1. DETAIL DESIGN REVIEW OCTOBER 26 TH 2012 Team P13656: L. Abatte, W. Fritzinger, P. Torab, K. Karauda

2. Project Management: Plan  Project Schedule Project Schedule

3. Design Proposal  Ultrasonic, self-contained unit

4. Design Proposal  http://prezi.com/kjnwnkg7awaz/ultrasonic- cleaning- system/?auth_key=30636a7d6cb66176bbd1c45f 00a37499b77e2f32 http://prezi.com/kjnwnkg7awaz/ultrasonic- cleaning- system/?auth_key=30636a7d6cb66176bbd1c45f 00a37499b77e2f32

5. Coating & Extrusion Die Compositions  SS 400  Honeycomb Extrusion Dies  TiN, TiC, TiCN (coatings) Carbon0.05Silicon1 Manganese1Chromium12 Phosphorus0.03Aluminum0.25 Sulfur0.03Iron85.64

6. Fundamentals of the Reaction SS 400 Extrusion Die TiN, TiC, or TiCN Mono-Layer Multi-Layer Bulk

7. Reaction Equations Set Up  Define the underling reactions  Obtain redox potentials and equilibrium constants for perspective reactions  Utilize non-linear reaction program analysis to generate reaction scheme  Define optimization based on reaction scheme

8. Reaction Sets  Redox Reactions  Decomposition of H2O2  Acidic Stabilization  Ti Redox reactions

9. Conditions & Functionalities  H2O2 concentration  35-50% composition  Temperature Range  Decomposition Temp H2O2 = 140F  2 acid system  Purpose of phosphoric acid  Addition of Nitric Acid or Sulfuric Acid  Amounts depend on % H2O2

10. From US Patent 0023943 Variable Stripping Parameters

11. Polarization Cell Components  Test Sample  Two Auxiliary Electrodes  Luggin Capillary  Salt Bridge Connection  Inert Gas Connections  Thermometer  Glass Container

12. Functionality of Polarization Cell  Adjusting potential of auxiliary electrode 1 to match the potential of the sample.  Measuring the current flowing across the other auxiliary electrode 2 and sample.  Reference current flowing between the two auxiliary electrodes.  Generation of a Taffel plot  Taffel plot deduced corrosion rate [mass/time]

13. Specifications

15. Coating & Extrusion Die Compositions  SS 400  Honeycomb Extrusion Dies  TiCN (coating) carbon0.05silicon1 Manganese1chromium12 phosphorus0.03aluminum0.25 sulfur0.03iron85.64

16. Reaction Equations Set Up  Define the underlying reactions  Obtain redox potentials and equilibrium constants for perspective reactions  Developing the reaction rates & heat generated by the exothermic reaction  Utilize non-linear reaction program analysis to generate reaction scheme  Define optimization based on reaction scheme

17. Reaction Sets  Redox Reactions  Decomposition of H2O2  Acidic Stabilization  Ti Redox reactions

18. From US Patent 20070023943 Variable Stripping Parameters

20. Validation Test Samples Bar Stock Dimensions  cross-section: square 2in x 2in  thickness: 0.5 in  Capillaries: 9 units, 1/16 in  Coating: TiCN  Body: 316 SS

21. Sample Picture

22. Variable Test Samples Panel Dimensions  Length = 2 in  Width = 2 in  Thickness = 0.025 in  Coating: TiCN  Body: 304 SS

23. Variable Test Sample  Sample Denotation  FREQUENCY: 2 samples  TEMPERATURE: 4 samples  COMPOSITION: 4 samples  FINAL/SPARES: 5 samples Total: 15 Samples

25. Polarization Cell Components  Test Sample  Two Auxiliary Electrodes  Luggin Capillary  Salt Bridge Connection  Inert Gas Connections  Thermometer  Glass Container

26. Functionality of Polarization Cell  Adjusting potential of auxiliary electrode 1 to match the potential of the sample.  Measuring the current flowing across the other auxiliary electrode 2 and sample.  Reference current flowing between the two auxiliary electrodes.  Generation of a Taffel plot  Taffel plot deduced corrosion rate [mass/time]

27. Prototype Testing  At this time there would be defined test conditions along with a prototype system.  The test will act as a check to the validation testing and variable testing.  Coated mini-dies will be used in the testing.  Reaction check

28. Supply & Cost Analysis for Testing

30. Pugh Chart

31. Project Management: Risks  Risk Matrix Risk Matrix

32. Bill of Materials - Rotational DescriptionSupplier P/NUnit PriceQuantityTotal CostSupplierOwnerLead TimeStatus Tank $01$0.00CTI N/AExisting NEMA 56 1/2hp wash-down motor59845K68$355.591 McMaster - CarrWillIn StockPlanned High-efficiency speed reducer6481K77$247.151 McMaster - CarrWillIn StockPlanned Corrosion resistant chain (1 ft.)5960K1$60.343$181.02McMaster - CarrWillIn StockPlanned Shielded thrust bearing60715K15$20.261 McMaster - CarrWillIn StockPlanned Stainless steel shaft (1")6526K55$114.571 McMaster - CarrWillIn StockPlanned Shaft collar (1")9665T2$68.651 McMaster - CarrWillIn StockPlanned Drive sprocket (10 teeth)6799K112$50.251 McMaster - CarrWillIn StockPlanned Driven sprocket (24 teeth)6799K127$99.801 McMaster - CarrWillIn StockPlanned 316 SS rectangular bar stock (6ft.)9083K11$74.121 McMaster - CarrWillIn StockPlanned Polycarbonate sheet (12"x36"x1/8")8574K265$32.481 McMaster - CarrWillIn StockPlanned

33. Rotational System

36. Bill of Materials - Ultrasound DescriptionSupplier P/NUnit PriceQuantityCostSupplierOwnerLead TimeStatus 6 Gallon Cleaning UnitSC-6$3,462.001 Severe CleanPeterTBDPlanned

37. Design Validation Preliminary Testing:  Necessary Equipment:  Small size ultrasonic tank  Square test pieces: 2 x 2 in 316 steel (0.50 in thick) Coating: TiC, TiN, TiCN (since the exact coating of the actual parts cannot be disclosed) Optionally: HSS drill bits can be used as test pieces (coated with TiN) H2O2 bath (composition equal to the one used by the customer)

38. Design Validation  Procedure:  Test pieces will be weighed and the initial weight will be recorded (prior to and after coating)  Test pieces will be submerged in the tank  Throughout the duration of the test, steel will be removed from the tank several times and weighed. This will provide the data necessary for establishing the rate at which the coating is being stripped from the parts by the bath.  Test will also provide the data for establishing the bath degradation rate since the ultrasonic tank will be at different pressure and temperature compared to the current setup.  Testing will be conducted for several test pieces to provide reliable data and avoid measurement error.  Once the data is obtained it will be analyzed and presented to the customer as well as faculty guides.

39. Design Validation  Variables:  Frequency: What value is optimal? Range of acceptable values  Temperature: Natural convection: temperature gradient throughout the tank (visit to vendor -> investigation)  Solution composition  Vibration intensity/ transducer strength  Cavitation strength  Jamestown Advanced demo

40. Design Validation  Vendors:  McMaster Carr for sheet metal/ steel pieces  Vergason for coating of the test pieces  All machining can be done in house utilizing the ME machine shop

41. Optional  In the future the design can be further expanded:  Level switch  Secondary containment tank  Piping system for fluid recycling purposes

42. Questions?