Grants totalling £1 million awarded for innovative interventions to increase D&I in engineering

  • New Diversity Impact Programme to tackle long-standing diversity challenges in university engineering departments in the UK
  • Projects funded will transform the outcomes and experiences of students from underrepresented groups, including those who are neurodiverse, disabled or from low socioeconomic background.
  • Wider engineering Higher Education sector to benefit from new tools and approaches to remove barriers to student progress

The Royal Academy of Engineering’s new Diversity Impact Programme has awarded its first grants of up to £100k each to 11 projects in university engineering departments that address the unequal outcomes experienced by students from diverse and underrepresented groups.

Launched in October last year, the Diversity Impact Programme aims to inspire change in university engineering departments so that all students succeed and the unique perspectives and experiences of engineers from diverse backgrounds continue to enhance the profession.

An important aspect of the programme is that the universities themselves define what they need to meet their diversity challenges. Among the 11 projects in this first cohort are many that focus on socioeconomic background and neurodiversity—two areas that are underserved by research and where available data suggests career progression and sense of belonging within engineering is weak. Several projects will explore the impact an inclusive culture can have on the outcomes of students from diverse and underrepresented groups; others focus specifically on disability, gender, race and ethnicity.

Universities from all over the UK will be involved and the interventions proposed vary from mentoring and work-based projects to the development of an inclusive culture and peer networks.

Dr Hayaatun Sillem CBE, Chief Executive of the Royal Academy of Engineering, said: “The Academy’s new Diversity Impact Programme has been designed to support universities in making a step change in diversity and inclusivity across engineering Higher Education. Our goal is to help universities to develop interventions, informed by evidence, that transform the outcomes of students from diverse and underrepresented backgrounds. It is vital that we seek innovative and creative ways to accelerate the pace of change rather than accepting that incremental improvement is all that is possible.

“There is an extensive evidence base supporting the benefits of diverse teams working in inclusive cultures but there is still a way to go in understanding how to deliver the culture of inclusion that unlocks the power of diversity. These projects will give us invaluable insights and experience that will be shared across the Higher Education community so that we can work collectively to drive positive change”.

The eleven projects being funding are as follows (value of award in brackets). More detail about each project can be found on the Academy’s website here.

  • De Montfort University (£95,306)
    Access to high-profile jobs: closing the gap

The project establishes an Engineering Sciences Learning Centre and Employability Programme co-designed and co-run with students that will reinforce their academic and professional confidence in pursuing high profile engineering career.

  • Imperial College London (£99,450)
    Engineering Progression from School to Year 2 at Imperial

Students from low socioeconomic backgrounds face significant barriers to progression. This innovative project supports students for an extended period as they transition from school into their first year and second years at Imperial. The project builds on a recent pilot project and provides strategic interventions and relationships at key moments in the student’s journey creating opportunities for leadership, academic and personal development as part of a broad package of support.

  • Kings College London (£82,642)
    Success for Black engineers

Attainment outcomes for Black engineers at undergraduate level, and for Black students of engineering subjects at school, are weaker than for their white counterparts. This project addresses this problem by providing tailored support for students at key moments in their journey. It trains students from the university’s existing Black community to become peer mentors and Black and minority ethnic staff to become academic mentors for these students. There is an explicit outcome for the university to increase its knowledge and understanding of the experience of Black engineering students. The project also supports wellbeing and personal development, acknowledging that academic attainment cannot be viewed separately from a student’s broader experience and growth.

  • Loughborough University (£65,000)
    Don’t forget the Mortar! A new approach to engineering education

This project considers the experiences and activities that form the culture of an institution outside of the core academic content. It acknowledges that this culture is often designed (explicitly or implicitly) by and for majority groups, which can leave people from underrepresented groups less able to navigate the culture and feeling excluded. This results in low levels of belonging which is a significant factor in attainment and retention.

  • Newcastle University (£98,661)
    Peer networks: cultivating an inclusive culture and sense of belonging

A lack of access to peer networks has been identified as a barrier to the success and feelings of belonging of engineering undergraduates from diverse and underrepresented groups. This project will examine the structures and accessibility of existing peer networks and identify and evaluate new opportunities to join and form networks to improve feelings of belonging and outcomes for students from all backgrounds.

  • Sheffield University (£95,782)
    Diversity Confidence in Engineering (DiCE)

Reflecting challenges in the wider sector, the university’s research suggests that students from underrepresented groups take longer to settle or be accepted, that neurodivergent students struggle to transition into and out of university, that there is an awarding gap between students from some Black, Asian and minority ethnic backgrounds and their peers from white backgrounds, and that women are less attracted to engineering programmes than men. Taking an approach that prioritises relationship building and collaboration, this project brings stakeholders together to build skills, empathy and practical frameworks with an explicit aim of developing a more inclusive culture that can shape engineering activity for the public good.

  • Swansea University (£98,722)
    50% for the Future

The representation of women within Swansea University’s mechanical engineering cohort is 8.5%. This project strives to address this underrepresentation via evidence-based, beneficiary defined interventions. The project has an ambitious overarching aim to act as a springboard to achieve “50% for the Future” equal representation of men and women, not only studying mechanical engineering at Swansea University, but within the profession.

  • University of Central Lancashire (£100,000)
    The EASE Zone

The development of entrepreneurial skills and professional networks are at the heart of this project. In order to tackle the low rate of transfer to employment and low rate of attraction into higher education for some underrepresented groups the project is embedding employers into the teaching and learning environment to build confidence, relationships, develop solutions and facilitate a more effective transition between education and the workplace.

  • University of East London (£66,250)
    Together Empowered: voicing minority groups in tackling climate change

This project models a way of addressing the lack of Equality, Diversity and Inclusion in the engineering profession and the benefits greater inclusion can bring to the key issues of our time. It does so by facilitating the engagement of engineering students from diverse backgrounds with industry partners to develop innovative solutions to the global issue of climate. As students collaborate with professionals to develop innovative solutions to mitigate the impacts of climate change they will develop skills, confidence and a new affinity with their chosen field. Industry partners will experience the benefit of engaging with diverse perspectives and be supported to develop the skills required to lead inclusive teams and cultures.

  • University of Plymouth (£93,667)
    Embedding systemic inclusion for neurodiverse and disabled engineering students

This project takes a system level approach to the experience of inclusion/exclusion for neurodiverse and disabled engineering students. It considers interventions that motivate stronger engagement and identification with engineering for students from these groups and has an equal focus on the institutional factors that affect outcomes. Interventions cover the creation of new accountability structures, co-creation methods applied to content creation, staff training, raising awareness of the lived experience of disabled and neurodiverse students as well as the creation of tools for use across the institution and beyond.

  • University of Strathclyde (£99,751)
    Strathclyde Engineering Scholars—equal outcomes for the most disadvantaged

Half of engineering students from disadvantaged backgrounds will not complete their degree. Those who do demonstrate lower attainment and are typically men. This project establishes a comprehensive, personalised ‘in-kind’ scholarship programme enabling those from the most disadvantaged backgrounds to access and successfully navigate university engineering education with equal outcomes before transitioning to professional graduate employment in alignment with their peers.

Projects will run for between 12 to 18 months. All grant recipients have demonstrated a commitment to transformative change and will join a community of practice to facilitate learning across the cohort of grantees and the wider engineering higher education sector.

This programme is funded through the Academy’s allocation of funding from the Department for Business, Energy and Industrial Strategy.

 

Notes for Editors

  1. The Royal Academy of Engineering is harnessing the power of engineering to build a sustainable society and an inclusive economy that works for everyone. In collaboration with our Fellows and partners, we’re growing talent and developing skills for the future, driving innovation and building global partnerships, and influencing policy and engaging the public. Together we’re working to tackle the greatest challenges of our age.

Media enquiries to: Pippa Cox at the Royal Academy of Engineering Tel. +44 207 766 0745; email: Pippa.Cox@raeng.org.uk

By |2022-03-30T16:15:13+00:00March 30th, 2022|Engineering News|Comments Off on Grants totalling £1 million awarded for innovative interventions to increase D&I in engineering

Academy responds to Russian invasion of Ukraine with support for at risk researchers

The Royal Academy of Engineering will be supporting a new programme of Fellowships for researchers at risk, which will be led by The British Academy in partnership with the Council for At-Risk Academics (Cara) and other national academies. The first priority for the scheme will be researchers based in Ukraine.

Funded by the Department for Business, Energy and Industrial Strategy, the £3 million package of support will enable researchers at risk to continue their work in the UK for up to two years by providing financial support to cover salary, research expenses and living costs as well as visas.

The lead body for this programme will be the British Academy. The Royal Academy of Engineering will support the scheme by bringing together Fellows to assess relevant proposals and to help with connections between displaced engineering and technology academics and the UK research and innovation community. Any enquiries about the scheme at this stage should be sent to researchersatrisk@thebritishacademy.ac.uk.

The Royal Academy of Engineering has also signed a joint statement by EuroCASE, The European Council of Academies of Applied Sciences, Technologies and Engineering, in support of the people of Ukraine, the Academy of Technological Sciences of Ukraine, academic freedom and the autonomy of science, research and innovation. The Academy has no active programmes or projects with Russian involvement.

Professor Sir Jim McDonald FREng FRSE, the Academy’s President, says:

“Our thoughts and sympathies are with anyone affected by the Russian invasion of Ukraine, which has impacted so many lives, including displacing many academics from their home country. This is particularly concerning to the international research and innovation community as there is already a very large volume of displaced academics as a result of crises in Afghanistan, Syria and elsewhere.

“As the UK’s National Academy for engineering and technology, we will be playing a role in supporting those affected in our community through the new researchers at risk programme. We are grateful to the Department for Business, Energy and Industrial Strategy for providing funding to enable this partnership, as well as to others – in the UK and internationally – supporting at risk academics. Through collaborative action we hope to protect our fellow engineers and the vital research and innovation they undertake to shape our lives for the better, and will continue to work with partners across the engineering community to lend our support.”

 

General information for engineers from Ukraine about working in the UK can be found on the Engineering Council website at www.engc.org.uk/refugees

 

By |2022-03-27T14:25:39+00:00March 27th, 2022|Engineering News|Comments Off on Academy responds to Russian invasion of Ukraine with support for at risk researchers

New industry-academia partnerships announced to address major engineering challenges

From new techniques to improve sanitation in developing countries to improved materials for use in nuclear fusion, the Royal Academy of Engineering is supporting eight new joint industry-academia research partnerships that will address some of the most complex challenges facing modern engineers.

Focusing on industry-relevant research across the full range of engineering disciplines, the Academy’s Research Chairs and Senior Research Fellowships scheme enhances the links between academia and businesses with each of the prestigious five-year positions co-sponsored by an industrial partner. Each awardee will establish a world-leading research group in their engineering field.

Commenting on the latest announcement of five new Research Chairs and three Senior Research Fellows, Professor Karen Holford CBE FREng FLSW, Chief Executive and Vice-Chancellor, Cranfield University and Chair of the Academy’s Research Committee, says: “It is very encouraging that one of the Academy’s longest established funding programmes—now in its 35th year—received among its strongest set of applications to date and the number of awards we have made this time reflects this. I remain endlessly impressed at just how creative engineers are at investigating solutions to real-world problems and these projects will deliver societal benefit not only in the UK but also globally. The partnerships that support innovative engineering like this are vital to our future health and prosperity and the Academy values them very highly.”

The Academy has funded 203 awardees since establishing the Research Chairs and Senior Research Fellowships programme in 1986.

The five Research Chairs and three Senior Research Fellowships appointed are listed below. More detailed information on each can be found here.

Research Chairs

Professor Daniele Dini FREng, Imperial College London
Shell Global Solutions / Royal Academy of Engineering Research Chair in Complex Engineering Interfaces

Climate Change is the single biggest threat to present and future generations and meeting our ambitious targets for net zero greenhouse gas emission will require technology mobilisation on an unprecedented scale. Understanding complex engineering interfaces in products and systems in operating environments is key to successfully delivering innovation in the energy sector. In collaboration with Shell, Professor Dini will address the challenges of predicting the behaviour of these critical interfaces and develop new design strategies. Applications will include lubrication and cooling of interfaces in electric vehicles and nanoscale materials and surface design for optimised energy harvesting/storage devices.

Professor Ruth Misener, Imperial College London
BASF / Royal Academy of Engineering Research Chair in Data-driven Optimisation

Professor Misener aims to transform the intersection between AI and the chemicals industry to help improve sustainability and energy efficiency. Developing data-driven, optimal decision-making under uncertainty is key to achieving a sustainable society. When coupled with societal values and sociological research, these numerical tools can contribute towards wider sustainability objectives, blending traditional, mechanistic model-based optimisation with data-driven optimisation. The long-term vision is to repurpose machine learning methods for the chemicals industry.’

Professor Michael Templeton, Imperial College London
Oxfam and Water For People / Royal Academy of Engineering Research Chair in Global Sanitation Technology

Using robust approaches to designing, testing, and implementing novel onsite sanitation technologies and processes, Professor Templeton aims to address engineering challenges associated with achieving the UN Sustainable Development Goal of universal access to safely managed sanitation. Examples will include more affordable, easier-to-assemble septic tank designs and modular methods to treat faecal sludge in rapidly urbanising cities and emergency settings. His approach combines laboratory experiments, fieldwork, mathematical modelling, and collaboration with in-country practitioners and end users to co-develop engineering solutions that will improve the lives of the poorest members of society in developing countries.

Professor Laurence Tratt, King’s College London
Shopify / Royal Academy of Engineering Research Chair in Language Engineering

The standard Virtual Machines (VMs) for programming languages such as Ruby and Python run programs slower than state-of-the-art alternatives with Just-In-Time (JIT) compilers, but many programs are only compatible with the standard VMs, which thus remain dominant. The poor performance of standard VMs damages productivity by wasting programmer time, gives users a poor experience of the software, and contributes to climate change by requiring more servers to be used than should be necessary. Professor Tratt aims to improve the performance of programming languages such as Ruby and Python by retrofitting them with state-of-the-art research techniques taken from JIT compilers. By ‘meta-tracing’ existing VMs, RetroJITs sidesteps the problem of manually creating a JIT, while simultaneously guaranteeing compatibility with programmer expectations.

Professor Yang Hao FREng, Queen Mary University of London
QinetiQ / Royal Academy of Engineering Research Chair in Software Defined Materials

Software Defined Materials, also known as ANIMATE materials, are ones that can be modified by simply uploading and updating computer software. Professor Hao aims to develop these materials to enhance future wireless connectivity in a way that is programmable and flexible for multifunctional applications and that integrates communication, sensing and computation. Complex devices and systems made from these materials will contribute to a circular economy by significantly reducing electronic waste and the cost of materials, as well as energy consumption and CO2 emissions.

Senior Research Fellows

Dr Charles MacLeod, University of Strathclyde
Babcock International Group / Royal Academy of Engineering Senior Research Fellow in Sensor-Driven Automated High-Integrity Welding

Welding—and the successful fusion of welded joints—is a critical manufacturing process utilised in multiple international sectors including energy, construction and transport. Traditionally, welding and inspection of high-integrity joints are separate, sequential processes, reducing productivity and increasing rework if defects are only detected at completion. This fellowship seeks to introduce the volumetric imaging capability of ultrasonics directly into the welding process and aims to deliver high-integrity welds right first time, every time.

Dr Mehrnoosh Sadrzadeh, University College London
Cambridge Quantum and British Broadcasting Corporation (BBC) / Royal Academy of Engineering Senior Research Fellow in Engineered Mathematics for Modelling Typed Structures

Recent advances in machine learning have led to significant improvements in reasoning about textual data, yet they are not at a level that makes them readily applicable to all application areas. Dr Sadrzadeh is working on a mathematical model that uses the theory of tensors—higher order algebraic objects native to quantum mechanics—to unify two historically disjointed fields of logic and statistics to enrich the machine learnt features of text with their logical compositions.

Dr Edmund Tarleton, University of Oxford
UKAEA / Royal Academy of Engineering Senior Research Fellow in Materials Modelling for Fusion Energy

STEP (Spherical Tokamak for Energy Production) is an ambitious programme to deliver a prototype fusion reactor that could pave the way for commercial reactors. Nuclear fusion has the potential to provide a new source of unlimited clean energy but the materials engineering challenges are significant due to the extreme conditions inside the reactor. This fellowship will apply the latest breakthroughs in materials modelling to simulate the behaviour of irradiated engineering alloys to help guide the design of STEP and contribute to making fusion energy a reality.

