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Manufacturing Defects (manufacturing + defect)

Distribution by Scientific Domains

Engineering	50%

Selected Abstracts

Fracture analysis of composite co-cured structural joints using decohesion elements

FATIGUE & FRACTURE OF ENGINEERING MATERIALS AND STRUCTURES, Issue 9 2004
P. P. CAMANHO
ABSTRACT Delamination is one of the predominant forms of failure in laminated composite structures, especially when there is no reinforcement in the thickness direction. To develop composite structures that are more damage tolerant, it is necessary to understand how delamination develops, and how it can affect the residual performance. A number of factors such as residual thermal stresses, matrix-curing shrinkage and manufacturing defects affect how damage will grow in a composite structure. It is important to develop computationally efficient analysis methods that can account for all such factors. The objective of the current work is to apply a newly developed decohesion element to investigate the debond strength of skin-stiffener composite specimens. The process of initiation of delaminations and the propagation of delamination fronts is investigated. The numerical predictions are compared with published experimental results. [source]

Mechanisms and modes for ignition of low-voltage, PVC-insulated electrotechnical products

FIRE AND MATERIALS, Issue 2 2006
Vytenis BabrauskasArticle first published online: 1 AUG 200
Abstract PVC is the most common insulation material used for wiring in low-voltage (LV) service. ,Low-voltage', in the context of this paper, is taken to be 120,240 VAC. The electrotechnical products considered include insulated wires, cables and cords, and also appurtenant termination devices, e.g. male plugs or female taps. Well-known factors leading to the ignition of PVC-insulated wiring and related products include: (a) manufacturing defects; (b) grossly excessive current; (c) over-insulation, sometimes augmented by overcurrent; (d) localized heating due to strand breakage; (e) localized heating due to mechanical strand severing by staples or nails; and (f) localized heating due to failed terminations. Other failure modes are known but have received only limited study. These include (i) excessive force and creep; (ii) chemical interaction effects; and (iii) breakdown under voltage surge conditions. Additional research is needed in these areas. The proximate cause of ignition involved with many of the above mechanisms is arc tracking (arcing across a carbonized path). In turn, it is shown that PVC is especially susceptible to becoming charred, it requiring only approximately 160°C for the material to become semiconducting during short-term exposure (around 10 h), while longer-term exposure (around 1 month) may cause failures at temperatures as low as 110°C. Some limited data exist which suggest that standard UL and IEC temperature classifications are unduly optimistic, as applied to PVC. Fire can originate if wiring or equipment cannot withstand a powerline surge. Mains-connected electrical appliances need to be designed to resist 6000 V surge voltages, even though this is not mandated in most of the current UL and IEC standards. Data are presented showing that the IEC 60112 wet-tracking test gives especially misleading results for PVC and should be improved or abrogated. Copyright © 2005 John Wiley & Sons, Ltd. [source]

Finite element and sensitivity analysis of thermally induced flow instabilities

INTERNATIONAL JOURNAL FOR NUMERICAL METHODS IN FLUIDS, Issue 10 2010
Jean-Serge Giguère
Abstract This paper presents a finite element algorithm for the simulation of thermo-hydrodynamic instabilities causing manufacturing defects in injection molding of plastic and metal powder. Mold-filling parameters determine the flow pattern during filling, which in turn influences the quality of the final part. Insufficiently, well-controlled operating conditions may generate inhomogeneities, empty spaces or unusable parts. An understanding of the flow behavior will enable manufacturers to reduce or even eliminate defects and improve their competitiveness. This work presents a rigorous study using numerical simulation and sensitivity analysis. The problem is modeled by the Navier,Stokes equations, the energy equation and a generalized Newtonian viscosity model. The solution algorithm is applied to a simple flow in a symmetrical gate geometry. This problem exhibits both symmetrical and non-symmetrical solutions depending on the values taken by flow parameters. Under particular combinations of operating conditions, the flow was stable and symmetric, while some other combinations leading to large thermally induced viscosity gradients produce unstable and asymmetric flow. Based on the numerical results, a stability chart of the flow was established, identifying the boundaries between regions of stable and unstable flow in terms of the Graetz number (ratio of thermal conduction time to the convection time scale) and B, a dimensionless ratio indicating the sensitivity of viscosity to temperature changes. Sensitivities with respect to flow parameters are then computed using the continuous sensitivity equations method. We demonstrate that sensitivities are able to detect the transition between the stable and unstable flow regimes and correctly indicate how parameters should change in order to increase the stability of the flow. Copyright © 2009 John Wiley & Sons, Ltd. [source]

Mechanical Behavior and Failure Analysis of Prosthetic Retaining Screws after Long-Term Use In Vivo.

JOURNAL OF PROSTHODONTICS, Issue 3 2008
Microhardness Analysis, Part 2: Metallurgical
Abstract Purpose: This study involved testing and analyzing multiple retrieved prosthetic retaining screws after long-term use in vivo to: (1) detect manufacturing defects that could affect in-service behavior; (2) characterize the microstructure and alloy composition; and (3) further characterize the wear mechanism of the screw threads. Materials and Methods: Two new (control) screws from Nobel Biocare (NB) and 18 used (in service 18,120 months) retaining screws [12 from NB and 6 from Sterngold (SG)] were: (1) metallographically examined by light microscopy and scanning electron microscopy (SEM) to determine the microstructure; (2) analyzed by energy dispersive X-ray (EDX) microanalysis to determine the qualitative and semiquantitative average alloy and individual phase compositions; and (3) tested for Vickers microhardness. Results: Examination of polished longitudinal sections of the screws using light microscopy revealed a significant defect in only one Group 4 screw. No significant defects in any other screws were observed. The defect was considered a "seam" originating as a "hot tear" during original casting solidification of the alloy. Additionally, the examination of longitudinal sections of the screws revealed a uniform homogeneous microstructure in some groups, while in other groups the sections exhibited rows of second phase particles. The screws for some groups demonstrated severe deformation of the lower threads and the bottom part of the screw leading to the formation of crevices and grooves. Some NB screws were comprised of Au-based alloy with Pt, Cu, and Ag as alloy elements, while others (Groups 4 and 19) were Pd-based with Ga, Cu, and Au alloy elements. The microstructure was homogeneous with fine or equiaxed grains for all groups except Group 4, which appeared inhomogeneous with anomalous grains. SG screws demonstrated a typical dendritic structure and were Au-based alloy with Cu and Ag alloy elements. There were differences in the microhardness of gold alloy screws from NB and SG as well as palladium alloy screws from NB. Conclusions: Significant differences within NB retaining screws and between NB and SG screws were found for microstructure, major alloy constituents, and microhardness. [source]