Table of contents

Preface

It is our great pleasure to welcome you to 2017 International Conference on Materials and Intelligent Manufacturing (ICMIM 2017) which was held during 21-23 August, 2017 in Singapore. ICMIM 2017 is dedicated to issues related to Materials and Intelligent Manufacturing.

The major goal and feature of the conference is to bring academic scientists, engineers, industry researchers together to exchange and share their experiences and research results, and discuss the practical challenges encountered and the solutions adopted. Professors from China, Japan and Singapore are invited to deliver keynote speeches regarding latest information in their respective expertise areas. It will be a golden opportunity for the students, researchers and engineers to interact with the experts and specialists to get their advice or consultation on technical matters, sales and marketing strategies.

This proceedings present a selection from papers submitted to the conference from universities, research institutes and industries. All of the papers were subjected to peer-review by conference committee members and international reviewers. The papers selected depended on their quality and their relevancy to the conference. The volume tends to present to the readers the recent advances in the field of materials processing technology and materials science, design and manufacturing systems, advanced design technology, etc.

We would like to thank all the authors who have contributed to this volume and also to the organizing committee, reviewers, speakers, chairpersons, sponsors and all the conference participants for their support to ICMIM 2017.

Prof. Jun Ding

National University of Singapore, Singapore

August 30, 2017

List of Conference Chairs, Technical Program Committee Chairs, Organizing Chair, Publication Chair, Technical Program Committee are also found in this pdf.

All papers published in this volume of IOP Conference Series: Materials Science and Engineering have been peer reviewed through processes administered by the proceedings Editors. Reviews were conducted by expert referees to the professional and scientific standards expected of a proceedings journal published by IOP Publishing.

Shielded metal arc welding (SMAW) process is one of the most commonly employed material joining processes utilized in the various industrial sectors such as marine, ship-building, automotive, aerospace, construction and petrochemicals etc. The increasing pressure on manufacturing sector wants the welding process to be sustainable in nature. The SMAW process incorporates several types of inputs and output streams. The sustainability concerns associated with SMAW process are linked with the various input and output streams such as electrical energy requirement, input material consumptions, slag formation, fumes emission and hazardous working conditions associated with the human health and occupational safety. To enhance the environmental performance of the SMAW welding process, there is a need to characterize the sustainability for the SMAW process under the broad framework of sustainability. Most of the available literature focuses on the technical and economic aspects of the welding process, however the environmental and social aspects are rarely addressed. The study reviews SMAW process with respect to the triple bottom line (economic, environmental and social) sustainability approach. Finally, the study concluded recommendations towards achieving economical and sustainable SMAW welding process.

In the process of micro milling stainless steel 310S, the influence of milling parameters (cutting depth, a_p, feed per tooth f_z, cutting speed v),and down and up milling method were revealed, which provides reference for controlling burrs of stainless steel 310S, improving surface quality and optimizing cutting process. Based on the orthogonal test method, the coated carbide micro diameter cutter was used and milling experiments were carried out on stainless steel 310S.Top burr size data information was collected and analyzed. Up milling is better than down milling because the shape and size of burr are relatively small. With the increase of cutting depth, the shape of burrs appears long fibrous and tearing and wavy serrated, which means the burr getting large and worse. In order to minimize burrs, it is the good way to choose the sharp cutting tools and up milling, control the cutting depth and select feed rate.

Super alloys are used to fabricate components in ultra-supercritical power plants. These hard to machine materials are processed using non-traditional machining methods like Wire cut electrical discharge machining and needs attention. This paper details about multi performance optimization of wire EDM process using Grey ANFIS. Experiments are designed to establish the performance characteristics of wire EDM such as surface roughness, material removal rate, wire wear rate and geometric tolerances. The control parameters are pulse on time, pulse off time, current, voltage, flushing pressure, wire tension, table feed and wire speed. Grey relational analysis is employed to optimise the multi objectives. Analysis of variance of the grey grades is used to identify the critical parameters. A regression model is developed and used to generate datasets for the training of proposed adaptive neuro fuzzy inference system. The developed prediction model is tested for its prediction ability.