Notes for Editors

  1. Research Chairs and Senior Research Fellowships aim to strengthen the links between industry and academia by supporting exceptional academics in UK universities to undertake use-inspired research that meets the needs of the industrial partners. Awardees are expected to:
  • Establish or enhance a world leading engineering research group
  • Deliver ‘use-inspired’ research that meets the needs of their industrial partners
  • Disseminate the outcomes of their research for appropriate academic impact
  • Become a self-sustaining research group by the end of the award (by securing substantial external grant income: RCUK, EU, industry, charities, etc.)

The Royal Academy of Engineering is harnessing the power of engineering to build a sustainable society and an inclusive economy that works for everyone. In collaboration with our Fellows and partners, we’re growing talent and developing skills for the future, driving innovation and building global partnerships, and influencing policy and engaging the public. Together we’re working to tackle the greatest challenges of our age.

Media enquiries to:

Pippa Cox at the Royal Academy of Engineering

T: +44 207 766 0745

E:  Pippa Cox

 

By |2022-03-24T08:22:23+00:00March 24th, 2022|Engineering News|Comments Off on New industry-academia partnerships announced to address major engineering challenges

Data-Driven Modelling of a Pelleting Process and Prediction of Pellet Physical Properties

Johnson Matthey Technol. Rev., 2022, 66, (2), 154

In the manufacture of pelleted catalyst products, controlling physical properties of the pellets and limiting their variability is of critical importance. To achieve tight control over these critical quality attributes (CQAs), it is necessary to understand their relationship with the properties of the powder feed and the pelleting process parameters (PPs). This work explores the latter, using standard multivariate methods to gain a better understanding of the sources of process variability and the impact of PPs on the density and strength of the resulting pellets. A compaction simulator machine was used to produce over 1000 pellets, whose properties were measured, with varied powder feed mechanism and powder feed rate. Process data recorded by the compaction simulator machine were analysed using principal component analysis (PCA) to understand the key aspects of variability in the process. This was followed by partial least squares (PLS) regression to predict pellet density and hardness from the compaction simulator data. Pellet density was predicted accurately, achieving an R2 metric of 0.87 in 10-fold cross-validation, and 0.86 in an independent hold-out test. Pellet hardness proved more difficult to predict accurately, with an R2 of 0.67 in 10-fold cross-validation, and 0.63 in an independent hold-out test. This may however simply be highlighting measurement quality issues in pellet hardness data. The PLS models provided direct insights into the relationships between pelleting PPs and pellet CQAs and highlighted the potential for such models in process monitoring and control applications. Furthermore, the overall modelling process boosted understanding of the key sources of process and product variability, which can guide future efforts to improve pelleting performance.

1. Introduction

Pelleting processes are used in the manufacture of a range of consumer and industrial products, including tableted pharmaceuticals, health products, consumer goods, food products and catalysts. In the manufacture of these pelleted products, it is important to produce pellets that are consistent in size, shape, composition, density and strength to ensure that they are fit for purpose. Usually, several of the aforementioned variables will be listed in the product specification along with appropriate bounds that need to be met. Poorly controlled pelleting processes can result in production of out-of-specification material, which is associated with negative economic and environmental impacts, and with potential safety implications in the case of pharmaceuticals for example. Conversely, operating pelleting processes with tight control over the CQAs can allow manufacturers to operate closer to the specification limits and to improve the product, the process economics and sustainability.

To establish tight control over a manufacturing process, it is important to control all the variables in the manufacturing process that have the potential to impact the product CQAs. Before that can be achieved, it is necessary to understand the relationships between the manufacturing variables and the product CQAs and to identify those that are most influential, as well as those that can be manipulated to control the product CQAs (1). Henceforth, knowledge of the interactions between process variables and the response of the process is critical. Typically, models are deployed to help us gain understanding of process behaviour. In the literature, there are three main approaches that have been applied to modelling pelleting process behaviour, these are mechanistic, data-driven and hybrid modelling approaches.

Traditionally, mechanistic models such as the Drucker-Prager Cap (DPC) model and finite element models have been applied to better understand the behaviour of materials undergoing compaction and their resultant physical properties. Wu et al. (2) used finite element methods (FEM) to gain understanding of the behaviour of pharmaceutical powders during compaction. The DPC model was used as the yield surface of the medium, representing failure and yield behaviours. Experiments were carried out using a compaction simulator with an instrumented die to calibrate the DPC model and to investigate the relationship between relative density of the powder bed and the applied pressure during compaction. The DPC model generated realistic powder properties that were fed into finite element analysis (FEA), which was able to accurately model the relationship between relative powder bed density and the compaction force. FEA also allowed close examination of the evolution of stress distribution during relaxation, which revealed narrow bands of localised intensive shear stresses where potential failure mechanisms can initiate. Several other works have utilised purely mechanistic approaches to model pelleting behaviour (37).

The drawback to mechanistic approaches is that they take significant human resource to develop and they are not easily adapted to new processes or scenarios. In contrast, purely data-driven approaches are very fast to develop and deploy and are easily adapted to new contexts. Several works have focused on the application of data-driven models to pelleting processes (815). Haware et al. (9) applied multivariate analysis to quantify the relationships between material properties of α-lactose monohydrate grades, PPs and the tablet tensile strength. The materials were tableted on a compaction simulator and the collected data were analysed with PCA and PLS regression. PCA provided insights into relationships between different powder and compression properties of the studied materials. PLS was successfully used to predict tablet tensile strength from the compression parameters, punch velocity and the lubricant fraction.

Li et al. (10) used multivariate analysis to evaluate the fundamental and functional properties of natural plant product (NPP) powders and their suitability for direct compaction. NPP powders were prepared by three different methods and data were produced in a single-punch compaction simulator. Results from a one-way analysis of variance, cluster analysis and PCA showed that the physical properties of the NPP powders were mainly determined by their particle structure, which derived from the preparation method. Stepwise regression analysis indicated that the compaction properties of the NPP powders could be improved by controlling physical properties, such as density, particle size, morphology and texture. Overall, the work provided guidance on the development of NPP powders for compaction.

Matji et al. (16) conducted a multivariate analysis on data from the production of ibuprofen tablets. In their study, regression methods were used to predict the CQAs of the tablets, such as disintegration time, dissolution, hardness, porosity and tensile strength, from the pressure applied in roller compaction (dry granulation) and tabletting. Tabletting compaction pressure was found to be positively correlated to disintegration time, tensile strength and hardness, and negatively correlated to the porosity and percentage of drug dissolved. Roller compaction pressure during dry granulation was observed to have those same correlations with the CQAs inversed.

More recent works have also focused on the development of hybrid models for pelleting processes, which combine mechanistic models with data-driven models to leverage benefits from both approaches (17, 18). For example, Benvenuti et al. (17) trained an artificial neural network (ANN) to model the relationship between macroscopic experimental results and microscopic parameters of discrete element method (DEM) simulations. The work showed that the ANNs could be used to generically identify DEM material parameters for any given non-cohesive granular material. Hybrid modelling approaches can offer great benefits where existing mechanistic models are available because they leverage the accuracy and interpretability of the mechanistic model, while offering increased flexibility.

In this work, a data-driven approach is used to model pelleting performance in order to gain a deeper understanding of the process behaviour and to understand the potential of such models for use in process monitoring and control. The work expands upon previous data-driven modelling of pelleting processes by exploring the impact of two different feeder mechanisms: a force feeder and a vibration feeder, operated at different speeds. Furthermore, the product studied is an inorganic catalyst material. Analysis of such materials in pelleting processes has not been widely reported in the literature. The pelleted catalyst product studied is manufactured by Johnson Matthey.

2. Equipment and Methods

2.1 Equipment

2.1.1 Compaction Simulator

The STYL’ONE Evolution (Romaco Kilian GmbH, Germany) compaction simulator, shown in Figure 1, is an instrumented single-punch pelleting machine that is designed to simulate production scale pelleting machines. The machine is fitted with an array of sensors, which record data throughout the pelleting process. The pelleting process can be broken down into four main events in sequence. These are: (a) filling of the die; (b) pre-compaction of the powder to rearrange the particles; (c) main-compaction of the powder to form the pellet; and (d) ejection of the pellet from the die.

Fig. 1.

Photos of the compaction simulator equipment: (a) the paddle feeder mechanism; (b) the vibration feeder; (c) blades in the paddle feeder mechanism which can be flipped upside down to change the blade angle; (d) the upper punch and the feeder mechanism, which swivels out of the path of the upper punch after filling the die

Photos of the compaction simulator equipment: (a) the paddle feeder mechanism; (b) the vibration feeder; (c) blades in the paddle feeder mechanism which can be flipped upside down to change the blade angle; (d) the upper punch and the feeder mechanism, which swivels out of the path of the upper punch after filling the die

2.1.2 Hardness Tester

The ST50 (SOTAX AG, Switzerland) is a semi-automatic tablet hardness tester, which was used to measure four properties of the tablets: weight, diameter, thickness (from which density is calculated) and hardness.

2.2 Experimental Work

The compaction simulator was used to produce approximately 200 pellets for each of six experimental runs that used different powder feeder setups. Two different powder feeder systems were used: (a) a force feeder which pushes powder over the die to allow it to fill; and (b) a vibration feeder which vibrates so that powder falls into the die. The force feeder was used in both a left and right orientation, which changes the angle of the blade that pushes the powder over the die. Finally, the feeders were operated at different speeds. The six experiments were assigned the following labels for convenience in the discussion:

  • ‘Left40’ – force feeder in the left orientation at speed 40%

  • ‘Left70’ – force feeder in the left orientation at speed 70%

  • ‘Right70’ – force feeder in the right orientation at speed 70%

  • ‘Vib20’ – vibration feeder at speed 20%

  • ‘Vib38’ – vibration feeder at speed 38%

  • ‘Vib70’ – vibration feeder at speed 70%.

The compaction simulator yields two datasets for analysis. The first dataset, X1, is a two-dimensional (2D) matrix containing both measured and derived variables (M) for the numerous pellets produced (N). This data table contains a summary of the pelleting process performance with the maximum force and displacement values in pre-compaction, main-compaction and ejection, as well as various derived parameters, for example, the compression energy. A full list of the variables in X1 is provided in Appendix A in the online Supplementary Information. The second dataset, X2, is a three-dimensional (3D) data matrix consisting of data collected for each measured process variable (K) regularly sampled over time (J) for numerous pellets produced (N). In contrast to X1 which contains selected measured values and derived parameters, X2 contains the raw data for the eight variables listed in Table I, recorded by the compaction simulator at 0.01 ms intervals.

Table I

Variables Recorded by the Compaction Simulator in a Time Series Format, X2

1 Lower punch displacement 5 Upper punch force
2 Upper punch displacement 6 Punches force difference
3 Distance between punches 7 Upper punch linear speed
4 Lower punch force 8 Lower punch linear speed

Pellets collected from the compaction simulator were manually transferred to the ST50 machine to be measured. The pellets were retained in the order that they were ejected to ensure that the pellet measurements could be correctly aligned with the compaction simulator data. The measured properties of the produced pellets (such as density and hardness) are recorded in the 2D data matrix, Y. In this work, the dependent variables of interest were pellet density and hardness.

2.3 Principal Component Analysis

In this work, PCA was implemented on the summary data X1 to understand the correlation between these variables and the similarities and differences between different shoe speed and feeder mechanism combinations. PCA involves decomposing the covariance matrix into a number of principal components (PCs), P, each of which is a weighted linear combination of the original variables. The scores of the PCA model, T, are the original data projected onto the new latent variable space. Plotting the scores against one another facilitates observation of the variance in the data in the latent variable space and allows patterns and clusters to be identified.

2.4 Partial Least Squares Regression

PLS regression was used to model the relationship between the compaction simulator variables in X2 and the measured pellet properties of interest: hardness and density. For model development, the data were split into a training set (80% of samples) and hold-out test set (20% of samples) for an independent test of model performance at the end of the process. Variable selection was carried out by the variable importance for projection (VIP) selection method (19). This involved fitting an initial model using all the variables and then selecting variables to keep based on their VIP score. Variables with a VIP score above 1 were selected. The optimal number of latent variables was determined based on minimisation of the mean absolute error (MAE) in 10-fold cross-validation. Python version 3.7 was used for all modelling work.

3. Pellet Density and Hardness Distributions

In order to compare the effect of the powder feeder mechanism and speed on pellet density and hardness, the distributions of pellet density and hardness were plotted for each experiment and pairwise t-tests were used to check for statistically significant differences in average pellet density and hardness. Figures 2(a) and 2(b) show the distributions of pellet density and hardness, respectively.

Figure 2 shows that the feeder configuration greatly influenced the level of variability in pellet density and hardness. In particular, experiments ‘Left40’ and ‘Right70’ produced a large amount of variability, while the vibration feeder resulted in much less variability at all speeds tested. The pairwise t-tests revealed statistically significant shifts in average pellet density and pellet hardness between the six experiments. For example, with the vibration feeder and the force feeder in ‘left’ orientation, increasing the speed of the feeder resulted in statistically significant increases in pellet density. Importantly, the distributions indicate that the vibration feeder results in more consistent pellet density and hardness than the force feeder, although the force feeder may be used in the ‘left’ orientation at high speed to minimise variability.

Fig. 2.

Boxplot and whisker diagrams showing the distributions of: (a) pellet density; and (b) pellet hardness, for each experiment. The orange line indicates the median, the edges of the box indicate the upper and lower quartiles and the whiskers mark the upper and lower quartiles extended by 1.5 times the interquartile range. The data shown is mean centred with unit variance

Boxplot and whisker diagrams showing the distributions of: (a) pellet density; and (b) pellet hardness, for each experiment. The orange line indicates the median, the edges of the box indicate the upper and lower quartiles and the whiskers mark the upper and lower quartiles extended by 1.5 times the interquartile range. The data shown is mean centred with unit variance

4. Principal Component Analysis of the Compaction Simulator Summary Data

PCA was used to assess the correlations between the variables in the compaction simulator summary dataset and their contributions to the overall process variability. The PCA model presented here was built on summary data from the experiments using the force feeder, namely ‘Left40’, ‘Left70’ and ‘Right70’. Figure 3 shows the variance explained by each PC in an eight PC model. The first PC explains 49.3% of the variation in the data, while PCs 2 and 3 explain 14.1% and 7.2%, respectively. Collectively, the first three PCs capture 70.6% of the variance in the data, while PCs 4 and beyond explain less than 5% of the variance each. Due to the exploratory nature of this analysis, it is preferable to consider all the PCs that are likely to be informative; however, determination of the number of PCs to include in the model is not critically important. In this work, the first three PCs were analysed because PC 4 and beyond capture very little variance and likely feature a low signal to noise ratio.

Fig. 3.

Explained variance versus number of PCs in the PCA model, which is built on summary data from the three experiments using the force feeder mechanism: ‘Left40’, ‘Left70’ and ‘Right70’

Explained variance versus number of PCs in the PCA model, which is built on summary data from the three experiments using the force feeder mechanism: ‘Left40’, ‘Left70’ and ‘Right70’

The scores of the PCA model for PCs 1 to 3 are displayed in Figure 4 and the most important variables – those with loadings of the highest magnitude for each PC – are displayed in Figure 5. PC 1 captures variation in the data that is present on a pellet-to-pellet basis within each of the three experimental runs and the scores overlap, i.e. there is no separation of the scores by experiment on PC 1. Figure 5(a) shows that the 49% of variation captured in PC 1 is attributed to the forces and energies involved in the pre-compaction, main-compaction and ejection events. The model also indicates that the forces and energies listed in Figure 5(a) are all positively correlated with one another.

Fig. 4.

Plots showing the scores of the PCA model for: (a) PC 1 versus PC 2; and (b) PC 1 versus PC 3. The percentage of variance explained by each PC is displayed in the brackets on each axis

Plots showing the scores of the PCA model for: (a) PC 1 versus PC 2; and (b) PC 1 versus PC 3. The percentage of variance explained by each PC is displayed in the brackets on each axis

Fig. 5.

