The use of friction stir welding for the production of Mokume Gane-Type materials

Mokume gane is a highly desirable and unique decorative material but production is difficult at both workshop and industrial levels. This paper describes a novel method for producing mixed metal, multi-colored, layered materials using friction stir welding (FSW) and compares the results with mokume gane made by a number of different conventional methods. FSW was invented in 1991 by TWI, a UK-based research and technology organization, and has found widespread use in the joining of aluminum and, more recently, steels. By adapting FSW it has been possible to successfully bond many layers of dissimilar metals such as silver, copper and brass, etc., while simultaneously producing unique patterns in the metal, minimizing further processing, reducing waste and potentially lowering costs. The technique avoids many of the problems experienced in workshop production, e.g., melting of lack of bonding, while allowing production of small, customized ingots and mass production of large sheets, with up to several square meters possible

The near wall effect of synthetic jets in a boundary layer

Copyright @ 2007 Elsevier Inc. All rights reserved.An experimental investigation to analyse the qualitative near wall effect of synthetic jets in a laminar boundary layer has been undertaken for the purpose of identifying the types of vortical structures likely to have delayed separation on a 2D circular cylinder model described in this paper. In the first instance, dye visualisation of the synthetic jet was facilitated in conjunction with a stereoscopic imaging system to provide a unique quasi three-dimensional identification of the vortical structures. Secondly, the impact of synthetic jet structures along the wall was analysed using a thermochromic liquid crystal-based convective heat transfer sensing system in which, liquid crystals change colour in response to the thermal footprints of a passing flow structure. Of the different vortical structures produced as a result of varying actuator operating and freestream conditions, the footprints of hairpin vortices and stretched vortex rings revealed a marked similarity with the oil flow pattern of a vortex pair interacting with the separation line on the cylinder hence suggesting that either of these structures was responsible in delaying separation. Conditions were established for the formation of the different synthetic jet structures in non-dimensional parameter space

An advanced numerical model of friction stir welding of DH36 steel

A numerical model of Friction Stir Welding (FSW) of DH36 steel plate (6mm thickness) has been developed using a CFD technique. Two welding speed conditions were used, a low welding speed of 200 RPM - 100mm/min, and a high welding speed of 550RPM- 400 mm/min. The heat generation, material flow and strain rate were calculated based on plastic deformation and frictional contact between the tool and workpiece. A CFD-based model has been produced to represent the asymmetry in temperature distribution between the advancing and retreating side, the material flow and the strain rate. The geometry of the model includes the tool plunged into the plate. The cooling system was also included in the simulation by calculating the heat flux lost for each part of the tool. The heat generated by viscous dissipation away from the tool was also taken into account. The total heat generated was divided into the individual tool parts (shoulder, probe side and probe end) and was found to be in good agreement with the experimental results for the areas affected by these parts. The maximum temperature obtained for the slow welding speed was 1012oC and for the high welding speed was 1250oC. Experimental metallographic examination has also been carried out on DH36 FSW steel plates to validate the CFD model. SEM analysis showed the formation of a fine microstructure of bainite, acicular ferrite and ferrite/cementite aggregate in the welded zone as compared to the ferrite/pearlite morphology in the base metal. It is found from the CFD and experimental results that the high speed welding conditions can produce defects such as wormholes and cracks in the welds associated with the probe side and probe end due to the lack of material flow especially on the advancing side. Tensile and fatigue testing were carried out for both slow and high welding speed samples, which broke outside the welded region in the tensile test, however, slow welding speed samples show more resistance to fatigue test and survived 644128 cycles, the high speed welding samples failed after 111,736 cycles under the same load

Modelling of friction stir welding of 304 stainless steel

A 3-D Eulerian steady-state CFD model has been developed to simulate the Friction Stir Welding (FSW) of 6mm plate 304 stainless steel (304SS). The Polycrystalline BoroNitride- Tungsten Rhenium (PCBN-WRe) hybrid tool was modelled with the workpiece in a fully sticking condition. The viscosity of stainless steel was calculated from the flow stress equation taken from a previous study of hot working carried out in a range of temperatures between 800oC-1200 oC and strain rates 0.001 s-1 to 5 s-1. The model predicted the temperature distribution in the Stirred Zone (SZ) for three welding cases including low, intermediate and high rotational speed/traverse speeds. The model also predicts that localised melting may occur if the tool rotational speed exceeds 400RPM. Finally, the model suggested a larger probe (12mm diameter at the shoulder base and 5.8mm length) with a stationary shoulder would prevent the localised melting and allow an increase in welding speeds without the associated introduction of stagnant zone related weld defects