One of the most common challenges for many of the mechanical engineers and also in the field of materials science is the issue of occurrences of wear of the material parts which is used in certain applications that involves such surface interactions. In this paper, wear behaviour of particular grade High Carbon High Chromium Steel and many most famously D2, H13, O1 known as the Viking steel has been studied, evaluated and analyzed under certain processing parameters such as speed, load, track diameter and time required for deep drawing process to know it's the wear rate and coefficient of friction. Also, the significance of the processing parameters which is used for wear testing analysis is also examined.

The effect of the rapid cryogenic treatment on hardness and wear resistance of several kinds of tool steel was examined. Two ways of cryogenic cooling were evaluated: direct immersion of the metallic samples into liquid nitrogen and three-stage rapid cryogenic cooling (1 – precooling in LN₂ to -20°C, 2 – formation on the sample of a frost layer from air by natural humidity, 3 – second cooling of the frost-covered sample in LN₂ to -195.7°C). Material in "as is" conditions and after a preliminary heat treatment (850°C) were used as the reference points.

The HV microhardness and the wear rate under dry abrasive friction were evaluated. Despite the very different types of the examined metals' nature, microstructure, and hardening mechanisms, the rapid cryogenic cooling improves both the hardness and the wear resistance values. For all investigated metals rapid cryogenic cooling assisted with the frost layer produces the best results.

Minimum quantity lubrication (MQL) is a cutting fluid (CF) application method that has given promising results in improving machining performances. It has shown that, the performance of cutting systems, depends on the work and tool materials used. AISI P20, and D2 are popular in tool making industry. However, the applicability of MQL in machining these two steels has not been studied previously. This experimental study is focused on evaluating performances of MQL compared to dry cutting, and conventional flood cooling method. Trials were carried out with P20, and D2 steels, using coated carbides as tool material, emulsion cutting oil as the CF. Tool nose wear, and arithmetic average surface roughness (Ra) were taken as response variables. Results were statistically analysed for differences in response variables. Although many past literature has suggested that MQL causes improvements in tool wear, and surface finish, this study has found contradicting results. MQL has caused nearly 200% increase in tool nose wear, and nearly 11-13% increase in surface roughness compared flood cooling method with both P20 and D2. Therefore, this study concludes that MQL affects adversely in machining P20, and D2 steels.

In this work, biodegradation behavior of poly (lactic acid) (PLA) and crosslinked PLA filled with two types of SiO₂, precipitated SiO₂ (commercial SiO₂) and SiO₂ from rice husk ash, were studied. Rice husks were first treated with 2 molar hydrochloric acid (HCl) to produce high purity SiO₂, before burnt in a furnace at 800°C for 6 hours. All components were melted bending by an internal mixer then hot pressed using compression molder to form tested specimens. FTIR spectra of SiO₂ and PLA samples were investigated. The results showed the lack of silanol group (Si-OH) of rice husk ash after steric acid surface modification, while the addition of particles can affect the crosslinking of the PLA. For biodegradation test by evaluating total amount of carbon dioxide (CO₂) evolved during 60 days incubation at a controlled temperature of 58±2°C, the results showed that the biodegradation of crosslinked PLA occurred slower than the neat PLA. However, SiO₂ incorporation enhanced the degree of biodegradation In particular, introducing commercial SiO₂ in PLA and crosslinked PLA tended to clearly increase the degree of biodegradation as a consequence of the more accelerated hydrolysis degradation.