Loadings for selected variables with the largest magnitude loadings for: (a) PC 1; (b) PC 2; (c) PC 3

Loadings for selected variables with the largest magnitude loadings for: (a) PC 1; (b) PC 2; (c) PC 3

In contrast to PC 1, PC 2 captures variation that separates the different experiments. Figure 5(b) shows this is largely attributed to differences in die filling height, ejection force and some derived parameters which are determined from die filling height, such as the compression and relaxation times. The large spread of the red markers in the vertical plane, corresponding to the ‘Right70’ experiment, indicates that this set up resulted in more variability in the die filling height compared to ‘Left40’ and ‘Left70’. The compaction simulator was calibrated to produce pellets of the same weight for each experiment; therefore, it is likely that the different feeder setups result in a different bulk density of the powder when it is initially filled into the die, explaining the differences in filling height.

Figure 4(b) shows the within group variability that is captured by PCs 1 and 3. All of the experiments overlap on PCs 1 and 3, while ‘Right70’ spreads across the largest area, indicating that this experiment has the largest variability on these PCs. Observing the distributions of the response variables, it is clear that ‘Right70’ produces pellets with the largest variation in pellet density and hardness. As shown in Figure 5(c), the main variables represented by PC 3 are the energies involved in the pellet ejection and the elastic energy calculated for the main-compaction event.

While the ejection plastic energy and compression energy correlated with the pre-compaction and main-compaction forces, the ejection energy and the ejection force appeared as key variables in PCs 2 and 3, indicating that that there is variance in the ejection force that is uncorrelated to pre-compaction and main-compaction force. PC 2 shows that ejection force is positively correlated to die filling height. An additional factor that may be influencing the ejection force that is not monitored, so not captured by the dataset, is the amount of lubricant present in the material.

5. Modelling Pellet Critical Quality Attributes

PLS regression models were developed to predict pellet density and pellet hardness, using the methodology outlined in Section 2. Table II shows the performance metrics obtained from cross-validation and testing of the two models for pellet hardness and density.

Table II

Performance Metrics Describing the Quality of the Model Fit in Cross-Validation and Testing

No. of latent variables Cross-validation R2 Cross-validation MAE Test R2 Test MAE
Density PLS model 4 0.87 0.09 0.86 0.08
Hardness PLS model 3 0.67 0.44 0.63 0.53

The performance metrics shown in Table II are for the models obtained after the variable selection procedure and tuning of the number of latent variables included in the model, as described in Section 2.4. The models for both pellet hardness and density performed well in cross-validation and testing. Pellet hardness however proved to be the more difficult to model and predict accurately, as the performance metrics demonstrate. The pellet density PLS model explained approximately 86% of the variance in both 10-fold cross-validation and independent testing. The MAE for the pellet density model was 0.17 and 0.18 in 10-fold cross-validation and independent testing, respectively. The cross-validation metrics indicate that the pellet density PLS model should have excellent predictive performance and the independent test on the held-out data supports this. The fit of the density PLS model to the training data and the testing data is shown in Figure 6.

Fig. 6.

Plots showing the fit of the PLS model for pellet density. The plots show: (a) the measured versus fitted values for the training data; (b) the residuals versus fitted values for the training data; (c) the measured versus predicted values for the test data; (d) the residuals versus predicted values for the test data

Plots showing the fit of the PLS model for pellet density. The plots show: (a) the measured versus fitted values for the training data; (b) the residuals versus fitted values for the training data; (c) the measured versus predicted values for the test data; (d) the residuals versus predicted values for the test data

Figure 6 shows that the density PLS model fits the data well in both training and testing, with the exception of a few outliers, which are likely to result from a mismatch between the X and Y data that occurred during the experimental process.

The pellet hardness PLS model explained approximately 67% and 63% of the variance in pellet hardness in 10-fold cross-validation and testing, respectively. The MAE for this model was 0.44 and 0.53 in cross-validation and testing, respectively. While this performance is not as good as the pellet density model, it indicates that the model has good predictive capability. Observation of the measured versus fitted values and the residuals in Figure 7 reveals that the model is good at fitting and predicting the low-hardness pellets but is far less accurate for the high-hardness pellets. The residuals in Figure 7(b) and 7(d) ‘fan-out’ and become much larger from –1 and above on the x-axis (scaled pellet hardness). The increasing residuals with increasing pellet hardness could be related to missing factors that are not captured in the compaction simulator data. It could however equally be the result of changes in the sensitivity of the measurement device at different hardness levels. Unfortunately, it is difficult to gain a good understanding of the reliability of the hardness measurement due to the test being destructive. Given that the model offers accurate prediction of low hardness pellets, the model could still be valuable in a process monitoring or supervisory process control applications, where identification of low hardness pellets could allow operators to intervene early and adjust PPs accordingly.

Fig. 7.

Plots showing the fit of the PLS model for pellet hardness. The plots show: (a) the measured versus fitted values for the training data; (b) the residuals versus fitted values for the training data; (c) the measured versus predicted values for the test data; (d) the residuals versus predicted values for the test data

Plots showing the fit of the PLS model for pellet hardness. The plots show: (a) the measured versus fitted values for the training data; (b) the residuals versus fitted values for the training data; (c) the measured versus predicted values for the test data; (d) the residuals versus predicted values for the test data

5.1 Interpretation of the Model Coefficients

The key predictive variable identified in both the pellet hardness and pellet density PLS models was the lower punch force. This variable featured the largest magnitude standardised regression coefficient in both models and correlated positively with both density and hardness. For the pellet density PLS model, the variable selection process identified four variables as important: (a) the lower punch force; (b) the punches’ force difference; (c) the upper punch displacement; and (d) the lower punch displacement. The lower punch force was the key predictor variable. The other three variables however contributed positively to the cross-validation and testing performance metrics. The metrics dropped slightly when these features were left out. The variable selection process for the pellet hardness model revealed that the lower punch force was the only significant variable contributing to this model.

Figures 8(a) and 8(b) show the time series profiles for the lower punch force coloured by pellet density and hardness, respectively. The plots facilitate visualisation of the correlations between density and lower punch force and hardness and lower punch force. In both cases, it is clear that the lighter coloured lines (high density and hardness) correspond to high forces in pre-compaction, main-compaction and ejection, while the darker lines (low density and hardness) correspond to lower forces. In other words, Figures 8(a) and 8(b) show that lower punch force correlates positively with density and hardness, respectively. The separation of the colours is clearer in Figure 8(a) and the colour gradient appears to be linear, whereas in Figure 8(b) the separation of the light and dark colours is less clear. In particular, the light colours corresponding to high hardness do not separate well from the red coloured average hardness pellets. This reflects the poorer predictive capability of the hardness PLS model, which produced larger errors for high hardness pellets.

Fig. 8.

The lower punch force profiles of the pellets from all six experiments coloured by: (a) pellet density; and (b) pellet hardness. The three peaks on each graph correspond to the pre-compaction, main-compaction and ejection events

The lower punch force profiles of the pellets from all six experiments coloured by: (a) pellet density; and (b) pellet hardness. The three peaks on each graph correspond to the pre-compaction, main-compaction and ejection events

6. Conclusions

The workflow for this study began with exploratory data analysis to observe and compare the distributions of pellet density and hardness and to understand the variance and correlation in the compaction simulator data. The distribution plots clearly showed that feeder configuration impacted both the average pellet density and hardness and the level of variability in those properties. Pairwise t-tests revealed that the shifts in mean density and hardness were significant in many cases. To minimise overall variability, the vibration feeder mechanism should be favoured over the force feeder mechanism, however, the force feeder mechanism can be optimised for consistency by running in the ‘left’ orientation at higher speeds.

PCA showed that the most important component of variance in the dataset was attributed to the forces and energies involved in the pre-compaction, main-compaction and ejection events. The main differences between the force feeder experiments that were highlighted were due to the die filling height and associated parameters, and some observable differences in overall variability. The high level of variability in pellet density and hardness for experiments ‘Right70’ and ‘Left40’ was also reflected in the energies and forces recorded in the compaction simulator summary data through the PC scores.

The PLS models that were developed for pellet density and pellet hardness performed well in cross-validation and testing. The key predictor variable in the models for pellet density and hardness was the lower punch force, which correlated positively with both. The density PLS model explained around 86% of the variance in the response, while the hardness PLS model explained around 65%. Both models offer predictive capability, however, the hardness model underperforms at predicting the medium to high hardness pellets. Unfortunately, it is difficult to gain a good understanding of the reliability of the hardness measurement due to the test being destructive. The questions raised in this study highlight the need to further validate the pellet hardness measurement in future work. For now, the learning from this work indicates that the pellet density can be used more reliably as an indicator of product quality than pellet hardness. Pellet density should therefore be the preferred basis for process monitoring and control applications.

If a similar model for pellet density can be developed using the data available from production scale pelleting machines, then there would be the potential for such a model to be used for process monitoring and control. This could provide real-time process monitoring that greatly improves upon existing techniques for monitoring pelleting performance, which are based on random sampling and testing of the pellets. The information could be used by plant operators at a supervisory level or in an automated control system to help inform and guide decision making to keep the process on track and producing on-specification material.

By |2022-03-18T13:35:42+00:00March 18th, 2022|Weld Engineering Services|Comments Off on Data-Driven Modelling of a Pelleting Process and Prediction of Pellet Physical Properties

Regional Talent Engines programme launches to support aspiring entrepreneurs

  • The Royal Academy of Engineering’s Enterprise Hub is opening applications for the September intake of its Regional Talent Engines programme for people based in Northern Ireland, North West England, North East England, and Yorkshire & the Humber
  • Successful applicants will receive a £20,000 grant and six months’ support to develop ideas for engineering innovation into startups
  • Applicants must hold a Further Education technical qualification or be an experienced mid-late career engineer

The Royal Academy of Engineering’s Enterprise Hub has opened a new round of applications for its Regional Talent Engines programme to support entrepreneurial mid-late career engineers and individuals from vocational backgrounds to develop innovative ideas. The Enterprise Hub will grant successful applicants £20,000 equity-free funding for living and business costs to help grow their ideas into startup businesses.

Designed to boost innovation in regions across the UK, applicants must be based in Northern Ireland, North West England, North East England, or Yorkshire & the Humber. The programme is targeted at people who either hold a technical qualification from a Further Education college or are experienced mid-late career engineers looking to bring an innovative idea to market.

In addition to funding, successful applicants will also receive six months’ support to prepare them for commercialising their engineering solutions. The Enterprise Hub will provide expert mentoring, training, one-to-one coaching, access to the Academy’s diverse network and meeting space in the Academy’s Taylor Centre. After completing the programme, participants will be invited to become Hub Members with lifetime support, including access to the Enterprise Hub’s facilities, training opportunities, and network of Academy Fellows, investors, experts, and advisors.

Speaking about the launch of the new programme, Ana Avaliani, Director of Enterprise and Sustainable Development at the Royal Academy of Engineering, said, “Our Regional Talent Engines programme supports ambitious mid-late career engineers and individuals with technical backgrounds who can often be underrepresented in the enterprise community. This programme hopes to cultivate their passion for creativity, problem-solving, and design to launch their own startups. With an emphasis on mentoring and skills development, participants can gain the confidence to begin new careers as entrepreneurs with equity-free financial backing from the Royal Academy of Engineering’s Enterprise Hub. We encourage anyone with an idea for an engineering or technological solution to apply.

“Having recently started the programme in Northern Ireland, North West England, North East England, and Yorkshire & the Humber, we are keen to champion diverse talent from across the regions of the UK. Our long-term aim is to strengthen local entrepreneurial ecosystems by helping launch successful engineering and technology businesses, creating jobs and economic prosperity.”

Applications are open until 23 May 2022 with the programme commencing in early September. Full details of the programme including guidance notes can be viewed on the Academy’s website. All applications for each regional programme must be submitted on the online grant system.

Notes for Editors

  1. The Enterprise Hub was formally launched in April 2013. Since then, we have supported over 290 researchers, recent graduates and SME leaders to start up and scale up businesses that can give practical application to their inventions. We’ve awarded over £11 million in grant funding, and our Hub Members have gone on to raise over £800 million in additional funding.
  2. The Royal Academy of Engineering is harnessing the power of engineering to build a sustainable society and an inclusive economy that works for everyone. In collaboration with our Fellows and partners, we’re growing talent and developing skills for the future, driving innovation and building global partnerships, and influencing policy and engaging the public. Together we’re working to tackle the greatest challenges of our age.

For media enquiries please contact: Chris Urquhart at the Royal Academy of Engineering Tel. +44 207 766 0725; email: Chris.Urquhart@raeng.org.uk

By |2022-03-17T00:01:00+00:00March 17th, 2022|Engineering News|Comments Off on Regional Talent Engines programme launches to support aspiring entrepreneurs

Towards the Enhanced Mechanical and Tribological Properties and Microstructural Characteristics of Boron Carbide Particles Reinforced Aluminium Composites: A Short Overview

Johnson Matthey Technol. Rev., 2022, 66, (2), 186

1. Introduction

Metal matrix composites (MMCs) are systematic combinations of two or more materials (one of the materials is a metal) engineered to achieve tailored properties (1). Thus, engineered MMCs have two or more chemically and physically distinct phases that are suitably distributed to provide properties not attainable with either of the individual phases (2). AMMCs exhibit better mechanical and physical properties than the aluminium-matrix alloy (35). The hardness and strength of AMMCs are significantly higher than that of the aluminium-matrix alloy, leading to improved wear resistance (6). AMMCs have found applications in aerospace, automotive, nuclear, telecommunications (7) and marine industries (6). The applications of AMMCs in the automotive and aerospace industry sectors can reduce fuel usage by replacing steel and cast-iron parts with lighter AMMCs. Some of these applications include pistons, piston rings, cylinder liners, connecting rods (1), cylinder blocks, driveshafts and brake drums (6). The tribological behaviour of particle reinforced AMMCs has been regularly reported. However, most of the studies have analysed the tribological behaviour of composites reinforced with SiC and Al2O3 particles. Besides these conventional reinforcement particles, aluminium alloys also can be reinforced with h-BN (8), TiC (9), TiO2 (10), ZrO2 (10) and B4C (11) to impart wear resistance. Studies on AMMCs reinforced with B4C particles have been limited mainly due to the higher cost of B4C particles than SiC and Al2O3 particles (12). Al-B4C composites are commonly used in automotive, sports (7) and neutron shielding applications (13).

B4C possesses excellent properties such as high hardness, low density, high melting point, chemical inertness and wear resistance, making it suitable for many high-performance applications (14). The hardness of B4C (Vickers Hardness under the load of 0.981 N (HV0.1) = 3200) is far superior to the hardness of conventional reinforcement particles, SiC (HV0.1 = 2500) and Al2O3 particles (HV0.1 = 1900) (15). The density of B4C (2.52 g cm–3) (16) is less than the density of solid aluminium (2.70 g cm–3) (17), which significantly improves specific properties. The densities of SiC, Al2O3 and B4C are 3.21 g cm–3, 3.92 g cm–3 and 2.52 g cm–3, respectively. The density of molten aluminium is 2.38 g cm–3 (17). Hence, it is evident that the difference in density between molten aluminium and B4C is lower when compared to the difference in density between molten aluminium and conventional reinforcement phases (SiC and Al2O3). This phenomenon minimises the sedimentation of B4C particles at the crucible bottom during stir casting (12). The abrasive resistance of B4C (0.4–0.422 (expressed in arbitrary units)) is higher than that of SiC (0.314 (expressed in arbitrary units)) due to its high hardness and strength (18).

This overview aims to discuss the microstructural characteristics, mechanical properties and tribological behaviour of Al-B4C composites. The different properties and microstructural characteristics of Al-B4C, Al-SiC and Al-Al2O3 composites are compared. Furthermore, the statistical significance of physical parameters (applied load, sliding speed and sliding distance) on the tribological behaviour of the composites is analysed. However, the literature that compares the microstructural characteristics, mechanical properties and tribological behaviour of Al-B4C, Al-SiC and Al-Al2O3 composites are insufficient. The literature on the statistical analysis of the tribological behaviour of Al-B4C composites is also sparse. Despite these shortcomings, this overview discusses the mechanical and tribological properties of the composites mentioned above. Section 2 gives a brief insight into the fabrication of Al-B4C composites through the stir casting technique. Section 3 compares the microstructural characteristics of Al-B4C, Al-SiC and Al-Al2O3 composites. Section 4 analyses the tribological behaviour of Al-B4C composites. The tribological properties of Al-B4C and Al-SiC composites are also compared in Section 4.

