Proceedings of Modern materials and methods in Engineeing

MODERN MATERIALS & METHODS IN ENGINEERING

ISTE Short Term Training Programme

2nd to 14th May, 2011

Coordinators

Dr. Job Thomas Dr. K.K. Saju

Organized by

School of Engineering COCHIN UNIVERSITY OF SCIENCE AND TECHNOLOGY

Kochi – 682022, Kerala

Proceedings of ISTE-STTP on Modern Materials and Methods in Engineering02nd to 14th May 2011

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School of Engineering, Cochin University of Science and Technology Kochi – 682 022, Kerala

Contents

Sl. No.

Title Author Page No.

1 Introduction to modern materials P.S. Sreejith, Cusat 1 2 Polymer nanocomposites K.E. George, Cusat 2 3 Optoelectronic thin films and materials M.K. Jayaraj, Cusat 3 4 Biopolymers, DNA and protein and its

engineering Sarita G. Bhat, Cusat 4

5 Materials for photonic applications V. P. N. Nampoori, Cusat 5 6 Strategies for sustainable manufacturing G. Madhu, Cusat 6 7 Nondestructive testing M.M. Abdulla,. Limra 8 8 Surface preparation and painting Gopinath, Limra 9 9 Advanced aerospace materials Tide PS, Cusat 10 10 Simulation of materials & manufacturing

processes with MSC software Madeshwara S K, CSM

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11 Corrosion control by methods and materials

A. Mathiazhagan, Cusat

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12 Sustainable material for soil and water conservation in the context of Kerala

Subha V, Cusat

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13 Modern cements and its application M.A. Joseph, UltraTech 14 14 Lightweight concrete Glory Joseph, Cusat 15 15 Laterized concrete for fire protection George Mathew, Cusat 16 16 Sustainable materials and construction Deepa G. Nair, Cusat 17 17 FRP applications in civil engineering S. Ramadass, Cusat 18 18 Fibre reinforced concrete Job Thomas, Cusat 19 19 Earthquake proofing methods in

skyscrapers Job Thomas, Cusat 20


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INTRODUCTION TO MODERN MATERIALS

Prof. P.S. Sreejith Division of Mechanical Engineering, School of Engineering, CUSAT

Mob.: 9447812820, E-mail: [email protected]

ABSTRACT The development of mankind is defined in terms of advances in materials: The Stone Age, The Bronze Age, and The Iron Age. The dramatic advances in architecture and building introduced by the Roman Empire were possible only because of the invention of a new material - concrete. The Industrial Revolution was to a large extend made possible by advances in the use of materials in industrial equipment, as was the rapid development of the railroads in the late nineteenth century, and the skyscrapers that began to define the skylines of American cities in the early twentieth century. In the last half century, the growth of materials technology has been explosive, and its impact on our daily lives, pervasive. Beginning with the invention of the transistor in the 50's, the electronics revolution, enabled by advances in materials, has dramatically and irreversibly changed our lives. Some of us remember the sage career advice given to Dustin Hoffman in the 1960's film The Graduate - "Plastics". The use of plastics is now so widespread that it is difficult to imagine life without them. The double edged sword inherent in the use of new technologies is apparent in today's concern with the disposal of non biodegradable plastics. While ceramics were the first Engineering Materials, finding application as building materials and pottery in the Stone Age, recent technological advances combined with their unique electrical properties, hardness, durability and heat resistance are making ceramics the material of the future. One of the most recent Nobel Prizes for Physics was awarded to Bednorz and Mueller of IBM for the discovery that certain complex ceramic materials will conduct electricity without resistive loss at temperatures substantially higher than those for conventional metallic superconductors. Artificial diamond is on the verge of having major impacts on fields as diverse as optics, wear coatings, and substrates for electronic circuits. In the near future, we can expect to find major advances in the use of ceramics in applications as diverse as microelectronics, superconductors, automotive and aircraft engines, prosthetic implants, and chemical process equipment. Today's fundamental research activities in the Universities and Research Laboratories give us confidence that we have not seen the end, but rather only the beginning, of advances in Materials Science and Technology that will profoundly affect the way we live our lives. We can expect to see biodegradable plastics produced by genetically engineered microbes, structural materials that are analogs of naturally occurring materials such as shell or bone, improved bioengineered materials to replace joints, bone tendons and skin, super hard materials with hardness greater than that of diamond, aircraft skins that can detect and respond to changes in ambient conditions or to structural damage, bridges made of strong, light weight fiber reinforced plastic composites, and road surfaces that will last for a human lifetime. We have just begun to see the impact of the Materials Revolution.


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POLYMER NANOCOMPOSITES

Prof. K.E. George Department of Polymer Technology, CUSAT


INTRODUCTION Today Polymers constitute an important class of engineering materials along with metals and ceramics. Eventhough polymers are not as strong as metals or cannot resist high temperatures/adverse conditions like ceramics there are many factors in the favour of polymers such as light weight, easy processability, corrosion resistance etc. Hence more and more engineering products are now being made from polymers replacing traditional materials. One great advantage of polymers is that their properties can be varied over a wide range by blending with other polymers or by adding modifying additives. When the reinforcement is the objective, rubbers are usually modified with particulate fillers like carbon black and plastics with fibrous fillers like glass. GRP (Glass reinforced Plastics) is usually a termoset plastic like polyester or epoxy reinforced with long fibres. But thermosets are not sutable for mass production techniques such as extrusion or injection moulding. Hence the most common method of reinforcing thermoplastics is by short fibres. With the advent of nanofillers the polymer modification scenario is undergoing a sea change. Nanofillers, due to their large surface area, are capable of reinforcing both plastics and rubbers and the loading required for efficient reinformcement is typically below five weight percentage. The principal types of nanofillers are carbon nanotube, nanoclay, nanosilica etc.

