Waste streams of hydrogen and helium mixtures are produced at the Kennedy Space Center during purging of the hydrogen systems and supply lines. This process is done prior to and after hydrogen servicing. The purged waste gases are lost to the atmosphere, resulting in an annual loss of 2 million and 0.1 million standard cubic meters of helium and hydrogen, respectively. Recovery of these gases will have an economic benefit. Metals, alloys, and intermetallics are known to react with hydrogen in favorable conditions; therefore, they have the possibility of serving as separating and recovery agents. In this study, Mg2Ni, VTiNi and LaNi5 were studied for the separation of H2 from He, using differential scanning calorimetry and thermal volumetric analysis. The ability of LaNi5 to react with hydrogen reversibly at room temperature was verified, and further analysis focused on this compound. Size reduction and activation of LaNi5 by mechanical milling was investigated using different milling parameters for the purpose of activating the material for hydrogen absorption. Because it has been shown that addition of aluminum to LaNi5 resulted in improved hydriding and dehydriding properties, that system was studied further here. In this study, aluminum was added to LaNi5 by mechanical milling. Hydriding properties and elemental compositions of the samples were determined afterwards. The hydrogen absorption rate and capacity were compared to that of LaNi5. Both LaNi5 and its Al doped derivatives exhibited a reduced rate of hydrogen uptake and a reduced hydrogen capacity in the presence of helium. The effects of coating the samples with either gold-palladium or platinum were investigated. It was observed that coating the samples with Pt reduced the negative effect of He, whereas AuPd coating did not have any effect. Larger scale studies were done using a continuous U-tube hydride reactor, built and tested for separation of H2¬ from a 20:80 H2:He mixture. The amount of hydrogen retained in the bed was determined and found to be less than that for the batch systems.

The twin objectives of the investigation were (i) to synthesize Al/Al2O3 metal matrix composites (MMCs) with uniform distribution of the Al2O3 reinforcement in the Al matrix and (ii) to evaluate the effect of volume fraction and size of the reinforcement on the mechanical behavior of MMCs. This was achieved by successful synthesis of Al-Al2O3 MMCs with volume fractions of 5, 10, 20, 30, and 50%, and particle sizes of 50 nm, 150 nm, and 5 µm of Al2O3 synthesized from blended component powders by a high-energy milling technique. A uniform distribution of the Al2O3 reinforcement in the Al matrix was successfully obtained after milling the powders for a period of 20 h with a ball-to-powder weight ratio of 10:1 in a SPEX mill. The uniform distribution of Al2O3 in the Al matrix was confirmed by characterizing these nanocomposite powders by scanning electron microscopy and X-ray mapping. The energy dispersive spectroscopy and X-ray diffraction techniques were employed to determine the composition and phase analysis, respectively. The milled powders were then consolidated for subsequent mechanical characterization by (i) magnetic pulse compaction (MPC) (ii) hot-isostatic pressing (HIP), (iii) vaccum hot pressing (VHP), and (iv) a combination of vaccum hot pressing and hot-isostatic pressing (VHP+HIP). However, successful consolidation of the powders to near-full density was achieved only through VHP+HIP for the 5 and 10 vol. % Al2O3 samples with 50 nm and 150 nm particle sizes. The fully dense samples were then subjected to mechanical characterization by compression testing and nanoindentation techniques. The strength and elastic modulus values obtained from compression testing showed an increase with increasing volume fraction and decreasing particle size of the reinforcement. The nanoindentation results were, however, contradictory, and the presence of residual stresses in the samples was attributed as the cause for the deviation in values.