2. Fabrication of Aluminium-Boron Carbide Composites

Many methods are available to fabricate MMCs, and the commonly used two primary processes are: (a) solid-state processes; and (b) liquid state processes (6). Liquid state processes include infiltration techniques (pressure infiltration and squeeze casting) and dispersion techniques (stir casting and compocasting). The stir casting (vortex addition) technique has been the most studied method for producing AMMCs due to its simplicity, flexibility, commercial viability and ease of processing (19, 20). The core requirement of the stir casting of MMCs is close contact and bonding between the ceramic phase and the molten alloy. The wettability of the ceramic particles to molten melt is inherently weak. Thus, intimate contact and bonding between them are enhanced by artificially inducing wettability or using an external force to weaken the thermodynamic surface energy barrier. One of the commonly used methods to incorporate, wet and uniformly distribute the ceramic particles is to add the particles to a vigorously stirred molten melt. The stirring action (external force) enhances wetting and ensures homogenous dispersion of reinforcement particles through the matrix. Wettability is also induced artificially by modifying the chemical composition of the matrix alloy: small quantities of reactive elements, such as magnesium, calcium, lithium or sodium, are added (20). The addition of magnesium improves the wettability of Al2O3 and SiC particles to the alloy matrix, which increases the wear resistance of Al-Al2O3-SiC hybrid composites (21).

Lashgari et al. (22) reported that during stir casting, the addition of magnesium improved wettability between the matrix (A356) and reinforcement particles (B4C). The reinforcement particles were preheated to enhance the wettability of the ceramic particles with the metal matrix. Details of the stir casting technique and the particle size of B4C particles are shown in Table I. Mahesh et al. (23) preheated the reinforcement particles to remove impurities and to enhance the wetting characteristics. Canakci et al. (24) observed that the vortex formed due to stirring holds the reinforcement particles dispersed in the melt, which ensured their uniform distribution. After particle addition, the composite melt is poured into a permanent mould. Kalaiselvan et al. (25) fabricated AA6061-B4C composites reinforced with 4 wt%, 6 wt%, 8 wt%, 10 wt% and 12 wt% B4C particles through the stir casting process. Uniform distribution of reinforcement particles was observed at all weight percent additions. Furthermore, X-ray diffraction (XRD) analysis of the composites revealed that there is no reaction of the AA6061 matrix with the B4C particles. This phenomenon shows the thermodynamic stability of B4C particles at the temperature (920°C) used for the stir casting of AA6061-B4C composites. The parameters used by Lashgari et al. (22), Mahesh et al. (23), Canakci et al. (24), Kalaiselvan et al. (25), Toptan et al. (26), Mazahery and Shabani (27), Toptan et al. (28) and Baradeswaran and Perumal (29) for the stir casting of Al-B4C composites are listed in Table I.

Table I

Details of Stir Casting Technique and Particle Size of Boron Carbide Particles

Parameters of stir casting and particle size of B4C Literature


Lashgari et al. (22) Mahesh et al. (23) Canakci et al. (24) Kalaiselvan et al. (25) Toptan et al. (26) Mazahery and Shabani (27) Toptan et al. (28) Baradeswaran and Perumal (29)
Composite type A356-B4C AA6061-B4C AA2014-B4C AA6061-B4C AA1070-B4C and AA6063-B4C A356-B4C AlSi-CuMg-B4C AA7075-B4C
Temperature of melt, °C 730 700 920 850 750 850 850
Stirring speed, rpm 720 600–700 450 and 350a 300 500 600 1000 500
Stirring time, min 20 3 and 4a 5 5 4
Pouring Temperature, °C 730 730 680 850 900 850
Particle size 65 μm (APSb) 20 μm (APS) 85 μm (APS) 10 μm (mesh size) 32 μm (APS) 1–5 μm 32 μm (APS) 16–20 μm
Particle preheat temperature, °C 250 250–600 400 400 850
Melting environment Argon Room Argon Room Room Argon Vacuum Room

3. Microstructural Characteristics and Mechanical Properties

Shorowordi et al. (30) studied the matrix-reinforcement interface of Al-20 vol% SiC (Figure 1(a)), Al-20 vol% Al2O3 (Figure 1(b)) and Al-13 vol% B4C (Figure 1(c)) composites produced through the stir casting technique.

Fig. 1.

Scanning electron microscopy (SEM) micrographs of the matrix-reinforcement interface: (a) Al-20 vol% SiC composite; (b) Al-20 vol% Al2O3 composite; and (c) Al-13 vol% B4C composite. Reprinted from (30), Copyright (2003), with permission from Elsevier

Scanning electron microscopy (SEM) micrographs of the matrix-reinforcement interface: (a) Al-20 vol% SiC composite; (b) Al-20 vol% Al2O3 composite; and (c) Al-13 vol% B4C composite. Reprinted from (30), Copyright (2003), with permission from Elsevier

The microstructure and interfacial characteristics of Al-SiC, Al-Al2O3 and Al-B4C composite are extensively reported in this study. The interfacial reaction product is not observed for the Al-B4C composite, unlike the Al-SiC composite, which revealed an apparent interfacial reaction. Furthermore, it was observed from the fracture surfaces that Al-B4C composite exhibited the strongest bonding at the matrix-reinforcement interface, and the bonding of Al-SiC composite is weak due to the low adherence of aluminium matrix to the SiC particles. In Al-Al2O3 composites, voids and microvoids are observed at the interface, indicating poor bonding. Moreover, particle distribution is found to be better for Al-B4C composite when compared to Al-SiC and Al-Al2O3 composites.

The mechanical properties of spray-cast Al 6061-15 vol% B4C and aluminium 6061-15 vol% SiC composites have been reported (31). The B4C reinforced composite exhibited significantly greater strength, strain to failure in tension and strain hardening compared to the SiC reinforced ones, due to strong bonding at the Al-6061-B4C interface (31). The strong bonding at the interface is ascribed to the chemical stability of B4C particles, the absence of interfacial reaction products and the excellent wetting of the particles by the matrix alloy. The wetting characteristics of the Al-6061-SiC composite are weaker than that of the Al-6061-B4C composite.

3.1 Influence of Boron Carbide Particles Addition on Hardness

Kalaiselvan et al. (25) studied the relationship between the weight percent addition of B4C particles and the hardness of the composites. Al-B4C composites were reinforced with 4 wt%, 6 wt%, 8 wt%, 10 wt% and 12 wt% B4C particles and fabricated through the stir-casting method. It can be observed from Figure 2 that both the micro- and macrohardness of the Al-B4C composites increase linearly with the increase in weight percent addition of B4C particles. This observation agrees with that of Hynes et al. (32), who reported that the microhardness of the aluminium-matrix composites increased with an increase in B4C particles addition of 5 wt%, 10 wt% and 15 wt%. Furthermore, almost unvaryingly, the microhardness of materials is higher compared to its standard macrohardness (33).

Fig. 2.

Effect of weight percent addition of B4C particles on the hardness of AA6061-B4C composites. Reprinted from (25), Copyright (2011), with permission from Elsevier

Effect of weight percent addition of B4C particles on the hardness of AA6061-B4C composites. Reprinted from (25), Copyright (2011), with permission from Elsevier

During hardness testing, the pressure induced by the indenter is partially accommodated by the plastic flow of the matrix but mainly by localised increase in the weight percent addition of hard reinforcement particles (34).

It has been reported that hard reinforcement particles inherently exhibit considerable resistance to indentation by the hardness tester. Hence the increase in weight percent addition of reinforcement particles leads to an increase in hardness. Furthermore, it has been reported that bonding between the matrix and reinforcement particles and the matrix-reinforcement interface plays a significant role in the hardness of the composites. The strong bonding between the matrix and reinforcement and their interface, which is free of reaction products, improves the capability of the matrix to transfer the indentation load to reinforcement particles. This phenomenon, in turn, leads to an increase in the hardness of the composites (25).

4. Tribological Properties of Boron Carbide Reinforced Aluminium Matrix Composites

An overview of the literature on the tribological properties of Al-B4C composites is provided in the following subsections. The tribological properties are controlled by the physical parameters (applied load, sliding speed and sliding distance) and material parameters (the type of reinforcement and volume fraction) (35). Hence, the overview is focused on analysing the influence of physical and material parameters on the dry sliding tribological behaviour of the composites. The relevant details of sliding wear studies are shown in Table II.

Table II

Details of Sliding Wear Studies of Boron Carbide Reinforced Aluminium Matrix Composites

Features of interest Literature


Lashgari et al. (36) Tang et al. (37) Sharifi et al. (38) Shorowordi et al. (39) Shorowordi et al. (40) Toptan et al. (28)
Process route Stir casting Powder metallurgy Powder metallurgy Stir casting Stir casting Stir casting
Particle size 65 μm (APS) 10–60 nm 40 μm 40 μm 32 μm (APS)
Weight or volume fraction of reinforcement particles 10 vol% B4C 5 wt% and 10 wt% B4C 5 wt%, 10 wt% and 15 wt% nano-B4C 13 vol% SiC and 13 vol% B4C 13 vol% SiC and 13 vol% B4C 15 vol% and 19 vol% B4C
Secondary process Heat treatment Hot rolling Hot extrusion Hot extrusion
Type of tribo-couple A356-B4C and DIN 100Cr6 steel disc AA5083-B4C and 45 carbon steel disc AISI 52100 steel and Al-B4C disc Al-SiC, Al-B4C and phenolic brake pad (disc) Al-SiC, Al-B4C and phenolic brake pad (disc) AISI 4140 steel and AlSi9Cu3Mg-B4C disc
Type of tribometer Pin-on-disc Pin size: 5 mm × 15 mm Pin-on-disc Pin diameter: 4 mm Pin-on-disc Disc diameter: 50 mm Pin-on-disc Pin size: 5 mm × 12 mm Disc size: 65 mm × 10 mm Pin-on-disc Pin size: 5 mm × 12 mm Disc size: 65 mm × 10 mm Pin-on-disc Pin diameter: 5 mm
Test parametersa L: 20 N, 40 N and 60 N S: 0.5 m s–1 D: 1000 m L: 50 N, 65 N and 80 N S: 0.6 m s–1, 0.8 m s–1 and 1.25 m s–1 D: up to 3000 m Mass loss measurement interval: 500 m L: 20 N S: 0.08 m s–1 D: varied up to 600 m Mass loss measurement interval: 25 m L: 15 N S: 1.62 m s–1 and 4.17 m s–1 D: 5832 m L: 15 N, 30 N, 44 N and 60 N S: 1.62 m s–1 D: varied up to 6000 m Total test duration: 1 h L: 20 N and 40 N S: 0.02 m s–1 and 0.03 m s–1 D: 200 m and 400 m
Wear mechanisms Delamination Abrasion and adhesion Delamination and abrasion Delamination and abrasion Abrasion, delamination and adhesion

4.1 Effect of Variation of Applied Load

Table II gives information regarding the materials, fabrication route, secondary process and tribological test parameters used in the study of Lashgari et al. (36). It is observed from Figure 3 that the wear resistance of heat-treated A356-10 vol% B4C composites decreased with an increase in applied load from 20 N to 60 N, due to the induction of different wear mechanisms. At 20 N applied load, long and continuous grooves (Figure 4(a)) are observed on the worn surface. The formation of these grooves is attributed to the induction of abrasive (cutting and ploughing) wear mechanisms.

Fig. 3.

Variation of wear resistance with applied load for a sliding speed 0.5 m s–1 and sliding distance 1000 m (not heat treated A356 alloys, heat treated A356 alloys, not heat treated A356-10 vol% B4C composites and heat treated A356-10 vol% B4C composites). Reprinted from (36), Copyright (2010), with permission from Elsevier

Variation of wear resistance with applied load for a sliding speed 0.5 m s–1 and sliding distance 1000 m (not heat treated A356 alloys, heat treated A356 alloys, not heat treated A356-10 vol% B4C composites and heat treated A356-10 vol% B4C composites). Reprinted from (36), Copyright (2010), with permission from Elsevier

Fig. 4.

SEM micrographs of worn surfaces of heat treated A356-10 vol% B4C composites: (a) Long and continuous grooves at 20 N; (b) cracks at 60 N (sliding direction is indicated as SD). Reprinted from (36), Copyright (2010), with permission from Elsevier

SEM micrographs of worn surfaces of heat treated A356-10 vol% B4C composites: (a) Long and continuous grooves at 20 N; (b) cracks at 60 N (sliding direction is indicated as SD). Reprinted from (36), Copyright (2010), with permission from Elsevier

Furthermore, the investigators observed that at applied loads of 20 N and 40 N, the B4C particles remained unfractured and carried the surface load, which resulted in a relatively undamaged worn surface. However, as the applied load was increased to 60 N, the worn surface underwent cracking parallel to the sliding direction (Figure 4(b)), and the primary wear mechanism induced was delamination.

4.2 Effect of Variation of Sliding Distance and Sliding Speed

Table II gives information regarding the materials, fabrication route, secondary process and tribological test parameters used in Tang et al. (37). The variation of AA5083-5 wt% B4C composite pin length is plotted against sliding distance, as shown in Figure 5. Low wear rate is observed up to 1000 m for the different applied load and sliding speed combinations tested. However, a significant increase in wear rate is observed from 1000 m to 3000 m. Abrasion operated until 1000 m sliding distance, and adhesion is induced as the sliding distance increased to 3000 m. The induction of an adhesion wear mechanism increases wear as a chunk of matrix material gets transferred to the counterface.

Fig. 5.

AA5083-5 wt% B4C composite: variation of pin length with sliding distance for different test combinations. Reprinted from (37), Copyright (2008), with permission from Elsevier

AA5083-5 wt% B4C composite: variation of pin length with sliding distance for different test combinations. Reprinted from (37), Copyright (2008), with permission from Elsevier

Figure 6 shows the variation of pin length reduction rate (average) and friction coefficient of AA5083-B4C composites against sliding speed when the applied load is 65 N (37). The AA5083-B4C composites are reinforced with 5 wt% and 10 wt% B4C particles. It is inferred from the plot (Figure 6) that the pin length reduction rate (average) increased with an increase in sliding speed.

Fig. 6.

AA5083-B4C composites reinforced with 5 wt% and 10 wt% B4C particles: variation of composite pin length reduction rate (average) and friction coefficient with sliding speed. Reprinted from (37), Copyright (2008), with permission from Elsevier

AA5083-B4C composites reinforced with 5 wt% and 10 wt% B4C particles: variation of composite pin length reduction rate (average) and friction coefficient with sliding speed. Reprinted from (37), Copyright (2008), with permission from Elsevier

Meanwhile, the friction coefficient decreased with an increase in sliding speed for both the AA5083-5 wt% B4C and AA5083-10 wt% B4C composites. Furthermore, it is observed that the wear rate exhibited by AA5083-10 wt% B4C composite is 40% lower than that of the AA5083-5 wt% B4C composite (37). This phenomenon suggested the significance of B4C particles concentration on the wear resistance of the composites. The increase in the concentration of B4C particles leads to their effective resistance to the abrasion imparted by work-hardened wear debris and hard counterface asperities (37).

4.3 Influence of Mechanically Mixed Layer

The importance of MML in reducing the wear rate of aluminium-matrix composites reinforced with conventional reinforcement particles has frequently been reported (4145). In the case of Al-B4C composites, Sharifi et al. (38) explained MML formation using cross-sectional scanning electron microscopy (SEM) images. The investigators also discussed the influence of MML on the wear rate of Al-B4C composites. Figure 7 shows that the wear rate decreased with 5 wt% (A5), 10 wt% (A10) and 15 wt% (A15) addition of nano-B4C particles. SEM and energy-dispersive X-ray spectroscopy (EDS) analysis of the worn surface revealed the formation of a dark layer which is chemically composed of aluminium, oxygen and iron. The presence of oxygen indicated an oxidation reaction, and the presence of iron indicated the transfer of steel debris from the counterface. The mechanical mixing of tribo-couple debris between two solid surfaces led to the formation of the MML. SEM cross-sectional micrographs of the MML (white layer (marked with arrow)) formed on 5 wt% (A5), 10 wt% (A10) and 15 wt% (A15) nano-B4C composite worn surfaces are shown in Figures 8(a), 8(b) and 8(c), respectively. The composites were tested at a sliding speed of 0.08 m s–1, applied load of 20 N and sliding distance of 25 m. Information regarding the materials, fabrication route and tribological test parameters used in Sharifi et al. (38) is shown in Table II. Furthermore, Monikandan et al. (46, 47) reported that the increase in applied load leads to the destruction of the MML, while the increase in sliding speed is conducive for its formation.

Fig. 7.

