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Detail Design Review October 26 th 2012

Detail Design Review October 26 th 2012. Team P13656: L. Abatte , W. Fritzinger , P. Torab , K. Karauda. Project Management: Plan. Project Schedule. Design Proposal. Ultrasonic, self-contained unit. Design Proposal.

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Detail Design Review October 26 th 2012

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  1. Detail Design ReviewOctober 26th 2012 Team P13656: L. Abatte, W. Fritzinger, P. Torab, K. Karauda

  2. Project Management: Plan • Project Schedule

  3. Design Proposal • Ultrasonic, self-contained unit

  4. Design Proposal • http://prezi.com/kjnwnkg7awaz/ultrasonic-cleaning-system/?auth_key=30636a7d6cb66176bbd1c45f00a37499b77e2f32

  5. Specifications

  6. Specifications

  7. Coating & Extrusion Die Compositions • SS 400 • Honeycomb Extrusion Dies • TiCN (coating)

  8. Reaction Equations Set Up • Define the underlying reactions • Obtain redox potentials and equilibrium constants for perspective reactions • Developing the reaction rates & heat generated by the exothermic reaction • Utilize non-linear reaction program analysis to generate reaction scheme • Define optimization based on reaction scheme

  9. Reaction Sets • Redox Reactions • Decomposition of H2O2 • Acidic Stabilization • Ti Redox reactions

  10. From US Patent 20070023943 Variable Stripping Parameters

  11. Validation Test Samples Bar Stock Dimensions • cross-section: square 2in x 2in • thickness: 0.5 in • Capillaries: 9 units, 1/16 in • Coating: TiCN • Body: 316 SS

  12. Sample Picture

  13. Variable Test Samples Panel Dimensions • Length = 2 in • Width = 2 in • Thickness = 0.025 in • Coating: TiCN • Body: 304 SS

  14. Variable Test Sample • Sample Denotation • FREQUENCY: 2 samples • TEMPERATURE: 4 samples • COMPOSITION: 4 samples • FINAL/SPARES: 5 samples Total: 15 Samples

  15. Polarization Cell Components • Test Sample • Two Auxiliary Electrodes • Luggin Capillary • Salt Bridge Connection • Inert Gas Connections • Thermometer • Glass Container

  16. Functionality of Polarization Cell • Adjusting potential of auxiliary electrode 1 to match the potential of the sample. • Measuring the current flowing across the other auxiliary electrode 2 and sample. • Reference current flowing between the two auxiliary electrodes. • Generation of a Taffel plot • Taffel plot deduced corrosion rate [mass/time]

  17. Prototype Testing • At this time there would be defined test conditions along with a prototype system. • The test will act as a check to the validation testing and variable testing. • Coated mini-dies will be used in the testing. • Reaction check

  18. Supply & Cost Analysis for Testing

  19. Pugh Chart

  20. Project Management: Risks • Risk Matrix

  21. Bill of Materials - Rotational

  22. Rotational System

  23. Rotational System

  24. Rotational System

  25. Bill of Materials - Ultrasound

  26. Design Validation Preliminary Testing: • Necessary Equipment: • Small size ultrasonic tank • Square test pieces: • 2 x 2 in 316 steel (0.50 in thick) • Coating: TiC, TiN, TiCN (since the exact coating of the actual parts cannot be disclosed) • Optionally: HSS drill bits can be used as test pieces (coated with TiN) • H2O2 bath (composition equal to the one used by the customer)

  27. Design Validation • Procedure: • Test pieces will be weighed and the initial weight will be recorded (prior to and after coating) • Test pieces will be submerged in the tank • Throughout the duration of the test, steel will be removed from the tank several times and weighed. This will provide the data necessary for establishing the rate at which the coating is being stripped from the parts by the bath. • Test will also provide the data for establishing the bath degradation rate since the ultrasonic tank will be at different pressure and temperature compared to the current setup. • Testing will be conducted for several test pieces to provide reliable data and avoid measurement error. • Once the data is obtained it will be analyzed and presented to the customer as well as faculty guides.

  28. Design Validation • Variables: • Frequency: • What value is optimal? • Range of acceptable values • Temperature: • Natural convection: temperature gradient throughout the tank (visit to vendor -> investigation) • Solution composition • Vibration intensity/ transducer strength • Cavitation strength • Jamestown Advanced demo

  29. Design Validation • Vendors: • McMaster Carr for sheet metal/ steel pieces • Vergasonfor coating of the test pieces • All machining can be done in house utilizing the ME machine shop

  30. Optional • In the future the design can be further expanded: • Level switch • Secondary containment tank • Piping system for fluid recycling purposes

  31. Questions?

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