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Shot peening can be used to recondition distorted steel conveyor belts.
Shot peening is a conservation process for flattening a deformed steel belt in which the surface of the belt is impacted by small stainless steel or carbon steel balls, called peening shot. Each ball hitting the belt functions as a peening hammer, forming a small indentation, or dimple, on the steel belt surface.
For the indentation to be formed, the steel belt surface layer must yield in tension.[ citation needed ][ clarification needed ] The compressed grains[ clarification needed ] help to restore the surface to its original shape by producing a hemisphere[ clarification needed ] of cold-worked metal, highly stressed in compression. Overlapping indentations create a continuous layer of residual compressive stress. It is well known that cracks will not lead up,[ clarification needed ] nor propagate in a compressive stressed zone. Since most fatigue and stress corrosion failures originate at the surface, the compressive stresses from shot peening significantly enhance the belt’s lifespan.[ citation needed ] Note that:
Press belts may become deformed and worn over time. The portable shot blasting unit is primarily used to flatten deformed press belts and prepare the belt material for reuse. Compact and lightweight, the unit is designed for field use and can be carried and operated efficiently. All necessary equipment (excluding the carriage frame and air compressor) fits into a box with dimensions of approximately 350 × 350 × 320 mm. The combined weight of the blaster, valve, air hose, and other components is about 25 kg, with the blasting machine itself weighing 9 kg.
A pair of universal channels (38 mm × 76 mm), typically 500 mm longer than the belt width, must be provided on-site. These channels are welded together to allow the blaster to move smoothly across the belt’s surface. The total installation time, including assembling the carriage frame, generally takes only a few hours, after which the peening process can begin.[ citation needed ]
An electric shut-off valve is mounted on the inlet air hose to protect the belt from over-blasting should it suddenly stop during the blasting operation. The valve solenoid must be connected (interlocked) to the press machine's power supply to be effective. For best blasting results, an air supply of 4,200 liters per minute is required at a pressure of 6 bar.[ citation needed ] A flexible air hose is supplied with the unit, connecting the blasting unit to the local air supply. All local supply pipes should have a minimum bore diameter of 1 inch. The recommended shot blasting medium is tungsten shot (beads) with a diameter ranging from 0.2 to 0.4 mm and a hardness exceeding 40 HRC.[ citation needed ] The machine operates by drawing a quantity of tungsten shot from the bottom of the scroll case into the high-velocity nozzles. The shot is blasted onto the surface of the belt, and most of the shot bounces back into the scroll case. The air is vented through the filter socks, and any shot carried with the air is filtered out and dropped back into the scroll case.
Since the 1980s, the standard procedure used to solve the problem of deformed belts was to turn the belt over, i.e. what was previously the back of the belt was used to form the new product side.[ citation needed ] The belt became flatter when turned due to the equalization of stresses on both sides. However, over time, the belt typically reverted to its original shape, albeit in the opposite direction. As a result, it often became necessary to turn the belt again after approximately one year. This process was extremely time-consuming and costly, as it required cutting the belt, dismantling it from the press, turning it and then reinstalling it. The reinstallation involved belt joining operations such as welding and grinding of the joint, as well as running-in procedures. Additionally, this process demanded specialized equipment for handling the belt, welding jigs, and skilled personnel for joint welding. Compounding the issue, production had to be halted during these operations, with stoppages lasting up to a week not uncommon. The steel belt shot peening process was introduced as a solution to address the belt cross-curvature problem.
A scuba set, originally just scuba, is any breathing apparatus that is entirely carried by an underwater diver and provides the diver with breathing gas at the ambient pressure. Scuba is an anacronym for self-contained underwater breathing apparatus. Although strictly speaking the scuba set is only the diving equipment that is required for providing breathing gas to the diver, general usage includes the harness or rigging by which it is carried and those accessories which are integral parts of the harness and breathing apparatus assembly, such as a jacket or wing style buoyancy compensator and instruments mounted in a combined housing with the pressure gauge. In the looser sense, scuba set has been used to refer to all the diving equipment used by the scuba diver, though this would more commonly and accurately be termed scuba equipment or scuba gear. Scuba is overwhelmingly the most common underwater breathing system used by recreational divers and is also used in professional diving when it provides advantages, usually of mobility and range, over surface-supplied diving systems and is allowed by the relevant legislation and code of practice.
An air compressor is a machine that takes ambient air from the surroundings and discharges it at a higher pressure. It is an application of a gas compressor and a pneumatic device that converts mechanical power into potential energy stored in compressed air, which has many uses. A common application is to compress air into a storage tank, for immediate or later use. When the delivery pressure reaches its set upper limit, the compressor is shut off, or the excess air is released through an overpressure valve. The compressed air is stored in the tank until it is needed. The pressure energy provided by the compressed air can be used for a variety of applications such as pneumatic tools as it is released. When tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes the tank. A compressor is different from a pump because it works on a gas, while pumps work on a liquid.
A hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas cylinders, boilers and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual leak detection, and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container.
A diving air compressor is a breathing air compressor that can provide breathing air directly to a surface-supplied diver, or fill diving cylinders with high-pressure air pure enough to be used as a hyperbaric breathing gas. A low pressure diving air compressor usually has a delivery pressure of up to 30 bar, which is regulated to suit the depth of the dive. A high pressure diving compressor has a delivery pressure which is usually over 150 bar, and is commonly between 200 and 300 bar. The pressure is limited by an overpressure valve which may be adjustable.