Variation of wear rate with 5 wt% (A5), 10 wt% (A10) and 15 wt% (A15) addition of nano B4C particles for a sliding speed 0.08 m s–1, applied load 20 N and sliding distance 25 m. Reprinted from (38), Copyright (2011), with permission from Elsevier

Variation of wear rate with 5 wt% (A5), 10 wt% (A10) and 15 wt% (A15) addition of nano B4C particles for a sliding speed 0.08 m s–1, applied load 20 N and sliding distance 25 m. Reprinted from (38), Copyright (2011), with permission from Elsevier

Fig. 8.

Cross-sectional SEM micrographs of worn surfaces showing the MML (marked with arrow): (a) 5 wt% nano B4C composite (A5); (b) 10 wt% nano B4C composite (A10); and (c) 15 wt% nano B4C composite (A15) (sliding speed 0.08 m s–1, applied load 20 N and sliding distance 25 m). Reprinted from (38), Copyright (2011), with permission from Elsevier

Cross-sectional SEM micrographs of worn surfaces showing the MML (marked with arrow): (a) 5 wt% nano B4C composite (A5); (b) 10 wt% nano B4C composite (A10); and (c) 15 wt% nano B4C composite (A15) (sliding speed 0.08 m s–1, applied load 20 N and sliding distance 25 m). Reprinted from (38), Copyright (2011), with permission from Elsevier

4.4 Beneficial Effects of Boron Carbide Particles Addition

Shorowordi et al. (39) compared the tribological properties of pure aluminium, Al-13 vol% B4C, and Al-13 vol% SiC composites at two different sliding speeds (1.62 m s–1 and 4.17 m s–1) and an applied load of 15 N. The investigators reported that pure aluminium experienced a higher wear rate than the composite at the sliding speed of 1.62 m s–1. At 4.17 m s–1, the wear rate of pure aluminium is very high, which led to the termination of the test at 1000 m before completing the selected test distance (5832 m). SEM analysis of the worn surface of the Al-B4C composite at 4.17 m s–1 revealed finely polished B4C particles and no sliding striations (Figure 9(a)). Meanwhile, at 4.17 m s–1, sliding striations were observed on the worn surface of the pure aluminium, which indicated ploughing of the ductile matrix by the hard counterface material (the ploughed region is marked with dotted lines in Figure 9(b)). It is evident that the worn surface of the aluminium-matrix was severely damaged, while the worn surface of the Al-B4C composite was damaged only mildly. After sliding for some duration, the tribo-contact was made of B4C particles and the counterface. The B4C imparted resistance against abrasion induced by the asperities of the counterface (18). Hence there was no ploughing of the composite. Moreover, in the case of composites, B4C particles bore a significant fraction of applied load during sliding; thus extending the applied load or sliding speed at which severe wear is induced. However, the unreinforced aluminium-matrix undergoes severe wear at much lower applied load or sliding speed than the Al-B4C composite. The information regarding the materials, fabrication route, secondary process and tribological test parameters used in the study is shown in Table II (39).

Fig. 9.

SEM micrographs of the worn surfaces at applied load 15 N and sliding speed 4.17 m s–1: (a) Al-13 vol% B4C composite (sliding distance 5832 m); (b) ploughed region (marked with dotted lines) of pure aluminium (sliding distance 1000 m). Reprinted from (39), Copyright (2004), with permission from Elsevier

SEM micrographs of the worn surfaces at applied load 15 N and sliding speed 4.17 m s–1: (a) Al-13 vol% B4C composite (sliding distance 5832 m); (b) ploughed region (marked with dotted lines) of pure aluminium (sliding distance 1000 m). Reprinted from (39), Copyright (2004), with permission from Elsevier

4.5 Comparison of Tribological Properties of Aluminium-Boron Carbide and Aluminium-Silicon Carbide Composites

It is inferred from the bar chart shown in Figure 10(a) that the Al-B4C composite in Shorowordi et al. (39) exhibited a lower wear rate than the Al-SiC composite at a sliding speed of 1.62 m s–1. The composites were tested for the applied load of 15 N and sliding distance of 5832 m. Figure 10(b) shows the steady-state friction coefficient of Al-B4C composites and Al-SiC composites. At the sliding speed of 1.62 m s–1, the Al-B4C composite exhibited a slightly lower steady-state friction coefficient than the Al-SiC composite. However, as the sliding speed increased to 4.17 m s–1, both composites appeared to attain similar steady-state friction coefficient values. It is reported that the friction coefficient of both the composites reached a steady-state value at a sliding distance between 500–600 m (39).

Fig. 10.

Bar charts of pure Al-13 vol% SiC and pure Al-13 vol% B4C composites: (a) wear rate; (b) friction coefficient (sliding speeds of 1.62 m s–1 and 4.17 m s–1, applied load of 15 N and sliding distance of 5832 m). Reprinted from (39), Copyright (2004), with permission from Elsevier

Bar charts of pure Al-13 vol% SiC and pure Al-13 vol% B4C composites: (a) wear rate; (b) friction coefficient (sliding speeds of 1.62 m s–1 and 4.17 m s–1, applied load of 15 N and sliding distance of 5832 m). Reprinted from (39), Copyright (2004), with permission from Elsevier

In related work, Shorowordi et al. (40) compared the tribological properties of the same tribo-couple by varying the applied load and sliding distance. Information regarding the materials, fabrication route, secondary process and tribological test parameters used in the study is shown in Table II. The wear rate of Al-SiC composite is higher than that of Al-B4C composite at high applied loads, which is attributed to the formation of cracks at the Al-SiC interface and the pullout of SiC particles from the worn surface (40). The presence of a brittle phase at the Al-SiC interface might be the reason for the formation of cracks and pullout of SiC particles (30). However, in the case of Al-B4C composite, particle pullout is not observed. It is to be noted that the interface of the Al-B4C composite is seemingly less brittle than that of the Al-SiC composite. The hardness of the B4C particle is also higher than that of the SiC particle, leading to the low wear rate of Al-B4C composite. The friction coefficient of the Al-B4C composite is slightly lower than that of Al-SiC composite, which is attributed to the presence of boron in the oxidised state on the worn surface of the Al-B4C composite.

4.6 Inferences Obtained from the Statistical Analysis

Statistical analysis is useful in the initial stages of the experimental findings. It aids in assessing the preliminary change in the trend of the responses (wear and friction coefficient) (4850). Toptan et al. (28) studied the tribological behaviour of AlSi9Cu3Mg-B4C composites reinforced with 15 vol% and 19 vol% B4C particles. Information regarding the materials, fabrication route and tribological test parameters used in the study is shown in Table II. A statistical method (24 full factorial design) was used to design the experiments; the four parameters varied for two levels are volume percent addition of B4C particles, applied load, sliding speed and sliding distance (28). Figures 11(a) and 11(b) show the normal probability plots of the wear rate and friction coefficient, respectively.

Fig. 11.

Normal probability plots of AlSi9Cu3Mg-B4C composites: (a) wear rate; (b) friction coefficient. Reprinted from (28), Copyright (2012), with permission from Elsevier

Normal probability plots of AlSi9Cu3Mg-B4C composites: (a) wear rate; (b) friction coefficient. Reprinted from (28), Copyright (2012), with permission from Elsevier

The normal probability plots reveal that the residuals lie very close to the normal probability line, which indicates that the residuals are fitted convincingly to the normal distribution (28). The normal distribution and lack of outlier residuals and absence of change in the slope of the normal probability line confirm that all relevant physical and material factors that influence the tribological behaviour were considered in the experimental study (51). Figures 12(a) and 12(b) show the main effects of the wear rate and friction coefficient, respectively (28). It is observed from the main effects plot (Figure 12(a)) that the wear rate increased with an increase in B4C particles addition, applied load and sliding distance. However, the wear rate decreased with an increase in sliding speed. Meanwhile, the friction coefficient increased with an increase in B4C particles addition and sliding distance (Figure 12(b)). The friction coefficient decreased with an increase in sliding speed and applied load.

Fig. 12.

Main effects plots of AlSi9Cu3Mg-B4C composites: (a) wear rate; (b) friction coefficient. Reprinted from (28), Copyright (2012), with permission from Elsevier

Main effects plots of AlSi9Cu3Mg-B4C composites: (a) wear rate; (b) friction coefficient. Reprinted from (28), Copyright (2012), with permission from Elsevier

The analysis of variance (ANOVA) technique analyses experimental data to give vital inferences: the impact of physical and material factors on the responses and the impact of interaction of physical and material factors on the responses (52, 53). ANOVA analysis by Toptan et al. (28) revealed that applied load, volume percent of B4C particles and interaction of sliding speed and applied load had statistically and physically significant influence on wear rate. The sliding distance and interaction of other physical parameters were not statistically or physically significant to influence the wear rate. The ANOVA analysis of the friction coefficient revealed that volume percent of B4C particles and applied load provided statistical and physical significance on the friction coefficient. Meanwhile, the sliding speed, sliding distance and interaction of physical parameters did not provide statistical and physical significance on the friction coefficient (28).

5. Summary

The fabrication and tribological properties of Al-B4C composites are discussed in this overview. The Al-B4C composites exhibited better particle distribution than Al-SiC or Al-Al2O3 composites. The bonding at the matrix-reinforcement interface is also strong, and the interface is free of the interfacial reaction product, which is not the case with Al-SiC and Al-Al2O3 composites. The presence of a brittle phase at the matrix-reinforcement interface reduced the wear resistance of Al-SiC composites. The friction coefficient of Al-B4C composites is lower than that of Al-SiC composites due to the presence of oxidised boron on the contact surfaces. The better tribological properties of Al-B4C composites compared to those of pure aluminium are due to the abrasion resistance imparted by the B4C particles. The wear mechanisms induced during wear studies of Al-B4C composites are plastic deformation, adhesion, abrasion and delamination. Statistical analysis revealed that the influence of physical and material factors and their interaction on the tribological behaviour is statistically significant.

To summarise, Al-B4C composites exhibit better microstructural characteristics than aluminium-matrix composites reinforced with SiC and Al2O3 particles. The tribological properties of Al-B4C composites are better than those of aluminium and Al-SiC composites; thus, these composites may be considered as a potential candidate for different tribologically crucial applications.

Acknowledgements

The corresponding author expresses sincere thanks to the Ministry of Human Resources Development, Government of India, for providing the fellowship to conduct his doctoral research. Furthermore, the authors sincerely thank the reviewers for their useful suggestions, and the Editor Ms Sara Coles and Editorial Assistant Mrs Yasmin Stephens for prompt responses and brilliant editing work.

The Authors

V. V. Monikandan is a Postdoctoral Researcher with the School of Minerals, Metallurgy and Materials Engineering, Indian Institute of Technology Bhubaneswar, India. Formerly, he was with Materials Research and Innovation Centric Solutions, India as a research associate. He received his PhD in tribological behaviour of aluminium matrix composites from the National Institute of Technology Calicut, India. He specialises in additive manufacturing of MMC coatings and synthesis of smart composites through pressureless infiltration process and biodegradable lubricants.

K. Pratheesh is a Professor of Mechanical Engineering and affiliated with Mangalam College of Engineering, Kottayam, Kerala, India. He received his PhD in grain size modification of aluminium-silicon alloys from the National Institute of Technology Calicut. His research interests include fabrication of as-cast alloys using liquid metallurgy technique, synthesis of grain modifier mixtures for non-ferrous alloy castings and solidification of castings.

P. K. Rajendrakumar is a Professor (HAG) of the Department of Mechanical Engineering, National Institute of Technology Calicut. His research interests include tribology, biomechanics and product design.

M. A. Joseph is a Professor (HAG) of the Department of Mechanical Engineering, National Institute of Technology Calicut. His research interests include MMCs, polymer materials and non-ferrous alloys.

By |2022-03-16T14:58:38+00:00March 16th, 2022|Weld Engineering Services|Comments Off on Towards the Enhanced Mechanical and Tribological Properties and Microstructural Characteristics of Boron Carbide Particles Reinforced Aluminium Composites: A Short Overview

Examination of the Coating Method in Transferring Phase-Changing Materials

The importance of functional processes that add value, create difference and increase market share in the textile sector is increasing day by day with developing technology. Not only aesthetic features but also functional features determine consumers’ wishes. For this purpose, technologies like plasma, sol-gel or microencapsulation can provide different functional properties to textile materials (1).

The microencapsulation process produces small spheres covered with a thin shell film to protect the active substance from outside. Using this technology, it is possible to protect easily perishable substances such as drugs, insecticides, antibacterials and antioxidants from environmental factors like heat, light and oxygen. In addition, the wearer is exposed to much lower doses of these substances. Using microcapsules in textile finishing makes it possible to produce resistant-to-wash textile products that are effective even when a less active substance is used. Another area where microcapsules can be used is energy storage (26).

Problems like the climate crisis, greenhouse gas emissions, air pollution, usage of finite resources and economic issues require solutions. Energy is needed for heating, air conditioning and ventilation. Energy storage plays an important role in conserving available energy and improving its utilisation since many energy sources, especially renewables, are intermittent. Short-term storage of only a few hours may be desirable in applications like clothes or curtains, while longer-term storage of a few months may be required in some applications like buildings, concrete or space clothes (79).

A phase-change material or PCM can store and release large amounts of energy. This energy is called latent heat. Latent heat is thermal energy released or absorbed, by a thermodynamic system, during a constant-temperature process — usually a first-order phase transition. Latent heat can be understood as heat energy in a hidden form which is supplied or extracted to change the state of a substance without changing its temperature. PCMs are classified as latent heat storage units. Each PCM has a specific melting and crystallisation temperature and a specific latent heat storage capacity. PCMs take advantage of latent heat that can be stored or released from material over a narrow temperature range. These materials absorb energy during the heating process as phase change takes place and release energy to the environment in the phase change range during a reverse cooling process. Textiles containing phase change materials react immediately to changes in environmental temperatures and the temperatures in different areas of the body. This system can be used in applications like protective clothing, beds, bedspreads, space suits, diving suits and curtains (1028).

For any PCM to be used in textile products, it must have certain properties. The main ones are: high melting or hydration temperature, high thermal conductivity, high specific heat capacity, minimum volume change during phase transformation, appropriate phase change temperature, repeatability of phase transformation, low corrosion and degradation tendency and non-toxicity. The textiles should pass certain flame retardancy standards with the PCM material applied. Choosing the appropriate PCM for the protective clothing is crucial for an ideal thermal insulation and regulation effect. Many factors should be taken into consideration while making this choice. What is expected from PCM to be added to a textile product to be used as a garment is to minimise the heat flow between the person and the outside environment by keeping the body temperature constant at a certain value that the person is comfortable with. Suitable materials for textile products in terms of phase change temperatures include: hydrate inorganic salts, polyhydric alcohol-water solution, polyethylene glycol (PEG), polytetramethylene glycol (PTGM), aliphatic polyester, linear long chain hydrocarbons, hydrocarbon alcohols or organic acids (2839).

In general, the impregnation and exhaustion method can be used to transfer microcapsules in the textile industry. In the impregnation method, a liquor is prepared and the capsules are mixed into this liquor at a certain rate. Afterwards, the fabric is absorbed into the float, passed through a foulard machine and the process is completed with pressure from cylinders. In the coating method, a coating paste is prepared and the capsules are added to the paste at a certain rate. The coating paste is then applied to the fabric. To date, little research has been done on possible applications of microcapsules in functional coating processes.

One of the most important problems of PCMs is low thermal conductivity. For example, paraffin has 0.22 W m−1 K−1 thermal conductivity when compared with >3000 W m−1 K−1 for multiwall carbon nanotubes (MWCNTs). Moreover, microencapsulated PCMs have a polymeric shell, which not only prevents the content from leaking but also resists heat transition. When capsules are transferred to the fabrics by coating, another viscous coating layer is added on the shell material of the capsule. It is thought that this feature will increase in cases where PCM capsules are transferred by the coating method compared to those transferred by the impregnation method (27, 4042).

Within the scope of this study, it is thought that the coating application can be applied especially in black out curtains. In this study, PCM microcapsules were used to develop thermoregulating textile materials and the effect of the microcapsules application method was examined. In this research, Mikrathermic® P PCM microcapsules were transferred to 100% cotton woven fabrics by the impregnation and coating methods. The thermal regulation properties of the fabrics were analysed by DSC and the surface morphological properties by SEM. In addition, the thermal properties of the fabrics were obtained with a thermal camera. Contact angles and water vapour permeability of coated and impregnated fabrics were investigated.

