Recently, considerable attention has been given to nickel-based superalloys used in additive manufacturing. However, additive manufacturing is limited by a slow build rate in obtaining optimal densities. In this study, optimal volumetric energy density (VED) was calculated using optimal process parameters of IN718 provided by additive manufacturing of laser powder-bed fusion. The laser power and scan speed were controlled using the same ratio to maintain the optimal VED and achieve a fast build rate. Cube samples were manufactured using seven process parameters, including an optimal process parameter. Analysis was conducted based on changes in density and melt-pool morphology. At a low laser power and scan speed, the energy applied to the powder bed was proportional to and not . At a high laser power and scan speed, a curved track was formed due to Plateau-Rayleigh instability. However, a wide melt-pool shape and continuous track were formed, which did not significantly affect the density. We were able to verify the validity of the VED formula and succeeded in achieving a 75% higher build rate than that of the optimal parameter, with a slight decrease in density and hardness.

In this study, we intend to develop a control valve with oxidation resistance for hydrogen fluoride that can be applied to the semiconductor production process. Operated Valves currently in use is a form of assembling an air cylinder to the valve body. These valves generally have a cylinder body made of aluminum (Al), so they may corrode depending on the external environment, and the solution leaks along the rod inside the cylinder, causing damage to parts due to corrosion. To solve this problem, the valve plug shape was developed by devising and applying a plug using a valve different from the existing method, and it is possible to block the inflow of hydrogen fluoride into the valve control unit, thereby preventing damage to parts as well as maintaining stable valve operation.

Ti-6Al-4V alloy has a wide range of applications, ranging from turbine blades that require smooth surfaces for aerodynamic purposes to biomedical implants, where a certain surface roughness promotes biomedical compatibility. Therefore, it would be advantageous if the high volumetric density is maintained while controlling the surface roughness during the LPBF of Ti-6Al-4V. In this study, the volumetric energy density is varied by independently changing the laser power and scan speed to document the changes in the relative sample density and surface roughness. The results where the energy density is similar but the process parameters are different are compared. For comparable energy density but higher laser power and scan speed, the relative density remained similar at approximately 99%. However, the surface roughness varies, and the maximum increase rate is approximately 172%. To investigate the cause of the increased surface roughness, a nonlinear finite element heat transfer analysis is performed to compare the maximum temperature, cooling rate, and lifetime of the melt pool with different process parameters.

A lot of sensor and control signals is generated by an industrial controller and related internet-of-things in discrete manufacturing system. The acquired signals are such records indicating whether several process operations have been correctly conducted or not in the system, therefore they are usually composed of binary numbers. For example, once a certain sensor turns on, the corresponding value is changed from 0 to 1, and it means the process is finished the previous operation and ready to conduct next operation. If an actuator starts to move, the corresponding value is changed from 0 to 1 and it indicates the corresponding operation is been conducting. Because traditional fault detection approaches are generally conducted with analog sensor signals and the signals show stationary during normal operation states, it is not simple to identify whether the manufacturing process works properly via conventional fault detection methods. However, digital control signals collected from a programmable logic controller continuously vary during normal process operation in order to show inherent sequence information which indicates the conducting operation tasks. Therefore, in this research, it is proposed to a recurrent neural network-based fault detection approach for considering sequential patterns in normal states of the manufacturing process. Using the constructed long short-term memory based fault detection, it is possible to predict the next control signals and detect faulty states by compared the predicted and real control signals in real-time. We validated and verified the proposed fault detection methods using digital control signals which are collected from a laser marking process, and the method provide good detection performance only using binary values.