Liquefaction is known to be an effective method for converting biomass into a biopolyol. The biomass liquefaction of oil palm fruit waste (PFW) in the presence of liquefaction solvent/polyhydric alcohol (PA): polyethylene glycol 400 (PEG400) using sulfuric acid as catalyst was studied. For all experiments, the liquefaction was conducted at 150°C and atmospheric pressure. The mass ratio of OPFW to liquefaction solvents used in all the experiments was, 1/3. Thermogravimetric analyses (TGA) were used to analyze their biopolyol and residue behaviors. It was found that thermal stability of oil palm mesocarp fibre (PM), oil palm shell (PS) and oil palm kernel (PK) fibre exhibited the first degradation of hard segment at (232, 104, 230°C) and the second degradation of soft segment at (314, 226, 412°C) as compared to PM, PS and PK residue which (229, 102, 227°C) of hard segment and (310, 219, 299°C) of segment, respectively. This behavior of thermal degradation of the hard segment and soft segment of biopolyol was changes after undergo solvolysis liquefaction process. The result analysis showed that the resulting biopolyol and its residue was suitable monomer for polyurethane (PU) synthesis for the production of PU foams.

This study investigates the acoustic properties of polymer foam composites (FC) filled with natural fiber. The FC were produced based on crosslinking of polyol, with flexible isocyanates and wood filler. The percentages of wood filler loading are 10, 15, and 20 wt% ratio of polyol. The FC also has a thickness of 10, 20 and 30 mm. The acoustic properties of the FC were determined by using Impedance Tube test, Optical Microscope (OM) and Mettler Toledo Density Kit test. The results revealed that FC20 with 30 mm in thickness gives the highest sound absorption coefficient (α) with 0.970 and 0.999, at low and high frequency respectively. FC20 also shows smallest pores structures size with 134.86 μm and biggest density with 868.5 kg/m³ which helps in absorbing sound. In this study, FC with different percentage loading of wood filler and different foam thickness shows the ability to contribute the absorption coefficient of polymeric foam at different frequency levels. Lastly, this type of FC is suitable for any type of sound absorption applications material.

A novel technique for producing stretchable and flexible conductive polyurethane nanofibrous membrane for flexible electronics applications has been developed. One of the most important challenges in fabricating polymeric membranes for flexible electronics is to enhance its sensitivity and conductivity maintaining its flexibility and stertchability. Wet electrospinning technique was used to fabricate thermoplastic polyurethane (TPU) nanofibers through a coagulant bath of a conductive grade co-polymer poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate) (PEDOT: PSS). A Kapton sheet was used as a substrate to load TPU/PEDOT: PSS nanofibers on it. The morphology and stability of the as-spun TPU/PEDOT: PSS nanofibers has been investigated. The fabricated TPU/PEDOT: PSS nanofibrous membrane has showed a well stabilized ohmic behaviour under a wide range of different temperatures up to 90 °C as well as different values of tensile strain up to 4.43 %, which makes it suitable for high temperature strain sensing applications.

The paper shows method of smart forming composite structures and fundamentals of propose fabrication technology. The presented method is based on innovative 3D printing technics with SMA (Shape Memory Alloy) fibres application. The SMA fibres layout cause an eccentric axial load after thermal activation. The result of this process is composite structures deflection in a predictable direction. The technology demonstrator sample was fabricated as well as numerical simulations were performed in aim of proof of concept. The identification process was developed to determine the layout of SMA fibres. The simulations were performed in MATLAB and ANSYS environment, where the genetic algorithm was used to identify geometrical parameters. The MAC (Modal Assurance Criterion) criterion was used to compare nodal solution with the predefined shape pattern. The simulation results shows possibilities of forming composite structures on the example of deflected beam.