2.1 Material

In this research, desized, 100% cotton fabrics (warp/weft yarn density of 34/17 yarns per centimetre) were used. Mikrathermic® P PCM capsules were provided by Devan Chemicals, Belgium. For the coating process, Mikracat B as a cross linker and L Mikrasoftener as a softener were supplied from Devan Chemicals. RUCO®-COAT PU 1110 polyurethane coating material was used for coating process and supplied from Rudolf Duraner, Turkey. EDOLAN® MR polyurethane binder was used for the impregnation method and provided by Tanatex, Switzerland to bond the microcapsules to the fabric. All other auxiliary chemicals used in the study were of laboratory-reagent grade.

2.2 Application of the Microcapsules to the Cotton Fabrics

The application of the capsules to the cotton fabrics was carried out by impregnation and coating methods. Fabrics were conditioned in accordance with ISO 139:2005 (43) at standard atmospheric conditions (20°C±2 and 65% RH±4) for 24 h. Capsule transfer prescriptions were made according to Tables I and II and in the same ratio to compare the application processes. Polyurethane was selected as binder and each experiment was repeated three times.

Table I

Capsule Transfer Prescription for Impregnation Method

Mikrathermic® P capsule, g l−1 EDOLAN® MR – PUR binder, g l−1 Pick-up ratio, % Drying Fixing
125 30 90 Temperature, °C Time, min Temperature, °C Time, min
80 10 140 3
Table II

Capsule Transfer Prescription for Coating Method

Content Polyurethane paste, g
Mikrathermic® P capsule 125
RUCO®-COAT PU 1110 770
Mikracat B cross-linking agent 100
L Mikrasoftener 5

The capsules were impregnated in a solution bath containing capsules (125 g l−1) and binding agent (30 g l−1), and then squeezed between rollers to 90% wet pick-up. Achieving long lasting effect, the fabric was exposed to drying for 10 min at 80°C and fixation process for 3 min at 140°C in a laboratory stenter (Table I).

Viscosities of the coating pastes were measured using a DV-II+Pro viscometer (AMETEK Brookfield, USA) and the viscosity of the coating paste was determined to be 9000 cps. Cotton base fabrics were coated with the above mentioned coating pastes using a laboratory type blade coating machine, as two layers of coating. It was subjected to intermediate drying at 100°C for 2 min between each layer. Coated samples were cured at 140°C for 3 min.

2.3 Evaluation of Treated Fabrics

SEM images were taken to obtain the existence of capsules on the textile surface from both coated and impregnated samples. Samples were gold-coated (15 mA, 2 min) to assure electrical conductivity. The measurements were taken at 2 kV accelerating voltage. The images were taken at 250× and 1000× magnification.

Thermal properties of the fabrics, such as melting and crystallising temperatures and enthalpies, were measured by DSC performed using a PYRISTM Diamond differential scanning calorimeter (PerkinElmer Inc, USA) to distinguish the capsules on the fabric with the help of characteristic endothermic or exothermic peaks. The samples were cooled down to −20°C and then heated up to 40°C at a constant rate of 10°C min−1 under a nitrogen flow rate of 60 ml min−1.

In order to examine the efficiency of the transferred capsules, the surface temperature of the raw fabric samples containing PCM was measured at a certain time interval by thermal camera as shown in Figure 1. Measurements in the system were made in an insulated box. Before measurement, the inner temperature of the box was heated to a constant temperature of 40°C and the test was carried out at this temperature. The inner temperature of the box was kept constant by means of a thermostat. Before measurement, the fabrics were conditioned for 12 h and placed in the box as quickly as possible. Once the fabric was placed in the box, the surface temperature was measured from a fixed point for 15 min. A thermal camera (Fluke Ti100 Thermal Imager, Fluke, USA; emission value 0.94) was used in the measurements and the temperature was recorded every 30 s.

Fig. 1.

Thermal camera system (18)

Thermal camera system (18)

When an interface exists between a liquid and a solid, the angle between the surface of the liquid and the outline of the contact surface is described as the contact angle θ (lower case theta). The contact angle (wetting angle) is a measure of the wettability of a solid by a liquid. In order to examine the hydrophilicity of the fabrics, the contact angle was examined. The measurements were carried out at 25°C using the Theta Lite T101 (Biolin Scientific, Sweden) model contact angle device. An image of approximately 5 μl of water droplet dropped onto the surface to be measured was recorded for 10 s by the device camera. Using the device software, an average of 200 data were recorded for 10 s for each sample and the arithmetic mean was taken.

Water vapour permeability is related to breathability of fabrics. Water vapour permeability of samples was determined by using M261 (SDL Atlas International, USA) model water vapour permeability tester according to BS 3424-34:1992-Method 37 (44). The amount of water vapour passed through the samples was determined after 24 h and permeability values were calculated. The test was repeated three times for each sample type.

After the capsules containing PCM were transferred to cotton fabrics by impregnation and coating methods, analyses were carried out on the fabrics.

3.1 Scanning Electron Microscopy

SEM images of the Mikrathermic® P PCM capsule are shown in Figure 2. Mikrathermic® P was around 3 μm and had a spherical shape as expected. SEM images of the PCM capsules transferred to cotton fabrics by coating and impregnation methods, enlarged 250 times and 1000 times, are given in Table III.

Fig. 2.

SEM images of Mikrathermic® P capsules (1000×)

SEM images of Mikrathermic® P capsules (1000×)

Table III

SEM Photomicrographs of Fabrics Treated with PCM Capsules

Fabric 250× 1000×
Coated
Impregnated

When the images were examined morphologically, it was observed that the capsules transferred by the impregnation method preserved their spherical form. PCMs transferred by coating remain under the coating polymer and were homogeneously distributed over the entire surface. These images showed that capsule application was successful for both impregnation and coating methods. It was observed that capsules were covered with the binder and fixed onto the textile surface of the cotton fabrics.

3.2 Differential Scanning Calorimetry Analysis

The DSC diagrams of coated and impregnated fabrics are given in Figure 3. The heat storage capacity of the Mikrathermic® P PCM microcapsule is 140 J g−1 according to the literature (4547). From the DSC curve given in Figure 3 and from Table IV, the amount of heat stored and emitted by the fabrics from the area under the endothermic and exothermic melting and solidification peaks and the temperatures at which heat storage and emission begins can be seen. According to the DSC analysis, similar values were obtained for coated and impregnated fabrics. The values are provided in Table IV in detail.

Fig. 3.

DSC diagrams of coated and impregnated fabrics with PCM capsules

DSC diagrams of coated and impregnated fabrics with PCM capsules

Table IV

Thermal Properties of Coated and Impregnated Fabrics

Fabric Melting point, °C Melting enthalpy, J g−1 Crystallisation point, °C Crystallisation enthalpy, J g−1
Coated 25.83 2.70 25.70 −1.45
Impregnated 25.72 2.64 25.61 −1.39

The melting process in fabrics coated with Mikrathermic® P microcapsules occurred between 25.83°C–31.04°C and the amount of heat energy stored by the cotton fabric during the melting period was measured as 2.70 J g−1. For the Mikrathermic® P microcapsule, the crystallisation process occurred in the range of 25.70°C–23.45°C and the cotton fabric released −1.45 J g−1 heat during crystallisation. Impregnated fabric absorbed 2.70 J g−1 at 25.72°C during melting and released −1.39 J g−1 at 25.61°C during crystallisation.

Thermal conductivity measures the capacity of temperature exchange between heat and cold passing through a material mass. Decreased thermal conductivity allows for a faster rate of heat transfer in a PCM, increasing the time required for the PCM to undergo a complete charge or discharge. The major shortcoming of PCM is its limited ability to exchange heat effectively due to low thermal conductivity. This suppresses the amount of heat that can be exchanged during melting processes and a lower thermal conductivity of solidification will occur at low temperatures. The effective thermal conductivity of PCM can be increased by many mechanisms such as inserting fins and adding a dispersion of high thermal conductivity nanoparticles (48, 49).

Although the process temperatures are very close to each other, coated fabrics changed state at higher temperatures compared to impregnated fabrics. The shifting of the process peaks to higher temperatures has been explained in the literature as the lower thermal conductivity of the fabric (50). This situation was interpreted as the lower thermal conductivity value of coated fabrics compared to impregnated fabrics resulting in melting and solidification at higher temperatures. However, considering that these data are very close to each other, it was thought that the capsules can be transferred to the fabrics by the coating method. Encapsulated PCMs which were transferred with coating and impregnation lead to lower thermal conductivity and increased heat capacity of a textile structure. They improve the thermal performance of textile material and therefore may save energy.

3.3 Thermal Camera

Depending on the change in ambient temperature, the fabric surface temperature change caused by PCM capsules was measured. For this purpose, a thermal camera was used to determine the heat regulation properties of fabrics that can store heat. Two measurements were taken from two different points in the fabric samples and their averages are shown in Figure 4.

Fig. 4.

Thermal camera results of the fabric

Thermal camera results of the fabric

The temperature-time curves are given in Figure 4. It can be seen from the graphs that the fabrics which were brought from a cold environment (4°C±2) to a warm environment (40°C±2) were warmed and the temperatures measured on their surfaces increased. On the other hand, it is observed that the heating time of the fabrics in a hot environment and the maximum temperatures reached were not equal. According to both measurement results, it can be seen that the raw fabric heats up the fastest. Similarly, the maximum surface temperature of the raw fabric was higher than the fabrics containing PCM. The raw fabric warmed to almost maximum temperature (about 42°C) in about 5 min. For fabrics containing PCM, the maximum temperature recorded was lower at the end of the measurement period. The maximum value recorded was 37°C for the fabric in which the PCM capsules were impregnated and 40–41°C for the fabric transferred with the coating. Thermal camera analysis was performed for 15 min. It was determined that the temperature of the fabrics remained at the last point which they reached for an extended period. During the measurement period, it was determined that the temperature measured on the surface of the fabric to which the PCM capsules were impregnated was 3°C to 5°C lower than the raw fabric surface temperature. It was determined that the surface temperature of the fabric to which the PCM capsules were transferred with the coating was 1–3.5°C lower than the raw fabric.

When the analysis results were evaluated, it was seen that the fabric with PCM transferred by the impregnation method has more effective temperature regulation. The impregnated fabric, which has the lowest temperature, absorbed more heat in the cold environment when the PCM structure was applied. It also appears that there was not a big difference between coating and impregnation methods in thermal camera analysis. The thermal camera method demonstrates the heat regulation ability of fabrics, but does not provide information about their performance in end-use areas. Therefore, for fabrics treated with coating and impregnation methods, performance evaluation according to the area of use will give the most accurate results. This shows that PCM capsules can also be transferred by the coating method, depending on the usage areas.

3.4 Contact Angle Measurement

In order to evaluate the hydrophilicity properties of raw fabric and PCM-transferred fabrics with different methods, contact angle measurement was made as shown in Figure 5.

Fig. 5.

Contact angle images of fabrics: (a) raw fabric; (b) coated fabric; (c) impregnated fabric

Contact angle images of fabrics: (a) raw fabric; (b) coated fabric; (c) impregnated fabric

The angle between the surface of the liquid and the outline of the contact surface is described as the contact angle θ. The contact angle is a measure of the wettability of a solid by a liquid. In the case of complete wetting, the contact angle is 0°. Between 0° and 90°, the solid is wettable and above 90° it is not wettable. When the analysis results were examined, water was completely absorbed by raw fabric in 5 s and this indicates that the fabric is hydrophilic. When comparing the transfer methods of PCM capsules, contact angle of impregnated and coated fabric was obtained as 42° and 73°, respectively. In general, the coating paste has a more viscous structure and this structure causes a thick layer to form on the fabric. Due to this structure, the surface energy of the fabric decreases and it gains water repellency. In the impregnation method, since a viscous structure is not obtained and a layer is not formed on the fabric surface, the contact angle becomes lower causing the textile material to be more hydrophilic than the coated one. This result, as expected, was that the coated fabric was more hydrophobic than the impregnated fabric.

3.5 Water Vapour Permeability

Water vapour permeability analysis was carried out to examine the comfort properties of the fabrics obtained. Water vapour permeability of samples are tabulated in Table V.

Table V

Water Vapour Permeability Results of Fabrics

Fabric Water vapour permeability, g m−2 per 24 h
Raw 625.44
Impregnated 619.02
Coated 352.18

The highest water vapour permeability was obtained from raw fabric with 625 g m−2 per 24 h permeability value. It was determined that the fabrics with PCM transferred by the impregnation method gave a similar result to the raw fabric. On the other hand, water vapour permeability of coated samples reduced to approximately 50% that of the raw base fabric in parallel with the contact angle results. This was due to the additional polyurethane coating layer which contributed mass transfer limitation through the fabric. Even the most breathable coating polymer applied to the samples would add a resistance to vapour flow by closing the pores and creating an additional layer (51). The water vapour permeability of a material plays an important part in evaluating the physiological wearing comfort of clothing systems or determining the performance characteristics of textile materials used in technical applications. Therefore, it is important to choose the transfer method of PCM capsules considering the area where the fabric will be used.

Within the scope of this study, PCM capsules were applied to textile materials with coating and impregnation methods, successfully. As a result of the study, it was observed that the capsules transferred by the impregnation method preserved their spherical form according to the SEM images. It was seen that PCMs transferred by coating remain under the coating polymer and were homogeneously distributed over the entire surface. When thermal properties of coated and impregnated fabrics were examined with DSC analyses, it was seen that thermal behaviours of fabrics treated by the impregnation and coating methods were similar.

According to the results of the thermal camera analysis, it was seen that the PCM transferred fabric with the impregnation method performs more effective temperature regulation than the coating method. The fabric with PCM transferred by the impregnation method makes more effective temperature regulation. The impregnated fabric, which has the lowest temperature, absorbed more heat in the cold environment when the PCM structure was applied. The impregnation method showed slightly better results according to the thermal camera although it was close to the coating method. As predicted, the contact angle of the coated fabric was higher and the air permeability was lower than the impregnated fabric. However, the thermal results obtained show that PCM capsules can also be transferred by the coating method. This situation makes the end use area of the fabric to be used important.

There are lots of clothing comfort properties of textiles such as heat transfer, thermal protection, air permeability, moisture permeability and water repellence. While it may be preferred to use the impregnation method where comfort features are important, PCM capsules can be transferred by the coating method if comfort features are not important. Performance evaluation according to the target properties of textile material will give the most accurate results for fabrics treated by coating and impregnation methods. The coating method may be an alternative to the impregnation method. Based on these results, fabrics in which the capsules are transferred by coating can be used in black out curtains. Fabrics to which capsules are transferred by impregnation can be used in bedding fabrics or clothes considering their comfort properties.

By |2022-03-11T12:59:42+00:00March 11th, 2022|Weld Engineering Services|Comments Off on Examination of the Coating Method in Transferring Phase-Changing Materials

Basics of Fourier Analysis of Time Series Data

Johnson Matthey Technol. Rev., 2022, 66, (2), 169

1. Introduction

There are few mathematical breakthroughs that have had as dramatic impact on the scientific process as the Fourier transform. Defined in 1807 in a paper by Jean Baptiste Joseph Fourier (1) to solve a problem in heat conduction, the integral transform, Equation (i):

(i)

and its inverse, Equation (ii):

(ii)

provide the framework to determine the spectral make up of a time varying function g(t) using Equation (i). Conversely, if the frequency domain is understood G(ω), the time signal can be derived using Equation (ii). The same analysis can be applied to spatial functions to yield wave number spectra and is the basis for a significant portion of wave optics, and is used in techniques such as Fourier transform infrared (FTIR) spectroscopy (2).

The transform, which is part of a wider family of integral transforms (3), had a profound impact on the development of much of 19th and 20th century mathematical physics. Previously intractable problems in optics, electromagnetism and acoustics became soluble. The insights these breakthroughs yielded paved the way for quantum mechanics and much of modern science. The famous Heisenberg uncertainty principle is actually just a mathematical property of the Fourier transform in Schrödinger’s wave mechanics (4). Domínguez gives a good overview of this history and some of the mathematical properties of the transform that make it so useful (5).

A significant hurdle with the practical application of the Fourier transform in real-world problems is that it is mathematically challenging to calculate for even the simplest of functions. As a consequence the transform is not taught in the UK until undergraduate level and even then only in mathematically heavy courses such as mathematics, physics and engineering. To make progress in practical problems numerical methods are generally required, meaning the practical application of the Fourier transform can feel like an esoteric part of computer science, rather than the scientific core of the modern world.

