The work presented in this paper focused on the recycling of ferrous scrap metal and its utilizat... more The work presented in this paper focused on the recycling of ferrous scrap metal and its utilization in the production of automobile brake drum. Cast iron scrap and steel scrap from old automobiles were selected as a case study with addition of graphite to improve the percentage of carbon and Ferro-silicon for inoculation. Brake drum and test bars were casted employing Electric Arc Furnace (EAF) and green sand-casting method. Micro-structural property of the recycled product was determined using metallurgical microscope with 200x magnification while chemical composition was determined using Optical Electron Spectrometer (OES). The photo-micrograph of the cast brake drum showed that a gray cast iron microstructure was obtained while the OES analysis showed an average composition of elements as: Fe 94.61 %, C 3.12 %, Si 1.38 %, Mn 0.475 %, S 0.003 %, P 0.008 %, and Cr 0.113 % along with trace amount of some other twelve elements which meets the minimum standard for Brake Drum application designated by Society of Automotive Engineering (SAE). Results from mechanical tests showed that Maximum Tensile strength of the of the material was 81.45317 MPa when the load was gradually applied within 7.788 sec to fracture, Hardness strength 97.73 HRB/228 HB, while Impact strength 2 J. The cast iron produced can be modified for use in other applications such as automobile engine blocks, discs, etc.
Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable c... more Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable corrosion mitigation procedure today. Integrity of ICCP systems depends among other important factors on the Anode material. Platinize-Titanium base materials were found to be the best anodes in ICCP systems but with high importation cost. In order to improve local contents and foreign exchange, an investigation was carried out on the potentials of locally produced anodes for ICCP system. Four Anodes were produced from different materials for this purpose. An aggressive environment was simulated by saturating soil with 1M solution of NaCl to form corrosion cells. A set of steel Pipe and Anode were buried in four different corrosion cells powered with direct current source to represent an ICCP system where the Anode performances were monitored in terms of depletion period, level of corrosion protection offered to the steel pipes and general electrochemical behavior of both the Pipes and the Anodes. Readings of the simulated corrosion cells environments' pH, pipe-to-soil potentials based on Cu/CuSO4 reference electrode, open circuit voltages and temperature were taken on daily basis. The test lasted for twenty-one days with the Anode from Lead material exhibited a good protection quality by showing only 10.22% depletion in comparison to the Cupper based and Aluminum based Anodes. From the results, it was concluded that Pb-based Anode produced locally can be a good candidate for ICCP system in aggressive environments.
The microstructural study via scanning electron microscope (SEM) and thermal study via differenti... more The microstructural study via scanning electron microscope (SEM) and thermal study via differential scanning calorimetric (DSC) study of Al-7%Si-0.3Mg/melon shell ash particulate composite has been carried out. The melon shell ash was used in the production of MMC ranging from 5% to 20% at interval of 5% addition using stir casting method. The melon shell ash was characterized using X-ray fluorescent (XRF) that reveal the presence of CaO, SiO 2 , Al 2 O 3 , MgO, and TiO 2 as major compounds. The composite was machined and subjected to heat treatment. Microstructural analyses of the composite produced were done using scanning electron microscope (SEM). The microstructure obtained reveals a dark ceramic (reinforcer) and white metallic phase. Equally, the 5 wt% DSC result gives better thermal conductivity than other proportions (10 wt%, 15 wt%, and 20 wt%). These results showed that an improved property of Al-Si-Mg alloy was achieved using melon shell ash particles as reinforcement up to a maximum of 20 wt% for microstructural and 5% wt DSC respectively. Ó 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Introduction The development of composite materials has changed the world especially in engineering fields. It is because most of composite materials have been created to show improved combination of mechanical characteristics such as stiffness, toughness and high temperature strength that cannot be met by conventional materials such as ceramic, metal alloys or polymers [1]. Many composites used today are at the leading edge of materials technology with performance and cost appropriate to ultra-demanding applications. Heterogeneous materials combining the best aspects of dissimilar constituents have been used by nature for millions of years [2]. Potential uses of metal matrix composites (MMCs) are numerous in industries and they include such areas of application as aerospace (propellers, tails), defense (missile-shells), automotive (drive shafts, brake disc), sports goods (golf clubs and mountain bicycle frames) and marine (yacht fittings) [3,4]. When compared with unreinforced matrix alloy, MMCs in general have superior mechanical properties, such as high strength, high stiffness, high wear resistance and a high temperature property. The driving force for research and development on particulate metal composites was a desire to produce a material with desirable features, characteristics of metal matrix composites without paying the high price of particulates [4]. In this present work, melon-shell ash was used as reinforcing phase to produce aluminum melon ash composite with composition of 0%, 5%, 10%, 15%, and 20% melon-shell ash. The scanning electron microscope (SEM) and differential scanning calorimetric (DSC) study was carried out on the composite. Almost all agro waste products in the world are burnt or buried underground because they make the environment unclean. This burning or burying sometimes constitute nuisance to the environment. However, utilization of melon shell in composite materials like the aluminum matrix composite will help not only in making the environment friendly in areas where this shells are mostly discarded , but can also be used as reinforcement in the production of composites. Experimental Materials and equipment Aluminum wire use for the investigation was obtained from northern cable company (NOCACO) Kaduna state, Magnesium and Silicon were obtained in its powdered form from a metal shop in Jos, Plateau State Nigeria. Some of the equipment used include charcoal furnace and stirrer, Digital weigh balance, cope and drag, http://dx.
