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Showing papers in "Journal of achievements in materials and manufacturing engineering in 2007"


Journal Article
TL;DR: A survey of the most common methods for the calculation of the surface free energy (SFE) of solids, utilizing the results of the contact angle measurements, is presented in this article.
Abstract: Purpose: The main purpose of this paper is the analysis of the most common methods for the calculation of the surface free energy (SFE) of solids, utilising the results of the contact angle measurements. The calculation deals also with the SFE at the interface, especially that at the surface of polymers and polymeric materials. The survey has been meant to ease the understanding of physical processes occurring at the solid-liquid interface and to help to find proper measuring methods with respect to various physical systems. Design/methodology/approach: The presented analysis has been based on the papers of the fundamental nature as well as on the specialised literature reports. The results of the experimental and theoretical studies of the author of this article are also considered. Findings: Different assumptions have been made in the individual methods for calculating the SFE of polymeric materials. Thus, the SFE values for a given material, obtained by various methods and with use of different measuring liquids, are not consistent. The method for the calculation of the SFE of porous or granulated materials, powders, and fibres, in which the Washburn equation is utilised, is very useful in practice. Currently, there is no appropriate alternative to this method. Research limitations/implications: The method for calculating the SFE with use of the equation of state requires further investigation, both experimental and theoretical. Further studies on the phenomena associated with penetration of the measuring liquids into the bulk of an examined material and on the relevant changes concerning this material, including the changes in its SFE, have also to be carried out. Practical implications: The presented results of the investigations may be applied in optimisation of the current and derivation of the new methods for calculating the SFE of solids and liquids, including mainly the SFE of polymers in the solid state. Originality/value: Because of differences in the assumptions made in most of the methods for the SFE calculation and of differences in the interactions between the individual measuring liquids and the examined material, the SFE values for various polymer materials may be compared with one another only when the contact angle measurements have been made using the same measuring liquids and when the SFE calculations have been performed by the same method.

345 citations


Journal Article
TL;DR: In this article, the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method was focused on the purpose of this research paper, which was analyzed using analysis of variance (ANOVA) method.
Abstract: Purpose: The purpose of this research paper is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. Design/methodology/approach: Experiment was designed using Taguchi method and 18 experiments were designed by this process and experiments conducted. The results are analyzed using analysis of variance (ANOVA) method. Findings: Taguchi method has shown that the depth of cut has significant role to play in producing lower surface roughness followed by feed. The Cutting speed has lesser role on surface roughness from the tests. Research limitations/implications: The vibrations of the machine tool, tool chattering are the other factors which may contribute poor surface roughness to the results and such factors ignored for analyses. Originality/value: The results obtained by this method will be useful to other researches for similar type of study and may be eye opening for further research on tool vibrations, cutting forces etc.

164 citations


Journal Article
TL;DR: In this article, the authors applied new technology in injection molding technique and investigation of reinforcement of PC as dispersed phase inside PP matrix (Table 1), and enrichment of those composites by nanoclay and analyzing mechanical behaviour of nanocomposites.
Abstract: Purpose: Purpose of this paper is the applying of new technology in injection moulding technique and investigation of reinforcement of PC as dispersed phase inside PP matrix (Table 1). Second aim of work is enrichment of those composites by nanoclay and analyzing mechanical behaviour of nanocomposites. Design/methodology/approach: According to design of experiments (DOE) specimens were injection moulded in the shape of rectangular bars. Additionally advanced technology of melt manipulation inside mold cavity after injection was used. To achieve this purpose Ferromatik Milacron injection moulding machine, equipped with externally controlled mold was used. Findings: Addition of nanoclay clearly presents highly reinforced system, especially for neat matrix. Evenly dispersed PC particles within PP majority show reinforcement as well. Inducement of shear rate in injection moulding radically improved absorption of energy in nanocomposite. Research limitations/implications: Different variation of material composition, such combination with other polymers and use of different reinforcements (flexible or either rigid) is required to be checked in the further work. Practical implications: Reinforcement obtained thanks to dispersed phase and nanofillers creates composites with improved mechanical properties. Originality/value: Morphology development reflects on mechanical behaviour. Its manipulation may affect and improve mechanical properties. Use of advanced technologies opens wide range of possibilities in processing of polymer based systems. At present there is limited number of research of processing-structure-properties relationships of polymer-polymer composites and nanocomposites.