REINFORCEMENT OF POLYETHYLENE TEREPHTHALATE (PET) BY CARBON NANOTUBES

It is observed that carbon nanotube acts as an efficient nucleating agent for PET and hence the crystallization of the polymer takes place at 10 to 20�C higher than that of pure PET even though the percentage crystallinity remains more or less unaffected. This means that carbon nanotube modified PET can be demoulded from an injection mould at a higher temperature and hence the production rate can be increased. Further, carbon nanotube modification is found to improve mechanical properties like tensile strength, tensile modulus, storage modulus, impact strength etc. significantly. All these improvements can be achieved when the carbon nanotube is added to PET in the molten stage. However, if the carbon nanotube is added to a dilute solution of PET the nanofiller can be dispersed more uniformly and hence the properties can be substantially improved.

REINFORCEMENT OF POLYPROPYLENE (PP) BY NANOCLAY AND NANOSILICA Nanoclay and Nanosilica are found to be efficient nucleating agents for PP by enhanceing the onset of crystallization as in the case of PET. Also these nanofillers are found to be efficient reinforcing agents for polypropylene. Another significant observation is that when nanofillers are added along with glass fibres synergistic composites are obtained. The reinforcement obtained by about 30% glass fibre alone can be matched by 10% glass fibre and 1% nanofiller.


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OPTOELECTRONIC THIN FILMS AND MATERIALS

Prof. M.K. Jayaraj Department of Physics, Cochin University of Science and Technology, Kochi 682022

Mob. 9447972104, Email: [email protected]

ABSTRACT Synthesis of nanoparticles and thin films has been a focus of an ever-increasing number of researchers world wide, mainly due to their unique optical and electronic properties which makes them ideal for a wide spectrum of applications ranging from displays [1], lasers [2] to in vivo biological imaging and therapeutic agents [3]. Large number of different preparation methods is reported to produce nanoparticles. Over the past decade a novel technique known as liquid phase pulsed laser ablation (LP-PLA) has aroused immense interest [4] and it involves the firing of laser pulses through liquids transparent to that wavelength on to the target surface. The ablation plume interacts with the surrounding liquid particles creating cavitation bubbles, which upon their collapse, give rise to extremely high pressures and temperatures. These conditions are, however, very localized and exist across the nano meter scale. Compared with the ablation in vacuum, formation of nanoparticles by pulsed laser ablation of targets in liquid environments has been less studied. Parameters like laser wavelength, pulse energy, pulse duration, repetition rate and nature of the liquid medium have influences on the ablation, nucleation, growth and aggregation mechanisms. The surfacatant free pure ZnO QD’s with out any byproducts using LP-PLA technique and the growth of ZnMgO/ZnO quantum well by pulsed laser deposition (PLD) will be discussed in this talk. In this review we present the general deposition techniques viz, pulsed laser ablation and RF magnetron sputtering. The Rf co-sputtering technique has been used for the growth completely transparent thin film transistors[5]. These amorphous oxide based thin film transistors opens up a new area called transparent electronics or invisible electronics which will revolutionise the consumer electronics.

Fig 1. TEM image and inset shows the SAED pattern of ZnO QD’s obtained by laser ablation with fluence 25 mJ/pulse in water. PL spectra (fig Middle) of ZnO QD’s prepared without (curve I) and with (curve II) oxygen bubbling. Inset shows the photo of highly transparent ZnO QDs. PL spectra of ZnMgO/ZnO MQW and ZnO thin film(fig. extreme right)

REFERENCES [1] K. Manzoor, S. R. Vadera and N. Kumar, App. Phys. Lett. 84 (2004) 284. [2] J. T. Andrews and P. Sen, J. Appl. Phys, 91 (2002) 2827. [3] X. Gao, Y. Cui, R. M. Levenson, L. W. K.Chung and S. Nie, Nature Biotechnology 22 (2004) 969. [4] G.W. Yang and J.B Wang , Appl. Phys. A-Mate., 71 (2000) 343. [5] K.J. Saji, M. K. Jayaraj, K. Nomura, T. Kamiya and H. Hosono, Journal of Electrochemical society 155(6), H390 (2008)


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BIOPOLYMERS, DNA AND PROTEIN AND ITS ENGINEERING

Prof. Sarita G. Bhat Department of Bio-tehnology, CUSAT

E-mail:[email protected]

INTRODUCTION Biopolymers are of different types, polynucleotide, polypepetides and polysaccharides. Some biopolymers like polylactic acid and poly hyroxy butyrates can be used as plastics, replacing the need for polystyrene and polyethylene based plastics. An enzyme is a protein molecule that is a biological catalyst, that have several industrial applications-in the food industry, meat and egg industry, backing industry, in the detergent industry to name a few. Recombinant DNA technology or genetic engineering has been used, via modification of amino acid sequences in the design and construction of new proteins or enzymes with novel or desired or modified functions. Protein engineering can also be used to manipulate the sizes and 3D conformations of protein molecules. Such manipulations are frequently used to discover structure-function relationships, as well as to alter the activity, stability, localization, and structure of proteins.