Fortunately, the great leaps in understanding that quantum mechanics gave us in electronics has ultimately led to a situation where anyone who wants to, can with a few lines of Python (6) code use sophisticated algorithms that have been developed in the post-World War II period. As such, calculations of the Fourier transform are readily available to those that would like to make use of them.

Unfortunately, the education around how to do practical Fourier analysis has become something of a dark art, which is often picked up in an ad hoc manner in postgraduate studies. The advent of accessible artificial intelligence algorithms has further obscured the basic techniques of Fourier analysis and created a strange scenario where even basic spectral methods are being conducted with inefficient computationally heavy neural network approaches.

In this short article we outline some basic practical steps for successfully conducting Fourier analysis. We will also give a few example Python scripts so the interested reader may apply these techniques to their data.

2. The Discrete Fourier Transform

The first challenge for any numerical method is the digitisation step during which the smooth curves of analytical functions must be turned into discrete numbers. There are two sources of data that are normally digitised:

Discussing these in turn, when an analytic function of time g(t) is evaluated, it is relatively trivial to generate the discretised function with N samples in the time window 0 < tT (Equations (iii) and (iv)):

(iii)

where

(iv)

The numerical value of δ is of crucial importance in numerical estimates of the Fourier transform. It places limits on what information is lost in the discretisation and plays a fundamental role in how experimental work should be designed. It is more usual to quote its reciprocal, which is the sampling frequency, fs (Equation (v)):

(v)

It is this frequency that appears in one of the most important results associated with the Fourier transform: Nyquist’s theorem (7). This result states (Equation (vi)):

(vi)

where B is the highest frequency component in the signal in g(t).

Nyquist’s theorem is particularly important as we turn our discussion to sampling experimental data. In theoretical work one can choose, in principle, δ to be as small as is necessary. However, in experimental work this is not an available option; the cost of data loggers increases significantly with the sampling frequency and data storage problems quickly become limiting. Moreover, in nearly all applications where data is recorded by a computer, signals are voltages recorded by an analogue to digital converter (ADC). To conduct scientific work a 12 bit ADC is the standard level. This means that a voltage signal varying between a nominal full-scale deflection ±10 V is recorded to the nearest 5 mV as defined in Equation (vii):

(vii)

When numerical results are compared to experimental results this level of precision must always be borne in mind, as the limitations of the sampling frequency or the voltage level are both likely to be significantly more coarse grain in the experimental work. An example of the effects of this digitisation step is shown in Figure 1. A 5.01 Hz sine wave has been sampled for 1 s, with a sampling frequency of 200 Hz. The blue dots denote the locations of the sampled data and the red curve the analytic form of a sine curve with this frequency.

The popular data analytics tool Jupyter (8) was used to generate the graph shown in Figure 1, this is part of the open-source data analytics bundle Anaconda. The code used is shown in Figure 2. The majority of the code is presentational and associated with plotting the graph using the Python library matplotlib (9). However, the numerical analysis makes use of the versatile NumPy library (10). The key lines for our discussion are lines 17 and 18, which generate two vectors Vs and Vss. The vector Vss is the smooth underlying 5.01 Hz sinusoidal signal and Vs is the signal sampled with a sampling frequency of 200 Hz. It is these two vectors that are manipulated in the sections that follow.

Fig. 1.

Example of a sampled sine curve. The dots denote the sampled data, the red curve the analytic values

Example of a sampled sine curve. The dots denote the sampled data, the red curve the analytic values

Fig. 2.

Python code used to generate Figure 1

3. The Fast Fourier Transform

Having defined the digitised signal, discrete Fourier transform (DFT) can be defined as shown in Equations (viii) and (ix):

(viii)

where

(ix)

The DFT is simple enough to code from first principles that it is often used as an example numerical problem to teach students how to use loops in a given programming language, however it is rarely used in production code because it is computationally inefficient. As the number of samples increases, the number of calculations increases with the square of the number of samples (O(N2)). If this efficiency problem had not been solved in a paper by Cooley and Tukey (11), where they introduced what is known as the fast Fourier transform (FFT), a significant amount of the telecommunications sector would not have been possible. The algorithm they published was actually first discovered by Gauss in 1809 in an unpublished paper and uses a divide and conquer technique. The original time series is split into odd samples and even samples; and then a recursive approach used to construct the Fourier spectrum. This is the reason that many implementations of this algorithm impose the restriction that the number of samples should be a power of two, as this improves the operational efficiency. The efficiency of the FFT scales as O(N log N) opened up the possibility of using Fourier analysis in technical areas that previously would not have been possible.

It is not an exaggeration to say the FFT revolutionised electronic engineering and in turn computer science. Nearly all digital communications rely on the FFT in some form. A measure of how integral to the mathematical sciences the algorithm has become is that improvements to the algorithm continue to the modern day, for example a particularly fast and robust implementation of the FFT called the ‘fastest Fourier transform in the West’ (FFTW) was developed and maintained by academics at the Massachusetts Institute of Technology (MIT), USA (12), and remains an active project. Despite how readily available FFT algorithms have become it is still easy to make mistakes when using them in a real-world example. A raw power spectrum of the time series shown in Figure 1 is shown in Figure 3. The spectrum is shown on a log scale to highlight the detailed features that might otherwise be missed.

Fig. 3.

The raw power spectrum of the sampled time series in Figure 1

The raw power spectrum of the sampled time series in Figure 1

The first and most important point is that the spectrum plotted is actually a power spectrum. Theoretically this is defined as Equation (x):

(x)

where the G*k is the complex conjugate of each Fourier component. The process of finding the power spectrum is lossy, as all phase information in the signal is lost. Despite this, there are many situations where the power spectrum is a much more useful quantity than the raw time series. In this example the large peak at 5.01 Hz, which is seven orders of magnitude above the noise floor, easily identifies the main frequency present in original times series. The code snippet in Figure 4 illustrates how simple using the FFT is with a modern analytics package like Jupyter. Line 2 takes the sampled data Vs from Figure 2, calculates the FFT and converts it into a power spectrum (by taking the absolute value and squaring each component of the vector). Line 3 is simply the calculation of the frequency associated with each bin in the spectrum and is determined by the original sampling frequency fs of the signal. The remainder of the snippet is about presenting the spectrum on a graph.

Fig. 4.

Python code used to generate Figure 3

4. Implementation of Fast Fourier Transform

The ideal nature of the original time series used to calculate the power spectrum shown in Figure 3 obfuscates some of the limitations of this naïve brute force use of the FFT. A typical experimental time series has underlying electrical noise and the time digitisation further distorts the signal. In the following sections we shall discuss the best practice that should be followed to get the best estimate of a power spectrum from an experimental signal. We first simulate what a noisy experimental signal might look like by adding Gaussian noise and then splitting the data into 20 different finite levels to simulate the effect of an analogue to digital converter. The three signals are shown in Figure 5. The digitised noisy signal is representative of many experimental signals met in practice.

Fig. 5.

The red curve is a theoretical sine wave. Gaussian noise has been added to this signal (blue signal) and finally this noisy signal has been digitised to simulate the effect of a coarse analogue to digital converter (orange dots). A sampling frequency of 200 Hz has been used

The red curve is a theoretical sine wave. Gaussian noise has been added to this signal (blue signal) and finally this noisy signal has been digitised to simulate the effect of a coarse analogue to digital converter (orange dots). A sampling frequency of 200 Hz has been used

The main challenge with any experimental setup is designing the experiment to give the best answers we can reasonably expect. The processing of a time series to give the most spectral insight is no different. In this section we will attempt to give some basic guidelines that a novice time series analyst should follow, where possible, when conducting spectral analysis.

4.1 Filter High Frequency Signals

The time series we are analysing nominally has a single harmonic component at 5.01 Hz. Nyquist’s theorem guides us as to what sampling frequency should be used. The 200 Hz sampling frequency used in Figures 1 and 3 is too high to get good details in the frequency range of interest. If we assume that we are interested in only whether the first two harmonics are present, then the sampling frequency should at most only be 40 Hz. This figure was arrived at by assuming the fundamental is at 5 Hz then the third harmonic is at 20 Hz. Nyquist implies we should then double this value. However, another consequence of the Nyquist theorem is that if a signal contains frequency components that are above the Nyquist frequency, for example due to electronic noise, then the FFT algorithm breaks down and higher frequencies are erroneously folded back into the low frequency bins.

Most ADC systems have some form of low pass filter that stops very high frequency noise being recorded. However, these filters are unlikely to be set at the correct frequency for any given application. An option that can be used if the raw data has been sampled at a sufficiently high frequency is to apply a low pass digital filter with a critical frequency sufficiently above the range of interest. It is common to choose a filter at the desired Nyquist frequency, in our case 20 Hz. The impact of applying such a filter is illustrated in Figure 6. Prior to applying the low pass filter there are components at higher frequencies that have the potential to obscure the underlying data. A similar effect can be achieved by using a separate electronic low pass filter to the experimental set up, again with the critical filter frequency set at the Nyquist frequency.

Fig. 6.

(a) The raw power spectrum of the noisy sampled time series shown in Figure 5 before (blue trace) and after a low pass filter (orange trace) is applied to the signal; (b) the impact of applying the low pass filter

(a) The raw power spectrum of the noisy sampled time series shown in Figure 5 before (blue trace) and after a low pass filter (orange trace) is applied to the signal; (b) the impact of applying the low pass filter

The code to apply the filter used here is shown in Figure 7. The vector Vs2 is the noisy sampled time series data shown in Figure 5 and the returned filtered signal Vs3 is the smoothed signal. We have used a simple Butterworth filter (13) as an example but there are many others available in the Python toolbox SciPy (14).

Fig. 7.

Python code used to filter the noisy data shown in Figure 5

Python code used to filter the noisy data shown in Figure 5

4.2 Downsampling

Once a low pass filter has been applied to the signal it is sensible to resample the data at the lower frequency to enable more details of the spectrum to be resolved in the region of interest. This process is called downsampling (15) and should only be done if there are no higher frequency components that are likely to interfere with the results. Since we have applied a low pass filter there are no higher components in the time series data, hence downsampling can be applied safely. The reasons for doing this are perhaps not obvious at first sight, but as discussed in the next section, the computational impact of having an oversampled time series can be significant, particularly when fine frequency resolution is required in the power spectrum.

4.3 Extend the Sampling Window

If one considers two notes of frequency f1 and f2 which are played at the same time, a third lower frequency can be heard. This is called a beat frequency, fb (Equation (xi)):

(xi)

If the notes are nearly the same frequency, the beat frequency becomes very small, vanishing to zero when they are identical. Guitarists sometimes use this effect to tune their instruments. This point illustrates that in order to distinguish between two frequencies of slightly different tones, the frequency resolution is limited by the length of the time series recorded. To increase frequency resolution one must record longer time series. The impact of increasing the sampling time frame can be quite dramatic. The power spectrum shown in Figure 8 is what is obtained if 25.8 s of data are used at the 40 Hz sampling frequency (1024 data points). The fundamental peak at 5.01 Hz is much sharper allowing for a better resolution of the frequency.

Fig. 8.

The raw power spectrum of the filtered time series shown in Figure 6 with a reduced sampling frequency for a single extended time window 25.8 s (blue spectra). The effect of averaging multiple spectra using Welch’s method is shown in the orange spectra

The raw power spectrum of the filtered time series shown in Figure 6 with a reduced sampling frequency for a single extended time window 25.8 s (blue spectra). The effect of averaging multiple spectra using Welch’s method is shown in the orange spectra

If the downsampling step had not been performed to get the same resolution, the number of data points included in the FFT would need to be increased five-fold for no benefit. It is tempting to simply take very long time series and then calculate the power spectrum with a very large number of data points. However, this can be counter productive, not to say computationally inefficient. The spectrum shown in Figure 8 has 512 different frequency bins for 0 < f < 0. 5fs, which gives a resolution of Equation (xii):

(xii)

If a frequency resolution finer than this is required then it is reasonable to use longer time series. However, fine resolution bins can lead to difficult-to-interpret noise floors. It is unlikely, for example, that there is a two order of magnitude difference in the power content of two adjacent bins outside of the main harmonics of any time series, yet that is what the blue spectrum shown in Figure 8 indicates. This wildly oscillating noise floor is an artefact of the discretisation, rather than a true reflection of the noise content of the signal.

4.4 Averaging Spectra and Window Functions

If one has the luxury of very long time series data being available, it is good practice to calculate multiple power spectra by splitting the data into separate time windows, and then reporting the mean result for each frequency bin. This is akin to conducting an experimental measurement multiple times and then reporting the mean results. This was first introduced by Bartlett (16, 17) and improved on by Welch (18) who introduced the idea of overlapping windows to reduce edge effects of the windows. The impact of averaging is illustrated by the orange power spectrum shown in Figure 8. This spectrum is the average of 39 separate spectra. The noise reduction is significant and variation between adjacent bins is significantly smaller.

The final improvement to our experimental power spectrum we will discuss is to use a non‐rectangular window function. The mathematical underpinning of the FFT assumes that the time series repeats for all time. As such, the finite time length has consequences on the shape of the power spectrum. The power spectrum of a box car window is convolved with the power spectrum of the repeating time series. Depending on the application a box car window is unlikely to be the best window to use. There are many windows available that may be more appropriate. Here we use the Hann (15) window to illustrate the point. The normalised power spectrum with a box car window and the Hann window is shown in Figure 9. The peak near 5 Hz is much narrower with the window function applied. This means that a better frequency resolution is achieved. The cost for this is that the amplitude information in the signal is distorted; the two signals have been normalised to the peak to assist in the comparison.

Fig. 9.

Normalised power spectra using a box car window (blue) and a Hann window (orange). The peak is much sharper using the Hann window function so is better for discriminating nearby frequencies

Normalised power spectra using a box car window (blue) and a Hann window (orange). The peak is much sharper using the Hann window function so is better for discriminating nearby frequencies

A function to bring together; the low pass filtering, the downsampling, the averaging and the incorporation of a Hann window is shown in Figure 10. This short function illustrates how easily all the ideas can be brought together using a modern data analytics language such as Python.

Fig. 10.

Python code bringing together low pass filtering, downsampling, a Hann window function and spectral averaging

Python code bringing together low pass filtering, downsampling, a Hann window function and spectral averaging

5. Conclusions

The application of the FFT to data is one of the most widespread numerical algorithms. It is integral to a huge amount of fundamental scientific research and engineering. In an industrial setting the power spectrum is used as a noise reduction method on many sensors, in the communication sector information is compressed using the FFT and in the laboratory many measurement techniques intrinsically make use of the FFT.

Many instruments report spectra directly, for example the output of an FTIR spectrometer, but it is always prudent to understand what analysis is being conducted on our behalf. As outlined here many analytical steps are happening and they may not be applicable to the analysis that we wish to conduct. Fortunately, many numerical packages are readily available that we as users can use to undertake our own Fourier analysis. All the graphs presented in this article have been generated from within a Jupyter notebook using the standard Python libraries bundled with Anaconda. These are readily available tools that we can all use if we have the inclination. Moreover, any time series can be analysed using Fourier analysis to reveal any possible underlying periodic behaviour. Atypical examples might be timesheets, holidays and production data.

The first stage of data analysis for nearly all time series data should be to understand the power spectra. The first step for a novice is to download the Anaconda bundle and start up the Jupyter executable, the second step is to search one of the many online tutorials (for example, (19)) in data analysis in Python and start experimenting. We are fortunate to live in an age when data analysis is an exceptionally easy thing to do. Let us all embrace this gift!

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  • By |2022-03-08T10:16:10+00:00March 8th, 2022|Weld Engineering Services|Comments Off on Basics of Fourier Analysis of Time Series Data

    Academy CEO shortlisted for the Veuve Clicquot Bold Woman Award

    The Veuve Clicquot Bold Woman Award 2022 finalists are (back row, l-r) Melanie Smith CBE, Dr Hayaatun Sillem CBE and Roni Savage. The Bold Future Award shortlist is (front row, l-r) Mursal Hedayat MBE, Victoria Hornby OBE and Lavinya Stennett

    Dr Hayaatun Sillem CBE, Chief Executive of the Royal Academy of Engineering and the Queen Elizabeth Prize for Engineering, has been shortlisted for the 2022 Bold Woman Awards by Veuve Clicquot. First launched in 1972, this will be the 50th year that Veuve Clicquot has honoured the impact of pioneering female leadership and entrepreneurship. 