Citation Bawa MA, Umaru OB, Oyewole SO, Onmikpa O. An investigation on the mechanical properties ... more Citation Bawa MA, Umaru OB, Oyewole SO, Onmikpa O. An investigation on the mechanical properties of heat treated A384 Aluminium alloy. ABSTRACT Research has been done to study the effect of heat treatment on the mechanical properties of A384 aluminium alloy. Aluminium scraps were collected, melt and cast to cylindrical rods of 20x300 mm. The first set of the produced alloy was annealed at 470°C for 3 hours, while the second set of samples were hardened by heating it to a solutionizing temperature of 470°C, followed by quenching in warm water and subsequently ageing to 120°C for 5 hours. The as-cast and heat-treated samples were then subjected to mechanical tests. The results revealed that the as-cast, precipitation hardened and annealed sample had a tensile strength of 75Mpa, 128Mpa and 93.4Mpa with hardness values of 37HRF, 91.50HRF, and 12HRF respectively. It was observed that the tensile strength of precipitation hardened sample is 71.8% greater than that of the as-cast, while the tensile strength of the annealed sample is 24.6% greater than the tensile strength of as-cast samples. From the result obtained, Heat treated samples have higher ultimate tensile strength, hardness and elongation values as compared with the as-cast. It can be concluded that the heat treatment operations have improved the mechanical properties of the aluminium alloy under investigation.
International Journal of Research Publications , 2019
Foundry sand, refer to a special sand use in the foundry workshop for either mould making or core... more Foundry sand, refer to a special sand use in the foundry workshop for either mould making or core making. In mould making, the sand is used to create a cavity of the pattern in the mould where the molten metal is poured to produce a casting. In core making, the sand is used to bake cores which cannot be obtained directly from the pattern. In this research, Gindiri and Kombun sands were investigated to find there suitability for use as foundry sand. The parameters investigated are chemical composition, cold crushing strength, and bulk density, apparent porosity, firing shrinkage, thermal shock resistance and refractoriness. The results showed that the sands consists of 62.004% and 54.007% Al2O3, 9.124% and 16.001% SiO2, 2.000% and 4.018% K2O, 1.000% and 1.019% CaO, 0.196% and 0.001% TiO2, 0.019% and 0.907% Fe2O3, 0.006% and 2.014% CuO, 0.007% and 6.017% ClO3, 0.129% and 0.907% ZnO, 0.001% and 0.801% ZrO2, 0.701 and 0.002% PbO, 0.501% and 0.041%NbO, 0.001% and 0.001% As, 0.007% and 0.003% P2, 228.9kg/cm2 and 205.7kg/cm2 cold crushing strength, 1.97g/cm3 and 1.84g/cm3 bulk density, 32.80% and 22.63% apparent porosity, 0.1% and 2% firing shrinkage, 10 and 15 cycles thermal shock resistance and less than 15000C and 14000C refractoriness. The sands are therefore recommended for production of refractory materials such as ceramics, furnace lining, potteries and building bricks as well as for the production of mold and core making.