COMBINATORIAL MUTAGENESIS Point and deletion mutants and hybrid proteins are constructed to obtain polypeptides with new properties. These proteins are either created individually, by site-directed mutagenesis, or they are generated as a large pool or library of millions of variants. The library is then screened or subjected to a special selection procedure to obtain the protein or proteins with the desired characteristics. In biotechnology, one is often interested in creating enzymes with new specificities. For example, an enzyme that can recognize a different substrate that can be converted into a valuable product would be attractive from a biotechnological point of view. Generally, simple mutations (to be introduced by site-directed mutagenesis, for example) are not expected to have as drastic effects as altering an enzyme's substrate recognition pattern, as many amino acid residues in the enzyme (often not close to one another in the primary structure of the protein) affect the binding pocket of the substrate in the enzyme. Obviously, several amino acid residues may need to be altered simultaneously to achieve the goal of altering substrate specificities. However, as any amino acid residue may be altered into 19 other ones, the number of amino acid combinations that can be made if mutations are introduced at various residues simultaneously can become very large. For example, if four amino acid residues are altered simultaneously, there are 19-to-the-power-of-4 (that is, over 100,000) different combinations in which this can occur. Generally, it is unknown which of these combinations is what one is looking for, as it is difficult to predict on the basis of a primary sequence what the three-dimensional structure of a protein (and of the active site) will be in detail. Therefore, instead of humans trying to decide what might work best, the best progress is often made by having essentially all different combinations made at the DNA level in different plasmids (can be done using degenerate oligonucleotides), use all these different plasmids as a mixture to transform E. coli, have E. coli express the different proteins (each E. coli cell and its clones will express one particular protein assuming it has taken up one plasmid molecule), and select the E. coli cell(s) that may be able to convert a new substrate. For example, if the protein is likely to be on the outside of the E. coli cell, one can select clones with proteins with high affinity for the new substrate by attaching the new substrate covalently to a column, wash E. coli over the column, and cells that come off slowest are likely to have protein with affinity for the substrate. Combinatorial mutagenesis does not limit itself to applications involving DNA. Peptides can also be synthesized from a degenerate mix of amino acid analogs, and the resulting mix of peptides can be screened for desired properties, in particular pharmaceutical applications. Moreover, RNA can be synthesized combinatorially, and degenerate RNA mixtures have been used to study features that are needed to provide RNA with catalytic properties. In any case, combinatorial mutagenesis provides virtually limitless possibilities for genetic engineering, and has become an important tool in biotechnology.


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MATERIALS FOR PHOTONIC APPLICATIONS

Prof. V. P. N. Nampoori International School of Photonics, CUSAT

E-mail: [email protected]

ABSTRACT .Photonic based devices find applications in several fields. There are materials with specific properties which are suitable for photonic applications. Two of the most important applications of photonics are optical signal processing and optical communications. This paper reviews basic theory and material properties which are relevant to optical signal processing and optical communication. For the benefit of those who want to enter into this fascinating field, an outline of necessary foundation theories is also included.


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STRATEGIES FOR SUSTAINABLE MANUFACTURING

Prof. G. Madhu Division of Safety and Fire Engineering, School of Engineering, CUSAT

Mob.: 9447366900, E-mail: profmadhu @cusat.ac.in

INTRODUCTION The Brundtland report entitled “Our Common Future” released in 1987 by United Nations World Commission on Environment and Development (WCED) popularized the concept of sustainable development which it defined as ‘meets the needs of the present without compromising the ability for future generations to meet their own needs’. The realization that there exists limits to what we could put into nature (in the form of pollution) as well as what we could take out of nature (in the form of raw materials) made industries and organizations starting to work towards practicing sustainable material/resource strategies such as resource efficiency, eco-efficiency and sustainable development. This also has made governments more active in imposing regulations and rules related to waste management and pollution. For industry, a widely-used and basic strategy to increase the efficiency with which we use available resources is to concentrate efforts on recovery of products or materials at the end of their useful life (which includes re-use, re-manufacturing, re-cycling and energy recovery and is termed the waste hierarchy) [1]. Though there are many techniques and concepts that are proposed to support a move toward sustainable manufacturing (such as local manufacturing, low carbon manufacturing, low temperature processing, etc), the strategies based on waste minimization; material efficiency; resource efficiency; and eco-efficiency have gained momentum all over the world. A variety of innovative pollution prevention techniques contribute much to these strategies. The most popular pollution prevention techniques are based on design for environment; toxics use reduction; and life cycle assessment [2].

DESIGN FOR ENVIRONMENT

The concept of design for environment (DFE) directs R&D teams to develop products that are environmentally responsible. This effort revolves on product design. The commonly adopted strategies in DFE are product system life extension and material life extension. Extending the life of a product can directly reduce environmental impact. In many cases, longer-lived products save resources and generate less waste because fewer units are needed to satisfy the same need. Doubling the life of a product translates into a pollution prevention of 50 % in process transportation and distribution and a waste reduction of 50 % at the end of the product’s life. Many of the products are retired early due to reasons like technical obsolescence, fashion obsolescence, degraded performance or structural fatigue caused by normal wear over repeated use, environmental or chemical degradation and damage caused by accident or inappropriate use. The specific strategies for product life extension are appropriate durability; adaptability; reliability; remanufacturability; and reusability [3]. Material life extension can be achieved through recycling. Recycling is the reformation or reprocessing of a recovered material. The US-EPA defines recycling as “ the series of activities, including collection, separation, and processing, by which products or other materials are recovered from or otherwise diverted from solid waste stream for use in the form of raw materials in the manufacture of new products other than fuel”. The recycled material can follow two major pathways: closed loop and open loop.


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TOXICS USE REDUCTION

The toxics use reduction (TUR) considers the internal risks and potential external pollution risks at the process and worker level.

LIFE CYCLE ASSESSMENT It defines the material usage and environmental impact over the life of a product. Sustainable embeds corporate environmental responsibility into material selection, process and facility design, marketing, strategic planning, cost accounting, and waste disposal. In life cycle design, designers begin material selection by identifying the nature and source of raw materials [4]. Then, they estimate the environmental impact caused by resource acquisition, processing, use, and retirement. The depth of the analysis and the number of life cycle stages varies with the project scope. Finally, they compare the proposed materials to determine the best choices. Minimizing the use of virgin material means maximizing the incorporation of recycled material. Sources of recycled feedstock include in-house process scrap, waste material from another industry, or reclaimed post consumer material. Material substitution can be made for product as well as process materials, such as solvents and catalysts. Eg., water based solvents or coatings can sometimes be substituted for high VOC alternatives during processing. Also, materials that do not require coating, such as some metals or polymers, can be substituted in the product. Resource conservation can reduce waste and directly lower environmental impact. A less material intensive product may also lighter, thus saving energy in distribution or use. When reduction is simple, benefits can be determined with a vigorous life cycle assessment (LCA). Energy-efficient products reduce energy consumption and green house gas emissions. For example,

1. Programmes to reduce the power consumption of gadgets like laser printers when inactive. 2. Upgrading lighting systems to be more energy efficient. / CFL, LED.

