Volume-10 , Issue-1 , Mar 2023, ISSN 2348-635X Go Back

• Open Access   Article

  Investigation of Shrinkage Porosity in a Nickel Based Super Alloy Blade by Using Computer Simulation

  M.R. Alizadeh, Y. Miladi, A. Khedmati

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.1-6, Mar-2023

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  Abstract
  In all experimental researches in investment casting process, real foundry experiences in producing a gas turbine blade has always been time consuming. In addition, cost of its production is very high. Therefore, using other beneficial way like software simulation investigation is a key step to design a suitable gating system before starting the casting process. In this research a simulation of gas turbine blade has been studied by ProcCAST software which is based on the Finite Element Method. For this reason, two different gates were simulated and compared to each other. Both systems had similar pouring cup and identical sprue. Casting condition such as casting temperature, method of wrapping insulators and the alloy were identical. In the first gating system volume fraction of feed to blade was 0.17 while in the second system this amount increase to 0.28. The results showed that in the first system the molten metal that exist in the pouring cup initiates its solidification stage before the gate; in effect, computer results showed that in this system after 14 minutes of pouring the molten metal, the gates’ pass was closed and was not able to fed the blade. In other words, simulated results displayed that contour of temperature in the pouring cup is completely below the contour of casting parts. As a result, shrinkage porosity was observed in the root of the blade. In the second gating system, however, the blockage of the gate was not observed and the correct thermal gradient lead to the producing a non-shrinkage porosity part. In fact, contour of temperature in the pouring cup is completely above the contour of casting parts.

  Key-Words / Index Term
  - Computer simulation, Gating system, Investment Casing, Nickel Based Super alloy

  References
  [1]. M. R. Alizadeh, “Simulation of Ni-Based Super-Alloy and Optimizing of its Mechanical Properties in a Near-Shaped Turbine Blade Part”, Hindawi Publishing Corporation ion Indian Journal of Materials Science, Vol. 1, pp.1-6, March 2015.
  [2]. M. Dumaillet and G. M. Wilson, “Comparison of flow modification trough foundry fitters using both water modeling and simulation software”, AFS Transactions, vol. 110, pp. 1–12, 2002.
  [3] D. Z. Li, J. Campbell, and Y. Y. Li, “Filling system for investment cast Ni-base turbine blades,” Journal of Materials Processing Technology vol. 148, no. 3, pp. 310–316, 2004
  [4]. S. H. Majidi and C. Beckermann,“ Effects of pouring condition and casting system design on air entrainment during mold filling”, American Foundry Society (AFS) Vol. 8, pp.1-6, , 2018.
  [5]. M. Naim shaikh, et al. “Optimization of multi-gate Systems in casting process: experimental and simulation studies”, IOP Conf. Series: Materials Science and Engineering Vol. 7, pp.12-19, 2018.
  [6]. F. Juretzko and D. Stefanescu, "Comparison of mold filling simulation with high speed video
  recording of real time mold filling”, AFS Transactions, vol. 113, pp. 1 -11, 2005.
  [7]. B. Sirrell, M. Holliday and J. B. Campbell, "Benchmark testing the flow and solidification modeling of Al castings," The Journal of The Minerals, Metals & Materials Society, vol. 48, pp. 20-23, 1996.
  [8] H. Dai, et al, “The study of titanium alloy precision casting turbine based on Procast”, IOP Conf. Series: Materials Science and Engineering, Vol. 1, pp.1-6, 2019.
  [9] A. Kheibari, et al, “Understanding the occurrence of the surface turbulence in a non-pressurized bottom gating system: Numerical simulation of the melt flow pattern”, Journal of materials, Design and Application 20 November. vol. 1, issue1. 2015

  Citation
  M.R. Alizadeh, Y. Miladi, A. Khedmati, "Investigation of Shrinkage Porosity in a Nickel Based Super Alloy Blade by Using Computer Simulation," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.1-6, 2023

• Open Access   Article

  FTA Analysis of the Winding in Steam Power Plant: An Insight into the Stator

  Ade Suhendar, Yanuar Z. Arief, Sinka Wilyanti, Rosyid R. Al-Hakim, Roma San Rego

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.7-13, Mar-2023

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  Abstract
  The stator winding generator is a significant equipment in the steam power plant (SPP), which converts mechanical energy into electricity. The windings of the turbine generator were mainly used for power generation, and the failure of the winding caused much damage to the stator. In this paper, fault tree analysis (FTA) was used to determine the initial condition of deterioration of the winding fault. FTA results are preliminary indications of stator fault. The investigation results found the binding tape aging and seal oil generator issues. At some point, the binding tape coils in several slots on the exciter and turbine sides were found as loose binding tape (coil binder) that is not tight (loose) and can be interpreted as aging conditions. The earth stator alarm was also confirmed.

