High operation speeds and thin coating films are desirable in many industrial applications. But the quality of the product, which is primarily determined by an optimum process window, is affected by non-uniformities and instabilities originating at higher operation speeds. Unlike other academic works, because of associated industrial relevance, particular attention was given towards the use of industrially relevant coating systems or generation of model fluids, which replicate the real coating solutions. One of the novelties of the research proposed lie in an integrated approach, utilising a range of comparative rheometrical techniques, with a focus on measurement of: (i) high strain rate shear viscosity [η], (ii) high strain rate uniaxial extensional viscosity [ηE] (iii) high strain rate elasticity (N1). Deformable roll coating, in terms of classification, is the ultimate metered coating flow. The flow is controlled by the combination of hydrodynamic force and elastic deformation effect, which could be complicated by the presence of non-Newtonian fluid. This study necessitated the design and construction of a sophisticated deformable coating rig with the ability to operate over a wide range of conditions. Although the irregularities and instabilities associated with the roller coating process has been studied previously, the concerned speeds of operation in this study is around three times higher. The main objectives of this study was to carry out a comprehensive experimental programme establishing relationship exist between film thickness, film quality and operating parameters. Main identified operating parameters are roll speeds, roll gaps or applied load between the rolls, the elasticity with thickness of elastomeric layer and different rheological properties of the coating fluids. Surface instabilities and air entrainment are identified as the major limitations to being able to coat at higher speeds. / Tata Steel Europe / The full text was made available at the end of the embargo, 1st July 2020

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The Superpave mix design system is being adopted by most of the states in the Unites States. Since the Superpave system was developed on the basis of data mostly obtained from medium to high traffic volume roads, there is a need to develop criteria for mix design for Hot Mix Asphalt (HMA) mixes for low traffic volume roads. In this study funded by the six New England states, research was carried out to develop a proper mix design system for low volume roads from the standpoint of durability properties and then, once a good mix design system was available, check it to determine if it meets required strength properties. For low volume roads the performance is primarily affected by the environment and not by traffic, the approach in this study has been to determine the optimum value of a key volumetric property and an optimum number of design gyrations for producing compacted HMA mixes with adequate resistance against aging/high stiffness related durability problems. Six mixes were obtained in which only one can be characterized as a fine mix, and the remaining five were all relatively close to the maximum density line - three of them were with 9.5 mm Nominal Maximum Aggregate Size (NMAS), and the other two were with 12.5 mm NMAS. Based on the results from performance testing, film thickness of 11 microns in samples compacted to 7 percent voids was found to be desirable from considerations of stability and durability and a design VMA of 16 percent was determined to be optimum for producing durable and stable mixes for low volume roads. Results from testing of in-place mixes from good performing 10 to 12 year old low volume roads indicated a design gyration of 50 for obtaining a void content of 4 percent for mixes with gradations close to the maximum density line.

Modelling the ice accretion in glaze regime for the supercooled large droplets is one of the most challenging problems in the aircraft icing field. The difficulties are related to the presence of the liquid water film on the surface in the glaze regime and also the phenomena associated with SLD conditions, specifically the splashing and re-impingement. The steady improvement of simulation methods and the increasing demand for highly optimised aircraft performance, make it worthwhile to try to get beyond the current level of modelling accuracy. A semi-empirical method has been presented to characterize the thin water film in the icing problem based on both analytical and experimental approaches. The experiments have been performed at the Cranfield icing facilities. Imaging techniques have been used to observe and measure the features of the thin water film in the different conditions. A series of numerical simulations based on an inviscid VOF model have been performed to characterize the splashing process for different water film to droplet size ratios and impact angles. Based on these numerical simulations and the proposed methods to estimate the thin water film thickness, a framework has been presented to model the effects of the splashing in the icing simulation. These effects are the lost mass from the water film due to the splashing and the re-impingement of the ejected droplets. Finally, a new framework to study the solidification process of the thin water film has been explored. This framework is based on the lattice Boltzmann method and the preliminary results showed the capabilities of the method to model the dynamics, thermodynamics and the solidification of the thin water film.

