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1 – 10 of 188Dongsheng Wang, Xiaohan Sun, Yingchang Jiang, Xueting Chang and Xin Yonglei
Stainless-clad bimetallic steels (SCBS) are widely investigated in some extremely environmental applications areas, such as polar sailing area and tropical oil and gas platforms…
Abstract
Purpose
Stainless-clad bimetallic steels (SCBS) are widely investigated in some extremely environmental applications areas, such as polar sailing area and tropical oil and gas platforms areas, because of their excellent anticorrosion performance and relatively lower production costs. However, the properties of SCBS, including the mechanical strength, weldability and the anticorrosion behavior, have a direct relation with the manufacturing process and can affect their practical applications. This paper aims to review the application and the properties requirements of SCBS in marine environments to promote the application of this new material in more fields.
Design/methodology/approach
In this paper, the manufacturing process, welding and corrosion-resistant properties of SCBS were introduced systematically by reviewing the related literatures, and some results of the authors’ research group were also introduced briefly.
Findings
Different preparation methods, such as rolling composite, casting rolling composite, explosive composite, laser cladding and plasma arc cladding, as well as the process parameters, including the vacuum degree, rolling temperature, rolling reduction ratio, volume ratios of liquid to solid, explosive ratio and the heat treatment, influenced a lot on the properties of the SCBS through changing the interface microstructures. Otherwise, the variations in rolling temperature, pass, reduction and the grain size of clad steel also brought the dissimilarities of the mechanical properties, microhardness, bonding strength and toughness. Another two new processes, clad teeming method and interlayer explosive welding, deserve more attention because of their excellent microstructure control ability. The superior corrosion resistance of SCBS can alleviate the corrosion problem in the marine environment and prolong the service life of the equipment, but the phenomenon of galvanic corrosion should be noted as much as possible. The high dilution rate, welding process specifications and heat treatment can weaken the intergranular corrosion resistance in the weld area.
Originality/value
This paper summarizes the application of SCBS in marine environments and provides an overview and reference for the research of stainless-clad bimetallic steel.
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Prasenjit Biswas, Deepak Patel, Archana Mallik and Sanjeev Das
The purpose of this paper is to develop a concept and design to cast Al alloys/metal matrix composites (MMCs) by continuous casting process. The various steps involved in the…
Abstract
Purpose
The purpose of this paper is to develop a concept and design to cast Al alloys/metal matrix composites (MMCs) by continuous casting process. The various steps involved in the evolution of the design have been reported and discussed in this study.
Design/methodology/approach
On the basis of developed design concept, initial prototype design has been prepared in this study. The casting process's melt flow pattern was studied via computer simulation, and the resulting changes were implemented in the original design. The single-phase fluid flow pattern through bottom feeding technique is studied. The equipment was fabricated based on computer simulation and water modelling studies. Finally, validation was performed for the preparation of Al alloys/ MMCs after parameter optimisation. The results were observed in the optical metallography to confirm the alloying and Al MMC preparation.
Findings
The developed continuous casting process with bottom feeding technique for the addition of constituent particles shows more efficiency in comparison to the existing batch processes. The final manufactured setup demonstrates effective Al alloy/MMC production as the basis for final fabrication has been accomplished by both computer simulation and water model test. In addition, the microstructure exhibits homogeneous distribution, validating the reliability of the setup.
Originality/value
Integrating continuous casting with continuous reinforcement or master alloy addition is novel in this area. The constraints that batch production had that have been rectified will also lower the contemporary cost of production.
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Bahubali Babanrao Sangame, Y. Prasannatha Reddy and Vasudev D. Shinde
The final properties of ductile iron are decided by the inoculant processing while pouring the melt. The shape and size of nodules generated during solidification are of paramount…
Abstract
Purpose
The final properties of ductile iron are decided by the inoculant processing while pouring the melt. The shape and size of nodules generated during solidification are of paramount importance in solidification of ductile cast iron. The purpose of this study is to examine the effect of different inoculant addition on the solidification of ductile cast iron melt through thermal analysis.