124 citations


Journal Article
TL;DR: In this paper, the characteristics of the materials applied as parts of aircraft engine turbines and the stationary gas turbines were characterized, and the principal technologies for manufacturing the heat resistant coatings and the erosion and corrosion resistant coatingings were characterized.
Abstract: Purpose: The following article demonstrates the characteristics of the materials applied as parts of aircraft engine turbines and the stationary gas turbines. The principal technologies for manufacturing the heat resistant coatings and the erosion and corrosion resistant coatings were characterized. Sample applications for the aforementioned coatings are presented: on turbine blades, compressor blades and on parts of combustion chambers of aircraft engines. Design/methodology/approach: The nickel-based alloys were characterized. The following methods of depositing diffusion aluminide coatings were described: pack cementation, out of pack and CVD (chemical vapour deposition). The properties of thermal barrier coatings obtained by thermal spraying and physical vapour deposition (PVD) were presented. Findings: : The structures of aluminide and platinum modified aluminide coatings, which displayed higher heat resistance during the cyclic oxidation test, were presented. The structure of TBC coatings was described as well. During aircraft engine tests, the compressor blades with multilayer type Cr/CrN coatings exhibited higher wear resistance than the coatings covered with Ti/TiN. Research limitations/implications: The aluminide coatings were deposited on nickel-based superalloys, which are typically used to manufacture turbine blades for aircraft engines. The multilayer nitride coatings were produced by Arc-PVD method. Practical implications: All the described technologies and coatings find applications on parts of aircraft engines. Originality/value: The presented advanced technologies of manufacturing protective coatings on the parts of aircraft engines were developed by the authors of the following study as parts of their planned scientific research, research projects, and purpose projects.

92 citations




Journal Article
TL;DR: The 5S methodology as discussed by the authors is the methodology of creating and maintaining well organized, clean, high effective and high quality workplace, which can be used to analyse the processes running on the workplace.
Abstract: Purpose: The aim of this paper is showing the 5S methodology. In this paper it was introduced the way of implementing the 5S methodology in the company. Design/methodology/approach: In the frames of own research it has been analysed and implemented the 5S rules in the production process. Findings: On the basis of the own research it can be stated, that introducing the 5S rules bring the great changes in the company, for example: process improvement by costs’ reduction, increasing of effectiveness and efficiency in the processes, maintenance and improvement of the machines’ efficiency, safety increasing and reduction of the industry pollution, proceedings according to decisions. Research limitations/implications: The 5S methodology permits to analyse the processes running on the workplace. The 5S is the methodology of creation and maintaining well organized, clean, high effective and high quality workplace. Practical implications: Own research clearly showed, that very essential is training of workers about the 5S rules. Essential thing is to divide activities on some main steps and to maintain the continuous

79 citations


Journal Article
TL;DR: In this article, the microstructure of the WE43 magnesium alloy in an as-cast condition was investigated using a Reichert metallographic microscope MeF2 and a HITACHI S-3400N scanning electron microscope with a Thermo Noran EDS equipped with SYSTEM SIX.
Abstract: Purpose: WE43 is a high-strength magnesium alloy characterized by good mechanical properties both at an ambient and elevated temperature (up to 300°C). It contains mainly yttrium and neodymium. The aim of this paper is to present the results of research on the microstructure of the WE43 magnesium alloy in an as-cast condition. Design/methodology/approach: For the microstructure observation, a Reichert metallographic microscope MeF2 and a HITACHI S-3400N scanning electron microscope with a Thermo Noran EDS equipped with SYSTEM SIX were used. A qualitative phase analysis was performed with a JEOL JDX-7S diffractometer. Microstrucutral examinations were performed JEOL 3010 transmission electron microscope. Findings: Based on the investigation carried out it was found that the microstructure of WE43 alloy after continuous casting consists of α-Mg matrix and irregular precipitates of Mg41Nd5, rectangular particles of MgY phase, particles of Mg24Y5, longitudinal precipitates of β (Mg14Nd2Y) compound at grain boundaries and the grain interiors. All of these phases contain yttrium and neodymium. Research limitations/implications: Future researches should contain investigations of the influence of heat treatment parameters on microstructure, corrosion resistance and mechanical properties of WE43 alloy. Practical implications: WE43 magnesium alloy is used in the aircraft industry, for wheels, engine casings, gear box casings and rotor heads in helicopters. Results of investigation may be useful for development casting technology of the Mg-Y-Nd alloys. Originality/value: The results of the researches make up a basis for the next investigations of magnesium alloys with addition of Y and Nd designed to exploitation at temperature to 300°C.