Processes that create major environmental impact should be replaced with more benign ones. This simple approach to impact reduction can be effective. E.g., copper sheeting for electronic products was previously cleaned with ammonium per sulfate, phosphoric acid, and sulfuric acid at facility X. The solvent system was replaced by a mechanical process that cleaned the sheeting with rotating brushes and pumice. The new process produces a nonhazardous residue that is disposed in a municipal solid waste landfill. Process designers should consider improving energy efficiency by: • Using waste heat to preheat process streams or do other useful work. • Reducing the energy requirement for pumping by using larger diameter pipes or cutting down frictional losses. • Reducing the energy use in buildings through more efficient heating, cooling, ventilation, and lighting systems. • Saving energy by using more efficient equipment. (e.g., electric motors, refrigeration systems).

CONCLUSIONS The commonly used sustainable manufacturing strategies fall into the pollution prevention category. It is necessary extend sustainability into other germane areas such as product design and supply chain. Companies have to continuously re-invent themselves in order to remain sustainable. A holistic approach considering all aspects of operations is necessary in order to reap maximum benefits.

REFERENCES [1] Arun N. Nambiar, Challenges in Sustainable Manufacturing, Proceedings of the 2010 International Conference on

Industrial Engineering and Operations Management, Dhaka, Bangladesh, January 9-10, 2010. [2] Abdul Rashid, Salwa H. , Evans, Stephen and Longhurst, Philip, A comparison of four sustainable manufacturing

strategies, International Journal of Sustainable Engineering, 1: 3, 214 — 229, 2008. [3] Freeman, H., et al., Industrial pollution prevention: a critical review. Journal of the Air and Waste Management

Association, 42 (5), 618–656, 1992. [4] Seliger, G., Kim, H-J.and Kernbaum, S. and Zettl, M., Approaches to sustainable manufacturing. Int.J. Sustainable

Manufacturing, vol. 1, pp. 58–77, 2008.


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NONDESTRUCTIVE TESTING

M.M. Abdulla LIMRA Group of Institutions, Kochi


ABSTRACT Non-destructive testing (NDT) is a wide group of analysis techniques used in science and industry to evaluate the properties of a material, component or system without causing damage. NDT methods may rely upon use of electromagnetic radiation, sound, and inherent properties of materials to examine samples. This includes some kinds of microscopy to examine external surfaces in detail, although sample preparation techniques for metallography, optical microscopy and electron microscopy are generally destructive as the surfaces must be made smooth through polishing or the sample must be electron transparent in thickness. The inside of a sample can be examined with penetrating electromagnetic radiation, such as X-rays or 3D X-rays for volumetric inspection. Sound waves are utilized in the case of ultrasonic testing. Contrast between a defect and the bulk of the sample may be enhanced for visual examination by the unaided eye by using liquids to penetrate fatigue cracks. One method (liquid penetrant testing) involves using dyes, fluorescent or non-fluorescing, in fluids for non-magnetic materials, usually metals. Another commonly used method for magnetic materials involves using a liquid suspension of fine iron particles applied to a part while it is in an externally applied magnetic field (magnetic-particle testing). Thermoelectric effect (or use of the Seebeck effect) uses thermal properties of an alloy to quickly and easily characterize many alloys. The chemical test, or chemical spot test method, utilizes application of sensitive chemicals that can indicate the presence of individual alloying elements.

REFERENCES [1] Cartz, Louis (1995). Nondestructive Testing. A S M International. [2] Charles Hellier (2003). Handbook of Nondestructive Evaluation. McGraw-Hill..


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SURFACE PREPARATION AND PAINTING

Gopinath LIMRA Group of Institutions, Kochi E-mail: [email protected]

INTRODUCTION. Painting is the most common way to protect steel structures. Before carrying out painting work, surface preparation must be properly taken. Here after is surface preparation procedure for steel structure painting.

STEEL SURFACE TREATMENT

1. Welded areas shall be checked to verify any defects that may affect the protection quality of coating paint. 2. Sharp edges shall be grinded to be round, smooth. Other imperfect weld or slag shall be treated by grinding

machine or sand paper. 3. Noncontinuous welding line shall be filled again by welding.

SURFACE PREPARATION 1. Thoroughly remove oil and grease out of the surface using solvent or other proper methods. 2. Thoroughly remove all “evidence” of salt and contaminants. 3. Sand blast to achieve standard SA 2.5 (surface is free from oil, grease and other contaminants) 4. Remove all the remaining during blasting by brush, pressed air or vacuum cleaner. Avoid re-contamination

caused by clothes or hand touching. 5. Sand blasting shall be taken from one area to another, so that cleaned areas must be rust preventive and painted

immediately before getting rust again. Surface ready for painting must be completely clean. No oxidized or contaminated is visible.

6. Surface temperature is at least 3 degrees above the dew point to avoid water condensing. (Dew point is depended on surface temperature and humidity).

7. Areas that cannot reach with blasting nozzle or less important can be mechanically treated with grinding machine

INSPECTION AND EVALUATION FOR STEEL SURFACE PREPARATION 1. Oil and grease check :Oil and grease check shall be carried out a 2-3 locations per square meter and in 40-50%

out of prepared area, as following: Drip some drops of gasoline onto checked area. Wait for 10-15 seconds then adsorb the remaining gasoline with a piece of filter paper. Drip some other drops of gasoline onto another piece of filter paper. Wait and check the two dry stains on paper by naked eyes. If two colors look the same the surface is accepted as free from oil and grease.

2. Dust check: Dust check shall be carried out on whole prepared surface. Use a magnifier with 6 times magnification to survey. No visible dust is okay.

3. Cleanness check: Dust check shall be naked eyes or a magnifier according to cleanness levels. It also can be checked by comparing to standard images in ISO 801-1:1998


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ADVANCED AEROSPACE MATERIALS

Prof. Tide PS Division of Mechanical Engineering, School of Engineering, CUSAT

Mob.: 94973 66401, E-mail: [email protected]

INTRODUCTION Aerospace materials are materials that have been developed for their use for aerospace applications. These materials require exceptional performance, strength, heat resistance, even at the cost of considerable expense in their production or machining. Others are chosen for their long-term reliability in this safety-conscious field, particularly for their resistance to fatigue. The field of aerospace materials is important as the practice is defined by the international standards bodies who maintain standards for the materials and processes involved.

