MSE SOP - User contributions [en]

Zoom

2022-05-24T19:20:09Z

Gcanzalo: Copied from old

[[Category: SOP]]
===Useful Links===
Michigan Tech's IT department has set up SOP like articles on how to use Zoom to schedule and have virtual meetings. Below are links to the main page and the most important articles.

[https://michigantechit.teamdynamix.com/TDClient/KB/?CategoryID=9701 MTU IT Main Zoom Information Page]

[https://michigantechit.teamdynamix.com/TDClient/KB/ArticleDet?ID=53181 Launching and Using Zoom]

[https://michigantechit.teamdynamix.com/TDClient/KB/ArticleDet?ID=53479 How to Schedule a Meeting]

===Adding Zoom Links to Google Calendar===

#Schedule meeting in Zoom as outlined in "How to Schedule a Meeting".
#When the meeting is scheduled click the button to add the meeting to Google Calendar to invite meeting members just like any other google calendar event (figure 1).
#When people are added to the google calendar event '''MAKE SURE TO ELIMINATE''' the google hangouts option for meeting place.
[[File: zoom.png | frame | Figure 1. Zoom Google Calendar Button.]]

Wood Magnesium Sample Polishing

2022-05-24T19:19:46Z

Gcanzalo: Copied from old

[[Category: SOP]]

==Safety==
•Must wear appropriate PPE (safety glasses and gloves when needed)

==Procedure==
# Start grinding with 240 grit silicon carbide sandpaper and a force around 20 N. To change the force to 20 N, turn the screw until the dot is aligned with the second line from the bottom.
# Let the grinder run for 1 minute and check to see if the sample is planar. If the sample is not planar, then run the grinder for an additional 30 seconds to 1 minute.
# Take the samples out and run them under water. Spray the samples with the air hose until they are dry.
# Spray the samples with ethanol and dry them with the air hose.
# Replace the 240 grit sandpaper with 320 grit sandpaper.
# Run the samples for 1 minute on the grinder.
# Take the samples out, rinse with water, and dry with the air hose. Then rinse the samples with ethanol and dry with the air hose.
# Repeat this process with 400, 600, and 800 grit sandpaper. Grind for 1 minute, rinse with water and dry, rinse with ethanol and dry, and replace with next grit.
# After completing the 800 grit stage, place the sample in the sonicator on 30 for about 10 minutes.
# Put a couple drops of the 3 µm diamond compound on an unwoven pad and spread it around with a gloved finger.
# Put Red Lube Polishing Lubricant on the pad to lubricate it. Do not put water on the pad.
# Grind for 5 minutes.
# Put the sample in the sonicator for another few minutes.
# Put a couple drops of the 1 µm diamond suspension on an unwoven pad.
# Put Red Lube Polishing Lubricant on the pad to lubricate it. Do not put water on the pad.
# Grind for 5 minutes.
# Run water on the grinder to make sure it is clean.
# Replace the pad with the diamond compound with a blue cloth pad and get the pad wet with water and a few sprays of Al3O2 with DI water.
# Run the grinder for about 90 seconds keep spraying the pad occasionally with the Al3O2 with DI water mixture to ensure that it stays wet.
# Run the samples for another 30 seconds with just water.
# Remove the samples and spray with ethanol. Make sure not to scratch the polished face when taking it out of the grinder.
# Dry with hair dryer. Make sure not to touch the polished face.

Wood Magnesium Sample Mounting

2022-05-24T19:19:23Z

Gcanzalo: Copied from old

[[Category: SOP]]

==Safety==
•Must wear appropriate PPE (safety glasses and gloves when needed)

==Procedure==
# Cut the squeeze cast samples out of the billet using a band saw in the machine shop.
# Section the samples using the wire EDM or the wet saw.
# Grind the edges of the sample with 240 grit sandpaper and the Spectrum System 1000 to make sure that they fit in the mounting press.
# Turn on the TP-7001 Mounting Press by pressing the switch on the back right side of the machine.
# Set the set point at 220˚C, the dwell time at 15 minutes, and the pressure at 80 psi.
# Put the sample on the stage with the face that you want facing down.
# Bring the stage all of the way down by pressing the down arrow on the mounting press.
# Dump about 100 cc’s (half a scoop) of blue diallyl phythalate down the shaft and then dump 200 cc’s (whole scoop) of Black Phenlic down the shaft.
# Screw the cap on until it stops and then turn it back about 1/8th of a turn.
# Press run and wait for the cycle to complete and the alarm to sound.
# Once the cycle is complete, press the down button until all of the pressure is released.
# Unscrew the cap and take it off. If you cannot get the cap off, make sure it is unscrewed all of the way and then press the up button until it comes off.
# Press the up arrow to bring the stage all of the way up to get the sample out. Be careful it may be hot.
# Cut the sample with the wet saw if the sample is too tall.
# Continue onto polishing of the sample.

Wire Drawing Procedure

2022-05-24T19:19:01Z

Gcanzalo: Copied from old

[[Category: SOP]]

=Saftey=

==Loss Prevention==

=Procedure=
# Acquire a 1 x 6 x 12” steel plate [[File:wire_drawing_using_die.jpg|150px|thumb|right|Figure 4: Wire drawer jaws pulling wire out of die]]
# Machine plate in ¼ x 6” rods
# Using a FENN 76-5, slowly insert the rod through rotating swaging blocks, at approximately midway midway of rods length, slowly remove the rod and reproduce on the other half [[File:steel rod and swaging block.jpg|150px|thumb|right|Figure 1: ¼” Steel rod resting on half a swaging block ]]
# Using that procedure, incrementally swage the rods from 1/4 “ to 0.140” swaging block diameter [[File:smaller swager operation.jpg|150px|thumb|right|Figure 3: Smaller swagger used to point head of a rod]]
# Using the {small swager name}, point the rod using 0.11”, 0.10” and 0.09” swaging block [[File:swager to reduce rod diameter.jpg|150px|thumb|right|Figure 2: Nate using big swagger to reduce diameter of the rod]]
# From there, insert the pointed head of the wire trough 0.1193” die and wire draw by clamping {Name wire drawing} jaws to the wire and draw
# Point and draw wire using decreasing diameters of swaging blocks and die and stop after 0.0802” diameter die
# Use hand pointer to reduce wire head diameter until it fits through {die that I missed} die then move to wire drawing
# Reproduce same procedure until after die 0.04021
# Anneal wire in furness for 30 minutes at 500℃
# Return to hand pointing and drawing till last die of 0.030” diameter [[File:final_wire_diameter.jpg|150px|thumb|right|Figure 6: 0.03” diameter wire at the end of procedure]]

Williamson IR Pyrometer

2022-05-24T19:18:38Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Safety=
This pyrometer will likely be used in and around hot environments, be away of any hot parts and surfaces in the area and be sure to wear proper high temperature protective gear.

=Procedure=
1) Set up tripod in desired location and mount the camera {{clear}}
2) Plug the temperature monitor device into the camera {{clear}}
3) Attach camera and monitor to a power source and turn on {{clear}}
4) Aim camera at desired testing point using laser guide (figure, “Williamson sight laser”) {{clear}}
5) Read and record temperature output from monitor (figure, bottom left, reading "Lo") {{clear}}

[[File:Pyrometer-SOP.jpg|thumb|Example Williamson Set Up]]

Welding wire ends

2022-05-24T19:18:14Z

Gcanzalo: Copied from old

[[Category: SOP]]

==Loss Prevention==
* This should only be followed by someone with moderate knowledge of TIG welder and welding safety. Do not attempt to use this SOP as a comprehensive guide to welding and the associated risks.
* Training on gas cylinders must be completed before use of them
* Proper training on safe operation of a welder should be done with a certified individual.
* Wear long sleeve, non-flammable, cotton clothes.
* Be aware of nearby sand or class D fire extinguishers for control of metal fires.
* Always ensure the welding mask is set to the appropriate shield level for the selected amps.
* Take care in handling the welded wires as heat is generated quickly and distributes throughout the wires.
* Avoid contact with the ground cable and arc during welding.
* Gloves are not necessary but can be used. Leather welding gloves are recommended.

== Set-Up==
# Select a .040" Ceriated Tungsten electrode. Grinding the tip to 30° with a grain parallel to the length of the wire. Belt sander is appropriate for this.
# Prepare the ends of the wires by straightening them and sanding the surface oxide off 2" from the end of the wire.
# Sand the working area of the work table to remove any oxide. Wash the area after sanding as well. Dry thoroughly.
# Clamp the wires to the table such that they are parallel with each other and overlap by 1/8" of an inch, touching by the sides. Clamps should be 2-3" from the contact area of the wires. Plastic clamps are required for this.
# Clamp the ground cable from the welder onto the work surface in an area that has been cleaned and is near the working area.