Modelling the ice accretion in glaze regime for the supercooled large droplets is one of the most challenging problems in the aircraft icing field. The difficulties are related to the presence of the liquid water film on the surface in the glaze regime and also the phenomena associated with SLD conditions, specifically the splashing and re-impingement. The steady improvement of simulation methods and the increasing demand for highly optimised aircraft performance, make it worthwhile to try to get beyond the current level of modelling accuracy. A semi-empirical method has been presented to characterize the thin water film in the icing problem based on both analytical and experimental approaches. The experiments have been performed at the Cranfield icing facilities. Imaging techniques have been used to observe and measure the features of the thin water film in the different conditions. A series of numerical simulations based on an inviscid VOF model have been performed to characterize the splashing process for different water film to droplet size ratios and impact angles. Based on these numerical simulations and the proposed methods to estimate the thin water film thickness, a framework has been presented to model the effects of the splashing in the icing simulation. These effects are the lost mass from the water film due to the splashing and the re-impingement of the ejected droplets. Finally, a new framework to study the solidification process of the thin water film has been explored. This framework is based on the lattice Boltzmann method and the preliminary results showed the capabilities of the method to model the dynamics, thermodynamics and the solidification of the thin water film.

Oil loss mechanisms in internal combustion engines have been subject to many researches. By the help of technological developments effects of several problems due to oil losses were examined and tried to be reduced. Environmental pollution and performance loss are important issues that oil consumption in internal combustion engines contribute. In this study the effects of individual parameters on the oil accumulation in 2nd land crevice of internal combustion engines, volume between top compression rings, were investigated. The study aimed to investigate the effects of oil film thickness and oil film temperature on the oil accumulation in the 2nd land which contributes to one of the mechanisms of oil consumption in internal combustion engines. Controlled experiments were performed on a modeled piston cylinder assembly. It was seen that oil accumulated in the 2nd land crevice by blow-by gases was affected by the film thickness of lubricating oil and the temperature of the lubricating oil. The amount of oil accumulated increased with increasing oil film thickness. The results also showed that below oil film thickness of 45 &amp / #956 / m / amount of oil accumulated increased with the increase of oil temperature.

