JNIOSH

Abstract of Special Research Report (RR-28)

National Institute of Occupational Safety and Health, Japan

Quenching Limits of Initial Flames in Narrow Tubes --An Approach to the Study of Quenching Volume--

RR-28-1
Toshihiro HAYASHI

: When an electric spark is discharged in a volume filled with an explosive gas mixture, a spherical flame kernel is usually formed and subsequently stable flame develops throughout the mixture. In some cases, however, where the spark energy or other conditions are not satisfactory, the subsequent flame propagation does not occur even if a flame kernel has been observed. There exists a critical volume of initial flame for the propagation of subsequent flame, and if a flame kernel could not expand beyond the critical volume, the flame quenches. This critical volume is called "quenching volume".
    In this report, quenching limits of initial flame are studied in narrow tubes with an attempt to measure quenching volume of explosive gas mixture instead of optical observations of freely expanding flame. Methane-air mixture is ignited by an electric spark of known energy at the closed end of a short narrow tube, which is connected to a larger chamber. Glass tubes with inner diameter of 6-20 mm are mainly used for the experiments. For a given tube, a hemi-spherical incipient flame is once formed but is soon diminished without further propagation through the tube if the pressure of the mixture is marginal. For higher pressures, flame propagates through the tube, and for lower pressures no flame kernel is observed. Critical pressures are usually below atmospheric for tubes under test and decreased for larger tubes.
    The relation between such critical pressure, referred as Limiting Pressure, and tube diameter is extrapolated so as to obtain a critical diameter for atmospheric pressure. This critical diameter is not the so called "quenching diameter" of the mixture, but is considered as "quenching diameter for initial flame", which may corresponds to quenching volume of the flame of atmospheric pressure. The critical diameter for stoichiometric methane-air mixture is estimated to be 5.4 mm by this study, whereas the values of quenching diameter have been reported as 3.33-3.38 mm. This means that methane-air flame never originates in a tube whose diameter is smaller than 5.4 mm and that tube diameter must be smaller than 3.3 mm for the quenching of propagating flame through methane-air mixture. The critical diameter by this report shows fairly good agreement with "critical radius" obtained by Arnold and Sherburne in the study of freely expanding flame on the burner tip.
    Effects of length and material of tube, of fuel content of the mixture and of spark energy on quenching of initial flame are also discussed. Furthermore, quenching behavior of fast burning hydrogen-air flames are compared to those of flames of methane-air mixtures.

Estimating Procedure of Critical Ignition Temperature and Self-heating Behaviors of Some Materials

