Titanium Laser Welding
This project aimed to understand the governing mechanisms behind weld hardness in laser-welded titanium sheets. Hardness measurements indicate increasing hardness with increased heat input and grain size, which is inconsistent with the general knowledge on hardness behavior. To understand this phenomenon, the oxygen content is measured in the fusion zone using EDS and XRD analyses. A greater amount of oxygen is detected in the fusion zone for samples with higher heat input. Results shows that while increased heat input increases the grain size, it also causes a greater chance of oxygen contamination by increasing the melt pool size.
Titanium CP1 Metallography
In a lot of references commercially pure Titanium was included in difficult materials for metallography procedure. They have very low hardness and the inheritance of the material so in this particular application note some useful points gathered due to the future ease of metallography. It’s worth to mention that metallography of Titanium commercially pure family is a time-consuming procedure and require a lot of passion and effort. Above all, commercially pure titanium grade 1 have lower hardness than others so it makes it is metallography procedure double harder.
Laser Cutting Kerf Width
This project delves into optimizing the laser cutting process for stainless steel 316L sheets, specifically focusing on the critical parameter of kerf width. Investigating laser power, cutting speed, focal point position, nozzle stand-off, and gas pressure, we aimed to strike a delicate balance to enhance cutting accuracy and minimize loss of material. Through meticulous experimentation, analysis, and the development of a robust model, we sought to achieve up to a 70% improvement in material efficiency while maintaining precision in the laser cutting process.
Automated Gasket Inspection System
This groundbreaking project introduces an automated gasket inspection system, utilizing laser technology and advanced image processing algorithms. This innovative system significantly reduces measurement errors, enhancing precision in assessing the width, thickness, angle, and shape of standard sealing gaskets. The development of a user-friendly Graphical User Interface (GUI) further streamlines the inspection process, making it accessible even for users with no coding expertise. This automated system increased accuracy, providing reliable and efficient gasket measurements.
Gasket Die Laser Hardening
Gasket Die Laser Hardening
The Gasket Die Laser Hardening project aimed to enhance the wear resistance of gasket dies used in plate heat exchanger’s sealing gaskets production. Utilizing laser beam technology, we navigated the challenge of hardening the edges for improved durability without compromising ductility. Extensive experiments, guided by optimal parameters, successfully increased the hardness of the die’s narrow edges, promising a doubled lifespan. This innovative approach, avoiding the need for post-machining, signifies a significant advancement in local surface hardening for steel components. The project underscores our commitment to precision engineering and advanced manufacturing techniques in optimizing laser materials processing methods.
Brazed Plate Heat Exchanger
In our brazing project, we utilized copper as filler metal for stainless-steel plates, chosen based on its optimal melting temperature. Through meticulous testing, we identified the suitable 30-micrometer thickness for consistent results. Our innovative brazing process, tailored for heating, holding, and cooling stages in a vacuum, ensures precise bonding without melting the base plates. Addressing challenges in material selection, filler metal thickness, and heat cycle optimization, our research advances efficient and reliable brazing practices for manufacturing of brazed plate heat exchangers.
Stellite Machining
Stellite, a cobalt-chromium superalloy with applications in aerospace, automotive, and biomedical industries, presents machining hurdles due to its formidable hardness, toughness, work hardening, and limited thermal conductivity. Challenges include excessive tool wear, poor surface finish, and dimensional inaccuracies. Addressing these demands strategic solutions, including specialized tool materials, applying coolant flood in specific locations, speed and feed optimization, rigidity reinforcement, and automation. Conquering these challenges requires a nuanced grasp of Stellite’s properties, ensuring the cost-effective manufacturing of high-performance components across various applications through purpose-driven machining methodologies.
Sheet Metal Forming Simulation
Stainless steel (SS316) plates within brazed plate heat exchangers are pivotal for guiding two fluids and facilitating heat transfer. Sheet metal forming simulation enables the prediction of defects like spring back and thinning. By adjusting the forming process parameters, these issues could be minimized. Leveraging the LS Dyna finite element software in this project, the forming simulation results, validated against experimental data, exhibited an error of less than 10% in calculating spring back and thinning.