==Welding Parameters==
# Insert the tungsten into the torch. Secure it such that there is 2-3x the diameter of the wire in stick out.
# Turn on the Miller 200 welder by flipping the switch in the back.
# Turn on the connected argon tank. A gas flow rate of 30 CFM is recommended for welding.
# Position the foot pedal underneath the work area such that it can easily be reached by the operator.
# Retrieve your welding helmet and set it to an appropriate level for the intended current. Shield level 9 was used here for 8 amps.
# Set the welder settings to the recommended settings for Mg as provided by the quick-start guide near the welder. A amperage of 8A is recommended for 1/16" Mg wire to start.
# All other settings can be left as is and changed as needed to adjust.

==Welding==
# Set up in front of the secured wire ends. Find a comfortable position for welding.
# Lower the helmet to cover your face.
# While holding the tungsten electrode 1/4" away from overlap of the wires, depress the foot pedal to start the gas flow and power the welder.
# The arc will begin and begin etching to remove oxide from overlapped area. Soon the area will stabilize and a high pitch, consistent buzz will be heard indicating the arc has stabilized. If it does not, stop the arc and adjust the settings.
# Begin waving the arc over the intended melting area and heating the metal.
# Melting will be indicated by flowing metal and a shiny melt pool. Note when this occurs in the overlapped area and continue heating for 4-5 seconds following this.
# After sufficient melting of the overlapped joint, release the foot pedal but do not remove the torch. The arc will cease but gas will continue to flow.
# After gas stops and the metal has cooled, release the wire clamps and observe the welded joint. Note whether or not full fusion has occurred throughout the thickness of the wire.
# If there is insufficient melting of the wire, continue the welding process while adjusting parameters until full penetration of the wire has occurred.
# Repeat this process with joins to obtain a full length wire. Sanding the joins may be necessary to reduce the diameter of the wire to desired size.

==Clean up==
# When finished welding, turn off the welder in the back and close the argon tank.
# Clean up any remnants of wire that may have been created during the welding process. Clean up the welding work area of any oxides and other debris.
# Wrap up the torch, ground table, and other wires and hand them over the weld cart
# Turn off the weld mask and return it.
# After ensuring all gas and welders is off, turn off the lights to the lab and leave.

WAAM Mg Metallography

2022-05-24T19:17:53Z

Gcanzalo: Copied from old

[[Category: SOP]]

==Loss Prevention==
*Safety glasses should always be worn in the metallography labs.
*Gloves should always be worn when working with chemicals such as etchants and alcohols.
*Wear a respirator when working with powders.
*Loose clothing should not be worn because it can get caught in the rotating table potentially causing injury.

== Mounting Procedure==
#Ensure that the bottom cover is secured and that the flange on the cylinder is on bottom which allows for easier removal of the mounting cup after the epoxy has set (figure 1)
[[File:Mounting cup.png|thumb| Figure 1. Epoxy mounting cup with flange on the cylinder located at the bottom.]]
#Cut samples into sections small enough to fit in the mounting cup without touching the edges (figure 1).
#Once cut, place sample in the mounting cup with the surface under examination face down..
#Mix epoxy resin and hardener, ensuring they are of the same epoxy, in a disposable plastic cup with a wooden tongue depressor and follow instructions on the hardener for mixing ratios.
#Pour epoxy mixture into mounting cup ensuring that sample does not move during pouring and that the sample is completely covered.
#Let the samples sit for the epoxy to harden for the time indicated on the instructions on the epoxy.

==Grinding & Polishing Procedure==
#Secure 320 grit silicon carbide paper in the auto-polisher and place samples in the sample slots (pointed out in figure 2).
[[File:Polisher.png|thumb| Figure 2. Auto-polisher set up.]]
#Apply a load of 20N to each sample by twisting the adjustment wheel such that the bolt (blue arrow in figure 3) inside of the slot above the sample is in line with the second line (red line in figure 3) from the bottom. The load can be adjusted by turning the wheel (yellow arrow in figure 3) above the sample clockwise or counterclockwise to increase or decrease the load, respectively. [[File:Zoom Polisher.png|thumb| Figure 3. Auto-polisher load adjustments.]]
#Run polisher with water constantly rinsing the pad until their is a planar surface of the sample.
#Lift auto-polisher head and ensure that they are secured before removing samples.
#Remove samples and rinse with water.
#Repeat steps 1-6 with 400, 600, 800, and 1200 grinding paper.
#After grinding with 1200 grit paper, rinse samples with water.
#Once rinsed with water, spray with ethanol over the sink, and then place samples in a beaker of ethanol ensuring the sample surfaces are not touched.
#Place the beaker with samples into the sonocator and run for about 3-5 minutes.
#To prep the auto-polisher for polishing, run the auto-polisher for ~30 seconds with water running but no paper on the stand and then '''thoroughly dry''' the sample holder and stand.
#Place the 6um polishing pad on the stand, ensuring it does not get water on it, and then secure samples with a load of 20N following step 2 again.
#Spray RedLube or GreenLube on the pad to lubricate and then polish for about 3 minutes.
#Repeat steps 7-8 and 11-12 with the 3um and 1um polishing pads.
#After 1um polsihing, 0.05 alumina polishing will be done.
#Place a nonwoven cloth polishing pad on the auto-polisher for 0.05um alumina suspension polishing.
#Clean the samples following steps 7-8 and replace in the auto-polisher.
#Run the auto-polisher for 90secs while spraying the alumina suspension onto the pad when squeaking is heard.
#Clean the samples following steps 7-8 after polishing with 0.05um suspension.

==Etching==
#In the fume hood, set up a watch glass with nital etchant in it, a beaker of water, and ethanol spray.
#Place sample surface for about 3 seconds in the nital solution and then '''immediately''' dunk into the beaker of water making sure not the hit the surface of the sample.
#Spray the sample with ethanol and airdry until sample and epoxy are completely dry.

==Metallography==
#Open the ScopeTek software on the computer which allows pictures to be taken by the microscope.

WAAM Fanuc Robot TP Programming

2022-05-24T19:17:32Z

Gcanzalo: Copied from old

[[Category: SOP]]

'''Safety & Loss Prevention'''

There is significant amount of information regarding safety procedures, therefore a separate SOP will be created. Please reference that before taking any action with this system.

'''Teach Pendant Overview'''

'''Frames'''

'''Create a Program'''

'''Points'''

'''Weld Start/End'''

'''Labels & Registers'''

'''Position Register Offsets'''

'''Weaves'''

'''Other Commands & Logic'''

WAAM Fanuc Robot Operation

2022-05-24T19:17:10Z

Gcanzalo: Copied from old

[[Category: SOP]]

'''Safety & Loss Prevention'''

There is significant amount of information regarding safety procedures, therefore a separate SOP will be created. Please reference that before taking any action with this system.

''''Special thanks to the WAAM 2020 Q&P Team For helping flesh out the steps seen below!''''

'''Operation Procedure'''

''Setup''
# Sand surface of the substrate to be welded. Use belt sander in the lab to remove flash rust
# Clean the surface of the substrate to be welded. Use Brakekleen or other surface cleaner and wipe to remove impurities
# Make sure the robot is in Teach Mode. There is a keyed switch on the front of the cabinet that will indicate what mode the robot is set to.
# Turn on the robot. This is done by turning the dial on the cabinet to the “ON” position.
# Wait for the Teach Pendant to boot up.
# Make sure the Teach Pendant is enabled. If it is not, turn the black knob on the upper left of the teach pendant to the “ON” position
# Ensure that the proper welding wire is setup on the machine. If not do the following.
## Process to be updated soon
# Jog robot out of the way to set up substrate if necessary.
## Choose desired coordinate system. Press the “COORD” button on the Teach Pendant until desired coordinate system is selected.
## Decrease the robot speed to ~10% by pressing “-%” key on Teach Pendant
## Depress & hold the Deadman Switch
## Make sure there are no other faults in the system. If there are no other faults, the “Fault” indicator will be green.
## While holding the “SHIFT” key, press and hold the directional key of the direction desired.
# Position substrate and secure as desired.
# Select Program
## Press the “SELECT” key on the Teach Pendant
## Scroll to desired Program
## Press the “ENTER” key on the Teach Pendant
# Press the “FCTN” key on the Teach Pendant and select “Abort All”
# If program uses a User Frame, do the following:
## Select the “World” Coordinate System
## Press Menu
## Select the “Setup” option
## Select “Frames”
## If the frame type that is displayed is not “User Frames”, Press “Other” and select “User Frame”
## Select desired user frame
### NOTE: User frame must match the user frame the program was programmed in.
## Scroll to Origin
## Jog robot to desired origin and press “Record”
## Scroll down to X-Axis
## Jog robot in positive X direction a few inches and press “Record”
## Scroll up to Origin and press “Move To”
## Wait for robot to move back to origin point
## Scroll down to Y-Axis
## Jog robot in positive Y direction a few inches and press “Record”
## Jog Robot out of the way
# With welding equipment disabled, perform a dry run of the first few lines of the program to make sure the robot path is free of obstructions.
## Press edit to return to the selected program
## Scroll to the first line of the program.
## Depress and hold the Deadman Switch
## Press and hold the “SHIFT” key on the Teach Pendant
## Press the “FWD” key on the Teach Pendant
## Release the Deadman Switch if the the robot is going to collide with an obstruction or after ensuring that the robot will clear all possible obstructions
# Jog the robot to a safe location where the nozzle on the Mig Gun is easily accessible
# Remove the nozzle from the Mig Gun
# Remove slag from inside the nozzle and in the contact tip
# Reinstall the nozzle on the Mig Gun
# Jog robot to a safe location where it will not collide with anything when the program begins to run.
# Connect ground to the Welding Table
# Connect Rapid-X Feedback cable to the Welding Table
# Ensure proper wire is on the spool holder
# Turn on Welding Machine by flipping the power switch to the “ON” position. The power switch is located on the front of the welding machine
# Turn on shielding gas by opening the valve on the top of the bottle
# Move the Teach Pendant to the outside of the cage.
# Close the cage door and lock it into position
# Turn on the exhaust fan by pressing the “START” button. The switch for the exhaust fan is located on the back wall near the corner of the cage
# Position UV curtain in front of the lab door
# Increase the robot speed to 100% by pressing the “+%” key on the Teach Pendant
# Enable Welding Equipment
## Press and hold the “SHIFT” key and press the “WELD ENBL” Key on the Teach Pendant
## The “Weld” indicator on the Teach Pendant will be green when the welding equipment is enabled