IOSR Journal of Mechanical and Civil Engineering, 2020
The use of waste materials (metal scraps, plastic and crop) to produce engineering components is ... more The use of waste materials (metal scraps, plastic and crop) to produce engineering components is currently attracting so much interest due to their low cost, availability and environmental impact. In this study, aluminium (Al) ingot prepared from beverage can scraps (BCS) was characterized. The composition, density, tensile strength, compression strength, wear rate, thermal conductivity, hardness, storage modulus, loss modulus and microstructure of the recycled Al ingot were determined. The result of the analysis showed the composition of the Al ingots to be 95.62%Al, 1.62%Mg, 1.32%Si, 0.693%Mn, 0.437%Fe, 0.162%Cu, 0.097%Zn, 0.024%Ti, 0.017%V, 0.006Ni, 0.005%Cr and 0.008%Pb. The density, ultimate strength, yield strength, percentage elongation, compression strength, hardness, wear rate, coefficient of friction, thermal conductivity and coefficient of thermal expansion of the Al ingots are 2.62gcm-3 ,138.03Nmm-2 , 118.65Nmm-2 , 0.9%, 411.15 Nmm-2 , 65.67HV, 0.12 mm 3 n-1 m-1 , 0.56, 191.58Wm-1 K-1 , and 0.11 o C-1. The values of these properties fall within the range of the density and strength properties of standard Al alloys. Also, the peak values of the Loss modulus and damping coefficient obtained through the dynamic mechanical analysis of the recycled Al ingot are 1118Nmm-2 at 46 o C and 0.029 at 45.8 o C respectively. The lightweight, high thermal conductivity, good wear resistance and good strength properties will make Al ingot good for use in structural application such as brake disc.
IOSR Journal of Mechanical and Civil Engineering, 2020
Wear is produced when two elements press against each other, such as apron liner, blow bars and c... more Wear is produced when two elements press against each other, such as apron liner, blow bars and crushing material. During this process, small materials from each element become detached, causing the surface to wear away. A primary factor in wear for crushing applications is abrasion. The blow bars on the rotor of an impact crusher wears faster because of the impact and rubbing with material during crushing. This contributes to about 60 % of the cost of wear parts in an impact crusher. This study is focus on wear analysis of rotor blow bars of a compound impact crusher used in limestone crushing. The wear rate on the blow bars were calculated using the measured length of the blow bar before and after crushing 100,000 tons of limestone. The blow bars are refilled and hard-faced to prolong it life span. However, wear analysis shows high wear toward the centre of the blow bar and this can be attributed to non-uniform feeding of the crusher. The wear rate was found to be 0.000160, at point A and E, 0.000172, at point B and D and 0.000194 mm/ton at point C. The blow bars wearing is due to trickle feed which gives uneven and excessive wear at the centre and reduces the life of the blow bar. The material feed rate was adjusted and uniform feed was maintained through the entire length of the blow bar. Rotor speed was checked and adjusted, cleaning was intensified in the chamberand discharge gap setting was adjusted to 50 mm. The wear on blow bar decreases to 0.000114 mm/ton of limestone crushed after the intervention with uniform and gentle radius profile on the blow bar.
The work presented in this paper focused on the recycling of ferrous scrap metal and its utilizat... more The work presented in this paper focused on the recycling of ferrous scrap metal and its utilization in the production of automobile brake drum. Cast iron scrap and steel scrap from old automobiles were selected as a case study with addition of graphite to improve the percentage of carbon and Ferro-silicon for inoculation. Brake drum and test bars were casted employing Electric Arc Furnace (EAF) and green sand-casting method. Micro-structural property of the recycled product was determined using metallurgical microscope with 200x magnification while chemical composition was determined using Optical Electron Spectrometer (OES). The photo-micrograph of the cast brake drum showed that a gray cast iron microstructure was obtained while the OES analysis showed an average composition of elements as: Fe 94.61 %, C 3.12 %, Si 1.38 %, Mn 0.475 %, S 0.003 %, P 0.008 %, and Cr 0.113 % along with trace amount of some other twelve elements which meets the minimum standard for Brake Drum application designated by Society of Automotive Engineering (SAE). Results from mechanical tests showed that Maximum Tensile strength of the of the material was 81.45317 MPa when the load was gradually applied within 7.788 sec to fracture, Hardness strength 97.73 HRB/228 HB, while Impact strength 2 J. The cast iron produced can be modified for use in other applications such as automobile engine blocks, discs, etc.
Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable c... more Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable corrosion mitigation procedure today. Integrity of ICCP systems depends among other important factors on the Anode material. Platinize-Titanium base materials were found to be the best anodes in ICCP systems but with high importation cost. In order to improve local contents and foreign exchange, an investigation was carried out on the potentials of locally produced anodes for ICCP system. Four Anodes were produced from different materials for this purpose. An aggressive environment was simulated by saturating soil with 1M solution of NaCl to form corrosion cells. A set of steel Pipe and Anode were buried in four different corrosion cells powered with direct current source to represent an ICCP system where the Anode performances were monitored in terms of depletion period, level of corrosion protection offered to the steel pipes and general electrochemical behavior of both the Pipes and the Anodes. Readings of the simulated corrosion cells environments' pH, pipe-to-soil potentials based on Cu/CuSO4 reference electrode, open circuit voltages and temperature were taken on daily basis. The test lasted for twenty-one days with the Anode from Lead material exhibited a good protection quality by showing only 10.22% depletion in comparison to the Cupper based and Aluminum based Anodes. From the results, it was concluded that Pb-based Anode produced locally can be a good candidate for ICCP system in aggressive environments.
This work is on the development of the G&M codes for the production of the Brake Disc using CNC p... more This work is on the development of the G&M codes for the production of the Brake Disc using CNC programming. This utilizes the knowledge of CNC machine language in developing the necessary machine codes that will be used for machining a prototype model of the Brake Disc used in automobiles. The dimensions of the output Brake Disc are Ø100mm x Ø20mm with a step turn of Ø70mm x Ø15mm. The prototype is machined by running the developed codes on a CNC milling machine and the work piece used is soft wood material. The work is aimed at developing these codes for the mass production of the Brake Disc with high precision in our automobile industries adding to the local content initiative. 1.0 INTRODUCTION: 1.1 Brake Disc: A disc brake is a wheel brake which slows rotation of the wheel by the friction caused by pushing brake pads against a brake disc with a set of calipers. The brake disc is usually made of cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix composites. This is connected to the wheel and/or the axle. To stop the wheel, friction material in the form of brake pads, mounted on a device called a brake caliper, is forced mechanically, hydraulically, pneumatically, or electromagnetically against both sides of the disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion to heat, and if the brakes get too hot, they become less effective, a phenomenon known as brake fade (Richard, 1994). In 1965 Brake Discs were introduced on automobiles. Brake Discs have greater stopping power than drum brakes and are usually installed on the front wheels to improve braking during sudden stops. Brake Discs consist of a metal disc, or a rotor, that is connected to the wheel (Carley, 2009). A device called a caliper rests on the edge of the rotor and holds two friction pads on either side of the rotor. Applying the brakes causes fluid to push a piston within the caliper, which pinches the brake pads against the rotor and slows the wheel. Brake Discs do not have return springs, like those in drum brakes, to disengage the brakes. Instead, a seal around the piston bends slightly when the brakes are applied and then retracts to pull the piston back away from the rotor when the brake pedal is released. Also, Brake Discs rely on a very small amount
The work presented in this paper focused on the recycling of ferrous scrap metal and its utilizat... more The work presented in this paper focused on the recycling of ferrous scrap metal and its utilization in the production of automobile brake drum. Cast iron scrap and steel scrap from old automobiles were selected as a case study with addition of graphite to improve the percentage of carbon and Ferro-silicon for inoculation. Brake drum and test bars were casted employing Electric Arc Furnace (EAF) and green sand-casting method. Micro-structural property of the recycled product was determined using metallurgical microscope with 200x magnification while chemical composition was determined using Optical Electron Spectrometer (OES). The photo-micrograph of the cast brake drum showed that a gray cast iron microstructure was obtained while the OES analysis showed an average composition of elements as: Fe 94.61 %, C 3.12 %, Si 1.38 %, Mn 0.475 %, S 0.003 %, P 0.008 %, and Cr 0.113 % along with trace amount of some other twelve elements which meets the minimum standard for Brake Drum application designated by Society of Automotive Engineering (SAE). Results from mechanical tests showed that Maximum Tensile strength of the of the material was 81.45317 MPa when the load was gradually applied within 7.788 sec to fracture, Hardness strength 97.73 HRB/228 HB, while Impact strength 2 J. The cast iron produced can be modified for use in other applications such as automobile engine blocks, discs, etc.
Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable c... more Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable corrosion mitigation procedure today. Integrity of ICCP systems depends among other important factors on the Anode material. Platinize-Titanium base materials were found to be the best anodes in ICCP systems but with high importation cost. In order to improve local contents and foreign exchange, an investigation was carried out on the potentials of locally produced anodes for ICCP system. Four Anodes were produced from different materials for this purpose. An aggressive environment was simulated by saturating soil with 1M solution of NaCl to form corrosion cells. A set of steel Pipe and Anode were buried in four different corrosion cells powered with direct current source to represent an ICCP system where the Anode performances were monitored in terms of depletion period, level of corrosion protection offered to the steel pipes and general electrochemical behavior of both the Pipes and the Anodes. Readings of the simulated corrosion cells environments' pH, pipe-to-soil potentials based on Cu/CuSO4 reference electrode, open circuit voltages and temperature were taken on daily basis. The test lasted for twenty-one days with the Anode from Lead material exhibited a good protection quality by showing only 10.22% depletion in comparison to the Cupper based and Aluminum based Anodes. From the results, it was concluded that Pb-based Anode produced locally can be a good candidate for ICCP system in aggressive environments.
The microstructural study via scanning electron microscope (SEM) and thermal study via differenti... more The microstructural study via scanning electron microscope (SEM) and thermal study via differential scanning calorimetric (DSC) study of Al-7%Si-0.3Mg/melon shell ash particulate composite has been carried out. The melon shell ash was used in the production of MMC ranging from 5% to 20% at interval of 5% addition using stir casting method. The melon shell ash was characterized using X-ray fluorescent (XRF) that reveal the presence of CaO, SiO 2 , Al 2 O 3 , MgO, and TiO 2 as major compounds. The composite was machined and subjected to heat treatment. Microstructural analyses of the composite produced were done using scanning electron microscope (SEM). The microstructure obtained reveals a dark ceramic (reinforcer) and white metallic phase. Equally, the 5 wt% DSC result gives better thermal conductivity than other proportions (10 wt%, 15 wt%, and 20 wt%). These results showed that an improved property of Al-Si-Mg alloy was achieved using melon shell ash particles as reinforcement up to a maximum of 20 wt% for microstructural and 5% wt DSC respectively. Ó 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Introduction The development of composite materials has changed the world especially in engineering fields. It is because most of composite materials have been created to show improved combination of mechanical characteristics such as stiffness, toughness and high temperature strength that cannot be met by conventional materials such as ceramic, metal alloys or polymers [1]. Many composites used today are at the leading edge of materials technology with performance and cost appropriate to ultra-demanding applications. Heterogeneous materials combining the best aspects of dissimilar constituents have been used by nature for millions of years [2]. Potential uses of metal matrix composites (MMCs) are numerous in industries and they include such areas of application as aerospace (propellers, tails), defense (missile-shells), automotive (drive shafts, brake disc), sports goods (golf clubs and mountain bicycle frames) and marine (yacht fittings) [3,4]. When compared with unreinforced matrix alloy, MMCs in general have superior mechanical properties, such as high strength, high stiffness, high wear resistance and a high temperature property. The driving force for research and development on particulate metal composites was a desire to produce a material with desirable features, characteristics of metal matrix composites without paying the high price of particulates [4]. In this present work, melon-shell ash was used as reinforcing phase to produce aluminum melon ash composite with composition of 0%, 5%, 10%, 15%, and 20% melon-shell ash. The scanning electron microscope (SEM) and differential scanning calorimetric (DSC) study was carried out on the composite. Almost all agro waste products in the world are burnt or buried underground because they make the environment unclean. This burning or burying sometimes constitute nuisance to the environment. However, utilization of melon shell in composite materials like the aluminum matrix composite will help not only in making the environment friendly in areas where this shells are mostly discarded , but can also be used as reinforcement in the production of composites. Experimental Materials and equipment Aluminum wire use for the investigation was obtained from northern cable company (NOCACO) Kaduna state, Magnesium and Silicon were obtained in its powdered form from a metal shop in Jos, Plateau State Nigeria. Some of the equipment used include charcoal furnace and stirrer, Digital weigh balance, cope and drag, http://dx.