ADVANCED MATERIALS & COMPOSITES

For many years, aircraft designers could propose theoretical designs that they could not build because the materials required to construct them did not exist. Aluminum is a very tolerant material and can take a great deal of punishment before it fails. It can be dented or punctured and still hold together. Composites are not like this. If they are damaged, they require immediate repair, which is difficult and expensive. An airplane made entirely from aluminum can be repaired almost anywhere. This is not the case for composite materials, particularly as they use different and more exotic materials. Because of this, composites will probably always be used more in military aircraft, which are constantly being maintained, than in commercial aircrafts, which require less maintenance. Making composite structures is more complex than manufacturing most metal structures. To make a composite structure, the composite material, in tape or fabric form, is laid out and put in a mould under heat and pressure. The resin matrix material flows and when the heat is removed, it solidifies. It can be formed into various shapes. In some cases, the fibers are wound tightly to increase strength. One useful feature of composites is that they can be layered, with the fibers in each layer running in a different direction. This allows materials engineers to design structures that behave in certain ways. For instance, they can design a structure that will bend in one direction, but not another. The greatest value of composite materials is that they can be both lightweight and strong. The heavier an aircraft weighs, the more fuel it burns, so reducing weight is important to aeronautical engineers. Despite their strength and low weight, composites have not been a miracle solution for aircraft structures. Composites are hard to inspect for flaws. Some of them absorb moisture. Most importantly, they can be expensive, primarily because they are labour intensive and often require complex and expensive fabrication machines. Aluminum, by contrast, is easy to manufacture and repair. Thermoplastics are a relatively new material that is replacing thermosets as the matrix material for composites. One of their big advantages is that they are easy to produce. They are also more durable and tougher than thermosets, particularly for light impacts. In addition to composites, other advanced materials are under development for aviation.

CONCLUSIONS

Aluminum still remains a useful material for aircraft structures and metallurgists have worked hard to develop better aluminum alloys. Alloying metals include Zinc, Copper, Manganese, Silicon and Lithium, and may be used singly or in combination. Aluminum-Lithium is one of the successful alloys and is approximately ten percent lighter than standard aluminum. Composites are materials that are combinations of two or more organic or inorganic components where one material serves as a matrix while the other serves as reinforcement. The greatest value of composite materials is that they can be both lightweight and strong. A number of current large aircraft manufacturers are looking to use composites more extensively within the wings and fuselage. The Boeing 787 is made of as much as 50% composite materials and uses a novel process of winding composite layers in the fabrication of large fuselage sections. Aircrafts have traditionally been made out of metal – usually alloys of Aluminium; now however, engineers are increasingly working with carbon fibre composites.


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SIMULATION OF MATERIALS & MANUFACTURING PROCESSES WITH MSC SOFTWARE

Madeshwara S K CSM Software Private Limited, Bangalore

Mob: 9632122911,E-mail: [email protected]

INTRODUCTION With the advent of numerous modern materials for specific applications, FEA software companies have been constantly upgrading themselves to model & analysis these materials with much ease. MSC Software a pioneer in engineering simulation has a wide range of products which simulates the reality of complex material systems in a simpler and accurate way.

LINEAR, NON-LINEAR & DYNAMICS ANALYSIS

Patran is a comprehensive pre- and post-processing environment for FEA analysis and helps engineers to virtually conceptualize, develop and test product designs. Used by the world’s leading manufacturing companies as their standard tool for the creation and analysis of simulation models, Patran links design, analysis, and results evaluation in a single environment. MD Nastran is an integrated simulation system with a broad set of multidiscipline analysis capabilities based on proven CAE technologies. MD Nastran enables product manufacturers to simulate everything from a single part to complex assemblies and carry out a diverse set of virtual tests. By providing a single platform for a wide range of applications, MD Nastran offers cost savings and efficiencies across engineering CAE teams. MD Nastran implicit module delivers a complete solution (pre-processing, solution, and post-processing) for implicit nonlinear FEA. It provides the easiest to use and most robust capabilities for contact, large strain, and multiphysics analysis available today to solve static and quasi-static nonlinear problems.

EXPLICIT & FLUID STRUCTURE INTERACTION

MD Nastran explicit module analyzes complex nonlinear behavior involving permanent deformation of structures. It enables you to study the structural integrity of designs to ensure that final products stand a better chance of meeting customer safety, reliability, and regulatory requirements. Patran & MD Nastran supports an array of material models such as Isotropic, orthotropic, anisotropic, composite, thermal isotropic, thermal orthotropic and thermal anisotropic to perform a variety of analyses. Some of the most commonly used material models are: • Isotropic Material • 2D Anisotropic Material • Heat Transfer Material Properties, Isotropic • Thermal Material Property • 2D Orthotropic Material • 3D Anisotropic Material • Fluid Material Property

• Material Stress Dependence • Elasto-Plastic Material Properties • Thermo-Elastic-Plastic Material Properties • Hyperelastic Material Properties • Gasket Material Properties • Elastoplastic + Failure property • Elastic property for solid element

Besides modeling of different types of materials, various manufacturing process can also be simulated. Some of them are: • Forming • Deep Drawing • Forging • Rolling

• Draping of composite materials. • Generation of flat patterns on composite

components.


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CORROSION CONTROL BY METHODS AND MATERIALS

Prof. A. Mathiazhagan Department of Ship Technology, CUSAT

Mob.: 9895185860, E-mail: alagan @cusat.ac.in

INTRODUCTION

Corrosion is the deterioration of a material as a result of reaction with its environment. A common example of metal corrosion is the rusting of iron. Most research into the causes and prevention of corrosion involves metals, since the corrosion of metals occurs much faster under atmospheric conditions than does the corrosion of nonmetals.