'''Welding Operation'''

''In Teach Mode''
# Move behind the UV curtain
# Scroll to the first line of the program
# Depress and hold the Deadman Switch
# Press and hold the “SHIFT” Key on the Teach Pendant
# Press the “FWD” key on the Teach Pendant
## Program will begin to run at this point
## NOTE: Both the “SHIFT” key and the Deadman Switch must be pressed at all times for the program to continue. As long as this condition is met, the program will run through to the end.
# Disable Welding Equipment
## Press and hold the “SHIFT” key and press the “WELD ENBL” Key on the Teach Pendant
# Decrease the robot speed to ~10% by pressing “-%” key on Teach Pendant
# Jog the robot out of the way

''In Auto Mode''
# Scroll to the first line of the program
# Disable Teach Pendant. This is done by turning the black knob on the upper left of the teach pendant to the “OFF” position
# Turn the Key Switch on cabinet to “Auto”
# Press the blue button labeled “Reset” on the cabinet to reset faults
# When ready to start the program, press the green button labeled “Start”. At this point, the program will begin to run
# Move behind UV curtain
# Allow Program to run
# After the program ends, turn the Key Switch on cabinet to “Teach”
# Enable the Teach Pendant. This is done by turning the black knob on the upper left of the teach pendant to the “ON” position
# Press the “RESET” button on the Teach Pendant
# Disable Welding Equipment. Press and hold the “SHIFT” key and press the “WELD ENBL” Key on the Teach Pendant
# Decrease the robot speed to ~10% by pressing “-%” key on Teach Pendant
# Jog the robot out of the way

'''Clean Up'''

# Allow sufficient time for part to cool. Parts could potentially be too hot to be handled with insulated gloves. Use caution when removing part and substrate from welding table
# Remove Part and substrate from welding table
# Shut off Shielding Gas
# Shut off Welding Machine
# Shut off Ventilation Fan
# Jog the robot to a safe position
# Shut off the robot
# Hang the Teach Pendant on the front of the cabinet in the designated location
# Return any tools used to their proper location
# Turn off lights and close door to the lab upon departure

WAAM Converting CAD to Fanuc Robot Program

2022-05-24T19:16:47Z

Gcanzalo: Copied from old

[[Category: SOP]]
== '''Creating Your CAD File''' ==
<gallery mode="slideshow">
Image:MRP1.1.jpg|Fig.1.1 Selecting Front Plane for creating Sketch.
Image:MRP1.2.jpg|Fig.1.2 Completing the Sketch in X-Y Plane.
Image:MRP1.4.jpg|Fig.1.3 Extruding the Sketch in the Z Direction.
Image:MRP1.5.jpg|Fig.1.4 Part Orientation similar to Robot Axis orientation.
Image:MRP1.3.jpg|Fig.1.5 Saving CAD file in ".STEP" format.
</gallery>
# To Create a Metal 3D Printed Part we should create a 3D model i.e. the CAD file first which can be done using any CAD or Solid Modeling Software.
# When we create a Part the only thing to remember is the orientation of the part the part should be built on the Front Plane (Fig.1.1) i.e prepare the sketch in the X-Y plane (Fig.1.2) and should be built in Z direction (Fig.1.3) in any Solid Modeling Software.
# Creating the part in the Front Plane allows the orientation of the part to align with the orientation of the Robot which is Similar to the Image shown in the Fig.1.4.
# Once the CAD file is created and saved the next step is to save the CAD file as ".STEP" file extension to a desired location (Fig.1.5) so that it could be imported into Power Mill Software.

=='''Importing your CAD File in Power Mill'''==
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:00:14) for this Step.
# Once you have your part created and saved into ".STEP" format now we need to import that into the Power Mill Software so that we can create a additive tool path.
# Open the "Autodesk Power Mill Ultimate 2021" application on the desktop.
# Once the application starts go to Files>>Import>>Model this will open a dialogue box which will ask you the location of the ".STEP" file which we saved earlier.
# Select the file from that location and click open
# Once the file is imported we get a information box stating the completion of Import.
# We now have our CAD model in the Power Mill Software ready to generate Levels.

=='''Creating Levels for your Part'''==
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:00:50) for this Step.
# Once the part is imported into the application we can now move on to creating Levels for the part.
# Click on Model Tab and then click on Create Level twice to create 2 new levels "2" and "3".
# New levels can be found out in the Explorer window under the "Levels, Sets and Clamps" Tab.
# We can see a total of 3 levels.
# Right click on the Level 2 and Rename it to "Base".
# Next Right click on Level 3 and Rename it to "Body".
# Now Click on the bottom surface of the Part and then click on the "Reverse Selected" Option from Model Tab.
# Once clicked on the "Reverse Selected" Option Right click on the Base Level that we created earlier in the Explorer window under the "Levels, Sets and Clamps" Tab and select "Acquire Selected Model Geometry".
# Once that is completed Click on the Small Light Bulb icon besides Base Level to turn off that level.
# Once Base level is turned off Select the remaining Geometry by Dragging the cursor across the geometry once the remaining geometry is selected Right click on the Body Level that we created earlier in the Explorer window under the "Levels, Sets and Clamps" Tab and select "Acquire Selected Model Geometry".
# To verify that we have selected all the geometry click on the Small Light Bulb icon besides Body Level to turn off that level, and you should not see any geometry on the screen.
# Once that is verified we know for sure that we have successfully created levels for our part.

=='''Tool Path Generation'''==
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:02:00) for this Step.
# Once we have our base and body level created we will now create the Additive Tool Path.
# Now click on Additive Tab and Click on Feature Construction Option.
# In the Feature Construction Window we will be first asked to select Base so Select base type as Plane and Surface as Base.
# Now select the Style as Raster and Feature Surface as the Body.
# Next in enter the Bead width and Stepover for the particular wire diameter.
# Next from the Feature Construction menu select the Raster tab and change the Ordering Type to Two way.
# Next change the Layer angle Type to Rotate and Rotational angle to 90 degrees.
# Next from the Feature Construction menu select the Layering tab change the Extent Defined by to Feature Extent.
# Once that is done Click on Calculate and once the Tool Path is generated Close the Feature Construction Window.
# So now we have the Additive Tool Path for our part, we can view the Tool path by simply turning off the Base and Body Level from the Explorer Menu.

=='''Simulating Generated Tool Path'''==
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:03:05) for this Step.
# Once we have our Additive Tool Path Created we will now setup our part on the Work table.
# We can also Rename the Tool Path by Right clicking on the selected Tool Path and selecting Rename option.
# We also need to activate the Tool Path in order to Simulate the Tool Path by Right clicking on the selected Tool Path and selecting Activate option.
# Now once the Tool Path is activated we need to Load our Robot into the cell.
# Click on the Robot Library Drop down menu from the Vertical Plugin Window, then double click on the FANUC and then double click on R1000iA and then double click the R1000iA-80F to load the robot.
# Once the Robot is loaded we can Simulate the Robot according to the Tool Path by going into the Simulation Tab and selecting the Tool Path which we created in the earlier step from the Entity Menu under Simulation Path.
# We can then just click on Play button from the Simulation Controls to see the actual simulation.
# We can vary the speed of the simulation using the speed control slider.
# We can now verify for any collisions of the Robot and also proper operation of the Tool Path.