A pressure vessel is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure.
A gas cylinder is a pressure vessel for storage and containment of gases at above atmospheric pressure. Gas storage cylinders may also be called bottles. Inside the cylinder the stored contents may be in a state of compressed gas, vapor over liquid, supercritical fluid, or dissolved in a substrate material, depending on the physical characteristics of the contents. A typical gas cylinder design is elongated, standing upright on a flattened or dished bottom end or foot ring, with the cylinder valve screwed into the internal neck thread at the top for connecting to the filling or receiving apparatus.
Hydraulic machines use liquid fluid power to perform work. Heavy construction vehicles are a common example. In this type of machine, hydraulic fluid is pumped to various hydraulic motors and hydraulic cylinders throughout the machine and becomes pressurized according to the resistance present. The fluid is controlled directly or automatically by control valves and distributed through hoses, tubes, or pipes.
Gas tungsten arc welding is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area and electrode are protected from oxidation or other atmospheric contamination by an inert shielding gas. A filler metal is normally used, though some welds, known as 'autogenous welds', or 'fusion welds' do not require it. A constant-current welding power supply produces electrical energy, which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma.
Shot peening is a cold working process used to produce a compressive residual stress layer and modify the mechanical properties of metals and composites. It entails striking a surface with shot with force sufficient to create plastic deformation.
In materials science and solid mechanics, residual stresses are stresses that remain in a solid material after the original cause of the stresses has been removed. Residual stress may be desirable or undesirable. For example, laser peening imparts deep beneficial compressive residual stresses into metal components such as turbine engine fan blades, and it is used in toughened glass to allow for large, thin, crack- and scratch-resistant glass displays on smartphones. However, unintended residual stress in a designed structure may cause it to fail prematurely.
A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-section, used mainly to convey substances which can flow — liquids and gases (fluids), slurries, powders and masses of small solids. It can also be used for structural applications; a hollow pipe is far stiffer per unit weight than the solid members.
A fitting or adapter is used in pipe systems to connect sections of pipe or tube, adapt to different sizes or shapes, and for other purposes such as regulating fluid flow. These fittings are used in plumbing to manipulate the conveyance of fluids such as water for potatory, irrigational, sanitary, and refrigerative purposes, gas, petroleum, liquid waste, or any other liquid or gaseous substances required in domestic or commercial environments, within a system of pipes or tubes, connected by various methods, as dictated by the material of which these are made, the material being conveyed, and the particular environmental context in which they will be used, such as soldering, mortaring, caulking, plastic welding, welding, friction fittings, threaded fittings, and compression fittings.
Laser peening (LP), or laser shock peening (LSP), is a surface engineering process used to impart beneficial residual stresses in materials. The deep, high-magnitude compressive residual stresses induced by laser peening increase the resistance of materials to surface-related failures, such as fatigue, fretting fatigue, and stress corrosion cracking. Laser shock peening can also be used to strengthen thin sections, harden surfaces, shape or straighten parts, break up hard materials, compact powdered metals and for other applications where high-pressure, short duration shock waves offer desirable processing results.
A pressure regulator is a valve that controls the pressure of a fluid to a desired value, using negative feedback from the controlled pressure. Regulators are used for gases and liquids, and can be an integral device with a pressure setting, a restrictor and a sensor all in the one body, or consist of a separate pressure sensor, controller and flow valve.
Oxy-fuel welding torch and oxy-fuel cutting are processes that use fuel gases and oxygen to weld or cut metals. French engineers Edmond Fouché and Charles Picard became the first to develop oxygen-acetylene welding in 1903. Pure oxygen, instead of air, is used to increase the flame temperature to allow localized melting of the workpiece material in a room environment.
Sandblasting, sometimes known as abrasive blasting, is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface or remove surface contaminants. A pressurised fluid, typically compressed air, or a centrifugal wheel is used to propel the blasting material. The first abrasive blasting process was patented by Benjamin Chew Tilghman on 18 October 1870.
Low plasticity burnishing (LPB) cold compresses metal to provide deep, stable surface residual stresses to improve damage tolerance and extend metal fatigue life; mitigating surface damage, including fretting, corrosion pitting, stress corrosion cracking (SCC), and foreign object damage (FOD). Improved fretting fatigue and stress corrosion performance has been documented, even at elevated temperatures where the compression from other metal improvement processes: low stress grinding (LSG) etc. relax. The resulting deep layer of compressive residual stress has also been shown to improve high cycle fatigue (HCF), low cycle fatigue (LCF), and stress corrosion cracking (SCC) performance.
The high-frequency impact treatment or HiFIT – Method is the treatment of welded steel constructions at the weld transition to increase the fatigue strength.
A steel belt is a type of conveyor belt used in many industries such as food, chemical, wood processing, and transportation.
In metallurgy, peening is the process of working a metal's surface to improve its material properties, usually by mechanical means, such as hammer blows, by blasting with shot, focusing light, or in recent years, with water column impacts and cavitation jets. With the notable exception of laser peening, peening is normally a cold work process tending to expand the surface of the cold metal, thus inducing compressive stresses or relieving tensile stresses already present. It can also encourage strain hardening of the surface metal.