Design/methodology/approach
Thermal analysis has recently grown as a tool for modeling the solidification behavior of ductile cast irons. Iron properties will be predicted by analyzing the cooling curve patterns of the melts and predicting the related effectiveness of inoculant processing. In this study, thermal analysis is used to evaluate the need for inoculation.
Findings
The amount and type of inoculation will affect the amount of undercooling during the solidification of ductile cast iron. It is found that the addition of 0.1 to 0.4 Wt.% inoculant lowers the austenite dendrite formation starting temperature while increasing the eutectic freezing temperature. Microstructure analysis revealed that the addition of inoculation increases the nodule count from 103 to 242 nodules. The beneficial effects of inoculation are sustained by an improved graphitization factor, which shows the formation of graphite nodules in the second phase of the eutectic reaction.
Originality/value
The inoculation treatment has improved metallurgical occurrences such as carbide to graphite conversion, graphite microstructure control, graphite nodule count at the start of solidification and the last stage of solidification, which determines the soundness of casting. The foundry industry can follow these steps for monitoring the solidification of ductile iron castings.
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Diana Irinel Baila, Filippo Sanfilippo, Tom Savu, Filip Górski, Ionut Cristian Radu, Catalin Zaharia, Constantina Anca Parau, Martin Zelenay and Pacurar Razvan
The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM…
Abstract
Purpose
The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM) processes, have gained significant attention in recent years. Their accuracy, multi-material capability and application in novel fields, such as implantology, biomedical, aviation and energy industries, underscore the growing importance of these materials. The purpose of this study is oriented toward the application of new advanced materials in stent manufacturing realized by 3D printing technologies.
Design/methodology/approach
The methodology for designing personalized medical devices, implies computed tomography (CT) or magnetic resonance (MR) techniques. By realizing segmentation, reverse engineering and deriving a 3D model of a blood vessel, a subsequent stent design is achieved. The tessellation process and 3D printing methods can then be used to produce these parts. In this context, the SLA technology, in close correlation with the new types of developed resins, has brought significant evolution, as demonstrated through the analyses that are realized in the research presented in this study. This study undertakes a comprehensive approach, establishing experimentally the characteristics of two new types of photopolymerizable resins (both undoped and doped with micro-ceramic powders), remarking their great accuracy for 3D modeling in die-casting techniques, especially in the production process of customized stents.
Findings
A series of analyses were conducted, including scanning electron microscopy, energy-dispersive X-ray spectroscopy, mapping and roughness tests. Additionally, the structural integrity and molecular bonding of these resins were assessed by Fourier-transform infrared spectroscopy–attenuated total reflectance analysis. The research also explored the possibilities of using metallic alloys for producing the stents, comparing the direct manufacturing methods of stents’ struts by SLM technology using Ti6Al4V with stent models made from photopolymerizable resins using SLA. Furthermore, computer-aided engineering (CAE) simulations for two different stent struts were carried out, providing insights into the potential of using these materials and methods for realizing the production of stents.
Originality/value
This study covers advancements in materials and additive manufacturing methods but also approaches the use of CAE analysis, introducing in this way novel elements to the domain of customized stent manufacturing. The emerging applications of these resins, along with metallic alloys and 3D printing technologies, have brought significant contributions to the biomedical domain, as emphasized in this study. This study concludes by highlighting the current challenges and future research directions in the use of photopolymerizable resins and biocompatible metallic alloys, while also emphasizing the integration of artificial intelligence in the design process of customized stents by taking into consideration the 3D printing technologies that are used for producing these stents.
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João Eduardo Sampaio Brasil, Fabio Antonio Sartori Piran, Daniel Pacheco Lacerda, Maria Isabel Wolf Morandi, Debora Oliveira da Silva and Miguel Afonso Sellitto
The purpose of this study is to evaluate the efficiency of a Brazilian steelmaking company’s reheating process of the hot rolling mill.
Abstract
Purpose
The purpose of this study is to evaluate the efficiency of a Brazilian steelmaking company’s reheating process of the hot rolling mill.
Design/methodology/approach
The research method is a quantitative modeling. The main research techniques are data envelopment analysis, TOBIT regression and simulation supported by artificial neural networks. The model’s input and output variables consist of the average billet weight, number of billets processed in a batch, gas consumption, thermal efficiency, backlog and production yield within a specific period. The analysis spans 20 months.