    Announcing its finalists on International Women’s Day, the Bold Woman Award celebrates excellent female leadership, honouring inspirational women with a proven record of business or organisational growth, underpinned by a commitment to supporting other women into leadership roles.

    Dr Sillem is the first female CEO of The Royal Academy of Engineering and co-founder of the Academy’s Enterprise Hub, which supports and funds UK tech and engineering entrepreneurs. Recognised as a major champion for diversity in STEM, she sits on multiple boards and councils and is an adviser to AccelerateHER, a network of female founders and partners with a mission to help women accelerate growth and scale companies.

    At the Royal Academy of Engineering, Dr Sillem is pioneering a sustainable, global society and inclusive economy. Named one of the ‘Inspiring 50 Women in Tech’, she chairs the UK government’s Business Innovation Forum, the St. Andrews Prize for the Environment, and co-chaired with Sir Lewis Hamilton his Commission to improve Black representation in UK motorsport. She is also a trustee of EngineeringUK and the Foundation for Science & Technology, a member of the UK government’s Levelling Up Advisory Council, a non-executive director of UNBOXED: Creativity in the UK and Laing O’Rourke, and an advisor to the Lloyd’s Register Foundation.

    Dr Sillem says: “I am honoured and delighted to be shortlisted for this unique award for bold leadership alongside some incredibly inspiring women who have achieved so much during their careers. Having chosen to work in a community where I have always been in a minority, I hope this visibility will help to challenge people’s perceptions of leadership in engineering.

    “Engineering is a fantastic career if you want to make a difference, improve people’s lives and shape the future. Through the Academy’s work, we want to inspire many more people from all parts of society to become engineers: engineering is for everyone and the engineering community should reflect the society we serve.”

    Also shortlisted for this year’s award are:

    • Roni Savage, MD & Founder of Jomas Associates, an Engineering & Environmental Company serving the Construction industry since 2009. Jomas was heralded as a high growth company by Goldman Sachs in 2017. The following year, Roni was awarded Black British Business Person of the Year.  She has worked on many major construction schemes across the UK and is Policy Chair for Construction for the Federation of Small Businesses (FSB).
    • Melanie Smith CBE, CEO of Ocado Retail, who has overseen the business’s phenomenal success as it increased revenue by 40% since 2019 – faster growth than any other grocery retailer – and personally led the firm’s strategy to keep the UK fed during the early phases of the pandemic.

    Pip Jamieson, Bold Awards judge and founder of The Dots, said:

    “This year’s shortlist honours women who are having a transformative impact on the UK, driving not just financial success but real change across industry and wider society. The Bold Future category in particular is dominated by those leading social enterprises and charitable organisations, reflecting a shift towards entrepreneurship that’s driven by ethical values and purpose. Alongside representing a new generation of pioneering leaders, these tremendous nominees are driving fresh initiatives that will truly improve the lives of many.”

    The accompanying Bold Future Award celebrates up-and-coming leaders of the future, honouring the women who will shape tomorrow. The finalists are:

    • Mursal Hedayat MBE,  Founder and CEO of Chatterbox. Chatterbox is on a mission to shake up the labour market by connecting talented yet marginalised people with opportunities in the digital economy. Their first product is an AI-powered, award-winning platform that helps companies improve cross-regional collaboration and cultural intelligence through the power of language learning.
    • Victoria Hornby OBE, Founder and CEO of Mental Health Innovations (Shout). Shout 85258 is the UK’s first free, 24/7 digital messaging service to help those struggling with mental health. The organisation has had over 1 million conversations since its inception.
    • Lavinya Stennett, Founder & CEO of The Black Curriculum, a social enterprise founded in 2019 working to teach and support the teaching of Black history all year round, aiming to empower all students with a sense of identity and belonging.

    Notes to editors

    1. The Bold Woman Award by Veuve Clicquot is a modern evolution of the Business Woman Award which has been running since 1972; the first and longest-running international accolade for female business figureheads. The judging panel includes Kristina Blahnik, CEO of Manolo Blahnik; Pip Jamieson, Founder of The Dots; Sian Westerman, Co-Chair at British Fashion Council Trust; Naomi Kerbel, Global Head of TV and Radio at Bloomberg; and Moira Benigson, Founder of MBS Group.  

    The winners will be announced at an award ceremony in London in September 2022.

    For more information on the awards see https://www.veuveclicquot.com/en-gb/bold-by-veuve-clicquot/about

    1. The Royal Academy of Engineering is harnessing the power of engineering to build a sustainable society and an inclusive economy that works for everyone.

    In collaboration with our Fellows and partners, we’re growing talent and developing skills for the future, driving innovation and building global partnerships, and influencing policy and engaging the public.

    Together we’re working to tackle the greatest challenges of our age.

    For more information please contact:

    Jane Sutton at the Royal Academy of Engineering

    T: +44 207 766 0636

    E:  Jane Sutton

     

    By |2022-03-08T09:00:00+00:00March 8th, 2022|Engineering News|Comments Off on Academy CEO shortlisted for the Veuve Clicquot Bold Woman Award

    “Digitalization”

    Johnson Matthey Technol. Rev., 2022, 66, (2), 164

    Introduction

    In recent years, whenever the subject of digitalisation or digital transformation is brought up for discussion, we normally observe two distinguishing reactions from the attendees: one group is excited and satisfied, the other, interested and worried. Of course, some have a good mixture of both. The former has been from companies, big or small, which have a clear digitalisation strategy in place from which obvious development and benefits have been achieved. For the latter, people are as keen as others on implementing solid steps to realise the long-waited benefit from business digitalisation. However, they are not quite sure where and what to start with, despite the continuously advancing technologies in the market. While still dealing with the COVID-19 pandemic, we were very curious about what the book “Digitalization” (1) would bring to help accelerate digital transformation for various organisations.

    Professor Schallmo and Professor Tidd are the editors of “Digitalization” with a list of distinguished researchers on the editorial board. Professor Schallmo is a well-known key researcher focusing on business digitalisation at various stages, and the development and application of the methods to innovate business models. “Digitalization” continues his research focus following his previous book “Digital Transformation Now!” (2).

    Besides his professorship of technology and innovation management at University of Sussex, UK, Professor Tidd has worked with numerous technology-based organisations globally on technology and innovation management projects. His view and experience of connecting innovation and digitalisation is always insightful. In conjunction with “Digitalization”, it is worth expanding the reader’s knowledge through his bestselling textbook on managing innovation (3).

    The book “Digitalization” is a collection of 25 research-based studies which have been arranged in sections to emphasise five aspects of digitalisation: ‘Digital Drivers’, ‘Digital Maturity’, ‘Digital Strategy’, ‘Digital Transformation’ and ‘Digital Implementation’. This arrangement gives a clear statement of the focus of each part. Throughout the book, the literature review of all subjects is very rich which should give the audience a wide range of further reading if required.

    Digital Drivers

    The very early challenges that all organisations face in digital transformation are to discover the right opportunities and initiatives holistically. In the section ‘Digital Drivers’, four articles explore this subject from different angles. Disaster management and future‐led innovation framework, presented by Vettorello (Swinburne University of Technology, Australia) et al., and technology‐oriented future analysis by Urbano (Politecnico di Milano, Italy) et al., aim to provide guidance to organisations on innovation management with fast and accurate decision making within highly dynamic and complex environments. We feel these concepts may also have a place for individual business units within a large organisation where specific needs of that business unit can be addressed to capture local opportunity.

    Chiaroni (Politecnico di Milano) et al. present a real example of how a circular business model has been applied in the building industry to realise business transformation from linear to circular by adopting digital technologies. Mutanov and Zhuparova (al-Farabi Kazakh National University, Kazakhstan) in the fourth article explain several fundamental reasons that commodity countries such as Kazakhstan and other post-Soviet countries are falling behind on digital transformation. These findings certainly show the great potential of digitalisation. Among the literature provided by the authors, two popular books written by Cross (4) and Tighe (5) are worthy of extra attention to expand ways of thinking and setting strategy.

    Digital Maturity

    ‘Digital Maturity’ in Part 2 focuses on discovering digitalisation opportunities from a different angle, by assessing the current digital development status of an organisation and comparing with others within the same business sector or even wider to draw action plans for its own needs. First, a systematic literature review is conducted by Ochoa-Urrego and Peña‐Reyes (Universidad Nacional de Colombia) which includes 22 publications on formal maturity model applications.

    The other two studies from Schallmo (Neu-Ulm University of Applied Sciences, Germany) et al. and Pierenkemper and Gausemeier (Heinz Nixdorf Institute, University of Paderborn, Germany) et al. emphasise a digital maturity models assessment of small and medium-sized enterprises (SMEs). It is recognised that the examined digital maturity models cannot provide a comprehensive digitalisation implementation plan for SMEs with an overarching vision like that typically seen at large corporations. Although Pierenkemper and Gausemeier list a few aspects of the presented model that may require further investigation, the study itself shows through examples how SMEs can produce a simple development plan for digitalisation using the model provided.

    Digital Strategy

    Once digitalisation objectives are determined, it is natural to move onto ‘Digital Strategy’ as presented in Part 3 on how we can capture the opportunities. The first paper in this part gives a deep dive on how disruptive innovation is used as business strategy or model for digital transformation among 80 companies in Germany. To expand the understanding of disruptive innovation, it is worth exploring relevant resources from the bestselling author (6). It is followed by Hartmann (HTW Berlin – University of Applied Science, Germany) et al. and Gernreich (Ruhr-Universität Bochum, Germany) et al. who separately address the importance of top management or an innovation manager who has the necessary knowledge in digitalisation and can drive to complete the plan for desired productivity and benefits.

    Kruft and Gamber (Technische Universität Darmstadt, Germany) in the fourth paper present a critical component of digital transformation: continuous culture change, which often poses an even bigger challenge on the entire journey of digitalisation. All organisations need to recognise the significance of cultural renewal and work closely with their employees to bring them along with progress. It is one of the core strategies to empower people with the right tools, knowledge and communication via digital platforms in the era of ever-changing technology.

    The focus in the paper from Koldewey (Heinz Nixdorf Institute, University of Paderborn) et al. falls in the mainstream of digitalisation, i.e., smart services interconnecting products with aftersales service. They demonstrate how they use a design research methodology to develop a smart service strategy through four comprehensive case studies. The last paper in Part 3, from Porté (Ecole Polytechnique Fédérale de Lausanne, Switzerland) et al., draws attention to the potential of using Systemic Enterprise Architecture Methodology (SEAM) to align business and IT perspectives on innovative projects. A project by the Society of Family Doctors (SFD) is used to showcase how we structure a problem based on who sees it and why, instead of the problem itself.

    Digital Transformation

    Part 4, ‘Digital Transformation’, expands on the first three parts of the book with papers from governments, universities and other parts of the public sector. Meier (University of Innsbruck, Austria) provides a systematic review of the literature on SME digitalisation. Her discovery agrees with a few other papers in the book on challenges that traditional SMEs face while adopting digitalisation: time, financial, human and technical resource constraints. For the public sector, Bjerke-Busch and Aspelund (Department of Industrial Economics & Technology Management, Norwegian University of Science and Technology) use Norwegian Court Administration (NCA) to explain the barriers for digital transformation in a typical public organisation.

    The study from Haslam (Centre for IS Management, Department of Politics and Society, Aalborg University, Denmark) et al. identifies a few key elements of how digital transformation has been accelerated at a Danish university during the pandemic period. Staying connected with the Danish Government, Rosenstand (Aalborg University) shows early work on applying a digital ecosphere canvas for cultivating multiple digital ecosystems at Digital Hub Denmark, a private-public partnership organisation. Jütting (Fraunhofer IAO, Fraunhofer Institute for Industrial Engineering, Center for Responsible Research and Innovation (CeRRI), Germany) et al. introduce the pro-poor digitalisation canvas as a conceptual framework aiming to act as a practical tool to evaluate the potential of digital innovations. The particular interest is to practically turn the objectives of the United Nations Sustainable Development Goals (SDGs) 1 (‘no poverty’) and 10 (‘reduced inequality’) into actions to minimise the digitalisation gap between the advanced and developing world.

    Digital Implementation

    Digital implementation, the focus of Part 5, is the step to really make the transformation. Although it is impossible to cover all areas in the implementation stage, the authors have attempted in-depth discussion in several major subjects. Gfrerer (University of Innsbruck) et al. lead the discussion in the composition of digital leadership and gender diversity, particularly targeting female managers and how they envisage their roles and challenges to digitalisation and innovation. Reis and Hunt (Thinkergy Ltd, Hong Kong and Thailand) in the second paper also focus on the effectiveness of leadership in digitalisation. They conclude by highlighting the importance of creative leaders in the success of digitalisation and such leaders can be trained up through selective programmes combining effective methodology and pedagogy.

    Schallmo and Williams (Neu-Ulm University of Applied Sciences) bring attention to an integrated theoretical approach to digital implementation which aims to realise digitalisation in four interactive dimensions and five procedural phases. The study presented in the fourth paper by Kruszelnicki (Creative Labs sp. zoo ul, Poland) and Breuer (UXBerlin Innovation Consulting and HMKW University of Applied Sciences for Media, Communication and Management, Germany) is particularly interesting. Three use cases are presented to show how Adobe Kickbox has effectively promoted ‘intrepreneurship’ to unlock innovation opportunities. Haag (TH Köln, Germany) et al. have sustainability at the centre of their research. Their main contribution is to provide the ‘design-to-sustainability matrix’ as a toolkit to address ecological challenges through the life cycle of both new and existing product development.

    The last two studies in this part put weight on innovation management. Johnsson (Blekinge Institute of Technology, Sweden) et al. explore the key success factors in evaluating innovation teams. In the last paper Colucci and Forciniti (Evidentia srl, Italy) recount the story of how Ferrari has transformed its business through an innovation management programme which involves management at all levels and processes at different stages.

    Conclusion

    On completing the book, although the questions we had at the start of this review are not fully answered, we were delighted to see several useful case studies presented throughout the book. When it comes to real implementation, we understand that it is impossible to write down all details due to confidentiality and variations in organisational status and need. The richness of the literature resources in this book provided by all authors is hugely beneficial to the audience to gain a theoretical foundation. There is also wide discussion on how digitalisation is applied to various areas of focus, including SMEs, developing countries, gender diversity, SDGs, high-tech industry leaders and the public sector. Digitalisation practitioners such as management and innovation consultants and organisations would find it useful to navigate through the business models and frameworks presented by several authors at different stages of digitalisation. Readers who are very new to the digital transformation subject may find this book too profound and pre‐study is needed to bridge the knowledge gap. Finally, digital transformation is often bundled with innovation for many good reasons. We highly recommend readers continuously explore ways of innovation (7) to identify and truly drive ideas through to implementation.

    “Digitalization”

    “Digitalization”

    The Authors


    Flora Chen is the Data Science Lead in Group IT at Johnson Matthey, UK. She has 15 years’ experience in global high-tech companies and has held technical and management roles spanning IT, engineering, operations, research and development (R&D) and quality. Since Flora joined Johnson Matthey in 2018, she has led several digital analytics projects, discovering and delivering the business value of data. Flora holds an MSc and PhD in Mechanical Engineering from Bristol University, UK, and is a chartered engineer.


    Richard Head is the IT Digital Strategy Partner at Johnson Matthey. Richard has 35 years’ experience in IT, data and analytics and has led global data and analytics teams at Financial Times Stock Exchange (FTSE) companies including Cadburys, Burberry and Diageo. Since joining Johnson Matthey in 2014 he initially led the data and analytics team on the global SAP® rollout. Subsequently he established the overall data platforms for both corporate and agile analytics and set up and built out the group data office before moving to his current role.


    Brendan Strijdom is the Architecture Office Manager at Johnson Matthey with oversight of digital and data innovations. He has 30 years’ experience working with leading edge companies and technology vendors pushing the boundary of what is possible across numerous industries and geographies. He has a BSc degree in Computer Science and in Psychology.


    Philippa Stone is currently seconded into Johnson Matthey’s IT Data Office as part of the Johnson Matthey UK Graduate Scheme. While roles in her early career have primarily focused on R&D and operations, Philippa recognises the value that digitalisation can bring and is now contributing to projects that improve use of data across Johnson Matthey. Philippa holds an MChem from Durham University, UK.

    By |2022-03-07T08:50:10+00:00March 7th, 2022|Weld Engineering Services|Comments Off on “Digitalization”
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