Citation Bawa MA, Umaru OB, Oyewole SO, Onmikpa O. An investigation on the mechanical properties ... more Citation Bawa MA, Umaru OB, Oyewole SO, Onmikpa O. An investigation on the mechanical properties of heat treated A384 Aluminium alloy. ABSTRACT Research has been done to study the effect of heat treatment on the mechanical properties of A384 aluminium alloy. Aluminium scraps were collected, melt and cast to cylindrical rods of 20x300 mm. The first set of the produced alloy was annealed at 470°C for 3 hours, while the second set of samples were hardened by heating it to a solutionizing temperature of 470°C, followed by quenching in warm water and subsequently ageing to 120°C for 5 hours. The as-cast and heat-treated samples were then subjected to mechanical tests. The results revealed that the as-cast, precipitation hardened and annealed sample had a tensile strength of 75Mpa, 128Mpa and 93.4Mpa with hardness values of 37HRF, 91.50HRF, and 12HRF respectively. It was observed that the tensile strength of precipitation hardened sample is 71.8% greater than that of the as-cast, while the tensile strength of the annealed sample is 24.6% greater than the tensile strength of as-cast samples. From the result obtained, Heat treated samples have higher ultimate tensile strength, hardness and elongation values as compared with the as-cast. It can be concluded that the heat treatment operations have improved the mechanical properties of the aluminium alloy under investigation.
International Journal of Research Publications , 2019
Foundry sand, refer to a special sand use in the foundry workshop for either mould making or core... more Foundry sand, refer to a special sand use in the foundry workshop for either mould making or core making. In mould making, the sand is used to create a cavity of the pattern in the mould where the molten metal is poured to produce a casting. In core making, the sand is used to bake cores which cannot be obtained directly from the pattern. In this research, Gindiri and Kombun sands were investigated to find there suitability for use as foundry sand. The parameters investigated are chemical composition, cold crushing strength, and bulk density, apparent porosity, firing shrinkage, thermal shock resistance and refractoriness. The results showed that the sands consists of 62.004% and 54.007% Al2O3, 9.124% and 16.001% SiO2, 2.000% and 4.018% K2O, 1.000% and 1.019% CaO, 0.196% and 0.001% TiO2, 0.019% and 0.907% Fe2O3, 0.006% and 2.014% CuO, 0.007% and 6.017% ClO3, 0.129% and 0.907% ZnO, 0.001% and 0.801% ZrO2, 0.701 and 0.002% PbO, 0.501% and 0.041%NbO, 0.001% and 0.001% As, 0.007% and 0.003% P2, 228.9kg/cm2 and 205.7kg/cm2 cold crushing strength, 1.97g/cm3 and 1.84g/cm3 bulk density, 32.80% and 22.63% apparent porosity, 0.1% and 2% firing shrinkage, 10 and 15 cycles thermal shock resistance and less than 15000C and 14000C refractoriness. The sands are therefore recommended for production of refractory materials such as ceramics, furnace lining, potteries and building bricks as well as for the production of mold and core making.
IOSR Journal of Mechanical and Civil Engineering, 2020
The use of waste materials (metal scraps, plastic and crop) to produce engineering components is ... more The use of waste materials (metal scraps, plastic and crop) to produce engineering components is currently attracting so much interest due to their low cost, availability and environmental impact. In this study, aluminium (Al) ingot prepared from beverage can scraps (BCS) was characterized. The composition, density, tensile strength, compression strength, wear rate, thermal conductivity, hardness, storage modulus, loss modulus and microstructure of the recycled Al ingot were determined. The result of the analysis showed the composition of the Al ingots to be 95.62%Al, 1.62%Mg, 1.32%Si, 0.693%Mn, 0.437%Fe, 0.162%Cu, 0.097%Zn, 0.024%Ti, 0.017%V, 0.006Ni, 0.005%Cr and 0.008%Pb. The density, ultimate strength, yield strength, percentage elongation, compression strength, hardness, wear rate, coefficient of friction, thermal conductivity and coefficient of thermal expansion of the Al ingots are 2.62gcm-3 ,138.03Nmm-2 , 118.65Nmm-2 , 0.9%, 411.15 Nmm-2 , 65.67HV, 0.12 mm 3 n-1 m-1 , 0.56, 191.58Wm-1 K-1 , and 0.11 o C-1. The values of these properties fall within the range of the density and strength properties of standard Al alloys. Also, the peak values of the Loss modulus and damping coefficient obtained through the dynamic mechanical analysis of the recycled Al ingot are 1118Nmm-2 at 46 o C and 0.029 at 45.8 o C respectively. The lightweight, high thermal conductivity, good wear resistance and good strength properties will make Al ingot good for use in structural application such as brake disc.