CORROSION CONTROL The first method involves applying a layer onto the steel that prevents an electrolyte to move at the steel surface, this layer is called a coating. The second method is commonly known as cathodic protection; anodes, or impressed current. The third method above is use of alloys that does not corrode in these environments. Method four allows the corrosion to proceed and incorporate enough structural material in the design to last for the intended service life. Coatings are barriers and they are most common method by which corrosion protection is obtained. Barriers hear means that they do not allow ions to penetrate the coating and get to the steel, and it does not permit movement of any existing ions at the steel surface. The use of anodes and/or impressed current protection systems is common. Anodes and “impressed current protection” systems provide protection on spots where the coating is damaged on the general under water area/underground soil. Most large metal structures are made from carbon steel-the world's most useful structural material. Corrosion resistance metals and alloys are used to prevent corrosion of steel structure and other critical components. Stainless steel, aluminum, Titanium, Nickel and copper based alloys are widely used as corrosion resistance materials due to their ability to form passive layer to resist corrosion. There is still today a certain corrosion allowance incorporated into the structural strength calculations. This means that even with defects in the anticorrosive systems there are not any structural problems occurring that for a relatively long time, which gives the owner time to plan the correct action.

CONCLUSIONS • There are many forms and mechanisms that cause corrosion. • Proper corrosion control saves money, improves operability and safety and protects the environment. • Corrosion control is complex task, requiring special expertise for successful design, construction and

maintenance in all fields of engineering.

REFERENCES [1] Fontana, M.G., and Greene, N.D., Corrosion Engineering, McGraw-Hill, New York, pp. 39-44 (1967). [2] Winston Revie, R, Uhlig’s, Corrosion handbook, John Wiley and sons Lnc, U.S (2000). [3] Jones, D. A., Principles and prevention of Corrosion, Macmillan Publishing Co., New York, 1992, p. 439.


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SUSTAINABLE MATERIAL FOR SOIL AND WATER CONSERVATION IN THE CONTEXT OF KERALA

Prof. Subha V. Division of Civil Engineering, School of Engineering, CUSAT

Mob.: 9447292584, E-mail: v.subha @cusat.ac.in

ABSTRACT

More than 70 percent of the rural people in Kerala have agriculture as their main source of income. The productivity has been affected negatively due to lack of water for irrigation during the summer season and soil erosion and flooding during the monsoon. This demand for a sustainable solution to conserve soil, and preserve water for the future. At the same time, about half a million people are working in the coir industry in Kerala to make ends meet, of which about 80 percent are women. The average income of such an individual is less than Rs 50/day. The majority of these people live under minimal living conditions. This paper brings these two issues together and puts forward a novel approach to resolving the predicaments in soil and water preservation while stimulating the coir industry, with a radically new idea of coir geotextiles.

REFERENCES [1] Vishnudas, S., Hubert H.G. Savenije, Pieter Van der Zaag,. Sustainability Analysis of two Participatory Watershed

Projects in Kerala. Physics and Chemistry of the Earth, 33, pp. 1-12. 2008 [2] Vishnudas, S., Hubert H.G. Savenije, Pieter Van der Zaag, Kunnathu R. Anil, Krishnan Balan,. Participatory Research

using Coir Geotextiles in Watershed Management - a case study in South India. Physics and Chemistry of the Earth. 33, pp. 41–47. 2008.

[3] Vishnudas, S., H. H. G. Savenije, P. van der Zaag, K. R. Anil, K. Balan, The protective and attractive covering of a vegetated embankment using coir geotextiles. Hydrology and Earth System Sciences, 10: 565–574. 2006


14


MODERN CEMENTS AND ITS APPLICATION

M.A. Joseph UltraTech Cement Ltd. Cochin Division


INTRODUCTION

Cement is a binder, a substance that sets and hardens independently, and can bind other materials together. Modern hydraulic cements began to be developed from the start of the Industrial Revolution, driven by three main needs:

• Hydraulic render (stucco) for finishing brick buildings in wet climates. • Hydraulic mortars for masonry construction of harbor works, etc., in contact with sea water. • Development of strong concretes.

TYPES OF MODERN CEMENT

The common classification of cement is given below. Portland cement Portland cement blends

• Portland blastfurnace slag cement • Portland pozzolana cement • White blended cements

• Colored cement Non-Portland hydraulic cements

• Supersulfated cements • Geopolymer cements

ORDINARY PORTLAND CEMENT

Ordinary portland cement is the most commonly used cement for a wide range of applications. These applications cover dry-lean mixes, general-purpose ready-mixes, and even high strength pre-cast and pre-stressed concrete.

PORTLAND BLAST FURNACE SLAG CEMENT Portland blast-furnace slag cement contains up to 70 per cent of finely ground, granulated blast-furnace slag, a nonmetallic product consisting essentially of silicates and alumino-silicates of calcium. Slag brings with it the advantage of the energy invested in the slag making. Grinding slag for cement replacement takes only 25 per cent of the energy needed to manufacture portland cement. Using slag cement to replace a portion of portland cement in a concrete mixture is a useful method to make concrete better and more consistent. Portland blast-furnace slag cement has a lighter colour, better concrete workability, easier finishability, higher compressive and flexural strength, lower permeability, improved resistance to aggressive chemicals and more consistent plastic and hardened consistency.

PORTLAND POZZOLANA CEMENT

Portland pozzolana cement is ordinary portland cement blended with pozzolanic materials (power-station fly ash, burnt clays, ash from burnt plant material or silicious earths), either together or separately. Portland clinker is ground with gypsum and pozzolanic materials which, though they do not have cementing properties in themselves, combine chemically with portland cement in the presence of water to form extra strong cementing material which resists wet cracking, thermal cracking and has a high degree of cohesion and workability in concrete and mortar.