74 citations



Journal Article
TL;DR: In this article, the morphology and composition of complex microstructure of the intermetallic phases in AlSi1Mg alloy were analyzed using optical light microscopy (LM), transmission (TEM) and scanning (SEM) electron microscopy in combination with X-ray analysis (EDS) using polished sample, and Xray diffraction (XRD) to identify intermetallics in aluminium alloy.
Abstract: Purpose: The main objective of this study was to analyze the morphology and composition of complex microstructure of the intermetallic phases in AlSi1Mg alloy. Design/methodology/approach: In this study, several methods were used such as: optical light microscopy (LM), transmission (TEM) and scanning (SEM) electron microscopy in combination with X-ray analysis (EDS) using polished sample, and X-ray diffraction (XRD) to identify intermetallics in AlSi1MgMn aluminium alloy. Findings: The results show that the as-cast microstructure of AlSi1MgMn alloy after slow solidification at a cooling rate 2˚C/min, consisted a wide range of intermetallics phases. By using various instruments (LM, SEM, XRD) and techniques (imagine, EDS) the: α-Al5FeSi, α-Al15(FeMn)3Si, Al9Mn3Si, α-Al12Fe3Si, Mg2Si intermetallic phases were identified. Research limitations/implications: In order to complete and confirm obtained results it is recommended to perform further analysis of the 6000 series aluminium alloys. Therefore it is planned to include in a next study, microstructure analysis of the alloy by using transmission electron microscopy technique (TEM). Practical implications: Since the morphology, crystallography and chemical composition affect the intermetallic properties, what involves changes of alloy properties, from a practical point of view it is important to understand their formation conditions in order to control final constituents of the alloy microstructure. This paper has provided essential data about various intermetallic phases precipitating in 6000 series aluminium alloys. Originality/value: This paper proposes the best experimental techniques for analysis of the intermetallic phases occurring in the 6xxx series aluminium alloys, provide wide description of the intermetallics formation through all possible reactions and data about their chemical composition, morphology and crystallography.

67 citations


Journal Article
TL;DR: In this paper, the authors describe results of application of thermography to evaluate the degree of fatigue degradation of epoxy-glass composites, which may be applied in the future in diagnostic procedures to nondestructive evaluation of high performance polymer composites.
Abstract: Purpose: The purpose of this paper was to describe results of application of thermography to evaluate the degree of fatigue degradation of epoxy-glass composites. Design/methodology/approach: Samples of epoxy-glass composite were subjected to fatigue degradation. During fatigue test, after defined number of cycles, samples were heated using infra-red heater and at the opposite side temperature increase was evaluated with thermovision camera. Findings: Analysis of achieved results allowed to elaborate relation between number of fatigue cycles and the degree of fatigue degradation. Such relation may be applied in diagnostic procedures. Research limitations/implications: Performed tests were of preliminary character and results will be applied to prepare research programme on thermographic testing of composites. Practical implications: Results of such tests may be applied in the future in diagnostic procedures to nondestructive evaluation of the degree of fatigue degradation of high performance polymer composites. Originality/value: Thermographic methods are applied up till now to non-destructive flaws detection. Proposed in the paper method may be applied to evaluate the degree of thermal and fatigue degradation in composites without any macroscopic flaws.

Journal Article
TL;DR: In this paper, the authors investigated the properties and microstructural changes in Friction Stir Welds in the aluminum alloy 6082-T6 in function of varying process parameters, and found that the tensile strength of the produced joints was tested and the correlation with process parameter was assessed.
Abstract: Purpose: Purpose of this paper is the investigation on the properties and microstructural changes in Friction Stir Welds in the aluminum alloy 6082-T6 in function of varying process parameters. Design/methodology/approach: Tensile strength of the produced joints was tested and the correlation with process parameter was assessed. Microstructures of various zones of FSW welds are presented and analyzed by means of optical microscopy and microhardness measurements. Findings: Mechanical resistance of test welds increased with the increase of travel (welding) speed with constant rotational speed. Softening of the material in weld nugget and heat affected zone was observed, of entity inferior that that of fusion welds. Origin of tunnel (worm hole) defects were found and analyzed. Research limitations/implications: The test welds were produced with various combinations of process parameters without the possibility of controlling the downward force. Further extension of applicable parameters combinations could be examined. Practical implications: The increase of mechanical resistance with increasing welding speed offers an immediate economic return, as the process efficiency is increased. Originality/value: Information contained herein can be useful to further investigate on the possibility of improving the properties of FSW welds, as well as the efficiency of the process.