RR-28-2
Takashi KOTOYORI and Michio NAITO

: In chapter 2, a relationship holding on an adiabatic self-heating process of zero-order is derived. When a material heats spontaneously at Ts K under zero-order adiabatic condition, Eq.1 holds generally. If we assume that the heating rate dTs/dt remains effectively constant within a minute temperature range near Ts, Eq.1 can be integrated to yield Eq.2, where Δt min is the time for sample temperature Ts to rise by a given minute temperature increment ΔTs deg from the initial temperature Ts, and c cal/g·deg, ρ g/cm3 and ΔH cal/mole are the specific heat, density and molar heat of reaction of the material, respectively. Thus both the apparent activation energy E and the apparent frequency factor A of the very slow self-heating reaction can be determined from the gradient (Eq.3) and intercept (Eq.4) of the experimental linear plot of log Δt against the reciprocal of Ts.
    In chapter 3, a relationship between Eq.2 and Frank-Kamenetskii's critical condition for thermal explosion (Eq.5) is discussed, where δc (dimensionless), λ cal/cm·min·deg and γ cm are critical parameter for explosion, thermal conductivity and the radius of the sample package, respectively. Eq.2 is concerned with the adiabatic case, whereas Eq.5 the nonisothermal. So far as the heating process is concerned, however, both equations deal with the similar slow heating process in the subcritical state prior to ignition. Thus an assumption may be thought legitimate that ΔH, E and A appearing in Eq.5 are equivalent to those of the heating decomposition reaction under adiabatic conditions. Eq.5 can be rewritten to give Eq.6. Substitution of Eq.3 and 4 into Eq.6 leads to Eq.7. As thermal conductivity λ is expressed in terms of thermal diffusivity a as in Eq.8, finally we obtain Eq.9. It is worth while to mention that the actual value of ΔH, E, A, λ and cρ of the material is not necessary, so far as the calculation of the critical ignition temperature Tc is concerned. It is only necessary to measure α for calculation of Tc, except for recording the adiabatic self-heating behavior at the initial slow heating stages of the material.
    In chapter 4, Tc of BPO in a commercial package of 10 kg is calculated. The adiabatic heating processes of BPO powder were recorded at temperatures ranging from 75 to 85 °C. Then the logarithm of the time Δt for Ts to rise by 1.25 deg from each Ts was plotted against the reciprocal of Ts according to Eq.2. The coefficients a and b were determined by the least-squares method to be 1.3739 × 104 and -36.3477, respectively. From these values E and A were obtained as follows : E = 62.87 kcal/mole, A = 8.75 × 1030 mole/cm3 ·min. This E value is near to an E value of 58 kcal/mole, which was reported on BPO based on the induction period6). The shape of the package was assumed to be an infinite cylinder (δc = 2) of 26 cm diameter, according to the dimension of it (27 cm × 27 cm × 40 cm). Thermal diffusivity of BPO at ρ = 0.5 g/cm3 was measured by the Xe flash method to be 5.76 × 10-2 cm2 /min5). Molar heat of reaction of BPO was taken from Fine's data8). On substituting these values into Eq.9, Tc is determined to be 79 °C. This value is fairly near to 82 °C, which is the value of SADT on solid BPO7).
    In chapter 5, a self-ignition accident of magnetite (Fe3O4 ) and its heating behavior are described. The weathering effect which is characteristic of most solid materials having oxidative heating properties was observed in this material (Fig.2). Thus, Fe3O4 granules show a vigorous tendency to heat due to oxidation immediately after it was taken out of the container ; it becomes, however, less active to oxidation, the longer it is exposed to air. Similarly the heating profile is also steeper at the initial stages in each run, but it shows a tendency to saturate gradually at the latter stages. This effect was verified by X-ray micro-diffractometry to be attributed to a fact that oxidation occurs predominantly near the surface of granules.
    In chapter 6, self-ignition accidents of dry spray mist of some oxidatively polymerizing paint and its heating behavior are described. Accidents of this type were experienced often in winter rather than in summer, contrary to common sense. Hydroperoxide (hpo) is probably present in the resin substrate, as the dry mist was found to heat even in nitrogen atmosphere (Fig.3 and 4). Linoleic acid/cotton wool mixture which had reserved for 6 days in a refrigerator at 7 °C showed a more vigorous heating tendency and a greater peroxide value than that reserved in an oven at 35 °C, other conditions being equal (Fig.6). Thus such situations were revealed that in winter hpo is, though slowly, formed in the resin substrate while the mist sticks to the wall, but the hpo is not consumed for polymerization due to lower ambient temperatures and is gradually accumulated in the dry mist ; whereas in summer it is actively consumed for polymerization, so that the paint mist gets to lose the tendency to heat spontaneously.
    In chapter 7, a comparative study of the adiabatic oxidative heating, rates of a series of unsaturated fatty acids is described. Times for Ts to rise by 2.5 deg from Ts at temperatures from 40 to 50 °C were measured for arachidonic acid (A), linolenic acid (B) and linoleic acid (C) in the form of mixture with cotton wool, respectively. The order of heating rate was A > B > C, in the ratio of 9.1 : 3.2 : 1 (Table 2 and Fig.8), However, Holman et al. reported that the relative rates of oxidation based on weight gain at 37 °C of acid esters mentioned above were 4.8 : 2.4 : 1, respectively9). This apparent inconsistency is probably due to the reason that the heating process proceeds on a mechanism which is not necessarily parallel with up-take of oxygen.
    In conclusion the apparatus was found to be effective, not only for recording the profile of the adiabatic self-heating process, but also for estimating Tc of various chemicals.

A Fracture Mechanics and Fractographic Study on the Fatigue Crack Propagation Behaviours in Some Castings

RR-28-3
Masazumi TANAKA

: Fatigue crack growth behaviours were examined using the methods of fractography and fracture mechanics, for five kinds of castings (an Al-alloy casting, two spheroidal graphite (S.G.) cast irons and two grey cast irons). This work was carried out as a part of a series of experimental works in this Research Institute to clarify the fatigue failure phenomena of metallic materials and also to get the information for analysis and prevention of failure accidents. The characteristic feature of these castings in this aspect was discussed in comparison with that of rolled materials (an Al-alloy 2017-T3 and a mild steel SB42) studied in the previous work.
    Plate specimens of 4 mm thick, 100 mm width and 200 mm length with a central slot were fatigued at the frequency range of 135 - 150 Hz, with stress ratios R (the ratio of minimum to maximum stress in one load cycle) ranging from -1.0 to 0.7. The macroscopic crack growth rates were determined as the slope of the surface crack length (l) to number of cycle (n) curves. Fracture surfaces were mainly observed directly, using a scanning electron microscope, and in some cases, using a transmission electron microscope with 2 stage chromium shadowed carbon replica. And an X-ray microanalyzer was used to measure the microscopic distribution of Si in a S.G. cast iron. The definition of striation and the measuring method of their spacings were based on those in the previous work.
    The main results of this work are summarized as follows ;
  (1) Macroscopic fatigue crack propagation rates for five kinds of castings are well described as a function of the effective stress intensity factor based on the Elber's crack closure concept taking account of stress ratio R.
  (2) The Al-alloy casting and S.G. cast irons have fairly high fatigue crack growth resistance similar to those of the rolled materials (an Al-alloy and steels respectively), but that resistance is lower for two grey cast irons.
  (3) Fatigue fracture and static fracture are easily distinguished macroscopically for Al-alloy casting and S.G. cast irons, but that is not the case for grey cast irons.
  (4) Besides fatigue striations, various microscopic features of fatigue fracture surface are observed in Al-alloy casting and S.G. castings, but few of them in grey cast irons.
  (5) The correlation between striation spacing and macroscopic crack propagation rate is good for S.G. cast iron, but not so good for Al-alloy casting.
  (6) The area percentage of intergranular fracture surface and spheroidal graphite area in S.G. cast irons, and that of transgranular fracture surface of pearlite colony in the sandmold grey cast iron, are respectively correlated to stress intensity factor, and may be used for the quantitative analysis of fatigue fracture surfaces of these castings.