Findings
The key findings include an average current efficiency of 81%, identification of influential variables (average billet weight, billet count and gas consumption) and simulated analysis. Among the simulated scenarios, the most promising achieved an average efficiency of 95% through increased equipment availability and billet size.
Practical implications
Additional favorable simulated scenarios entail the utilization of higher pre-reheating temperatures for cold billets, representing a large amount of savings in gas consumption and a reduction in CO2 emissions.
Originality/value
This study’s primary innovation lies in providing steelmaking practitioners with a systematic approach to evaluating and enhancing the efficiency of reheating processes.
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Çağın Bolat, Nuri Özdoğan, Sarp Çoban, Berkay Ergene, İsmail Cem Akgün and Ali Gökşenli
This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the…
Abstract
Purpose
This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the literature. The main goal of this endeavor is to create a casting machining-neural network modeling flow-line for real-time foam manufacturing in the industry.
Design/methodology/approach
Samples were manufactured via an industry-based die-casting technology. For the slot milling tests performed with different cutting speeds, depth of cut and lubrication conditions, a 3-axis computer numerical control (CNC) machine was used and the force data were collected through a digital dynamometer. These signals were used as input parameters in neural network modelings.
Findings
Among the algorithms, the scaled-conjugated-gradient (SCG) methodology was the weakest average results, whereas the Levenberg–Marquard (LM) approach was highly successful in foreseeing the cutting forces. As for the input variables, an increase in the depth of cut entailed the cutting forces, and this circumstance was more obvious at the higher cutting speeds.
Research limitations/implications
The effect of milling parameters on the cutting forces of low-cost clay-filled metallic syntactics was examined, and the correct detection of these impacts is considerably prominent in this paper. On the other side, tool life and wear analyses can be studied in future investigations.
Practical implications
It was indicated that the milling forces of the clay-added AA7075 syntactic foams, depending on the cutting parameters, can be anticipated through artificial neural network modeling.
Social implications
It is hoped that analyzing the influence of the cutting parameters using neural network models on the slot milling forces of metallic syntactic foams (MSFs) will be notably useful for research and development (R&D) researchers and design engineers.
Originality/value
This work is the first investigation that focuses on the estimation of slot milling forces of the expanded clay-added AA7075 syntactic foams by using different artificial neural network modeling approaches.
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Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…
Abstract
Purpose
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.
Design/methodology/approach
Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.
Findings
In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.
Originality/value
With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.
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Ewa Sońta-Drączkowska and Agnieszka Krogulec
This study seeks to illuminate the managerial tensions inherent in implementing scaled agile (on the organizational, top management, middle management and team levels) and to…
Abstract
Purpose
This study seeks to illuminate the managerial tensions inherent in implementing scaled agile (on the organizational, top management, middle management and team levels) and to frame these challenges within the broader context of project management.
Design/methodology/approach
The study adopts a grounded theory approach and delves into a qualitative dataset sourced from 34 interviews with subject matter experts actively engaged in scaling agile initiatives within large organizations spanning various industries. Additionally, the data have been enriched through a comprehensive literature review of the existing body of knowledge on scaling agile.
Findings
As a result of our investigation, we propose a framework of managerial tensions in scaling agile in large corporate settings and a series of research propositions and questions that may contribute significantly to the body of knowledge surrounding the phenomenon of “deprojectification” and propose agenda for the future studies in the field of project management.
Research limitations/implications
The study also carries significant managerial implications. Firstly, based on the insights from the practice of scaling agile in large corporate setting, management can build awareness of the challenges inherent of transitioning to agile practices. This may help to anticipate the possible problems and proactively develop strategies how to address them. Secondly, management can be instructed about contingencies inherent in scaling agile, along with the potential disfunctions and side effects (unintended outcomes) that may emerge during the transition process. Thirdly, project management practitioners can gain insights on how scaling agile may cause shifts in the approach to managing projects, project team management and competencies that need to be developed to cope with environments where various approaches to managing projects coexist.
Practical implications
These insights can aid in the agile transition process, beginning with directing managerial attention toward contextual factors and progressing through potential challenges at the organizational, top management, middle management and team levels. Furthermore, the study highlights possible dysfunctionalities and side effects of scaling agile, shedding light on the “dark side” of agile.