IOSR Journal of Mechanical and Civil Engineering, 2020
Wear is produced when two elements press against each other, such as apron liner, blow bars and c... more Wear is produced when two elements press against each other, such as apron liner, blow bars and crushing material. During this process, small materials from each element become detached, causing the surface to wear away. A primary factor in wear for crushing applications is abrasion. The blow bars on the rotor of an impact crusher wears faster because of the impact and rubbing with material during crushing. This contributes to about 60 % of the cost of wear parts in an impact crusher. This study is focus on wear analysis of rotor blow bars of a compound impact crusher used in limestone crushing. The wear rate on the blow bars were calculated using the measured length of the blow bar before and after crushing 100,000 tons of limestone. The blow bars are refilled and hard-faced to prolong it life span. However, wear analysis shows high wear toward the centre of the blow bar and this can be attributed to non-uniform feeding of the crusher. The wear rate was found to be 0.000160, at point A and E, 0.000172, at point B and D and 0.000194 mm/ton at point C. The blow bars wearing is due to trickle feed which gives uneven and excessive wear at the centre and reduces the life of the blow bar. The material feed rate was adjusted and uniform feed was maintained through the entire length of the blow bar. Rotor speed was checked and adjusted, cleaning was intensified in the chamberand discharge gap setting was adjusted to 50 mm. The wear on blow bar decreases to 0.000114 mm/ton of limestone crushed after the intervention with uniform and gentle radius profile on the blow bar.
The work presented in this paper focused on the recycling of ferrous scrap metal and its utilizat... more The work presented in this paper focused on the recycling of ferrous scrap metal and its utilization in the production of automobile brake drum. Cast iron scrap and steel scrap from old automobiles were selected as a case study with addition of graphite to improve the percentage of carbon and Ferro-silicon for inoculation. Brake drum and test bars were casted employing Electric Arc Furnace (EAF) and green sand-casting method. Micro-structural property of the recycled product was determined using metallurgical microscope with 200x magnification while chemical composition was determined using Optical Electron Spectrometer (OES). The photo-micrograph of the cast brake drum showed that a gray cast iron microstructure was obtained while the OES analysis showed an average composition of elements as: Fe 94.61 %, C 3.12 %, Si 1.38 %, Mn 0.475 %, S 0.003 %, P 0.008 %, and Cr 0.113 % along with trace amount of some other twelve elements which meets the minimum standard for Brake Drum application designated by Society of Automotive Engineering (SAE). Results from mechanical tests showed that Maximum Tensile strength of the of the material was 81.45317 MPa when the load was gradually applied within 7.788 sec to fracture, Hardness strength 97.73 HRB/228 HB, while Impact strength 2 J. The cast iron produced can be modified for use in other applications such as automobile engine blocks, discs, etc.
Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable c... more Impressed Current Cathodic Protection (ICCP) system has been adjudged to be the most acceptable corrosion mitigation procedure today. Integrity of ICCP systems depends among other important factors on the Anode material. Platinize-Titanium base materials were found to be the best anodes in ICCP systems but with high importation cost. In order to improve local contents and foreign exchange, an investigation was carried out on the potentials of locally produced anodes for ICCP system. Four Anodes were produced from different materials for this purpose. An aggressive environment was simulated by saturating soil with 1M solution of NaCl to form corrosion cells. A set of steel Pipe and Anode were buried in four different corrosion cells powered with direct current source to represent an ICCP system where the Anode performances were monitored in terms of depletion period, level of corrosion protection offered to the steel pipes and general electrochemical behavior of both the Pipes and the Anodes. Readings of the simulated corrosion cells environments' pH, pipe-to-soil potentials based on Cu/CuSO4 reference electrode, open circuit voltages and temperature were taken on daily basis. The test lasted for twenty-one days with the Anode from Lead material exhibited a good protection quality by showing only 10.22% depletion in comparison to the Cupper based and Aluminum based Anodes. From the results, it was concluded that Pb-based Anode produced locally can be a good candidate for ICCP system in aggressive environments.
