Development Of Continuous, Direct-feedback Control Systems For Sintering Of Metallic Components
Prof. Diran Apelian (PMRC-Metal Processing Institute, WPI, Worcester, MA)
Dr. Marc Baum (Oak Crest Institute of Science, Pasadena, CA)
The program consists of the development and field testing of a continuous, direct-feedback system for the control and optimization of the delubrication process during the sintering of powder metallurgy compacts. The system will be based on a continuous sensor, measuring lubricant decomposition products, and an intelligent process control model; this novel technology is expected to have broad applications in the powder metallurgy industry, and sintering processes used in other industries. The research seeks to increase energy efficiency, reduce waste and pollutant emissions, and increase the productivity of the domestic Supporting Industries. The optimization and control of delubrication will reduce cycle times, and increase efficiencies as called for by the Powder Metallurgy industry and the Heat Treat industry Roadmaps, respectively.
The Roadmap for Powder Metallurgy as well as Heat Treating has identified controls and sensors to better monitor the sintering process as a key challenge and an opportunity. Moreover, the proposed program also responds to identified high-priority Research Needs in High-Temperature Processes, specifically sintering. The "Industry of the Future Roadmaps" that will benefit from this research is primarily the steel sector. Benefits include improved quality of processed parts and enhanced productivity, along with enhanced energy efficiency and environmental performance, through applications of the new process control system.
The total cost of the proposed program over a period of four years is: $1,607,589. The non-federal cost share commitments total $804,000 over a period of four years. Participating corporations are members of PMRC consortium along with CPMT member companies, and have committed to support the program of research with their involvement, guidance, and support of equipment and supplies. The proposed research aims to develop and beta-test a continuous, direct-feedback control system for the sintering of metallic components. This R&D effort will span laboratory design and evaluation work, as well as comprehensive field-testing of the complete system in a number of environments representative of the thermal processing industry, relevant to sintering of metal powder compacts. The project is anticipated to take four years to reach completion and is expected to yield a tested prototype control system ready for commercialization.
The proposed 4-year research program aims to achieve the following milestones:
- Develop and test a laboratory sensor capable of measuring gas-phase aliphatic hydrocarbons and carbon dioxide continuously and automatically by infrared absorption spectroscopy,
- Conduct further laboratory studies to fully characterize products of thermal decomposition for a variety of common lubricants,
- Evolve the laboratory sensor into a robust prototype,
- Conduct first-level field tests at a site with a suitable industrial furnace,
- Modify/upgrade sensor based on field experience,
- Develop direct-feedback model based on sensor readings and process conditions,
- Conduct comprehensive beta-testing of the sensor and model at various commercial sites representative of a range of sintering processes,
- Analyze metal parts produced during these tests as a function of operating conditions,
- Quantify economic, energy, and environmental benefits resulting from using the process control system.
The scope of the effort will be directed at developing a process control system applicable to a broad range of iron and aluminum sintering processes. Members of the PMRC and CPMT will be actively involved from the start to ensure rapid technology transfer.
Maintained by webmaster@wpi.eduLast modified: October 23, 2007 08:50:43