=='''Creating Robot Program'''==
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:03:20) for this Step.
# Once we have the Robot imported and Tool Path created we can now move on to create the Robot Program.
# Before creating the Robot Program we need to ensure that the Tool Path which we created is Active which can be done by Right Clicking the Tool Path and selecting Activate option we can see ">" symbol besides the Tool Path name which indicated that the Tool Path is Active.
# Click on the Robot Control drop down menu in the Vertical Plugin Window.
# Click on the Home button the on the Rewind button above it then click the Play record button.
# Once the simulation is recorded click on Save Simulation which will open up a Window asking the name for the file.
# Name the file and click Save.
# Once that is done click on the Robot Program drop down menu in the Vertical Plugin Window.
# Enter a suitable Program name.
# Now Right click in the area below to add a the Entity we saved earlier and click on Add a Toolpath and click Active toolpath simulation.
# Once that is done click on Write robot NC Program which will give us the ".LS" program file to be used on the actual Robot.

=='''Modifying Robot Program'''==
<gallery mode="slideshow">
Image:MRP2.jpg|Fig.8.1 Opening '.LS' Program file from Power Mill in Notepad.
Image:MRP1.jpg|Fig.8.2 Make sure the Name of the ".LS" file matches the Program name in the fist line of the Program.
Image:MRP3.jpg|Fig.8.3 Positional Information of the Points.
Image:MRP4.jpg|Fig.8.4 Replacing Speed and Termination type of the motion Highlighted in red with Weld Start Instruction.
Image:MRP5.jpg|Fig.8.5 Replacing Speed and Termination type of the motion Highlighted in red with Weld End Instruction.
</gallery>
# Follow the Steps and the [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Reference Video] (0:04:40) for this Step.
# Once we have the Robot Program from the Power Mill Software we are required to make certain changes to the Program so that it can be loaded on to the Robot.
# Open the Robot Program with ".LS" File Extension with a Notepad application as shown in Fig.8.1.
# Make sure that the Name of the ".LS" file matches the Program name in the fist line of the Program if not exactly type in the name of the program as shown in Fig.8.2.
# Next we need to replace the Robot Configuration in the Program from "CONFIG : 'F U T, 0, 0, 0'" to CONFIG : 'N U T, 0, 0, 0' using the Replace Function in Notepad.
#*Click on Edit Tab and then click on Replace Function.
#*Copy exactly " '''''CONFIG : 'F U T, 0, 0, 0'''''' " and Paste it into "Find what" Box.
#*Copy exactly " '''''CONFIG : 'N U T, 0, 0, 0'''''' " and Paste it into "Replace with" Box.
#*Click on "Replace All" Option and close the Replace Function Window.
# Next we need to Change the values of Rotational Axis of the Robot which are W, P, and R to run the program.
#*Click on Edit Tab and then click on Find Function.
#*Copy exactly " '''''/POS''''' " and Paste it into "Find what" Box.
#*Click on "Find Next" Option and close the Find Function Window.
#*You will see the Positional Information of the Points as shown in Fig.8.3.
#*Copy " '''''W = 0.000 deg, P = 0.000 deg, R = -2.522 deg''''' " for this example. (You need to copy the text from your program which may be different from this example).
#*Click on Edit Tab and then click on Replace Function.
#*Paste the Copied text into "Find what" Box.
#*Copy exactly " '''''W = 177.328 deg, P = -.149 deg, R = 85.013 deg''''' " and Paste it into "Replace with" Box.
#*Click on "Replace All" Option and close the Replace Function Window.
#Next we need to add Weld Start Instruction into the Program.
#*Click on Edit Tab and then click on Find Function.
#*Copy exactly " '''''! Cutting Move Starts ''''' " and Paste it into "Find what" Box
#*Click on "Find Next" Option and close the Find Function Window.
#*Copy " '''''8mm/sec CNT50''''' " for this example which will be the previous Program line to what we have found in the previous step as show in Fig.8.4. (You need to copy the text from your program which may be different from this example).
#*Click on Edit Tab and then click on Replace Function.
#*Paste the Copied text into "Find what" Box.
#*Copy exactly " '''''WELD_SPEED FINE : Weld Start[1,1]''''' " and Paste it into "Replace with" Box.
#*Click on "Replace All" Option and close the Replace Function Window.
#Next we need to add Weld End Instruction into the Program.
#*Click on Edit Tab and then click on Find Function.
#*Copy exactly " '''''! Cutting Move Ends ''''' " and Paste it into "Find what" Box
#*Click on "Find Next" Option and close the Find Function Window.
#*Copy " '''''17mm/sec CNT50''''' " for this example which will be the previous Program line to what we have found in the previous step as show in Fig.8.5. (You need to copy the text from your program which may be different from this example).
#*Click on Edit Tab and then click on Replace Function.
#*Paste the Copied text into "Find what" Box.
#*Copy exactly " '''''WELD_SPEED FINE : Weld End[1,1]''''' " and Paste it into "Replace with" Box.
#*Click on "Replace All" Option and close the Replace Function Window and Close the file.
#*Now Click on Save File and Close the file.
# Now we can Copy the Program that we just Modified on to a USB Drive to Load it into the Robot Controller.

=='''Loading Program into the Fanuc Robot'''==
# Once we have the Program copied onto a USB Drive plugin the USB drive into the USB Port on the Operator Panel.
# Then on the teach pendant click "Menu" then "File" and then select the first option i.e. the (all files) option.
# This will show all the ".LS" on the USB drive bring down the cursor on the Program you want to load and and press "F3" to Load the Program.
# If the Program is loaded it shows on the bottom of the Teach pendant screen that the program has been loaded.

=='''Running the Program'''==
# Once the Program is Loaded into the Robot now press "Select" Key to view all the programs loaded on to the Controller.
# Select the appropriate Program that was loaded into the controller at an earlier step and press Enter on the teach pendant.
# Now press Function key on the teach pendant and select Abort All function by pressing enter.
# Now press Shift + Step key on the teach pendant to Test the program in the Step mode.
# Now press Shift + FWD key on the teach pendant to test the program line wise make sure that the robot is moving over the substrate and not colliding with the fixture.
# Now Press Shift + Weld Enbl Key on the teach pendant which will enable welding on the robot.
# Make sure the speed of the robot is at 100% to ensure proper operation of the robot.
# Make sure the cursor is on the first line of the program by pressing Shift + UP arrow key on the teach pendant.
# Next place the teach pendant on to its holder.
# Once that is checked turn the Key on the Operator Panel to Auto Mode.
# Next Turn off the Teach Pendant using the switch on top left side of the teach pendant.
# Now press Fault Reset Button (Blue color button) on the Operator Panel to clear any faults and make sure to check the fault indicator and if everything is right it should be off.
# Now press the Cycle Start button (Green color button) on the Operator Panel by lifting the safety cover over it.
# A message will pop up on the teach pendant asking "Would you like to continue......" select Yes and press Enter on the teach pendant.
# Again press the Cycle Start button (Green color button) on the Operator Panel to start printing (welding).
# The robot should start printing (welding) on the substrate.

=='''Video References'''==
# [https://drive.google.com/file/d/1hXojXCCQeLfZg-PEvlHLlJ22M1X88Mjz/view?usp=sharing Converting CAD to Robot Program]
# [https://drive.google.com/file/d/1cxuSxUSDI7Z13_ZcGrcXDo4eKjhSDejm/view?usp=sharing Staring the Robot, Loading the Program and Turing off the Robot]
# [https://drive.google.com/file/d/10943Rk03yy8z-W4c6TV5Kt7H9lrKtrO9/view?usp=sharing Piano Dog Sample Program]

Vickers Hardness Testing

2022-05-24T19:16:25Z

Gcanzalo: Copied from old

[[Category: SOP]]

<big><big>Loss Prevention</big></big>
# Do not adjust equipment after starting a test

<big><big>Procedure</big></big>

<big>Section 1: Instrument Setup</big>
# Existing indentations can be measured using the macro-Vickers scope (figure 1)
[[File:VickersMachine2.jpg|thumb]]
# Check to ensure the proper magnification setting is selected on the instrument. The proper setting is indicated by "(X10)" on the "LENS" knob. Turn the power switch to "ON". This panel can be viewed in figure 2.
[[File:VickersKnobs.jpg|thumb|Figure 2: Controls]]
# Zero the machine (calibrate) by using the following steps:
* Position a sample on the stage under the lens, such that no indentation is visible. The lens and indenter can be seen in figure 3.
[[File:VickersIndenter.jpg|thumb|Figure 3: Lens and indenter]]
* Focus the image by moving the stage up and down with the vertical control knob.
* Look into the eyepiece and move the two measurement lines together, using the control knobs on the lens. The lines should JUST touch, so that no light is visible between them.
* Firmly press the "ZERO button on the measurement panel (figure 4). An audible beep will be heard.
[[File:VickersScreen.jpg|thumb|Figure 4: Measurement panel]]

<big>Section 2: Instrument Calibration</big>
# Microvickers calibration:
*Use a calibration standard before staring the experiment (ID 11564).
*Need hardness of 384±5 to pass.

