A review on surface integrity of steel fibre reinforced fly ash geopolymer using lathe operation N. Kamilah, M. Fathullah, M. M. A. Abdullah, Meor Ahmad Faris, Faheem Tahir, Z. Shayfull, S. M. Nasir, M. Shazzuan, and A. Z. W. Wazien
Citation: AIP Conference Proceedings 2030, 020064 (2018); doi: 10.1063/1.5066705 View online: https://doi.org/10.1063/1.5066705 View Table of Contents: http://aip.scitation.org/toc/apc/2030/1 Published by the American Institute of Physics
A Review on Surface Integrity of Steel Fibre Reinforced Fly Ash Geopolymer using Lathe Operation N Kamilah1,a), M Fathullah1,2,b), M M A Abdullah2,3, Meor Ahmad Faris2,3, Faheem Tahir2,3, Z Shayfull1,2, S M Nasir1,2, M Shazzuan1 and A Z W Wazien2,3 1
School of Manufacturing Engineering, Universiti Malaysia Perlis, Kampus Tetap Pauh Putra, 02600 Arau, Perlis, Malaysia. 2
3
Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, 01000 Kangar, Perlis, Malaysia.
Faculty of Engineering Technology, Universiti Malaysia Perlis (UniMAP), 02100, Padang Besar, Perlis, Malaysia.
a)
Corresponding author:
[email protected] b)
[email protected]
Abstract. This article reviews on previous studies of geopolymer. Ordinary Portland Cement (OPC) has been used over the than hundred years for material construction especially as a binder in the production of concrete. The potential of an alternative binder material with no cement usage (cementless) called as “geopolymer” will introduce in machining industry. Further research will be conducted in looking for the potentiality of steel fibre when added to the host materials of geopolymer. The history of the development geopolymer will be described. The types of base materials used in the formation of geopolymer in machining will be explained in details.
INTRODUCTION Manufacturing industry nowadays is heavily driven by business pressure, market trends, sustainability of manufacturing and new technologies [1-4]. Machining of sustainable materials is now amongst topics of debate across the globe. To achieve sustainable and cleaner production objectives by reducing the environmental footprint of machining is required. As developing alternate manufacturing process technologies for replacing machining is still an unreasonable task, avoiding the negative environmental effect of machining can be achieved essentially by operating modification of remaining processes [5]. Besides, it is necessary to develop tools and relevant performance measures which will be able to take sustainability into interpretation as a significant parameter of the processes. The evaluation assumed will hopefully contribute to convincing the industry of the facts of sustainable machining technologies [6]. It is vital to creating quantitative predictive models for sustainable product design and manufactures in order the necessary part of these components of sustainability in product making. Usually, the most challenges situation that industry has to face is to design and manufacture sustainable and environment-friendly products. The sustainable product should be eco-friendly through its life cycle. The manufacturing processes must be more than recent requirements of functionality. This can be done by reducing the use of material or by replacing with more sustainable materials, decrease energy consumption and eliminate waste during manufacturing processes [7].
Green Design and Manufacture: Advanced and Emerging Applications AIP Conf. Proc. 2030, 020064-1–020064-4; https://doi.org/10.1063/1.5066705 Published by AIP Publishing. 978-0-7354-1752-6/$30.00
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PREVIOUS WORKS ON GEOPOLYMER MACHINING Most studies in geopolymer machining in CNC machining was not carried out in any numbers of areas. However, the geopolymer has been widely used in the construction field in the production of cement concretes and other commercials application such as arts and archaeology and resins and binders. So far, however, there are few research that indicates on the physical properties, mechanical properties and chemical properties that can be related on compression strength1of the steel fibre reinforced fly ash geopolymer based materials with the materials other than geopolymer that widely used by the CNC machining.
INTRODUCTION TO GEOPOLYMER Geopolymer is non-crystalline solid with three-dimensional aluminosilicate materials having ceramic-like properties produced and hardened at ambient temperature [8]. The geopolymer is produced through a process called geopolymerization under a high alkaline condition with the occurrence of alkali hydroxide and silicate solution [8]. The process started when the reactive aluminosilicate is dissolving and discharging free silicon tetraoxide [SiO4] and aluminium tetraoxide [AlO4] in solution. The tetrahedral unit formed amorphous geopolymers by allocation oxygen atoms linking alternate to polymeric precursor. Geopolymer can be presented in 2-dimensions of the “monomers” formed into the solution by: -Si-O-Al-O[Poly(silalate)], or -Si-O-Al-O-Si-O [Poly(silalate-siloxi)], and etc. where each of oxygen bonds bent due to the condensation reaction ties the neighbouring Si or Al in tetrahedral. The monomers, silicon, and aluminium hydroxide molecules then ensue to Poly-condense or known as polymerization to form a rigid chain or nets of oxygen bonded tetrahedral by applying mild heat basically around ambient or up until 90OC.