To remove phosphorus from the effluent of public wastewater treatment facilities, hundreds of enhanced phosphorus treatment processes have been introduced nationwide. However, these processes have a few problems including excessive maintenance cost and sludge production caused by inappropriate coagulant injection. Therefore, the optimal decision of coagulant dosage and automatic control of coagulant injection are essential. To overcome the drawbacks of conventional phosphorus removal processes, the integrated sedimentation and dissolved air flotation(SeDAF) process has been developed and a demonstration plant(capacity: 100 m3/d) has also been installed. In this study, various jar-tests(sedimentation and / or sedimentation·flotation) and multiple regression analyses have been performed. Particularly, we have highlighted the decision–making algorithms of optimal coagulant dosage to improve the applicability of the SeDAF process. As a result, the sedimentation jar-test could be a simple and reliable method for the decision of appropriate coagulant dosage in field condition of the SeDAF process. And, we have found that the SeDAF process can save 30 – 40% of coagulant dosage compared with conventional sedimentation processes to achieve total phosphorus (T-P) concentration below 0.2 mg/L of treated water, and it can also reduce same portion of sludge production.

As aeration is an energy-intensive process, its control has become more important to save energy and to meet strict effluent limits. In this study, predictive aeration control based on the respirometric method has been applied to the sequencing batch reactor (SBR) process. The variation of the respiration rate by nitrification was great and obvious, so it could be a very useful parameter for the predictive aeration control. The maximum respiration rate due to nitrification was about 60 mg O2/L‧h and the maximum specific nitrification rate was about 7.5 mg N/g MLVSS‧h. The aeration time of the following cycle of the SBR was daily adjusted in proportion to that which was previously determined based on the sudden decrease of respiration rate at the end of nitrification in the respirometer. The aeration time required for nitrification could be effectively predicted and it was closely related to influent nitrogen loadings. By the predictive aeration control the aerobic period of the SBR has been optimized, and energy saving and enhanced nitrogen removal could be obtained.

Sludge transporting pipes in wastewater treatment plant are easy to be clogged with struvite when the digested sludge and dehydrated filtrate are transported through the pipes, which lowers the efficiency of sludge treatment system in a WWTP. pH is one of the most important factors in struvite formation, and carbon dioxide separated from biogas can be used to control pH and struvite formation. By controlling pH, the amount of dehydrating agent can be reduced by about 10%, which saves the budget for facility maintenance. As CO2 is reused and dehydrating chemicals are saved, the approach can contribute to global warming gas reduction.

바이오파울링은 역삼투막 여과 공정에서 운전 성능을 저해하는 주요 원인이다. 이전 연구들은 분리막 표면에 발생하는 바이오파울링을 제어하기 위해서 화학적 세정제를 주입하는 방법을 주로 사용하였다. 화학적 세정제의 주입은 분리막의 손상뿐만 아니라 이차적으로 수계 오염을 발생시키기 때문에 주입 농도와 운영 방법에 주의가 요구된다. 이러한 문제를 극복하기 위해, 본 연구에서는 분리막 표면에 생물막 저해제를 고정하여 바이오파울링을 제어하는 연구를 수행하였다. 표면 고정화를 위한 방법으로 Layer-by-layer 기술을 적용하였고, 생물막저해제로 클로르헥시딘과 글루타알데하이드를 사용하였다. 막 표면의 생물막 저해제 고정화는 미생물의 부착 억제 및 사멸로 생물막 형성이 지연되어 운전 성능이 유지되는 효과를 나타냈다.

In this study, various physical cleaning methods such as physical washing and osmotic backwash, were conducted to understand membrane fouling properties by employing real secondary wastewater effluent (SWWE). In addition, microfiltration (MF) and ultrafiltration (UF) pretreatments were compared to maximize removal of organic matter and to control membrane fouling efficiently. Organic foulants deposited on the active layer of FO membrane were observed by fouling behavior test. The relationship between concentrations of natural organic matter and membrane fouling was also investigated from the bench-scale FO tests.

In the present study, we investigate the effects of milling time and the addition of a process control agent (PCA) on the austenite stability of a nanocrystalline Fe-7%Mn alloy by XRD analysis and micrograph observation. Nanocrystalline Fe-7%Mn alloys samples are successfully fabricated by spark plasma sintering. The crystallite size of ball-milled powder and the volume fraction of austenite in the sintered sample are calculated using XRD analysis. Changes in the shape and structure of alloyed powder according to milling conditions are observed through FE-SEM. It is found that the crystallite size is reduced with increasing milling time and amount of PCA addition due to the variation in the balance between the cold-welding and fracturing processes. As a result, the austenite stability increased, resulting in an exceptionally high volume fraction of austenite retained at room temperature.