Wear properties of aluminum matrix composites reinforced with silicon carbide particulate of 10 vol.% addition was investigated in as-sintered and heat-treated conditions under varying loads at -5, -25, -45 and -65N using a ball on flat type of wear test. The composite was fabricated by powder injection molding and sintering at 650 °C for 3 hours. Solution treatment was carried out at 550 °C for 2 hours followed by age-hardening at 160 °C for 6 hours. SEM and XRD results indicated Al and SiC_p are present as matrix and reinforcement, while AlN, Al₂Cu and Mg₂Si were also detected. Further precipitation of Al₂Cu and Mg₂Si in heat-treated samples promoted maximum macro and micro Vickers hardness values, which were achieved at 161 and 157 H_v respectively. Wear weight loss increased with increasing minus load level. The coefficient of friction was found in the range of 0.042-0.048. Wear mechanisms were determined as the combination of abrasive, adhesion and oxidation.

In this study, the fatigue crack propagation behaviour in the Al alloy-hybrid MMC bi-material system has been investigated. Three-point bending fatigue test is carried out on the Shimadzu servopulser machine. The plastic replica technique is used to observe the crack growth during cyclic loading. The crack growth rate is analyzed at different stress intensity factor range, ΔK. The experimental results showed that the crack growth decelerates in the MMC layer side and maximum crack retardation occurs on the boundary of the bi-material system. Near the boundary of the bi-material, the crack tip becomes curved, which reduces the crack growth rate in the vicinity of the boundary of the bi-material even at higher ΔK. The particle-matrix interfacial debonding, as well as particle fracture, is observed in the hybrid MMC layer during fatigue loading.

Adsorption energy and partial density of states of S at three typical positions on 4H-SiC (001) surface were calculated which based on the density functional theory (DFT).The results show that S adsorption is the most stable in the bridge position and unstable in the hollow. The density of states near the Fermi level can be effectively reduced by using the S atom on the surface of 4H-SiC. The adsorption and desorption of CO on the surface of S passivated 4H-SiC at different applied electric fields were calculated by selecting hollow of S atom adsorption. It turned out that the positive electric field is not conducive to the adsorption of CO and the reverse is favorable for adsorption, but when the forward electric field F is greater than 2eV/Å/e the desorption behavior of S atom is more obvious. Because of the S atom is positively charged which made the Si-C bond length increases rapidly under the action of electric field.

In this paper, a 2D Halbach array with the hexagon permanent magnets is introduced. The expression of magnetization intensity is derived by superposition principle and Fourier series. The expression of magnetic flux density is derived by magnetic scalar potential and method of separation of variables. The assumption of the relative permeability of magnet equals 1.0 is needless because of the compact structure. The accuracy of the expression is verified by comparing with the finite element model. The expression can be directly used in real time control by selecting the proper iteration steps for the coefficients.

Elastomers are used in a wide variety of structural and engineering applications. They exhibit a nonlinear elastic stress-strain behaviour known as hyperelasticity which is generally described by hyperelastic strain energy functions. The question raised in the current study was; which model can accurately describe and predict the actual behaviour of the elastomer nanocomposites. The tensile data were used to fit the various elastomeric material models available in MSC.MARC finite element analysis package. The relative percentage error was calculated to determine the goodness of fit in order to select the best model. Numerical results showed that the third order deformation model was the best among the various material models since giving a maximum relative error of fit was 2.7% at small and large strains. To verify the effectiveness of third order deformation model, FE simulations for tensile test was carried out. The results showed that the third order model is sufficiently enough to regenerate the experimental data for uniaxial test and efficiently capture the hyperelastic behavior as good as the experiments.

In this paper, a simple and efficient edge detection technique is proposed. It is based on the properties of the hyper smoothing function and the fundamentals of modified local binary pattern and hence, called as HY-LBP. The main advantage of the proposed approach is that the relationship between surrounding pixels and centric one is calculated effectively and extract the surrounding information discriminatively. The counting scheme that counts the number of image points whose pixel values are greater or equal than that of the central pixel help to reduce the noise and blurring effects. Thus, HY-LBP can effectively deal with the noises, blurring, and contrast variation. The effectuality and feasibility of the proposed approach is demonstrated on various synthetic and real time images. Experimental results have shown the effectiveness as well as the better performance of the proposed approach for edge detection as compared to the other existing methods. The presented method can be used in metal sheet defect detection applications.