<big>Section 3: Indentation Measurement</big>
# Position the indenter above the sample in place of the lens and press start.
# Return the lens to its original position and focus the image such that the sample surface is clear (not the indentation itself). This is important such that the edges of the indentation are in sharp focus.
# Starting with the left (or lower) measurement line (controlled by the left/lower knob), move the line outside the indentation, and bring it in slowly towards the indentation until it just touches the corner.
# Repeat step 3 for the right/upper measurement line (controlled by the right/upper knob). Do not move the left/lower line while adjusting the right/upper line.
# Press the measurement button.
[[File:VickersLensHorizontal.jpg|thumb|Figure 5: Horizontal measurement knob mechanism]]
# Rotate the measurement knob mechanism 90°, and repeat steps 3-5.
[[File:VickersLensVertical.jpg|thumb|Figure 6: Vertical measurement knob mechanism]]

Vacuum Impregnation

2022-05-24T19:16:00Z

Gcanzalo: Copied from old

[[Category: SOP]]

Vacuum Impregnation is a method used to infiltrate porous samples with an epoxy type resin that allows for grinding/polishing of samples with minimal damage to the samples. This was intended to help the MMC-SD group view crushed pores and potential areas of closed porosity in the carbonized wood samples.

=Loss Prevention=
* The vacuum impregnation machine pulls a vacuum on the samples. Safety glasses should be worn as vacuum chambers have a inherent risk to them.
* While working with the resin, nitrile gloves should be worn to avoid contact with the skin.

=Procedure=
Sample Prep
*Samples must be made to fit in the sample cups commonly used for metallography. It Is preferable to not have any part of the samples above the height of the cup as well.
*To reduce the amount of leaked epoxy aluminum foil can be used at be put in between both part of the sample cup, this will also aid in removal of the cap.
Vacuum Impregnation
#The resin used is a 2 part epoxy, for our resin, a weight ratio of 20:5 was used for resin:hardener. The total weight of epoxy depends on the number of samples, for ours 100 total grams was more than enough for 4 cups.
#The vacuum impregnator has two chambers, the left is for the resin, the right for the samples. two vaccuum fittings connected by a hose for the epoxy to flow connects the two.
#The resin side uses a black vacuum fitting, the right uses a larger, silver one. When putting the fittings on the hose, make sure two o-rings are used between the fitting and its bolt As shown in the image.
#Place the resin in left chamber and samples in the right, adjust the hose so that the tube reaches the bottom of the resin beaker, and the sample side fitting can be turned to point at each sample cup. Make sure the black fitting has the set screw closing off the tube before turning on the vacuum chamber.
#The top valve is the vacuum valve and the bottom valve is the purge. Begin with vacuum open for resin, closed for samples, and purge closed for both resin and samples. The O-rings that each chamber has on the plexiglass face may need to be maneuvered to help pull the vacuum.
#If too much bubbling occurs in the resin slowly open the purge to relieve pressure.
#Once a vacuum is pulled close the vacuum valve and open it for sample chamber.
#After a vacuum is pulled align the hose over a sample cup and slowly release set screw and begin filling cups.
*Adjust the set screw to adjust the flow
*Adjust the purge valve to control bubbling
Clean Up
#Once bubbling has finished the chambers can be purged and samples removed.
#clean the inside of the chambers with ethanol
#Throw away hose
#It may be necessary to weight down samples if the resin is more dense than the sample, take samples out of chamber and cover, and allow at least 24 hours to cure.

Ultrasonic Modulus

2022-05-24T19:15:35Z

Gcanzalo: Copied from old

[[Category: SOP]]
= Safety =
No Safety Parameters noted

NOTE: Machine and Transducers are FRAGILE

=Device and Sample Set-Up=
#Attach LCM-74-4 transmitting wire and turn on the Olympus 38DL PLUS.
#Attach appropriate transducer for wave type being measured.
#Programs for these experiments were pre-set into the Olympus 38DL PLUS and can be recalled by pressing the “XRDR - RECALL”. The arrow keys may be used to select the proper program.
#* Longitudinal wave velocity program: M112
#* Transverse wave velocity program: Shear- Lift
#**When in doubt, the name of the program you should be using may match a program that shares the name of the transducer being used.
#Prep samples by recording thickness measurements at least three marked locations on each sample. These will be the areas that are tested.
#Apply a small amount of the appropriate couplant at each test site.
=Standard Operation Procedure=
#Select the red “MEAS” button to return to the main data screen.
#Prior to each measurement enter in the measured thickness. Select “2ND-F” and “XRDR-RECALL”. The value can be changed with the up and down arrows. To exit the window press “ENTER” or “MEAS”.
#Wave velocity readings are taken at test sites by firmly holding transducer in the couplant at marked testing areas.
#*DO NOT DRAG THE TRANSDUCER ALONG THE SAMPLE
#Once the reading displayed on the Olympus 38DL PLUS stabilizes, record the shown value in μm/s.
#Wipe samples and transducers clean with tissues and ethanol in between the use of different couplants and transducers.
#Modulus Calculations can be performed using the following equations... 

:::::G=ρvs2 
:::::v=(2-(vl/vs)2)/(2*(1-(vl/vs)2 
:::::E=2(1+v)G

:::::*Where G=Shear Modulus of the Material, vs represents the velocity of the wave in shear, ρ is the density of the material,vl is the velocity of the longitudinal wave, and v is Poisson's ratio

Tinker-Omega Sand Mixer

2022-05-24T19:15:12Z

Gcanzalo: Copied from old

[[Category: SOP]]
= Safety Precautions/Loss Prevention=
#Wear nitrile gloves to prevent skin irritation due to resin and catalyst.
#The sand mixer is in the foundry so safety glasses and green coat must be worn at all times.
#No food or beverage is allowed in this location.
#“Emergency Stop” button available on the machine can be used to immediately stop the mixer’s motor in case of imminent danger of injury or damage.
#*Note: The “Stop” option of the machine’s operating joystick can be used to stop mixing within 6 seconds. This should be used in non-emergent situations.
= Standard Operation Procedure=
==Machine Preparation==
#[[File:Annotatedports.jpg|Machine controls located on machine head.|300px|thumb|right]]Verify that the sand hopper is full.
#Turn on main power. The “POWER ON” button may also be turned on once the controller has booted up.
#Remove resin and catalyst hoses from test stand. Check both nozzles and ports for sand or other residue that must be removed prior to operation.
#Perform similar inspection of the sand discharge port and clean build-up as necessary.
#By using the “MANUAL” controls on Allen-Bradley software, run a small amount of resin through resin hose into the designated waste container to establish flow (Resin OFF -> ON). Once complete and hose is off, place hose into its designated port.
#Repeat previous step with catalyst hose. Secure hoses with screw system located by ports once complete.
==Machine Operation==
#Navigate to the “AUTO RUN” screen prior to the mixing of any sand.
#[[File:Annotatedcontrols.jpg|Machine controls located on machine head.|200px|thumb|right]]On the controls on the mixer’s head, set the knob settings to A1 or A2 for continuous run.
#Use the joystick on the same controls to run sand mixture into waste bin for about 3-5 seconds to prime mixer.
#The knob settings should now be changed to setting that is specific for the mold type being made (labelled on side of mixer controls). This will dispense the amount of sand necessary to fill the mold dimensions.
#Move prepared mold onto vibration table in front of mixer.
#Keeping the machine head over the sand waste barrel, use joystick to begin filling processes. Move machine head over mold after it has ran for 3 seconds over waste barrel.
#While/After sand has been dispensed, use provided tools to uniformly pack the sand mixture into the mold.
#Allow 10-15 minutes for mixture to cure. After it may be removed from mold for casting.
#For every 2-3 molds made, the sand discharge port must be cleaned. Turn on the “E-STOP” button while doing so. Use available tools (metal bar, threaded rod, saw, etc.) to breakup sand build up as much as possible.
==Machine Shutdown==
#With “E-Stop” on, clean the discharge port of the sand mixer.
#Pull “E-Stop” button back out and enable system by pushing the green “POWER ON” button.
#Select “Gate A” in manual screen to purge mixer into waste barrel. Let the mixer run for about 5 seconds before unselecting the button to turn it off.
==Nozzle & Port Maintenance==
#Obtain a small container of water (is typically a coffee container). Remove the resin hose from its port and submerge nozzle in water.
#Repeat first step with kerosene and the catalyst hose. The container of kerosene can be found in the flammables cabinet of the deformation lab (usually is in labelled paint can).
#While nozzles are soaking, use the black brush located in the “Cleaning Tools” can to scrub the resin port with water from container. Rinse brush several times throughout process.
#Repeat previous step with soft tan brush and kerosene for catalyst port.
#Use respective brushes to clean the nozzle openings for both the resin and catalyst components. Resin nozzle/hose may need several second to drain prior to this step.
#Return nozzles to test stand once cleaned properly.