15


LIGHTWEIGHT CONCRETE

Prof. Glory Joseph Division of Civil Engineering, School of Engineering, CUSAT


INTRODUCTION Production and use of lightweight concrete has received considerable interest in the construction field during the last two decades. The technical, practical and economical benefits of high strength lightweight concrete have special attractions for applications in high-rise buildings, offshore and marine structures, long span bridges etc. A decreased density in the same strength level combined with high durability can lead to cost-effective engineering solutions for superstructure, foundation and pre-cast units. High strength lightweight concrete meeting the requirements of construction industry can be produced by the use of lightweight aggregates (LWA) than other types of lightweight concretes (aerated, no fines concrete etc.) because the strength of the concrete can be controlled to the required level by varying the percentage volume or the type of aggregate. High strength concrete without increase in cement content can be achieved by using right proportion of mineral admixtures and chemical admixtures. The brittle failure, which is more pronounced in high strength lightweight concrete, can be modified by introduction of fibers in the matrix, which will improve the post peak behaviour.

LIGTWEIGHT AGGREGATE CONCRETE Lightweight aggregate concrete (LWAC) uses either natural or artificial lightweight aggregates with density ranges from 400 to 900 kg/m3. The natural materials used for producing artificial lightweight aggregates are clay, perlite, shale and slate and industrial byproducts are pulverized fuel ash, blast furnace slag, industrial waste, sludge etc. Lightweight concrete using artificial aggregates, produced from industrial byproducts makes it more sustainable and environment friendly. Pelletization and hardening of palletized aggregates are the two main processes in the manufacture of artificial aggregates. Most of the commercially available aggregates such as expanded clay or shale, and sintered fly ash aggregates use heat treatment of 1000 to 14000C. However depending on the material composition of raw material, artificial aggregates with adequate engineering performance may be obtained by moist curing of pelletized particles. The essential requirement of lightweight aggregate is its dense exterior shell with high internal porosity. Because of high porosity and water absorption, the interaction of paste matrix and lightweight aggregate is different from that of normal concrete. Porous surface of LWA improves the interfacial bond between the aggregate and cement paste by providing interlocking sites for the cement paste forming a dense and uniform interfacial zone. Enhanced hydration and internal moist curing due to reserve water available in the aggregate pores makes LWAC less sensitive to curing. In structural lightweight concrete elastic modulus of aggregate is similar to that of the matrix resulting in significantly lower stress concentrations at the aggregate matrix interface and less micro cracking. Absence of micro-cracks in the concrete is the reason for the low permeability and excellent durability of lightweight concrete. REFERENCES [1] Bijen, J.M.J.M. (1986) Manufacturing processes of artificial lightweight aggregates from fly ash. The

International Journal of Cement Composites and Lightweight Concrete, 8, 191-198. [2] Chi, J.M., R. Huang, C.C. Yang and J.J. Chang (2003) Effect of aggregate properties on the strength and

stiffness of lightweight concrete. Cement & Concrete Composites, 25,197-205. [3] Zhang, M.H. and O.E. Gjorv (1991) Mechanical properties of high-strength lightweight concrete, ACI Materials

Journal, 88(3), 240-247.


16


LATERIZED CONCRETE FOR FIRE PROTECTION

Prof. George Mathew Division of Safety and Fire Engineering, School of Engineering, CUSAT


ABSTRACT Fire remains one of the most serious potential risks to buildings, especially for industrial structures made with steel. Most structural materials are affected when exposed to high temperature. One of the methods of protecting steel against fire is by encasing it with concrete (jacketing). Such concrete should perform its required function against fire and generally strength is not a governing criterion. Performance of concrete exposed to fire is affected by factors like the type of aggregate, cement, the temperature and duration of the fire, the rate of heating, size and shape of structural members, moisture content of concrete etc.. With the fast depleting state of natural resources like sand and aggregate, it is time to look for alternate materials for making concrete. Since performance is more important than strength when exposed to fire, concrete made using marginal materials could be effectively used for protecting steel against fire. One of the potential marginal materials that can be used in concrete is Laterite. Laterite is abundantly available in many parts of the world. Laterite aggregate can be considered as one of the marginal materials. Concrete made with such materials will help in sustaining the fast depleting natural resources like sand and aggregate. Control concrete specimen has been cast with natural sand as fine aggregate and crushed granite as coarse aggregate. Corresponding laterised concrete has been cast by replacing sand and aggregate with weathered laterite all in aggregate. Specimens were heated to 200oC, 400oC and 600oC and were cooled to room temperature by two methods - one by air cooling and the other by water cooling. The specimens were then tested to determine their compressive strength, tensile strength and modulus of elasticity. The surface cracking behavior and colour change of specimens were also observed after cooling under both the methods. Based on the test results, it could be concluded that laterised concrete can be considered as an alternate fire protection material to cement concrete.

REFERENCES [1] E. G. Butcher and A. C. Parnell, Designing for Fire Safety, John Wiley and Sons, Great Briton, 1983. [2] F. F. Udoeyo, U. H. Iron and O.O. Odim, Strength Performance of Laterised Concrete, Journal of Construction and

Building Materials, Elsevier 20 (2006) 1047-1062. [3] S. Chandrakaran, Characteristic Behavior of Lateritic Concrete, Journal of Institution of Engineers, 77 (1996) 129-132. [4] M. A.Salu, Long Term deformations of Laterised Concrete short columns, Journal of Building and Environment, 38

(2003) 469-477. [5] J. A.Osunade, The influence of Coarse Aggregate and Reinforcement on the anchorage bond strength of Laterised

Concrete. Journal of Building and Environment, 37 (2002) 727-732. [6] J.A.Osunade, Effect of replacement of Lateritic soils with Granite fines on the Compressive and Tensile strengths of

Laterised Concrete. Journal of Building and Environment, 37 (2002) 491-496. [7] M. A. Salu and L.A.Balogun, Shrinkage Deformations of Laterised Concrete, Journal of Building and Environment, 34

(1999) 165-173. [8] F.F. Udoeyo, R.Brooks, P.Udo-Inyang and C. Iuji, Residual Compressive Strength of Laterized Concrete Subjected to

Elevated Temperatures, Research Journal of Applied Science, Engineering and Technology (2) 3 (2010) 262-267.