When laser work continuously, laser and external environment will cause damage to the laser window. The paper analysis the working environment of the equipment and the main factors that cause the window damage. Emulate mirror deformation of the laser emission window under the coupling of force and heat, fit the shape change law of different material windows in force thermal coupling by MATLAB. The results show that high energy laser will have a serious influence on the surface microstructure of windows, splicing window can greatly reduce the influence of window deformation on laser emission, ZnSe' characteristic of materials is best suited for producing wide band iraser emission windows.

The motion control system which is constructed by using the programmable controller and the motion controller has been widely applied to various mechanical systems. This paper takes a cross slide as an example, the motion control system is composed of the GE FANUC PAC and DSM324i, and the movement performance simulation model is established. The motion performance by linear acceleration and deceleration algorithm in the case of two axis synchronous movement is analyzed. The relation between the displacement command and the parameters of the acceleration and the velocity is derivated, and the trajectory curve of movement performance under a variety of instruction is gained. The control instruction meet the linear motion is designed by the model.

Sustainable development has been recognized globally as one of the major driving forces towards the current technological innovations. To achieve sustainable development and attain its associated goals, it is very important to properly address its concerns in different aspects of technological innovations. Several industrial sectors have enjoyed productivity and economic gains due to advent of automation technology. It is important to characterize sustainability for the automation technology. Sustainability is key factor that will determine the future of our neighbours in time and it must be tightly wrapped around the double-edged sword of technology. In this study, different impacts of automation have been addressed using the 'Circles of Sustainability' approach as a framework, covering economic, political, cultural and ecological aspects and their implications. A systematic literature review of automation technology from its inception is outlined and plotted against its many outcomes covering a broad spectrum. The study is more focused towards the social aspects of the automation technology. The study also reviews literature to analyse the employment deficiency as one end of the social impact spectrum. On the other end of the spectrum, benefits to society through technological advancements, such as the Internet of Things (IoT) coupled with automation are presented.

Packaging technology of the micromachined quartz tuning fork gyroscopes by vacuum welding has been experimentally studied. The performance of quartz tuning fork is influenced by the encapsulation shell, encapsulation method and fixation of forks. Alloy solder thick film is widely used in the package to avoid the damage of the chip structure by the heat resistance and hot temperature, and this can improve the device performance and welding reliability. The results show that the bases and the lids plated with gold and nickel can significantly improve the airtightness and reliability of the vacuum package. Vacuum packaging is an effective method to reduce the vibration damping, improve the quality factor and further enhance the performance. The threshold can be improved nearly by 10 times.

In this paper, a computer aided system for parametric design of combination dies is presented. The system is developed using knowledge based system technique of artificial intelligence. The system is capable to design combination dies for production of sheet metal parts having punching and cupping operations. The system is coded in Visual Basic and interfaced with AutoCAD software. The low cost of the proposed system will help die designers of small and medium scale sheet metal industries for design of combination dies for similar type of products. The proposed system is capable to reduce design time and efforts of die designers for design of combination dies.

High-density cement mixed with crumb rubber has been studied to be a gamma ray and neutron shielding material, especially for photonuclear reactions that may occur from accelerators where both types of radiation exist. The Buildup factors from gamma ray scattering, prompt and secondary gamma ray emissions from neutron capture and mechanical properties were evaluated. For buildup factor studies, two different geometries were used: narrow beam and broad beam. Prompt Gamma Neutron Activation Analysis (PGNAA) was carried out to determine the prompt and secondary gamma ray emissions. The compressive strength of samples was evaluated by using compression testing machine which was central point loading crushing test. The results revealed that addition of crumb rubber increased the buildup factor. Gamma ray spectra following PGNAA revealed no prompt or secondary gamma ray emission. Mechanical testing indicated that the compressive strength of the shielding material decreased with increasing volume percentage of crumb rubber.

