned surfaces, the wear patterns that these coatings suffer during the turning of materials and relating these wear mechanisms to the coated tool’s life expectancy. Some lubrication conditions present a more sustainable alternative to current methods used in the turning process; the employment of coated tool inserts under these conditions is a current popular research topic, as there is a focus on opting for more eco-friendly machining options.
It is crucial to monitor the levels of Non-Ionizing Radiation (NIR) to which the general population may be exposed and compare them to the limits defined in the current standards, in view of the ...rapid rise of communication services and the prospects of a connected society. A high number of people visits shopping malls and since these locations usually have several indoor antennas close to the public, it is therefore a kind of place that must be evaluated. Thus, this work presents measurements of the electric field in a shopping mall located in Natal, Brazil. We proposed a set of six measurement points, following two criteria: places with great the flow of people and the presence of one or more Distributed Antenna System (DAS), co-sited or not with WiFi access points. Results are presented and discussed in terms of the distance to DAS (conditions: near and far) and flow density of people in the mall (scenarios: low and high number of people). The highest peaks of electric field measured were 1.96 and 3.26 V/m, respectively corresponding to 5% and 8% of the limits defined by the International Commission on Non-Ionizing Radiation Protection (ICNIRP) and the Brazilian National Telecommunication Agency (ANATEL).
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Due to Inconel 718’s high mechanical properties, even at higher temperatures, tendency to work-harden, and low thermal conductivity, this alloy is considered hard to machine. The machining of this ...alloy causes high amounts of tool wear, leading to its premature failure. There seems to be a gap in the literature, particularly regarding milling and finishing operations applied to Inconel 718 parts. In the present study, the wear behavior of multilayered PVD HiPIMS (High-power impulse magnetron sputtering)-coated TiN/TiAlN end-mills used for finishing operations on Inconel 718 is evaluated, aiming to establish/expand the understanding of the wear behavior of coated tools when machining these alloys. Different machining parameters, such as cutting speed, cutting length, and feed per tooth, are tested, evaluating the influence of these parameters’ variations on tool wear. The sustained wear was evaluated using SEM (Scanning electron microscope) analysis, characterizing the tools’ wear and identifying the predominant wear mechanisms. The machined surface was also evaluated after each machining test, establishing a relationship between the tools’ wear and production quality. It was noticed that the feed rate parameter exerted the most influence on the tools’ production quality, while the cutting speed mostly impacted the tools’ wear. The main wear mechanisms identified were abrasion, material adhesion, cratering, and adhesive wear. The findings of this study might prove useful for future research conducted on this topic, either optimization studies or studies on the simulation of the milling of Inconel alloys, such as the one presented here.
Additive manufacturing is defined as a process based on the superposition of layers of materials in order to obtain 3D parts; however, the process does not allow achieve the adequate and necessary ...surface finishing. In addition, with the development of new materials with superior properties, some of them acquire high hardness and strength, consequently decreasing their ability to be machined. To overcome this shortcoming, a new technology assembling additive and subtractive processes, was developed and implemented. In this process, the additive methods are integrated into a single machine with subtractive processes, often called hybrid manufacturing. The additive manufacturing process is used to produce the part with high efficiency and flexibility, whilst machining is then triggered to give a good surface finishing and dimensional accuracy. With this, and without the need to transport the part from one machine to another, the manufacturing time of the part is reduced, as well as the production costs, since the waste of material is minimized, with the additive–subtractive integration. This work aimed to carry out an extensive literature review regarding additive manufacturing methods, such as binder blasting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet laminating and vat polymerization, as well as machining processes, studying the additive-subtractive integration, in order to analyze recent developments in this area, the techniques used, and the results obtained. To perform this review, ScienceDirect, Web of Knowledge and Google Scholar were used as the main source of information because they are powerful search engines in science information. Specialized books have been also used, as well as several websites. The main keywords used in searching information were: “CNC machining”, “hybrid machining”, “hybrid manufacturing”, “additive manufacturing”, “high-speed machining” and “post-processing”. The conjunction of these keywords was crucial to filter the huge information currently available about additive manufacturing. The search was mainly focused on publications of the current century. The work intends to provide structured information on the research carried out about each one of the two considered processes (additive manufacturing and machining), and on how these developments can be taken into consideration in studies about hybrid machining, helping researchers to increase their knowledge in this field in a faster way. An outlook about the integration of these processes is also performed. Additionally, a SWOT analysis is also provided for additive manufacturing, machining and hybrid manufacturing processes, observing the aspects inherent to these technologies.
Duplex stainless steels are being used on applications that require high corrosion resistance and excellent mechanical properties, such as the naval and oil-gas exploration industry. The components ...employed in these industries are usually obtained by machining; however, these alloys have low machinability when compared to conventional stainless steels, usually requiring the employment of tool coatings. In the present work, a comparative study of TiAlSiN coating performance obtained by these two techniques in the milling of duplex stainless-steel alloy LDX 2101 was carried out. These coatings were obtained by the conventional direct current magnetron sputtering (dc MS) and the novel high power impulse magnetron sputtering (HiPIMS). The coatings were analyzed and characterized, determining mechanical properties for both coatings, registering slightly higher mechanical properties for the HiPIMS-obtained coating. Machining tests were performed with varying cutting length and feed-rate, while maintaining constant values for axial and radial depth of cut and cutting speed. The surface roughness of the material after machining was assessed, as well as the wear sustained by each of the tool types, identifying the wear mechanisms and behavior of these tools, as well as registering the flank wear values presented for each of the tested tools. The HiPIMS-obtained coating exhibited a very similar behavior when compared to the other, producing similar surface roughness quality. However, the HiPIMS coating exhibited less wear for higher cutting lengths, proving to be a better choice in this case, especially regarding tool life.
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