1. Sponsor: Carrier Corporation Advisor: Dr. H. El-Mounayri May 3, 2007 Design Team: Mike Abel Braden Duffin Simon Marin Joe McGuire

2. Presentation Outline Background Requirements Development Final Design Evaluation Recommendations Questions

3. Design Objective Design a custom cyclic corrosion device for testing material samples. The device must replicate conditions encountered in actual furnace applications. Environmental conditions include hot air, chemical exposure, and humidity.

4. Performance Requirements Controlled temperature range of 70- 400° Fahrenheit Humidity: 85% Corrosive Chemical Exposure Controllable and variable cycle transitions (30-60 sec. transitions) Other (weight, cost, size, power, safety)

5. Development Concepts generation included QFD, functional flow analysis, function-concept mapping, decision matrix, etc… Designed housing concept using ProEngineer Researched commercially available components (heat element, fan, valves, chemical pump, etc…) Performed analyses to determine necessary component performance Redesigned housing to fit suitable components

6. Final Design (Front View) Heat Chamber Heating fan Cooling Fan Valves Fume hood Representation

7. Final Design (Rear View) Chamber Vent Drain Pan Chemical / Water spray inlets External Cover

8. Final Design (Internal View) Test Samples Chemical Nozzle Water Nozzle

9. Design Evaluation Verification of the requirements was obtained from: Procured component specifications ProEngineer model geometry Part weights and dimensions Computational Fluid Dynamics (CFD) simulations

10. CFD Model and Boundaries Heating Element Heating Fan Heat side valve Cool side valve Cooling Fan Vent

11. Requirements Verification CFD Analysis Temperature range requirement: 70-400ºF Temperature range achieved: 70-500ºF Temperature transition time requirement: < 60 seconds Actual time to heat chamber: > 200 seconds Actual time to cool chamber: 25 seconds

12. Steady-state heating simulation Flow streamlines colored by temperature Demonstrates capability to exceed temperature requirement Internal temperature is 475-500 ºF

13. Cooling time simulation Demonstrates cooling time capability Simulation time is 25 seconds Internal temperature drops from 500 to 80ºF

14. Heating time simulation Demonstrates heating time capability Simulation time is 200 seconds Final Internal temperature is 340ºF Needs optimization

15. Requirements Verification Humidity: 85% (predicted, not verified) Uniform Chemical Vapor Spray (based on procured nozzle and pump specs.)

16. Requirements Verification Safe to be handled (warning: some heated surfaces and ventilation) System maintenance and cleaning: All parts exposed to chemicals are stainless steel. All individual part weights are below 60 lbs. Fits in hood dimensions (verified by ProE model) Holds 6 coupons (Target: 2)

17. Requirements Verification Powered by 110 V (based on procured components specs.) System can be automated (All parts can be electrically controlled) System Cost $2799 - $8389 depending on valve choice (Target: $3000)

18. Heat Cycle Recommendation Objective: decrease time to heat chamber Currently using preheated air to facilitate heating Increase amount of preheated air: Increase volume of heat chamber Increase surface area of heat strip Add heat strip Add second heat chamber Optimize air flow Entry vents Exit vent

19. Valve Recommendation Objective: Meet initial budget requirements, minimize long term costs Xomox butterfly valve: $3345 each Highest quality heat and corrosion resistance 2” long McMaster swing check valve: $550 each Lower quality heat and corrosion resistance 6” long Likely requires regular replacement Design custom valve in house?

20. Questions