Journal Article
TL;DR: In this article, a new deposition system allowing for simultaneous radio frequency plasma activated chemical vapour deposition (RF PACVD) and DC magnetron sputtering is presented in a hybrid deposition chamber.
Abstract: Purpose: Very interesting combination of mechanical, physical and chemical properties of carbon films results in many possibilities of their industrial applications. Unfortunately the area of their usability is restricted due to poor adhesion caused by high internal stress. This problems are being solved using many different techniques including the deposition of Me:C (metal containing) gradient layers. A new deposition system allowing for simultaneous radio frequency plasma activated chemical vapour deposition (RF PACVD) and DC magnetron sputtering is presented in this paper. Design/methodology/approach: Ti:C gradient carbon layers were deposited on steel in a hybrid deposition chamber, employing radio frequency (13.56 MHz) plasma and DC magnetron sputtering. Layers with different thicknesses obtained by varied deposition parameters were examined. Friction coefficients and wear resistances were measured using the ball-on-disc method. Findings: Presented hybrid deposition system makes it possible to obtain thicker and still well adherent layers. Wear resistance was also improved noticeably and became several times better then for carbon layers with the same friction parameters. Research limitations/implications: Owed to the plasma based deposition method is the difficulty in covering complicated shapes. Use of materials other than titanium as a magnetron target, although certainly possible, is not covered in this paper. Practical implications: Ti:C gradient layers offer better wear resistance and allow for obtaining thicker carbon layers important in many tribological applications. They can be used where low friction coefficients are required. Originality/value: The combination of plasma deposition and magnetron sputtering in one process. This allows us to obtain varied gradients of chemical and phase composition in the deposited layers.

Journal Article
TL;DR: In this paper, a parametric model is adopted and the technique of element "birth and death" is used to estimate the effect of thermal properties and weld efficiency on residual stresses in butt weld joints.
Abstract: Purpose: A parametric model is adopted and the technique of element “birth and death” is used to estimate the effect of thermal properties and weld efficiency on residual stresses in butt weld joints. Design/methodology/approach: Residual stresses and distortions on butt welded joints are numerically evaluated by means of finite element method. The FE analysis allows to highlight and evaluate the stress field and its gradient around the fusion zone of welded joints, higher than any other located in the surrounding area. Findings: The main conclusion is the significant effect of varying the value of the conductivity on residual stresses. Practical implications: Several experimental destructive and non destructive techniques for directly measuring residual stress have been developed. However, the application of these methods in practice is usually limited by either cost or accuracy. Numerical simulation based on finite element techniques, therefore, offers a comprehensive solution for the prediction of residual stress and strain as well as welding distortion in complex welded structures.

Journal Article
TL;DR: In this article, the authors investigated the influence of heat treatment parameters on the structure light and transmission electron microscopy methods and determined the mechanical properties of dual-phase steel by means of tensile test.
Abstract: Purpose: The aim of the paper is to design heat treatment conditions of dual-phase steel and to determine their influence on the structure and mechanical properties of steel. Design/methodology/approach: The heat treatment of the C-Mn steel in order to obtain a dual-phase ferritic – martensitic structure of desirable phase fractions was realized. To investigate the influence of heat treatment parameters on the structure light and transmission electron microscopy methods were used. Mechanical properties were determined by means of tensile test. A strain hardening exponent as a function of true strain was evaluated, too. Findings: It was found that an initial structure influences essentially the morphology of martensite in an obtained dual-phase structure. It can occur as a network, fine fibres or islands in a ferritic matrix of high dislocation density in the vicinity of diffusionless transformation products of austenite. The best combination of strength and ductile properties has a steel with the martensite in a form of fine fibres. Research limitations/implications: Investigations concerning using the thermomechanical treatment to obtain a ferritic – martensitic structure of steel are required. Practical implications: The established heat treatment conditions can be useful for manufacturing dualphase structure sheets characterized by high strength and ductile properties as well as a good suitability for metalforming operations. Originality/value: The relationship between the initial structure and martensite morphology in dual-phase steels was specified.