Detection of Gamma Rays of Up to 50 TeV From the Crab Nebula

Gamma rays with energies greater than 7 TeV from the Crab pulsar/nebula have been observed at large zenith angles, using the Imaging Atmospheric Technique from Woomera, South Australia. CANGAROO data taken in 1992, 1993 and 1995 indicate that the energy spectrum extends up to at least 50 TeV, without a change of the index of the power law spectrum. The observed differential spectrum is \noindent $(2.01\pm 0.36)\times 10^{-13}(E/{7 TeV})^{-2.53 \pm 0.18} TeV^{-1}cm^{-2}s^{-1}$ between 7 TeV and 50 TeV. There is no apparent cut-off. The spectrum for photon energies above $\sim$10 TeV allows the maximum particle acceleration energy to be inferred, and implies that this unpulsed emission does not originate near the light cylinder of the pulsar, but in the nebula where the magnetic field is not strong enough to allow pair creation from the TeV photons. The hard gamma-ray energy spectrum above 10 TeV also provides information about the varying role of seed photons for the inverse Compton process at these high energies, as well as a possible contribution of $\pi ^{\circ}$-gamma rays from proton collisions.Comment: 19 pages, 4 figures, LaTeX2.09 with AASTeX 4.0 maros, to appear in Astrophys. J. Let

A Holder Continuous Nowhere Improvable Function with Derivative Singular Distribution

We present a class of functions $\mathcal{K}$ in $C^0(\R)$ which is variant of the Knopp class of nowhere differentiable functions. We derive estimates which establish \mathcal{K} \sub C^{0,\al}(\R) for 0<\al<1 but no $K \in \mathcal{K}$ is pointwise anywhere improvable to C^{0,\be} for any \be>\al. In particular, all $K$'s are nowhere differentiable with derivatives singular distributions. $\mathcal{K}$ furnishes explicit realizations of the functional analytic result of Berezhnoi. Recently, the author and simulteously others laid the foundations of Vector-Valued Calculus of Variations in $L^\infty$ (Katzourakis), of $L^\infty$-Extremal Quasiconformal maps (Capogna and Raich, Katzourakis) and of Optimal Lipschitz Extensions of maps (Sheffield and Smart). The "Euler-Lagrange PDE" of Calculus of Variations in $L^\infty$ is the nonlinear nondivergence form Aronsson PDE with as special case the $\infty$-Laplacian. Using $\mathcal{K}$, we construct singular solutions for these PDEs. In the scalar case, we partially answered the open $C^1$ regularity problem of Viscosity Solutions to Aronsson's PDE (Katzourakis). In the vector case, the solutions can not be rigorously interpreted by existing PDE theories and justify our new theory of Contact solutions for fully nonlinear systems (Katzourakis). Validity of arguments of our new theory and failure of classical approaches both rely on the properties of $\mathcal{K}$.Comment: 5 figures, accepted to SeMA Journal (2012), to appea

Note on a variation of the Schröder-Bernstein problem for fields

summary:In this note we study fields $F$ with the property that the simple transcendental extension $F(u)$ of $F$ is isomorphic to some subfield of $F$ but not isomorphic to $F$. Such a field provides one type of solution of the Schröder-Bernstein problem for fields

Mulsemedia: State of the art, perspectives, and challenges

Mulsemedia-multiple sensorial media-captures a wide variety of research efforts and applications. This article presents a historic perspective on mulsemedia work and reviews current developments in the area. These take place across the traditional multimedia spectrum-from virtual reality applications to computer games-as well as efforts in the arts, gastronomy, and therapy, to mention a few. We also describe standardization efforts, via the MPEG-V standard, and identify future developments and exciting challenges the community needs to overcome

Defects in Friction Stir Welding of Steel

Defects associated with friction stir welding of two steel grades including DH36 and EH46 were investigated. Different welding parameters including tool rotational and tool traverse (linear) speeds were applied to understand their effect on weld seam defects including microcracks and voids formation. SEM images and infinite focus microscopy were employed to identify the defects types. Two new defects associated with the friction stir welding process are introduced in this work. The first defect identified in this work is a microcrack found between the plunge and the steady state region and attributed to the traverse moving of the tool with unsuitable speed from the plunge-dwell to the steady state stage. The tool traverse speed has recommended to travel 20 mm more with accelerated velocity range of 0.1 from the maximum traverse speed until reaching the steady state. The maximum recommended traverse speed in the steady state was also suggested to be less than 400 mm/min in order to avoid the lack in material flow. The second type of defect observed in this work was microcracks inside the stirred zone caused by elemental precipitations of TiN. The precipitates of TiN were attributed to the high tool rotational speed which caused the peak temperature to exceed 1200 °C at the top of the stirred zone and based on previous work. The limit of tool rotational speed was recommended to be maintained in the range of 200-500 RPM based on the mechanical experiments on the FSW samples