Thermo Recorder (TR-75wb) and T&D Thermo App (iOS)

2022-05-24T19:14:44Z

Gcanzalo: Copied from old

[[Category: SOP]]

=TR-75wb Thermo Recorder: Guide for T&D Thermo Mobile Application (iOS) =
==Initial App Set-Up==
#Download the app “T&D Thermo” from app store.
#Launch the application and click the list symbol in the upper left-hand corner of initial screen.
#Select “App Settings”.
#Select “Account Management” and fill out the necessary information to log into the T&D WebStorage Service.
#*Username: tdgc9161
#*Password: Contact Russell Stein
#After logging in, the app should again display the “App Settings” screen. Select “Add Device” and enter in the serial number and registration code for device.
#*Contact Russell Stein for device information.
#Again, the user should be taken to the “App Settings” screen. Select “Warning Notification” and select alarm preferences for when a warning has been triggered by device.

==Pre-Recording Device Settings==
#Navigate back to initial home screen. The device registered in step 5 should now appear on screen. Tap on device name to launch device controls.
#*On this screen, the user can monitor the TR-75wb’s battery life, Bluetooth connection, and data status.
#Select “WebStorage” located in the bottom menu bar. Here the device user can control nearly all recording settings. After adjusting the following settings, always tap “Apply” at bottom of the individual setting screens so that they may be applied to the device. These settings should be set prior to turning the device on so that unneeded recordings do not begin.
#*Rec Settings: Change recording interval to appropriate setting for application.
#* Name Settings: Add names as needed for the device, group, and channels options.
#*Warning Settings: Turn on upper and lower warnings for device and enter prompted information. Judgement time and battery life warnings can also be set.
#**Note: Check that warning limit units match units shown in the application.
#*Network Settings: This determines how often the T&D Thermo app and T&D WebStorage Service receives data from device. Select appropriate time interval.
#*Other Settings: Adjust units on time scale of recorded data.
#*Settings Table: Use this option to review all settings currently active for device and specific channels. If settings that the user selected are not shown, then “Apply” was probably not selected after setting adjustments were made.

==Using Bluetooth to Schedule Recording==
#Check that iPhone Bluetooth settings are on and functional.
#Turn on TR-75wb and wait until internet connection has been established. This is indicated by a NON-blinking Wi-Fi symbol with the word “WEB” directly below it.
#On the device control screen of mobile app, select “Bluetooth” from the bottom menu bar. This may take a minute to connect.
#Once Bluetooth connection is confirmed, the application will launch a screen similar to the “WebStorage” screen outline in the “Device Settings” section of these instructions.
#Select ”Rec Settings”. Here, the user may program a start time for data recording or begin collection immediately. Apply settings when finished and the application will send start time instructions to device.
#*At this point, the “REC” symbol should be flashing on the TR-75wb’s screen if everything functioned properly.
#All other settings previously set should be applied to recording automatically. These settings can be reviewed in the “Settings Table” for correctness.
==View Currently Recording Data==
#Anyone who is logged into the MSE T&D WebStorage Service account on the mobile application should be able to view data being recorded in the “WebStorage” tab of the main device control screen.
#*Keep in mind that the data will only be sent to this forum on the time interval set in “Network Settings” portion of device set-up
#*It seems like the best way to “refresh” the displayed graph is to go back to previous screen then reselect “WebStorage”.
#*On this screen in the upper right-hand corner, the user may tap the downwards arrow to save current data to the “Files” tab of the device control screen at any point during recording.
#To view warnings, select “Warnings” from the bottom menu bar of main device control screen.
==Ending a Recording==
#Check that iPhone Bluetooth settings are on and functional.
#On the device control screen of mobile app, select “Bluetooth” from the bottom menu bar.
#Once Bluetooth connection is confirmed, select ”Rec Settings”. Tap stop recording to end data collection.
#Turn off device.
==Reset Data for Next Test==
'''This is important so that the following user of the TR-75wb and T&D Thermo app will be able easily monitor their data as it is collecting.'''
#Go to the T&D WebStorage website ( https://www.webstorage-service.com/ ) and login to the MSE account.
#*Username: tdgc9161
#*Password: Contact Russell Stein
#Click on the "Devices" option on the menu found on the left side of the screen.
#Previously registered devices should be displayed here. Click the "Settings" button next to the device you just used. A new window should pop up.
#In the top right-hand corner of pop-up window, select "Reset Data" and agree to clearing recorded data.
#Exit out of pop-up window and T&D Webstorage tab.

Tensile Testing

2022-05-24T19:14:20Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Loss Prevention=
*Safety glasses must be worn at all times due to possible projectile debris
*Be aware that mechanisms on the Instron 4206 move and may crush hands/objects.
*Locate the E-STOP button and be use as necessary to immediately stop testing if it becomes hazardous.

=Calibration=
==Load Cell==
*The load cell is checked annually against a reference load cell that is calibrated to NIST and AL2A standards.
*The calibration standard used to check the load component for the machine is ASTM E4.
*The load cell must be less than 1% deviation and repeatability across the range of the load cell.

==Extensometer==
*The extensometer is checked frequently using a dial micrometer
*The calibration standard for extensometers is ASTM E83
*There is no record of calibration numbers but less than 1% deviation is preferred

=Standard Operating Prodedures=
==Machine and Software Set-Up==
#Turn on Instron 4206 and launch the accompanying Test Works software with the proper test template for tensile testing.
#Check that the proper load cell and extensometer (if being used) are registered. Go to “Configure Device” to see registered devices. If incorrect, select the devices from the drop down list and click the “calibrate” button.
==Sample Set-Up==
#[[File:Annotatedtensile.jpg|Proper sample set-up for tensile testing.|400px|thumb|right]]Measure and record sample length, width, and thickness in inches using calipers. Use a marker to define the area measured as length.
#For Instron 4206 and sample set up :
#*Place the sample into lower grips so that it is vertical. Grips should only contact the larger, rectangular areas located at both ends of the sample.
#*Use handset or Test Works controls to move crosshead to align with the upper section of the sample. Tighten upper grips ensuring that the sample is untwisted and secured.
#** If you get a handset error message, the handset controller is active and the equipment will not operate b the software. You have to disable the handset by pushing the top right button with the lock on it.
#*Attach the extensometer if you are using one on to the tested length of the sample. Remove the pin prior to testing.
==Running Test==
#Zero all channels on the Test Works software by right clicking bottom of screen.
#Press the green arrow key on Test Works to begin the test. The software will prompt for sample labels and geometry prior to loading.
#Monitor sample during test for slippage from either the upper or lower grips.
#Test Works will notify users when the test is complete. Remove the sample carefully.
#The TestWorks software will prompt the user to return the crosshead to return to its initial position.
#* Do not auto return the cross head until the sample has been removed from the grips. Failure to do so will result in the sample being crushed and possible equipment damage.
#Save necessary figures, test files, and raw data files for proper analysis.
#* If you wish to export your data to Excel. Click the specimen you wish to export and click File/Export/Preview/Specimen. This will open a text file and save the text file in a separate location and open in excel.

Tensile Bar Testing

2022-05-24T19:13:56Z

Gcanzalo: Copied from old

[[Category: SOP]]
'''Loss Prevention:'''
Equipment is powerful and could be harmful if touched while test is running. Keep hands clear of equipment unless the test is over. Wear appropriate PPE as test specimens could send off projectiles. Always know wear nearing fire exit is, in case of an emergency.

Swager and Macbee wire drawing machines

2022-05-24T19:13:26Z

Gcanzalo: Copied from old

[[Category: SOP]]

=Saftey=
==Loss Prevention==
==PPE==

=Swager Procedure=
==Startup==
#Check over the machine for unsafe conditions.
#Select the correct dies from the die drawer/die area.
#Open the front face of the swager by pulling the pin on the right side. {A}
#Place the dies into the swager with the smaller diameter end facing inward. Use shims when needed, but try to evenly spread them to both sides. [[File:swager1.jpg|150px|thumb|right|Image {A} swager face]]

==Operation==
#Press the start button on the left hand side of the machine. {B}
#Place the head of your wire/bar into the hole and ease it slowly into the machine until it has been properly swaged. Use a wooden block and push with your hip if it wont go in.
#If the wire won’t go in, try going a level higher than previous.
#Do not wear gloves, other than nylon ones. Use a cloth to protect your hands from sharp parts. [[File:swager2.jpg|150px|thumb|right|Image {B} ]]

==Shutdown==
#Pull the wire out of the machine and then press the stop switch.{B}
#Remove the dies from the machine and place them back on the shelf.
#Clean up your workspace.