Journal Article
TL;DR: In this paper, a review of modern magnetic materials development and their application possibilities is presented, taking into account the development of manufacturing technology of these materials which by obtaining the maximum possible values of properties allows for simplification of machines and devices construction with use of magnetic elements.
Abstract: Purpose: The purpose of the paper is characteristic of properties and application possibilities of modern soft magnetic materials and to show the influence of them on the developed of modern technology in different branches of techniques. Another aspect involved in the paper is to present the material and technological solution which makes possible obtaining soft magnetic composite materials: nanocrystalline material – polymer type. Design/methodology/approach: The main base of the paper is to show the properties and possibilities of application of modern soft magnetic materials with taking into consideration the development of manufacturing technology of these materials which by obtaining the maximum possible values of properties allows for simplification of machines and devices construction with use of magnetic elements. Findings: Modern soft magnetic materials have optimum technology of production with properties that allow for miniaturizing, simplification and lowering the costs of devices. Practical implications: The usability of modern soft magnetic materials as inductive component in electronic industry depends upon further investigations. Originality/value: The paper is the review of modern magnetic materials development and shows the material and technological solution which make possible obtaining magnetic composite materials with assumed properties.

Journal Article
TL;DR: In this article, the analysis of riveted joints of plate elements made from the carbon-fibre-reinforced plastics (CFRP) and from the 6061 aluminium alloy was carried out with IDEAS software package employing the FEM.
Abstract: Purpose: The project included analysis of strain, cracking, and failure of riveted joints of plate elements made from the carbon-fibre-reinforced plastics (CFRP) and from the 6061 aluminium alloy. Design/methodology/approach: The modelled static tensile strength test carried out for the plates from CFRP and from the 6061 aluminium alloy joined with the steel rivet. Computer simulation was carried out with IDEAS software package employing the FEM. Findings: Simulations using the mesh with a bigger number of FEM elements do not yield better accuracy of calculations and do not improve convergence with the results of laboratory experiments. Only the calculation time gets longer. Computer simulation has also show that the type of contacts employed between elements affects the results significantly. Research limitations/implications: For the composite materials, joints between materials and computer simulation examinations are planed. Practical implications: Results obtained for the mesh with 4 and 5 FEM elements are the closest to the results of laboratory experiments, which is confirmed by the strain plot. Simulations using the mesh with a bigger number of FEM elements do not yield better accuracy of calculations and do not improve convergence with the results of laboratory experiments. Only the calculation time gets longer. Computer simulation has show that the type of contacts employed between elements affects the results significantly. Originality/value: The paper presents influence of fibre mesh closeness on convergence of the results with laboratory tests. Simulation results were collected and compared with the laboratory static tensile strength tests results.

Journal Article
TL;DR: In this article, a roll cast of a thin strip of recycled Al-3%Si-0.6%Mg alloy was used as the body of an auto mobile for high speed roll casting.
Abstract: Purpose: Purpose of this paper is to clear the possibility of high speed roll casting of thin strip of recycled Al3%Si-0.6%Mg alloy. Investigation of the mechanical properties of the roll cast recycled Al-3%Si-0.6%Mg strip was purpose, too. Design/methodology/approach: Method used in the present study was high speed twin roll caster and low temperature casting. These methods were used to realize rapid solidification, and increase of casting speed. Findings: Findings are that recycled Al-3%Si-0.6%Mg was could be cast at speed of 60 m/min. This strip was 3.1 mm-thick. As cast strip could be cold-rolled down to sheet of 1 mm-thick. 180 degrees bending test was operated on the sheet after T4 heat treatment and crack was not occurred at the outer surface. This result means the roll cast recycled Al-3%Si-0.6%Mg can be used as the body of the auto mobile. Research limitations/implications: Research limitation is that the width of the strip was 100 mm and investigation of the properties was not enough for practical use. Wider strip must be cast using the twin roll caster of the size for production. Practical implications: Practical implications are as below. The economy sheet for the auto mobile can be produced by the high speed twin roll caster. Al-3%Si-0.6%Mg can be used both the casting and plastic forming. Therefore, fractionation in the recycle of the aluminum alloy will becomes easy. The content of Fe in the recycled aluminum alloy increases. Fe becomes intermetallic of AlSiFe. Si for Mg2Si becomes deficient. 3%Si was enough for Mg2Si if AlSiFe was precipitated. Al-3%Si-0.6%Mg is suitable for recycle. Originality/value: The economy sheet of Al-3%Si-0.6%Mg can be made by the high productivity of the HSTRC. The result of this report contributes to make the economy aluminum alloy sheet for the automobile.