  Key-Words / Index Term
  Alarm Earth Stator Fault, Electric Steam Power Plant, Fault Tree Analysis, Generator Failure

  References
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  Citation
  Ade Suhendar, Yanuar Z. Arief, Sinka Wilyanti, Rosyid R. Al-Hakim, Roma San Rego, "FTA Analysis of the Winding in Steam Power Plant: An Insight into the Stator," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.7-13, 2023

• Open Access   Article

  Ceramic Filter Effect on Surface Defects in Nickel Based Superalloy

  M.R. Alizadeh, Y. Miladi, M. Naseri, A.M. Kolagar

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.14-18, Mar-2023

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  Abstract
  Surface defects are common defects in casting process and directly related to the purity of molten metal and using ceramic filter. In fact, producing a part in investment casting free of any defects is almost implausible. These defects are usually displayed as cluster or star at nights defects on surface of casting part and finally may lead the part to be rejected. In this study the effects of ceramic filter on reduction of surface defects in nickel based superalloy gas turbine blade has been studied. The mesh of filter was 10 ppi, and its thickness was 20 mm with two diameters of 40 and 70 mm for gate and cup filter respectively. To comparison of surface defects content, another ceramic mold without ceramic filter into the gate in vacuum induction melting furnace and with same casting condition was poured at 1420°C. After casting, fluorescent penetrant inspection was applied on each blade and also surface grain size of the blades was compared with each other. The results show that when ceramic filter is used into the gate, the surface defects are 4 times less. In addition, those blades that poured with filter had finer grain size. The reason for finer gran size can be related to the better temperature distribution in the mold.

  Key-Words / Index Term
  Surface Defects, Ceramic Filter, Investment Casing, Nickel Based Superalloy.

  References
  [1]. D.N. Shivappa1, Rohit, A. Bhattacharya, “Introduction of common defects in investment casting”, Stone beyond the Engineering, April, Vol.2, No.3, pp. 127-133, March 2014.
  [2]. R. Rajkolhe, J. G. Khan, “Defects, Causes and Their Remedies in Casting Process”, international Journal of Research in Advent Technology, Vol.2, No.3, pp. 375-383, March 2014.
  [3]. M.Antosz, et al. “Influence of printed ceramic filters on temperature field distribution during investment casting of thin-walled Ni-based superalloys’’, The 73rd Word Foundry Congress, Vo1.3, pp.01-05, 319-320, September 2018.
  [4]. P. W. Marek et al., “A study of technological properties of Investment casting waxes”, Applied Plasma Science, Vol. 10, pp 37-40, 2015.
  [5] J.-C. Gebelin and M. R. Jolly, “Modelling filters in light alloy casting processes (or “What really happens when aluminium flows through a filter”)”, AFS transactions, Vol.2, pp. 375-383, March 2014.
  [6]. M. R. Alizadeh, “Simulation of Ni-Based Super-Alloy and Optimizing of its Mechanical Properties in a Near-Shaped Turbine Blade Part”, Hindawi Publishing Corporation ion Indian Journal of Materials Science, Vol., pp. 1-6, March 2015.
  [7]. F.Hsu , C. Li, J. Campbell, “Ceramic Foam Filters in Runner System Desighn for Casting”, Key Engineering Materials Vol. 573, pp. 19-29, 2014.
  [8]. Stephan Giebing and Andreas Baier, “Reasons for Blockages in Ceramic Foam Filters in Iron and Steel Casting”, Foseco Germany, Vol., No.3, pp. 16-23, March 2014.
  [9]. M. R. Alizadeh, Y. Miladi, “Influence of Ceramic Filter on Surface Defects in Investment Casting” , World Academics Journal of Engineering Sciences, Vol. 8, issue.1, pp.32-35, March 2022.

  Citation
  M.R. Alizadeh, Y. Miladi, M. Naseri, A.M. Kolagar, "Ceramic Filter Effect on Surface Defects in Nickel Based Superalloy," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.14-18, 2023

• Open Access   Article

  Use of Continuity of Fluid Flow for Tackling the Location Dependency of Wind Turbines

  Sk Asraful Karim

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.19-23, Mar-2023

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  Abstract
  There is a problem with wind turbines: in order to work, they need sufficient wind velocity, which is why we cannot plan a wind turbine anywhere. That’s why we should use the concept of continuity of fluid flow to reduce the location dependency, increase the wind speed, and generate energy anywhere from wind turbines. In the same way that we use wind turbines to generate power, but in this case, we will regulate the wind velocity.