17


SUSTAINABLE MATERIALS AND CONSTRUCTION

Prof. Deepa G. Nair Division of Civil Engineering, School of Engineering, CUSAT


ABSTRACT The use of sustainable building materials and construction helps to conserve natural resources and protect the environment for present and future generations. Some of the theme areas one should look into in sustainable construction process are given below

- Carbon Credits - Carbon Dioxide Sequestration - Rating of sustainable materials. - Embodied energy from production. - Energy requirements for transport and use. - Energy management during construction. - Energy management during use of the buildings and infrastructures. - Greenhouse gas reduction. - Life cycle analysis. - Making construction materials durable. - Maintaining quality and durability while achieving sustainability. - Maintenance and repair technologies for sustainability of buildings and infrastructure. - Mass balance - sources and final destinations of materials. - Recycling of municipal solid waste (MSW) and energy savings - Use of recycled or recyclable by-products in construction

Leadership in Energy & Environmental Design (LEED) is an internationally recognized green building certification system, providing third-party verification that a building or community was designed and built using strategies intended to improve performance in metrics such as energy savings, water efficiency, CO2 emissions reduction, improved indoor environmental quality, and stewardship of resources and sensitivity to their impacts. For a sustainable practice of construction, sustainable sites, energy and atmosphere, materials and resources and innovation and design process are to be considered.


18


FRP APPLICATIONS IN CIVIL ENGINEERING

Prof. S. Ramadass Division of Civil Engineering, School of Engineering, CUSAT


INTRODUCTION Fiber reinforced polymer(FRP) composite materials have developed into economically and structurally viable construction materials for buildings and bridges over last 20 years. FRP composite materials used in structural engineering typically consist of glass, carbon, or aramid fibers encased in a matrix of epoxy, polyester, vinyl ester, or phenolic thermo setting resins that have fibre concentrations greater than 30% by volume. They have been used in structural engineering in a variety of forms which are briefly discussed in this topic.

VARIOUS FORMS OF FRP PRODUCTS • FRP reinforcements for concrete structural members • FRP tendons for pre-stressed concrete members • FRP strengthening systems(strips, sheets and fabrics) for retrofitting of reinforced concrete structural

members • FRP profiles (I section, L sections, tube, channels sections etc) for trusses

Overview, raw materials, manufacturing methods, selected FRP manufacturers, properties and design basis and the published design guides, codes of practices and specifications for FRP composites in structural engineering, key conference series and archival journals for FRP reinforcements in concrete structural members, FRP tendons in pre-stressed concrete members, FRP strengthening systems for shear and flexure and FRP profiles are briefly covered.

CONCLUSIONS Over the last decade, there has been significant growth in the use of FRP composite materials as construction materials in structural engineering. Now at the beginning of the twenty-first century, the structural engineering community is about to centre a stage in which structural design with FRP composites is poised to become a routine as structural design with classical structural materials such as masonry, wood , steel and concrete.

REFERENCES [1] L.C. Bank, Composites for construction: Structural design with FRP materials, John Wiely & Sons Inc., NJ, 551p, 2006 [2] FRP-strengthened RC structures, J. G. Teng, John Wiley and Sons, 2002, 245 pages [3] Reinforced concrete design with FRP composites, H.V.S Ganga Rao, N.Taly,P.V.Vijay, CRC press 2006,282 pages


19


FIBRE REINFORCED CONCRETE

Prof. Job Thomas Division of Civil Engineering, School of Engineering, CUSAT


ABSTRACT Concrete is strong in compression and weak in tension. Addition of steel fibres in concrete mitigates the effects of poor tensile capacity of concrete. The strength and deformability of concrete increases with the increase in steel fibre content. The fibres bridging across the crack effectively resist the opening up of crack in concrete. The mechanics based model proposed by Naaman for representing the behavior of fibre reinforced concrete has been discussed. The major advantages and application of fibre reinforced concrete are presented.

REFERENCES [1] Thomas J., Fracture properties of concrete containing flat plastic fibres, Journal of Structural engineering, IUP, April,

2010. [2] Thomas, J. and Prakash, V.S., Strength and behaviour of plastic fibre reinforced concrete, Journal of Structural

engineering, SERC, March, 1999


20


EARTHQUAKE PROOFING METHODS IN SKYSCRAPERS

Prof. Job Thomas Division of Civil Engineering, School of Engineering, CUSAT


INTRODUCTION

An earthquake is the result of a sudden release of energy in the Earth's crust and is associated with seismic waves. Three seismic waves striking on a building structure is classified into three, namely, P-wave, S-wave and surface waves. The P-waves are compression or push-pull waves moving in the vertical direction. The S-waves are lateral waves moving in the vertical direction. Surface waves are lateral waves moving in the horizontal direction. The structure vibrates when subject to the sequential ground movement due to P-, S- and surface waves. The earthquake proofing methods in skyscrapers are base isolation, bracing and active mass dampers.

BASE ISOLATION

The base of the building is isolated from the ground. For base isolation from horizontal vibrations, Elastomeric Isolator , Sliders and Rotating Ball Bearing isolator are used. Proving dampers made up of steel or lead at the column base is another approach to isolate the building from vertical vibrations.

BRACING

In bracing, oil dampers or metal friction dampers are connected in X- form in the rectangular framing. These dampers resist the lateral sway of the structure.

ACTIVE MASS DAMPERS The active mass dampers are also known as tuned mass dampers. The active mass located in the building is mobilized with a control device to oppose the lateral movement of the building.

CONCLUSION Base isolation and bracing systems are simple technique of earthquake proofing. The active masses controlled by the complex algorithm can also be utilized for the earthquake proofing of high-rise buildings

REFERENCES [1] Agarwal P., Shrikhande M., Earthquake resistant design of structures, Prentice-Hall of India, 2006. [2] Meirovitch L., Elements of vibration analysis, McGraw-Hill, 1986 [3] Paz M., Structural dynamics, CBS Publishers, 1987.

Documents

Proceedings of Modern materials and methods in Engineeing