=Macbee Procedure=

==Startup==
#Check over the machine for unsafe conditions.
#Select the correct die from the die drawer.
#Ensure proper lubricant has been used.
#Place the die in the die holder. Run your swagered/pointed wire through the die and firmly place it into the wire grabber on the end of the chain.{D} If the chain does not reach the wire, jog the machine into place using the jog button and the left/right toggle switch. {C} [[File:swager3.jpg|150px|thumb|right|Image {C} ]]

==Operation==
#Once the wire is firmly in place, start the machine at a slow speed and ease into a higher one. Control this with the silver speed dial. {C}
#Ensure the aluminum guard is put into place as soon as the machine is ready to run.
#Never reach under the guard during operation!
#Remember you can alway press the Emergency Stop Button on top of the machine! [[File:swager4.jpg|150px|thumb|right|Image {D} ]]

==Shutdown==
#When the wire is close to being fully drawn, slow the machine with the silver speed dial. {C}
#When the wire comes fully through the die it will release a lot of tension. A loud noise will occur. The wire will uncoil a large amount. Stand behind the machine near the end of drawing!
#Once the wire is fully through the die stop the machine, remove the die from the machine, clean it and place it back in the die drawer.
#Clean up your workspace.

Steel Metallography Standard Operating Procedure

2022-05-24T19:13:01Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Saftey=
==Loss Prevention==
In Metallography hazardous chemicals and high-speed equipment could be hazardous if proper safety precautions are not utilized when operating equipment and using chemical solutions. To prevent these mistakes proper training and use of PPE. Along with keeping hands away from polishing wheels and using spray containers to prevent spills on skin or clothing.

==Materials==
*grinding pads (grit 60, 120, 240, 320, 400, 600)
*polishing pads (for diamond and alumina)
*hand polisher
*Ethanol (in spray bottle)
*Hair dryer
*steel samples

*
*pictures needed:
**grinding
**diamond polishing with red lube and diamond paste
**alumina polishing
**macro-etching with (have someone else get this picture)
**micro-etching (have someone else get this picture)

=Procedure=
==hand polishing==
#place grinding pad of 60 grit onto polishing wheel
#turn on polishing wheel

Squeeze Casting Mg with Preforms

2022-05-24T19:12:40Z

Gcanzalo: Copied from old

[[Category: SOP]]

=Safety=
Squeeze casting is performed by Loukas, but if present during the the process, involves the same risks as in a foundry except the molten metal is being squeezed at high temperatures. When entering the the pouring room at Loukas, safety glasses, steel toed shoes and foundry jackets, "greens" should be worn while in the room. During pouring additional PPE such as full body Kevlar "silvers", Kevlar gloves, and protective mask should be worn.

=Procedure=
# A 6" ID pipe was used to create the billets for the MMC-group samples. Which consisted of two "preforms" ~2cm in diameter, 1 cm thick each.
# The billet is placed onto the squeeze casting machine, and the inside is layered with a proprietary coating to help release the billet from the pipe.
# The two samples are placed in the press, the tray holding the samples was removed before metal was removed for the actual run [[File:SqueezeCast.jpg|Squeeze Casting Press with Preforms.|320px|thumb|right]]
# The plunger is pre-heated to 600°F
# The Mg+2wt% Zn Alloy is heated to 1350°F in a furnace next to the squeeze casting machine.
# A cover gas of CO2 and R134yf is used to prevent oxidation of the magnesium while in the molten state.
# The Mg alloy is poured from a ladle immedeitly into the machine and squeeze casting is performed with a pressure of 2000 psi.
# The billet is then allowed to air cool

SOP How To

2022-05-24T19:12:11Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP on writing an SOP. Click on the "Edit" tab, top, right, to open this page in the editor (an account is required). Select all or a portion the text and copy it to the clipboard (ctrl-c). Paste into the new document you wish to create following the instructions, just below. Update text and filenames in the new document to create the document you wish to produce, then save it. Don't create a new page if the SOP already exists! Instead, edit the existing SOP.

=Title of Page Must Be Sufficiently Descriptive=
# To create a new page, type the desired page title, using Title Case, into the wiki search box, e.g., "My SOP Name.
# If the page does not already exist, the search will return 'Create the page "My SOP Name" on this wiki!'. Click the name to create the new page.
# The new page will open in the editor.
# At the very top of the page, enter <nowiki>[[Category: SOP]]</nowiki>. Failure to do so will essentially render the SOP invisible as it will not show up in the SOP list. It can then only be found by a search or if the complete page name is known. Note that underscores (_) will replace spaces in the page name.
# Paste the contents of the clipboard (which you populated with some or all of the contents of this page) using ctrl-v.
# Edit the new page to include the text and pictures required by your SOP.

=Start with Safety=
* Really should be called "loss prevention", which is both personal safety and maintaining equipment in a safe, operational condition, i.e. don't break yourself or people around you, and don't break the machine.
* Note even "obvious" safety/loss issues. What is obvious to you may not be to someone else. For example: "Freshly cast parts are HOT when demolded. Handle only with tongs. Never use your hands, even when wearing protective gloves." Or: "Always start moving the machine at a slow speed and ensure no collision will take place before increasing speed."
* Be concise, but complete. Use short sentences. Overlong explanations suffer tl;dr and/or are difficult to understand.

=Then the Procedure=
# Break the task into short, logical steps.
# Use a numbered list indicating the sequence in which steps take place.
# Create a list item for each step.
# Write what you would say to someone if you were training them in person.
# Be concise, descriptive and use short sentences, e.g., "Move the disconnect to the up position until it firmly clicks into place."
# [[File:power_on.jpg|Make sure the picture is useful.|150px|thumb|right]] Use suitable pictures where appropriate; not every step requires a picture. Highlight portions of the picture to indicate the specific item you are talking about so its location and appearance is clear to the reader.
#* Pictures should support text, not replace text.
#* Add the picture as a thumbnail. The full-size picture is viewable by clicking the thumbnail.
#* The simplest way to add new pictures is to copy/paste an existing picture link while editing, and then changing the filename and caption. Then save changes.
#* The page will then contain a link to upload the new picture.
#* Keep pictures 1024px x 768px or smaller. Resize them before uploading, or you may get an error.
#* The final text in the list item containing the picture should be <nowiki>{{clear}}</nowiki>. This causes the parser to leave white space below the text, making it more clear which step the picture belongs with. Edit this page to see an example.{{clear}}
# The pursuit of perfection is admirable, but misguided. Do your best to be complete, but consider this is a living document, readily edited as necessary. Focus on loss prevention when preparing your SOP.

==If the Task has Subtasks, Use Subheadings==
* There may be instances where several tasks, each having multiple steps, are required to complete an overall larger task.
* Break the larger task into subtasks and separate subtasks by placing them under a subheading.
* Heading hierarchy is based on the number of equal (=) signs at the start and end of a line. Click the Edit tab and view the contents of this page for an example.

=Formatting Text and Images=
* [https://www.mediawiki.org/wiki/Help:Formatting See mediawiki formatting help] for detailed formatting information.
* [https://www.mediawiki.org/wiki/Help:Images See mediawiki images help] for detailed image formatting information.