  Key-Words / Index Term
  Renewable energy ,Wind energy ,Wind, Wind turbine, Continuity of fluid flow, Ogive cone

  References
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  Citation
  Sk Asraful Karim, "Use of Continuity of Fluid Flow for Tackling the Location Dependency of Wind Turbines," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.19-23, 2023

• Open Access   Article

  Development of a Motorized Leafy Vegetable Slicing Machine for Vegetables

  Mary Adewale, Abdulganiy Raji, Adewale Sedara

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.24-36, Mar-2023

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  Abstract
  In this study, a leafy vegetable slicer machine was developed for the local vegetable consumed in Nigeria, which are Fluted Pumpkin (Ugu), Green Amaranth (Efo Tete), and African Amaranth (Efo Soko). The main parts of the machine are the hopper, slicing unit, sieve, rotating shaft, and transmission unit. Fabricated with locally sourced materials and leafy vegetables were sourced from local farmers. Three-speed levels (300, 500, and 700 rpm) and feeding mass (0.2, 0.25, and 0.3 kg) were used to evaluate the slicing efficiency, percentage retained, and capacity of the machine for the three varieties of leafy vegetables. The highest efficiency of 95.2% was attained at a speed of 500 rpm for the African amaranth variety, and the operating time was 57secs; 94.0% was attained at a speed of 700 rpm for the Fluted pumpkin variety, and the operating time was 79secs and 92.1% was attained at a speed of 700 rpm for Green amaranth variety and the operating time was 57 secs. The machine slicing capacity ranges from 3.58 to 19.28 kg/hr. The highest percentage retained was 49.6%, obtained at a speed of 500 rpm, and the operating time was 64 secs for the African amaranth variety. The result of the Analysis of Variance on the slicing capacity of the three varieties of leafy vegetables shows that speed had a significant effect (p<0.05) on the slicing capacities, while the effect of feeding was not significant, and the effect of speed on the slicing efficiency of the three variants of leafy vegetables was not significant (p<0.05). This equipment can decrease human drudgery and make chopping vegetables much faster and easier.

  Key-Words / Index Term
  leafy vegetable, slicer machine, slicer efficiency, Fluted Pumpkin (Ugu), Green Amaranth (Efo Tete), African Amaranth (Efo Soko)

  References
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  Citation
  Mary Adewale, Abdulganiy Raji, Adewale Sedara, "Development of a Motorized Leafy Vegetable Slicing Machine for Vegetables," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.24-36, 2023

• Open Access   Article

  Mechanical Characterization of Duplex Stainless Steel Joined by Gas Tungsten-arc Welding (GTAW) and Shielded Metal-arc Welding (SMAW): A Comparative Study

  Jamilu Ya’u Muhammad, Usman Shitu Adam, Haruna Abba Usman, Anas Abdullahi Muhammad, Abubakar Abdulkarim

  Research Paper | Journal-Paper (WAJES)

  Vol.10 , Issue.1 , pp.37-41, Mar-2023

  Abstract

  Full-Text HTML

  References

  Citation

  Abstract
  Stainless steel is among most applicable materials in industries due to its good mechanical properties. The present study compared the mechanical properties of duplex stainless steel when joined together by using gas tungsten-arc welding and shielded metal-arc welding. Two duplex stainless steel were used in this work, whereby each sample was cut to form V-groove butt for welding purpose. After welding of the sample, lubricating oil is used as quencher for 30 minutes before undergoing for the analysis. A microstructure study was carried out by scanning electron microscopy (SEM). The average ferrite volume proportion attained in the GTAW weld zone is greater than that of SMAW. The tensile strength, hardness, and energy absorbed in impact test in the GTAW were all higher than that of SMAW. It is recommended that for the good transformation of the ferrite-austenite, the cooling rate should be high in each welding process.

  Key-Words / Index Term
  Hardness, Impact Test, Microstructure, Tensile Strength, Weld Zone

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  Citation
  Jamilu Ya’u Muhammad, Usman Shitu Adam, Haruna Abba Usman, Anas Abdullahi Muhammad, Abubakar Abdulkarim, "Mechanical Characterization of Duplex Stainless Steel Joined by Gas Tungsten-arc Welding (GTAW) and Shielded Metal-arc Welding (SMAW): A Comparative Study," World Academics Journal of Engineering Sciences, Vol.10, Issue.1, pp.37-41, 2023