Journal Article
TL;DR: In this paper, a modification of some well-known integrated lines consisting in the introduction of the cooling machine between roughing and finishing trains, instead of reheating machine gives a possibility to realize a controlled rolling.
Abstract: Purpose: Technical – economic aspects of the introduction of integrated technological lines for the production of metallurgical products are presented in the work. They have a special importance for microalloyed steels used in different branches of the industry. Design/methodology/approach: The analysis was carried out on a basis of requirements concerning hotworking of microalloyed steels with high mechanical properties produced by the use of the controlled rolling and thermo-mechanical processing. Findings: A modification of some well-known integrated lines consisting in the introduction of the cooling machine between roughing and finishing trains, instead of reheating machine gives a possibility to realize a controlled rolling. Moreover, using retention shields makes possible to manufacture the products by the thermomechanical processing. Research limitations/implications: There is a necessity to adjust technological parameters to precise controlling a course of material processes. Practical implications: Development of demands concerning integrated lines enabling to realize the controlled rolling and thermo-mechanical processing. Originality/value: Manufacturing mass-scale products from microalloyed steels in integrated energy-saving lines.

Journal Article
TL;DR: In this paper, the changes of the structure in the power station boiler and turbine components made of low cast steel Cr-Mo-V after long time creep service are presented, and the observed changes in the structure and in the precipitation composition are applied to evaluation of the condition of the components in further industrial exploitation.
Abstract: Purpose: of this publication is to present the changes of the structure in the power station boiler and turbine components made of low cast steel Cr-Mo-V after long time creep service. Design/methodology/approach: The material of the research studies has been obtained from Polish power stations. All examined elements have exceeded their assessed life of 100.000 hours. The microstructures of the elements have been observed using a scanning electron microscope. The investigation of the development of the precipitation processes has been done by X-ray diffraction phase analysis. Findings: The microstructures and phase compositions of the residues, obtained from the elements, depend on life exhaustion extent. Practical implications: The presented method can be used for evaluation and qualification of structural changes in power station boiler and turbine components operating in creep conditions. Originality/value: The observed changes in the structure and in the precipitation composition are applied to evaluation of the condition of the components in further industrial exploitation.

Journal Article
TL;DR: In this paper, the authors describe and discuss the processing and characterization of quartz particulate reinforced aluminium-silicon alloy matrix composite and find that the tensile strength of the composites decreases with the increase in addition of nanoparticles.
Abstract: Purpose: This paper describes and discusses the processing and characterization of quartz particulate reinforced aluminium-silicon alloy matrix composite. Design/methodology/approach: In this regard, quartz-silicon dioxide particulate reinforced LM6 alloy matrix composites were fabricated by carbon dioxide sand molding process with different particulate volume fraction. Tensile tests and scanning electron microscopic studies were conducted to determine the maximum load, tensile strength, modulus of elasticity and fracture surface analysis have been performed to characterize the morphological aspects of the test samples after tensile testing. Findings: Hardness values are measured for the quartz particulate reinforced LM6 alloy composites and it has been found that it gradually increases with increased addition of the reinforcement phase. The tensile strength of the composites decreases with the increase in addition of quartz particulate. Research limitations/implications: The results allows to determine the structure and properties of the aluminium silicon matrix composite materials. Originality/value: In addition, this research article is well featured by the particulate-matrix bonding and interface studies which have been conducted to understand the processed composite materials mechanical behavior and it was well supported by the fractographs taken using the scanning electron microscope (SEM).

Journal Article
TL;DR: In this paper, a vertical type twin roll caster for strip casting of aluminum alloys was devised, which was thinner than 3 mm and could be cast at speeds higher than 60 m/min.
Abstract: Purpose: In the present study, effectiveness of a high-speed twin roll caster for recycling aluminum alloy was investigated. Design/methodology/approach: The effects of the high-speed twin roll caster on alleviating the deterioration of mechanical properties by impurities were investigated. Properties of the cast strip were investigated by metalography, a tension test, and a bending test. Findings: A vertical type twin roll caster for strip casting of aluminum alloys was devised. The strip, which was thinner than 3 mm, could be cast at speeds higher than 60 m/min. Features of the twin roll casters are as below. Copper rolls were used and lubricant was not used in order to increase the casting speed. A casting nozzle was used to set the solidification length precisely. Heat transfer between melt and the roll was improved by hydrostatic pressure of the melt. Separating force was very small in order to prevent sticking of the strip to the roll. Low superheat casting was carried out in order to improve microstructure of the strip. In the present study, effectiveness of a high-speed and high-cooling rate twin roll caster of the present study for recycling aluminum alloy was investigated. Fe was added as impurity to 6063 and A356. The roll caster of the present study was useful to decrease the influence of impurity of Fe.