GEOPOLYMER AS SUSTAINABLE MATERIALS Geopolymer is the most established material and the final alternating product of the Earth. Some geopolymeric materials can last for a long time due to their unique geopolymeric structure, so-called three-dimensional crosslink. Herein, the crosslink between inorganic and organic materials can be achieved. Based on the study, a small content of organics is a key parameter governing the strength and stability of material in a large volume of inorganics [9]. In a different study, it becomes the best option of environmental protection and sustainability because it applies waste reduction by reusing coal mining waste products to produce geoplymer. For example of geopolymer type of material is fly ash concrete based to give some low negative influences of the environment such as abiotic depletions, human toxicity, freshwater ecotoxicity, terrestrial ecotoxicity and acidification [10]. In another present study of fly ash is using recycled Class F fly ash actually develops many properties of ECC, especially reduced drying shrinkage, tighter crack width, and more robust tensile strain ductility. Therefore, understanding the fundamental micromechanics of critical composite properties is the key to positively take sustainability into [11].
TYPES OF GEOPOLYMER USE Fly ash is the excess from the combustion of coal or by-product of coal-burning power plants which is extensively available worldwide and which is more than 600 million tons of fly ash is generated each year worldwide and 80% is disposed of in landfills [7] leads to the anthropogenic pollution. Fly ash is rich in silicate and alumina, along these lines it reacts with a basic an alkaline for make aluminosilicate gel that ties the aggregate [10]. The common materials used as an alkaline solution in producing fly ash-based geopolymer are sodium silicate and potassium hydroxide [10, 11].
TYPE OF FIBRE USED Fibres, then again, are by and large short, broken, and arbitrarily dispersed all through the solid part to create a composite development material known as fibre reinforced concrete (FRC). Fibres utilized as a part of concrete based composites are fundamentally made of steel, glass, and polymer or got from natural materials. Fibres can control
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cracking all the more adequately because of their inclination to be more firmly dispersed than conventional reinforcing steel bars. It ought to be featured that fibre utilized as the solid support isn't a substitute for regular steel bars. Fibres and steel bars have distinctive parts to play in cutting edge solid innovation, and there are numerous applications in which the two fibres and ceaseless reinforcing steel bars ought to be used [13]. Besides, the development of steel fibre reinforced concrete in 1874 by Bernard improved the mechanical performance of concrete such as has the ability of excellent tensile strength, flexural strength, shock resistance, fatigue resistance, ductility and crack arrest [14, 15]. More, the addition of fibres to cementations materials works on a similar theory whereby fibres act to transmit tensile forces across a crack [16]. In the hardened state, when fibres are properly bonded, they interact with the matrix at the level of micro-cracks and effectively bridge these cracks thereby providing stress transfer media that delays their coalescence and unstable growth. If the fibre volume fraction is sufficiently high, this may increase the tensile strength of the matrix [14]. Based on the previous study, Mohammadi et al. [17] claimed that the high amount of short fibres is responsible for proper workability parameters and compressive strength and workability of fibre reinforced geopolymer concrete are influenced by the proportions and properties of the constituent materials that make the composite [18, 19]. The study carried out by Antonius et al. [15] proved that the steel-fibre concrete maintained it is good ductility performance, even when exposed to substantially high temperatures. Else, from the previous experiments has been carried out, the addition of steel fibre will increase the compressive strength by a certain percentage and will also increase the tensile strength of high strength concrete to potentially produce improvements in1the workability of high1strength1concrete.1The compressive strength of steel fibre reinforced concrete usually ranges between 60MPa-100MPa. Song and Hwang [120] stated that the compressive strength increases at the volume fraction of 1.5% steel fibre used, which means that the highest compressive strength is produced at a volume of 1.5%. As the amount of steel fibre increases to 2%, the compressive strength decreases slightly.
CONCLUSION Review on the geopolymer concrete fibres has been discussed in this paper including the introduction of geopolymer concrete fibres, the base material used, and type of fibres use. The chemical composition for base material becomes a factor to the contribution toward the properties of product. The performance of development of different types fibres reinforced in concrete always been discussed and mostly a better properties of geopolymer concrete have been produced especially in terms of mechanical properties. Therefore, it is an interesting to study the new performance of geopolymer in machining and their effects in relation to the surface roughness of the materials. Apart from that, the steel fibre reinforced fly ash geopolymer itself based has its own stabilities characteristics that is interesting to be explored.
ACKNOWLEDGMENTS The authors would like to acknowledge the support from the Fundamental Research Grant Scheme (FRGS) under a grant number of FRGS/1/2016/STG07/UNIMAP/02/1), from the Ministry of Higher Education Malaysia. Grant Application ID 218885-247922 and code 9003-00572. Also, thank you to Universiti Malaysia Perlis.
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