This work is on the development of the G&M codes for the production of the Brake Disc using CNC p... more This work is on the development of the G&M codes for the production of the Brake Disc using CNC programming. This utilizes the knowledge of CNC machine language in developing the necessary machine codes that will be used for machining a prototype model of the Brake Disc used in automobiles. The dimensions of the output Brake Disc are Ø100mm x Ø20mm with a step turn of Ø70mm x Ø15mm. The prototype is machined by running the developed codes on a CNC milling machine and the work piece used is soft wood material. The work is aimed at developing these codes for the mass production of the Brake Disc with high precision in our automobile industries adding to the local content initiative. 1.0 INTRODUCTION: 1.1 Brake Disc: A disc brake is a wheel brake which slows rotation of the wheel by the friction caused by pushing brake pads against a brake disc with a set of calipers. The brake disc is usually made of cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix composites. This is connected to the wheel and/or the axle. To stop the wheel, friction material in the form of brake pads, mounted on a device called a brake caliper, is forced mechanically, hydraulically, pneumatically, or electromagnetically against both sides of the disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion to heat, and if the brakes get too hot, they become less effective, a phenomenon known as brake fade (Richard, 1994). In 1965 Brake Discs were introduced on automobiles. Brake Discs have greater stopping power than drum brakes and are usually installed on the front wheels to improve braking during sudden stops. Brake Discs consist of a metal disc, or a rotor, that is connected to the wheel (Carley, 2009). A device called a caliper rests on the edge of the rotor and holds two friction pads on either side of the rotor. Applying the brakes causes fluid to push a piston within the caliper, which pinches the brake pads against the rotor and slows the wheel. Brake Discs do not have return springs, like those in drum brakes, to disengage the brakes. Instead, a seal around the piston bends slightly when the brakes are applied and then retracts to pull the piston back away from the rotor when the brake pedal is released. Also, Brake Discs rely on a very small amount
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Papers by Bawa Mohammed
mould making, the sand is used to create a cavity of the pattern in the mould where the molten metal is poured
to produce a casting. In core making, the sand is used to bake cores which cannot be obtained directly from
the pattern. In this research, Gindiri and Kombun sands were investigated to find there suitability for use as
foundry sand. The parameters investigated are chemical composition, cold crushing strength, and bulk
density, apparent porosity, firing shrinkage, thermal shock resistance and refractoriness. The results showed
that the sands consists of 62.004% and 54.007% Al2O3, 9.124% and 16.001% SiO2, 2.000% and 4.018%
K2O, 1.000% and 1.019% CaO, 0.196% and 0.001% TiO2, 0.019% and 0.907% Fe2O3, 0.006% and 2.014%
CuO, 0.007% and 6.017% ClO3, 0.129% and 0.907% ZnO, 0.001% and 0.801% ZrO2, 0.701 and 0.002%
PbO, 0.501% and 0.041%NbO, 0.001% and 0.001% As, 0.007% and 0.003% P2, 228.9kg/cm2 and
205.7kg/cm2
cold crushing strength, 1.97g/cm3
and 1.84g/cm3 bulk density, 32.80% and 22.63% apparent
porosity, 0.1% and 2% firing shrinkage, 10 and 15 cycles thermal shock resistance and less than 15000C and
14000C refractoriness. The sands are therefore recommended for production of refractory materials such as
ceramics, furnace lining, potteries and building bricks as well as for the production of mold and core making.
mould making, the sand is used to create a cavity of the pattern in the mould where the molten metal is poured
to produce a casting. In core making, the sand is used to bake cores which cannot be obtained directly from
the pattern. In this research, Gindiri and Kombun sands were investigated to find there suitability for use as
foundry sand. The parameters investigated are chemical composition, cold crushing strength, and bulk
density, apparent porosity, firing shrinkage, thermal shock resistance and refractoriness. The results showed
that the sands consists of 62.004% and 54.007% Al2O3, 9.124% and 16.001% SiO2, 2.000% and 4.018%
K2O, 1.000% and 1.019% CaO, 0.196% and 0.001% TiO2, 0.019% and 0.907% Fe2O3, 0.006% and 2.014%
CuO, 0.007% and 6.017% ClO3, 0.129% and 0.907% ZnO, 0.001% and 0.801% ZrO2, 0.701 and 0.002%
PbO, 0.501% and 0.041%NbO, 0.001% and 0.001% As, 0.007% and 0.003% P2, 228.9kg/cm2 and
205.7kg/cm2
cold crushing strength, 1.97g/cm3
and 1.84g/cm3 bulk density, 32.80% and 22.63% apparent
porosity, 0.1% and 2% firing shrinkage, 10 and 15 cycles thermal shock resistance and less than 15000C and
14000C refractoriness. The sands are therefore recommended for production of refractory materials such as
ceramics, furnace lining, potteries and building bricks as well as for the production of mold and core making.