Application of a Maximum Tensile Strain Criterion to the Fracture of Grinding Wheels --A Case of the Fracture of Vitrified Grinding Wheels under Diametral Compression Test--

RR-28-4
Soichi KUMEKAWA and Etsuji YOSHIHISA

: Disk specimens and ring specimens which are made of vitrified grinding wheels are loaded along the diameter until they split, and the relation between grinding wheel strength in biaxial state of stress and that in uniaxial state of stress is investigated by adopting the maximum tensile strain criterion for fracture.
    Therefore the both equivalent stress of the maximum tensile strain in each state of stress is in good agreement.
    The summary from the experimental results is as follows :
  (1) Poisson's ratio of the disk specimen measured just before fracture under diametral compression test is 0.27.
  (2) Contact width between the disk specimens and loading plates is about the valve of 0.2 times the diameter of the disk specimens (see Table 2)
  (3) Under diametral compression tests using crack detect circuits as shown in Fig.5 and Fig.6, a initiation crack in the ring specimen grows at the edge of inner hole along the loading axis and that in the disk specimen grows outer part along the loading axis not at the center.
  (4) The both equivalent stress of the maximum tensile strain in the disk and in the ring is in good agreement on the basis of the above results (1) to (3). (see Table 4)
  (5) Fracture of the disk and the ring specimens which are made of vitrified grinding wheels can be explained well by adopting the maximum tensile strain criterion from the experimental results described above.

Experimental Investigation on Electrostatic Charging of Spherical Metal in Corona Discharge

RR-28-5
Yasuyuki TABATA

: Theoretical studies and laboratory experiments on particle charging under the circumstances existing the corona discharge have been made by many investigators for a wide range of conditions. The first quantitatively experimental results on particle charging in the corona field were obtained by H. Rohmann in 1923. Theoretical formula with charge quantity of the spherical particle was derived by M. M. Pauthenier and M. Moreau-Hanot in 1932. But charge quantity of particles is not simply obtained by the theoretical formula, because charging-field strength (electric field strength) and ion density of corona field represented as functions in the theoretical formula are not directly determined by analysis and/or experiments.
    This paper presents the experimental formula and results with electrostatic charging of particles imparted by ion bombardment of the corona discharge. This experimental formula for charge quantity of particles in the corona field is given by
      Qp = 12πε0a2 f1(V, pf2(V ) / [ f2(V ) + 4ε0v¯zf1f1(V, p ) ]
where Qp is the charge quantity of the particle penetrating through the path p in corona field, ε0 the permittivity of free space, a the radius of the particle, the average velocity of the running particle, z the distance related with the corona electrode geometry, f1(V, p ) the experimental equation can be introduced by use of saturation charge of the particle and f2(V ) the corona discharging characteristics, are obtained by experiments. This experimental formula for charge quantity is written by the measurable electrical quantities related to the corona discharge ; voltage supplied to the corona electrode, corona current and corona area etc.
    The experiments were carried out to verify this experimental formula for spherical metal (5,7 mm diameter) in a coaxial cylindrical corona section (20 cm diameter, 10 cm length). It was confirmed, from the experiments that the experimental data fitted fairly well on a curve obtained by this experimental formula and that charge quantity of the individual particle could be calculated from this experimental formula. It will be possible to apply this experimental formula to the design of the charging processes for electrostatic powder engineering.

Bilateral Control of Artificial Fingers System Drived by the Electroviscous Fluid Dynamic Properties of Electro-Viscous-Fluid Clutch (the Winslow Clutch) as on Element of the Control

RR-28-6
Noboru SUGIMOTO, Taiji KONDO and Kiyoshi FUKAYA

: In order to control functionally so many degrees of freedom of the Artificial multi-fingers system, Electro-Viscous-Fluids Clutches were developed and used in our study, which are different from any existing control method.
    The general properties of the clutch were measured and investigated from the points of view of induced torque, response time of the torque and stability through the cylindrical type of the clutch.
    As the result, the clutch were controllable with as wide the range as 0 - 8.7 kg·cm and with satisfactory rapidity of response. As for the stability of the clutch, though some kinds of electrodes such as S45C, brass, A2017 (aluminium), Copper gilded, through analysis, were ionized and saluted into the medium and then make the stability of the clutch worse, in case of platinum gilded electrode, which has small ionization tendency, the stability of the clutch has been improved extremely.
    The Winslow clutches, though could be said to be superior to other type of clutching with respect to rapid response and stability, have as simple a structure as cylinder disc, which makes driving element of the hardware system smaller and then capable of giving the system more degrees of freedom. Besides, in this study, the control system of induced force using the Winslow clutches of the cyclindical type were developed and investigated. As the result, it was confirmed that the force was controllable with satisfactory response and small error.

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