Machines operating in dusty environments, such as mining and civil works, are prone to premature failure, leading to production losses. To address this problem, this research project examines the interaction between solid contaminants and the bearing micro-geometry, in lubricated surface contacts. In particular, it seeks to identify anti-wear additives that are effective in reducing wear under abrasive conditions, making machine elements more dirt tolerant. In general, the influence of antiwear additive is so small that it is difficult to isolate it. Manufactures often make claims about their antiwear products, which are difficult to verify. Hence, there is a need to characterising the antiwear additives available with a well-defined parameter, making it easier for consumers to compare the efficacy of various additives, and be able to select the most suitable additive for a given environment. Effect of micro-geometry parameters such as radial clearance, out-of-roughness and surface roughness was examined and a Film Shape Factor (FSF) – also termed gamma ratio – has been proposed for ensuring adequate separation of journal bearings operating in hydrodynamic lubrication regime, where the out-of-roundness values are higher than the surface roughness values. In this research, an experimental study has been conducted on journal bearings, to examine the influence of five antiwear additives on the bearing wear and micro-geometry. The test additives were provided by the industry partner without revealing their chemical identity or composition; however, these included some of the most commonly used antiwear additives. The tests were performed under three conditions: pure base oil, base oil containing contaminants, and base oil containing contaminants treated with five different additives. The experiments were aimed at choosing one wear measuring technique that evaluates the performance of an individual additive reliably, and based on this technique the additives were characterised. To achieve these objectives, a multi-wear parameter approach (MWPA) was developed, which employed three main wear measurement methodologies, i.e. weight loss, micro-geometry and particle counts –to examine the effect of the antiwear additives. Minimum oil film thickness was also measured to study the lubrication status in the bearing contacts. The MWPA helped in comparing different wear measuring methods, and in selecting the most reliable one. This approach also helped in developing short duration wear tests, thereby saving time, while still getting reliable results without repeating these. Wear experiments were performed on seven sets of bronze bearings and steel sleeve shafts. The test contaminant was 16 micron Aluminium oxide Al2O3 powder mixed in oil with 4% concentration by weight. These solid contaminants were treated with five different antiwear additives to study their influence on the bearings. Bearings were operated such that the minimum oil film thickness in the bearing was equal to the size of the contaminants. These tests were run for a constant sliding distance of 7536m. The results showed that most of the wear measuring techniques do not suit heavily contaminated test conditions. However, the out-of-roundness technique proved to be the most reliable and practical. Based on this technique a methodology was developed which gave a wear characteristic number (N). A unique value of N can be derived for each additive, thereby ranking the additives for their efficacy. The finding of this research provides a better understanding of the methodologies used for measuring wear in journal bearings subjected to dusty environments, and examines the efficacy of each one of these. The wear characteristic number (N) can be used by manufacturers with support from international standards organisations, so that the users can confidently choose the most appropriate antiwear additive for their application. Machines operating in a dusty environment, such as mining industry and civil works are prone to premature failure with subsequent production losses. In response to this problem, this research project examines the interaction between solid contaminant particles and the lubricant film micro-geometry in lubricated surface contacts. In particular, it seeks to identify lubricant anti-wear additives, which are effective in reducing wear under abrasive conditions and thus making machine elements more dirt tolerant.

The internal combustion engine is still at the heart of the vast majority of vehicles manufactured worldwide today. For these applications reciprocating pistons are typically employed to convert the pressures generated by internal combustion into mechanical work required by the vehicle. Of the energy supplied to the engine as a whole approximately 17% is lost by means of mechanical friction. The piston ring - liner and piston skirt - liner conjunctions contribute approximately 30% of the overall friction losses in almost equal proportions. It is, therefore, important to note that reduction in piston assembly friction would have a significant effect on the fuel consumption and, therefore, performance of engines manufactured today. In order to reduce the effect of friction it is of critical importance that the model and predictions made alongside the design of engine components accurately represent the real incycle conditions encountered in practice. Much of the published research to date has excluded the effects of global thermo-elastic distortions on the lubrication of the piston skirt. In cases where this effect has been studied, it has been for relatively low engine speeds or loads on relatively stiff conjunctions. In motorsport applications the expected component lifespans are much shorter than in the usual OEM production vehicles. Reduction in component mass, particularly in reciprocating components has been at the centre of these recent gains. The effect of mass reduction coupled with the increased BMEP observed in high performance engines emphasises the importance of underlying mechanisms of lubrication. This thesis develops the modelling methodology for piston skirt-cylinder liner conjunction for the motorsport and high performance engine applications. It presents a multi-body, multiscale approach to the prediction of the lubrication conditions of the skirt-liner conjunction, incorporating realistic measured boundary conditions. It highlights the effect of inertial loading observed at high speeds in such applications. Using the methodology developed in this work, future improvements in friction may be accurately predicted though the use of the modular boundary and component contributions used throughout. Crucially though, the models created have been scrutinised and verified using instantaneous ultrasonic film thickness measurements non-invasively from the conjunction. One of the key findings of the thesis is that the component stiffness profiles have a significant effect on the dynamics of the piston assembly. The shape of the conjunction at a given instant, and thus the contact condition, is largely governed by the interaction between the themo-mechanical distortion of the contiguous solids, as well as changes in lubricant characteristic responses. The iso-viscous elastic mechanism of lubrication has been identified as being the dominant mechanism of lubrication.

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