This paper seeks to present a multi-control method that can contribute to effective control of the production line with multiple bottleneck processes. The multi-control method is the production system that complements shortcomings of CONWIP and DBR, and it is designed to determine the raw material input according to the WIP level of two bottleneck processes and WIP level of total process. The effectiveness of the production system developed by applying the multi-control method was verified by the following three procedures. Raw material input conditions of the multi-control method are as follows. First, raw materials are go into the production line when the number of the total process WIP is lower than established number of WIP in total process and first process is idle. Second, raw materials are introduced when the number of WIP of two bottleneck processes is lower than the established number of WIP of each bottleneck process. Third, raw materials are introduced when the first process and in front of bottleneck process are idle even if the number of WIP in the total process is less than established number of WIP of the total process. The production line with two bottleneck processes was selected as the condition for production environment, and the production process modeling of CONWIP, DBR and multi-control production method was defined according to the production condition. And the optimum limited WIP level suitable for each system was obtained by applying a genetic algorithm to determine the total limited number of WIP of CONWIP, the limited number of WIP of DBR bottleneck process, the number of WIP in the total process of multi-control method and the limited number of WIP of bottleneck process. The limited number of WIP of CONWIP, DBR and multi-control method obtained by the genetic algorithm were applied to ARENA modeling, which is simulation software, and a simulation was conducted to derive result values on the basis of three criteria such as production volume, lead time and number of goods in-progress.

As the sequencing batch reactor process is a time-oriented system, it has advantages of the flexibility in operation for the biological nutrient removal. Because the sequencing batch reactor is operated in a batch system, respiration rate is more sensitive and obvious than in a continuous system. The variation of respiration rate in the process well represented the characteristics of biological reactions, especially nitrification. The respiration rate dropped rapidly and greatly with the completion of nitrification, and the maximum respiration rate of nitrification showed the activity of nitrifiers. This study suggested a strategy to control the aeration of the sequencing batch reactor based on respirometry. Aeration time of the optimal aerobic period required for nitrification was daily adjusted according to the dynamics of respiration rate. The aeration time was mainly correlated with influent nitrogen loadings. The anoxic period was extended through aeration control facilitating a longer endogenous denitrification reaction time. By respirometric aeration control in the sequencing batch reactor, energy saving and process performance improvement could be achieved.

In this study, we divided the process operation scenarios into three categories based on raw water temperature and turbidity. We will select and operate the process operation scenario according to the characteristics of the raw water. The number of algae in the DAF treated water has been analyzed to be less than 100 cells/mL. These results indicated that the DAF process is effective in removing the algae. In addition, the scenario of the integrated management decision algorithm of the DAF process was developed. DAF pilot plants (500 m3/day) process has shown a constantly sound performance for the treatment of raw water, yielding a significantly low level of turbidity (DAF treated water, 0.21~1.56 NTU).

A membrane module including grid was designed and introduced to MBR (membrane bio-reactor) for the purpose of better control of membrane fouling. It could be anticipated that the grid enhances the shear force of fluid-air mixture into the membrane surface by even-distributing the fluid-air to the membrane module. As MLSS concentration, packing density which is expressed in the ratio of the housing and the cross-sectional area of membrane fibers (Am/At) and air-flow rate were changed, membrane foulings were checked by monitoring fouling resistances. The total fouling resistance (Rc+Rf) without grid installation (i.e., control) was 2.13×1012 m-1 , whereas it was reduced to 1.69×1012 m-1 after the grid was installed. Regardless of the grid installation, the Rc+Rf increased as the packing density increased from 0.09 to 0.28, however, the increment of resistance for the grid installation was less than that of the control. Increase in the air flow rate did not always guarantee the reduction of fouling resistance, indicating that the higher air flow rate can partially de-flocculate the activated sludge flocs, which led to severer membrane fouling. Consequently, installation of grids inside the housing have brought a beneficial effect on membrane fouling and optimum air flow rate is important to keep the membrane lowering fouling.