Journal Article
TL;DR: In this article, the authors introduced the new method of analysing the costs in the production process by using the method of activity-based costing, which can be used with success to carry on the quality costs' account.
Abstract: Purpose: The aim of this paper is showing the activity-based costing. In this paper it was introduced the new method of analysing the costs. Design/methodology/approach: In the frames of own research it has been analysed the costs in the production process by using the method of the activity-based costing. Findings: On the basis of the own research it can be stated, that realization of activity-based costing permits on very detailed acquaintance with costs of undertaken activities in a company. Research limitations/implications: Method of activity-based costing permits on more efficient monitoring of costs which are carried by a company on producing a product and on the quality management system, than the traditional methods of costs’ analysis. Practical implications: Own research clearly showed, that very essential is breaking activities’ costs as detailed as possible. Essential thing is to divide activities first on more general, and then on more and more detailed. Originality/value: Activity-based costing permits to eliminate these places in organization where carried costs are useless or do not give the desirable effect. This method can be used in all companies. Activity-based costing can be used with success to carry on the quality costs’ account.

Journal Article
TL;DR: In this article, the authors dealt with one segment of broader research of universality systematicness in application of seven basic quality tools (7QC tools) in different areas that include power plant, process industry, government, health and tourism services.
Abstract: The paper is dealing with one segment of broader research of universality systematicness in application of seven basic quality tools (7QC tools). The research was carried out in different areas that include power plant, process industry, government, health and tourism services. The aim of the research was to show on practical examples that there is real possibility of application of 7QC tools. Furthermore, the research has to show to what extent are selected tools in usage and what reasons of avoiding their broader application are. The simple example of successful application of one of quality tools are shown on selected company in process industry.

Journal Article
TL;DR: In this paper, the effect of Cu content on the microstructure and mechanical properties of AC AlSi9CuX series alloys has been investigated, and it was found that the increase of the Cu content to 2 wt% leads to change of the Al+Si eutectic morphology, resulting in a grate increase in the ultimate tensile strength and ductility values compared to the alloys include 1 and 4 wt % of Cu.
Abstract: Purpose: In order to gain a better understanding of how to control the as-cast microstructure, it is important to understand the evaluation of microstructure during solidification and understanding how influence the changes of chemical concentration on this microstructure and mechanical properties. In this research, the effect of Cu content on the microstructure and mechanical properties of AC AlSi9CuX series alloys has been investigated. Design/methodology/approach: The experimental alloy used in this investigation were prepared at the University of Windsor (Canada) in the Light Metals Casting Laboratory, by mixing the AC AlSi5Cu1(Mg) commercial alloys and two master alloys AlSi49 and AlCu55, in a 10 kg capacity ceramic crucible. Optical microscope, transition electron microscope and scanning electron microscope were used to characterize the microstructure and intermetallic phases. Secondary dendrite arm spacing measurements were carried out using an Leica Q-WinTM image analyzer. Compression tests were conducted at room temperature using a Zwick universal testing machine. Rockwell F–scale hardness tests were conducted at room temperature using a Zwick HR hardness testing machine. Vickers microhardness tests were conducted using a DUH 202 microhardness testing machine. Findings: It was found that the increase of Cu content to 2 wt% leads to change of the Al+Si eutectic morphology, resulting in a grate increase in the ultimate tensile strength and ductility values compared to the alloys include 1 and 4 wt % of Cu. Based on the X–ray phase analysis was found, that change of Cu content don’t influences on the phases composition of investigated alloy. Practical implications: The aim of this work is describe in detail the solidification process in a number of AC AlSi9CuX foundry alloys. In investigated alloys there were identified five phases, which can suggest together witch thermal analysis, that in these alloys occur four solidification reactions. Originality/value: The carried out work confirmed the solidification reaction of AC AlSi9CuX foundry alloys and shown influence of Cu content on the microstructure and mechanical properties.