Originality/value
The study contributes to the expansion of the empirical database on the implementation of agile practices in large organizational settings. It plays a role in defining and delineating the phenomenon of scaling agile within the context of project management and outlines a research agenda for future project management studies. Additionally, our study adds to the ongoing discourse surrounding the “deprojectification” effect that can occur during the scaling of agile. Lastly, it establishes connections between project management and software development literature regarding the implementation of agile at scale.
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Serkan Ağseren and Süleyman Şimşek
This study aims to prevent occupational accidents occurring in the manufacturing industry by means of touch sensors. When the occupational accidents occurring in the manufacturing…
Abstract
Purpose
This study aims to prevent occupational accidents occurring in the manufacturing industry by means of touch sensors. When the occupational accidents occurring in the manufacturing industry around the world are examined, it is seen that approximately 88% of occupational accidents occur from “dangerous movement” and 10% from “dangerous situation.” Although some studies related to safety culture studies, safety studies in design and collective or personal protective measures have been started, they have not been brought to an adequate level. It is observed that studies on dangerous movements continue even in many developed countries. In this study, first of all, a literature study was conducted. Occupational accidents experienced in the manufacturing sector in Turkey have been examined. In line with these investigations, a prototype circuit protection system has been developed that can prevent accidents caused by dangerous movement. With the circuit, its applicability and effectiveness were measured by conducting experiments on different manufacturing machines. The prototype circuit applied in this paper was made based on the logic of protective measures made on sawstop machines used in different sectors. In the experimental study conducted, it was observed that in 30 experiments conducted with a prototype on ten separate manufacturing machines, it stopped the machines 26 times at minimum and 29 times at maximum. On average, when looking at the system efficiency values, it was seen that the system was 81.6% effective, and it was observed that positive results could be obtained when converted into a real product.
Design/methodology/approach
In this study, their contribution to the prevention of work accidents caused by presses and rotary accents from machines used in the manufacturing industry by means of touch sensors used in Industry 4.0 was examined.
Findings
With Industry 4.0, different automation systems began to be switched in many areas and sectors. Studies have started on different sensors used also in Industry 4.0 in occupational health and safety studies, but it is seen that they have not been applied at an adequate level. It should be designed in such a way as to prevent errors or stop these errors in the studies performed. Today, sensors are produced at much lower costs than before. In addition, the constantly developing technology provides great convenience for these applications.
Research limitations/implications
This study was applied for press and cylinder machines from manufacturing machines. This study has been tried for machines producing a maximum pressure of 300 tons.
Originality/value
A prototype was designed. Trials were done on some machines by prototype. There could be improve and find different solutions for safety problems in the industry with this perspective.
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Akansha Mer and Amarpreet Singh Virdi
Introduction: Small- and medium-sized enterprises (SMEs) play a vital role in the economic development of economies by generating job opportunities. Considering their…
Abstract
Introduction: Small- and medium-sized enterprises (SMEs) play a vital role in the economic development of economies by generating job opportunities. Considering their significance, understanding the challenges and skills required in these enterprises becomes essential and timely.
Purpose: This study aims to discuss the limitations and skill gaps faced by SMEs in emerging economies, such as India, Indonesia, Brazil, China, Malaysia, Ghana, Hungary, Saudi Arabia, South Africa, Türkiye, UAE, Iran, Kazakhstan, Türkiye, Zambia, Romania, and Vietnam.
Methodology: The study adopts a systematic review and meta-synthesis approach, utilising a literature review to comprehensively analyse, synthesise, and map the existing literature by identifying overarching themes.
Findings: The study examines the challenges SMEs encounter in emerging economies, including resource scarcity, limited access to credit, inadequate infrastructure, low technology adoption, restricted global market access, and ineffective marketing strategies. There is a notable shortage of skilled labour and development initiatives within SMEs in India even though the country has a sizeable pool of qualified workers. There is a pressing need for additional technical and managerial skills to remain competitive in the market. The findings of this study will assist HR managers in addressing skill shortages among employees in SMEs operating within emerging economies
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