Porous aluminum was fabricated using space holder process. The spherical carbamide powder and silica sand were used as space holder and reinforcement materials, respectively. Aluminum powders were mixed with five different silica sand contents and were then mixed with 10 wt.% carbamide powder. The mixed powders were cold compression at 400 MPa and sintered at 550 °C for 5 hours. Microstructure of specimen was characterized by scanning electron microscope. Hardness and compressive strength were also investigated in this study. It was found that microstructure and mechanical properties of porous aluminum strongly depended on silica sand contents. From SEM observation, it is clearly seen that addition of silica sand led to increasing pore in the porous aluminum. Mechanical properties of porous aluminum can be enhanced by silica sand particle reinforced.

With the rapid development of economy in China, the requirement for railway passenger and cargo transportation becomes higher and higher. Increasing speed and developing heavy-haul transportation can effectively improve the transportation capacity of railway. The requirement for rail steels with higher ability of abrasion resistance becomes urgent. Two kinds of rails, i.e., 880 MPa-grade and 980 MPa-grade rail steels, were laid on cargo line with 500 m short radius curve. The service performances of the tested steels were continuously tracked and analyzed during operation of total 22.5 million tons loads. Macro morphology, light band width, surface hardness and profile of rails were investigated. The results show that the performance of 980 MPa-grade rail steel is superior to that of 880 MPa-grade rail steel at same circumstance. Therefore, 980 MPa-grade rail should be selected in the cargo line with small radius curve.

Red scale is a kind of strip surface defects which usually appear in Si-containing steels, so that it is important to study the oxidation process of Si-containting steels in order to control this defect. In the prsent study, oxidation epxeriments at different temperatures were conducted for a Si-containing steel, and the morphologies of the oxide scale in the Si-containting steel were investigated. The results show that the oxide scales of the Si-containing steel mainly consist of three layers. The outer layer is Fe₂O₃, the middle layer contains FeO and Fe₃O₄, and the inner layer is composed of of Fe₂SiO₄ and FeO. When the heating tmepraure is above the melting temperature of Fe₂SiO₄ (1173 °C), FeO distributes on Fe₂SiO₄ in the form of dot or lamella and Fe2SiO4 shows net-like morphology. However, when the heating temperate is below 1173 °C, no FeO is observed within Fe₂SiO₄ and Fe₂SiO₄ is blocky. In addition, the distribution of Si mainly concentrates in the inner layer and the concentration of oxigen decreases from the outer layer to the inner layer.

The article describes the results of studying the problems of industrial wastewater treatment using higher aquatic vegetation (hydrophytes) in the former mining enterprise of the Far Eastern Federal District (FEFD). They are aimed at reducing the negative environment impact of toxic tin ore wastes. The material of research were drainage, mine and slime waters as well as Lemna minor and Common reed grass (Phragmites communis). In the work conventional modern physico-chemical, chemical, biological and mathematical-statistical methods were used, as well as in the process of research the methods of atomic absorption spectrophotometry for AAS and mass spectrometry with inductively coupled plasma on ISP-MS ELASN DRS II PerkinElmer was applied.

The data obtained in the course of the experiment (2015-2016), indicate that a degree of wastewater treatment, using Lemna minor, is high. Virtually, all compounds of toxic chemical elements contained in industrial wastewater (zinc, cobalt, nickel, cadmium, iron, manganese, lead, etc.) were fully absorbed by a hydrophyte. Pollutant extraction was almost 95%. The obtained results of the study in laboratory conditions proved the possibility of effective use of the Lemna minor for the purification of drainage and mine waters.

A key contribution of this paper is the relationship between possible toxic metals contained in industrial wastewater and a higher degree of absorption by their higher aquatic vegetation. These hydrophytes absorb these possible toxic metals in an aqueous medium and are contaminated with these heavy metals.