Journal Article
TL;DR: In this article, the authors investigated the Al2O3+TiC type oxide tool ceramics and cemented carbides with the multicomponent (Ti,Al)N and gradient Ti(C,N) coatings with use of the cathodic arc evaporation CAE-PVD method.
Abstract: Purpose: Investigation of the Al2O3+TiC type oxide tool ceramics and cemented carbides with the multicomponent (Ti,Al)N and gradient Ti(C,N) coatings deposited with use of the cathodic arc evaporation CAE-PVD method. Design/methodology/approach: SEM, confocal microscopy, X-ray qualitative microanalysis of elements, X-ray qualitative phase analysis. Findings: It was stated that investigated materials have a dense, compact structure and their fracture surface topography attests their high brittleness, characteristic especially for the oxide ceramic materials. The coatings were put down uniformly onto the investigated substrate materials. They have a columnar, fine-graded structure. Practical implications: Pro-ecological dry cutting processes without the use of the cutting fluids and in the „Near-Net-Shape” technology. Originality/value: Application of multicomponent (Ti,Al)N and gradient Ti(C,N) types of coatings onto sintered tool materials in order to improve cutting properties of the tools.

Journal Article
TL;DR: In this article, the changes of the mechanical properties and structure in material components of the power station boiler after long-term creep service made of Cr-Mo-V low-alloyed steel.
Abstract: Purpose: of this paper is to present the changes of the mechanical properties and structure in material components of the power station boiler after long-term creep service made of Cr-Mo-V low-alloyed steel. Design/methodology/approach: The investigated material has been obtained from the Polish power stations. All examined elements have exceeded their assessed life of 100 000 hours. Mechanical properties and structure examinations were carried out on materials after long-term service in creep conditions. The microstructure have been observed using a light and a scanning electron microscope. The investigation of the development of the precipitation processes were done by X-ray diffraction phase analysis. Findings: Carbide precipitations evolution in correlation to the life exhaustion extent were presented. Residual life in creep short tests was done. Residual life in correlation to changes structure and developed of carbide precipitation processes were presented. Practical implications: The presented methods can be used for materials evaluation operating in creep conditions. Originality/value: The presented results changes in the mechanical properties, structure and in the precipitation processes are applied to evaluation of the condition of the elements in further industrial service.

Journal Article
TL;DR: A detailed review of the approach to development of the agent-based Intelligent Manufacturing from the fundamental considerations to the latest hands-on developments is presented in this article, along with the main areas in which they can be implemented, and which require further research.
Abstract: Purpose: Summary of the state-of-the-art of the Distributed Artificial Intelligence applied to Intelligent Manufacturing. Main applications are presented along with different technologies applied in these areas. Design/methodology/approach: Intelligent Manufacturing area was split into many segments, which require different approach to intelligent problem solving. Multiagent systems negotiation needs were analysed and cooperation issues in the form of clustering, cloning, and learning were analysed in search for the relevant tools. Findings: Detailed review of the approach to development of the agent based Intelligent Manufacturing from the fundamental considerations to the latest hands-on developments. Research limitations/implications: Many presented technologies call for detailed study before they can be implemented in practice. Originality/value: Thorough review of the Distributed Artificial Intelligence approach to current agile manufacturing needs. Key technologies are pointed out along with the main areas in which they can be implemented, and which require further research.

Journal Article
TL;DR: In this paper, a model description of a deformation process under the conditions of mechanical and thermal interactions has been developed to describe the stress-strain behavior of materials and the validation of the model has been performed.
Abstract: Purpose: The main problem addressed in the paper is the description of a deformation process under the conditions of mechanical and thermal interactions. Design/methodology/approach: The mathematical modelling has been used to describe the stress-strain behaviour of materials. The method of fatigue testing has been adopted to determine experimentally stress-strain characteristics. The method based on the long term own experience in thermo-mechanical investigations and new European Code-of-Practice for Thermo-Mechanical Fatigue Testing. Findings: An appropriate model description has been developed. Fatigue examinations of the P91 steel that is used in power industry, were carried out. The validation of the model has been performed. So far, experimental verification of the usefulness of the model description to determine the stress-strain characteristics’ course for a selected value of the phase shift angle between the temperature and total strain cycles has been made. It has been found that the proposed model reflects the deformation process nature very well in variable temperature, strain and stress conditions. Hence, a conclusion seems to be justified that the approach presented in the paper could constitute the right basis for appropriate constitutive equations, which depict the material behaviour under thermo-mechanical conditions. Research limitations/implications: The developed description should be useful in problems of fatigue behaviour predictions of materials under different mechanical and thermal loadings in industry practical applications and in research problems connected for instance with fatigue life criteria description and validation. Originality/value: The new material characteristics have been shown in the work and the own new method of the material fatigue behaviour prediction. The work is addressed to researchers interested in problems of material testing and material behaviour prediction under different loadings that we can meet in the operation practice.