<p> The purpose of this project was to develop an Adaptive Control Algorithm for a CNC milling machine. The milling machine is controlled by a 2100A Hewlett Packard mini-computer. The Adaptive Control Software has to operate in unison with an already available Numerical Control Software. Both these programmes are stored in the computer and the computer operates on them with the aid of the interrupt pulses received from the Time Base Generator located in the Controller.</p> <p> The Adaptive Control Software should be capable of optimising the milling process, that is enabling the milling machine to operate at the highest feed-rate without violating or overriding the maximum permissible values of the horizontal force and torque acting on the cutter. These maximum values of the force and torque are determined from the tool strength and capacities of the servo drives and spindle motor. Further, the machine should be able to arrive at the above feed-rate in the shortest possible time interval without causing cyclic variations in the feed-rate which could lead to an unstable system. The programme should be able to obtain ten samples of the parameters per revolution of the spindle. The feed-rate thus obtained (after comparing with the maximum and minimum feed-rates of the machine and making any corrections, if necessary) should be stored in a memory location accessible to the Numerical Control Programme. The instantaneous values of the force and torque are transmitted to the computer via the transducers attached on the spindle of the machine and the Analog-to-Digital Processor, therefore, the Adaptive Control Software will have to communicate with the Analog-to-Digital Processor in order to receive the values of the forces and torque. Thus the above mentioned requirements will have to be met by this piece of software. With this end in view, the following algorithm was developed.</p> <p> The algorithm consists of two portions, namely, the Data Reading Routine and the Policy Routine. The former accepts the two horizontal forces (which are phase shifted by 90°) and the torque acting on the cutter by communicating with the Analog-to-Digital Processor. However, all these three parameters are received through the same channel from the Analog-to-Digital Processor as such a method of identifying the variables was necessary. For this purpose, the Data Reading Routine consists of software capable of communicating with the Analog-to-Digital Processor at time intervals of 10 m.sec. and receiving the data in a digital form, decoding the input and ascertaining which input parameter was received. The Policy Routine has two modes of operation viz., the constraint and optimizing modes. This routine ascertains the critical error and arrives at the new feed-rate depending on the Policy used. After checking the value of this feed-rate with the maximum and minimum feed-rates available on the machine (and corrections made if necessary), the suitable value of this feed-rate is stored in a memory location accessible to the Numerical Control programme. This gives the general structure of the Adaptive Control Algorithm developed in this project.</p> / Thesis / Master of Engineering (MEngr)

Flood cooling is primarily used to cool and lubricate the cutting tool and workpiece interface during a machining process. But the adverse health effects caused by the use of flood coolants are drawing manufacturers' attention to develop methods for controlling occupational exposure to cutting fluids. Microlubrication serves as an alternative to flood cooling by reducing the volume of cutting fluid used in the machining process. Microlubrication minimizes the exposure of metal working fluids to the machining operators leading to an economical, safer and healthy workplace environment. In this dissertation, a vegetable based lubricant is used to conduct mist, microstructure and wear analyses during end milling AISI 1018 steel using microlubrication. A two-flute solid carbide cutting tool was used with varying cutting speed and feed rate levels with a constant depth of cut. A full factorial experiment with Multivariate Analysis of Variance (MANOVA) was conducted and regression models were generated along with parameter optimization for the flank wear, aerosol mass concentration and the aerosol particle size. MANOVA indicated that the speed and feed variables main effects are significant, but the interaction of (speed*feed) was not significant at 95% confidence level. The model was able to predict 69.44%, 68.06% and 42.90% of the variation in the data for both the flank wear side 1 and 2 and aerosol mass concentration, respectively. An adequate signal-to-noise precision ratio more than 4 was obtained for the models, indicating adequate signal to use the model as a predictor for both the flank wear sides and aerosol mass concentration. The highest average mass concentration of 8.32 mg/m3 was realized using cutting speed of 80 Surface feet per minute (SFM) and a feed rate of 0.003 Inches per tooth (IPT). The lowest average mass concentration of 5.91 mg/m3 was realized using treatment 120 SFM and 0.005 IPT. The cutting performance under microlubrication is five times better in terms of tool life and two times better in terms of materials removal volume under low cutting speed and feed rate combination as compared to high cutting speed and feed rate combination. Abrasion was the dominant wear mechanism for all the cutting tools under consideration. Other than abrasion, sliding adhesive wear of the workpiece materials was also observed. The scanning electron microscope investigation of the used cutting tools revealed micro-fatigue cracks, welded micro-chips and unusual built-up edges on the cutting tools flank and rake side. Higher tool life was observed in the lowest cutting speed and feed rate combination. Transmission electron microscopy analysis at failure for the treatment 120 SFM and 0.005 IPT helped to quantify the dislocation densities. Electron backscatter diffraction (EBSD) identified 4 to 8 µm grain size growth on the machined surface due to residual stresses that are the driving force for the grain boundaries motion to reduce its overall energy resulting in the slight grain growth. EBSD also showed that (001) textured ferrite grains before machining exhibited randomly orientated grains after machining. The study shows that with a proper selection of the cutting parameters, it is possible to obtain higher tool life in end milling under microlubrication. But more scientific studies are needed to lower the mass concentration of the aerosol particles, below the recommended value of 5 mg/m3 established by Occupational Safety and Health Administration (OSHA).

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