Slow Cut Saw

2022-05-24T19:11:44Z

Gcanzalo: Copied from old

[[Category: SOP]]

== Safety/Loss Prevention ==
* Spinning parts, remove any loose clothing, or accessories that could be caught
* PPE (Personal Protective Equipment) is required to use the saw, mainly safety glasses
* Oil and sample particles may fly during the cutting process
* Un-Monitored process due to the time it takes to make a cut. Be sure to have a barrier with a note to ensure other lab users due not disturb the process

== Equipment ==
* Buehler Isomet Low Speed Saw
* Diamond Abrasive Wheel
* 4 Weights of varying sizes
* Iso-Cutting Fluid
* Allen Wrench
* Barrier to prevent any outside meddling and splashing of cutting oil

== Process ==
=== Set Up and Cutting ===
# Ensure saw is off and on lowest speed
# Remove any weights on saw
# Secure sample in jaws with the Allen wrench
# Plug in the saw
# Lift sample off the blade and turn on the saw
# Add any needed weights while specimen is off the blade before lowering the arm and beginning the cut
# Watch the cut for a few minutes to ensure no complications are or will arise. Increase the speed slowly as needed
# Set up splash barrier
# Study for all the exams you have this week while specimen is being cut

=== After Cut ===
# Turn saw speed down to minimum value and stop the saw
# Remove weights from arm
# Remove sample from the jaws and retrieve cut end from oil
# Unplug and clean saw
# Enjoy the now cut piece of material

=== Notes ===
Lift specimen off the blade when adding or removing weight, as well as turning the saw on or off

Sheldon Lathe

2022-05-24T19:11:22Z

Gcanzalo: Copied from old

[[Category: SOP]]
= Safety Precautions/Loss Prevention=
[[File:Lathe.jpg|Figure 1 - Basic components of lathe.|500px|thumb|right]] Lathes can be very dangerous if used improperly or without extensive training or experience. Please contact foundry staff if you need assistance with the lathe.
#Wear proper PPE throughout duration of operation. Needed PPE includes:
#*Safety glasses
#*Closed-toed, protective shoes
#*Short shirt, long pants
#Observe and learn proper operation by someone trained to operate lathe.
#Keep hands and other objects away from spindle and is operating.
#*If you have long hair, please tie it back if are operating or the lathe.
#Never make rapid positioning/axial movements unless aware of end stop.
#Avoid operating lathe distracted (music, double tasking, talking, etc.).
=Standard Operating Procedure=
==Work Holding==
A three-jaw chuck is installed on the left side of the lathe track. This set of jaws will automatically center cylindrical workpieces to within 0.003” of the axis of the machine axis. It is important to note that as less volume of your piece is secure in the chuck, more difficult it will be to turn.
#Use specific “T” wrench to close the chuck’s jaws to the approximate size of your sample.
#Place the sample in the vice then tighten the chuck with wrench until your sample is secured and centered.
#Remove the wrench before operation.
==Changing Tools and Tool Options==
[[File:Tools.jpg|Figure 2 - Tools avaible to lathe users.|400px|thumb|right]]The deformation lab has four types of lathe tools shown in Figure 2 that fit on the lathe’s quick-change tool post.
#Select proper tool for your sample and ensure there are no loose fastenings.
#Slide the tool onto the quick-change tool post while holding longer tool post lever to relieve pressure, almost like a puzzle piece.
#While pressure is still off the tool (tool post lever), adjust the height of your tool using the knurled and standard nuts on the top of tool post.
#* Please keep in mind that the cutting bit of the tool should be just BELOW the center of your work piece. Bring the live center near the tool post to gauge this height.
#The angle of the tool may also be altered by loosening the bolt on top of the tool post and turning as needed.
#Retighten post prior to lathe operation by reapplying pressure with the tool post lever.
==Feed & Speed==
Feed refers to how fast stock is being removed from a piece (lateral motion); speed refers to the RPM of the spindle (rotational motion). The lathe can be changed to a variety of feed/speed combinations. It is good to research which feed/speed is best to be using for your material and purpose. If you are unsure, experiment with your piece at 500 RPM.
{| class="wikitable" |+ Feed/Speed Combinations |- ! Low Speed, Low Feed !! High Speed, Low Feed !! Low Speed, High Feed !! High Feed, High Speed |- | ExampleA || ExampleB || ExampleC |- | Example || Example || Example |- | Example || Example || Example |- | Example || Example || Example|}
===Adjusting Speed===
[[File:SpeedBelts.jpg|Figure 3|400px|thumb|right]]The lathe is usually operated in the “Direct Drive” gear position but moving the gear to low will switch the lathe into back gear. There is a small chart on the side of lathe titled “Spindle Speeds RPM” that lists available speeds. Below are the steps to changes the speed of the lathe:
#Ensure lathe is off and open the “Belt Speed” panel (Figure 3).
#Flip the red lever to disengage the belt.
#Adjust the belt to the pullies either to the left or right.
#*Moving the belt left will DECREASE belt speed.
#*Moving the belt right will INCREASE belt speed.
#Once the speed has been changed and the belt is properly seated on pullies, flip the red lever again to re-engage the belt.
#*You may check if the belt is properly seated by spinning the spindle by hand and observing the belt.
===Adjusting Feed===
[[File:FeedGrids.jpg|Figure 4|400px|thumb|right]]The lathe’s feed rate is controlled by a knob and grid system. There is both an alphabetical and numerical grid. Feed decreases as the knob are moved up alphabetically/numerically. Therefore, “A1” is the fastest feed rate and “F10” is the slowest. The lathe’s feed direction is controlled by a similar system and follows the same steps as feed rate.
#With the lathe off, wiggle the feed knobs while turning the chuck by hand. Slowly work the knob to the desired setting.
#Ensure the spindle no longer turns freely, or else it is not in gear.

==Tailstock Parts and Operation==
The tail stock is the right half of the lathe mechanisms used to hold a work piece in place. Please see the diagram below for an explanation of the parts of the tailstock

There are two tailstock tools available in the deformation lab: a live center tool and a Jacobs (drill) chuck. The live center tool is best for supporting longer work pieces. The Jacobs chuck, more commonly known as a drill chuck, can hold drill bits or reamers that have a shank size of up to 0.5”.

To replace a tailstock tool:
#Turn the crank until the tail stock tool loosens up and the tool can be pulled out.
#Extend the tailstock spindle until more than 1” out of the tailstock.
#Ram the tailstock tool’s taper into the tailstock spindle.
To Drill or Ream with Jacobs chuck:
#Turn off the machine prior to set-up.
#Follow steps above to insert Jacobs chuck into tailstock.
#Use yellow chuck key to tighten drill bit or reamer into chuck.
#Secure your work piece into the three-jawed chuck (left side of lathe) and turn machine on.
#Bring the drill near the face of the work piece.
#Gently bring the drill bit to the face of the work piece and put enough pressure on it to create a small dent.
#*This will help guide the drill and reduce wobbling.
#Begin drilling by locking the tailstock to the ways and using the crank to push the spindle into the work piece.
#*If there is too much wobble, drill the hole out with a center drill first.
#*If the drill bit slips inside the Jacobs chuck, try tightening it further.
==Automatic Feed Usage==
[[File:Carriage.jpg|Figure 5 - Basic components of lathe's carriage.|500px|thumb|right]]The lathe has settings avaible that will move the cutter/carriage at a fixed rate in a single direction without the user needing to manually control the cutter. Below are the directions to test this option in both the X and y directions.
===Engaging Carriage/X-Axis Feed===
#Position the carriage far enough away from the workpiece that you will be able to test the direction of motion without running into the workpiece, chuck, or tailstock.
#Turn on the spindle.
#Using the leftmost lever on the carriage, engage the feed by pulling the lever out towards you.
#*NOTE: THIS WILL BEGIN MOVING YOUR CUTTER.
#If the direction of motion is wrong, disengage the feed by pressing the lever down.
#Stop the machine, adjust the feed direction, and then try again.

===Engaging Carriage/Y-Axis Feed===
#Position the carriage far enough away from the workpiece that you will be able to test the direction of motion without running into the workpiece, chuck, or tailstock.
#Turn on the chuck.
#Using the rightmost lever on the carriage, engage the feed by pulling the lever out towards you.
#*NOTE: THIS WILL BEGIN MOVING YOUR CUTTER.
#If the direction of motion is wrong, disengage the feed by pressing the lever down.
#Stop the machine, adjust the feed direction, and then try again.

==Turning==
Turing is when a user removes stock radially from a work piece to reduce its diameter.
#Make sure work piece is secure in the chuck.
#Once spindle is on, move the cutting tool closer to the face of the workpiece.
#Use cross-slide dials (located on cutting tool carriage) to adjust the tool to a distance that will remove the desired amount of stock.
#* One mark on the dial will yield removing ~0.002” from the piece’s diameter.
#*DO NOT try to take off a large amount in stock in one pass. Plan on doing several passes to get piece to desired diameter.
#Either manually or automatically (x-axis feed) move the tool along the x-axis of piece to begin cut.
#Use small amounts of cutting fluid when needed.

==Troubleshooting==
#While turning, drilling, or reaming a piece, are you hearing a sharp screeching sound?
#*Decrease your spindle speed and apply coolant.
#Does your piece have a poor surface finish?
#*Leave diameter of workpiece at approximately 0.010" greater than desired diameter. Remove this final bit of stock at half the automatic feed rate you were taking before.
#*Make sure the cutting bit is sharp and apply coolant if all else fails. Keep in mind that some materials, like softer aluminum castings, are incredibly difficult to get a good finish on.
#Does your piece keep producing long, curly strings/chips by cutting tool while turning?
#*With stronger materials, disengage automatic feed to break the chip away from the tool and discard. These pieces may be very sharp and strong (it is basically steel ribbon), so it can either cause injury to user or machine if not removed before it builds up.

SEM Sample Preparation of Mg Tensile Bars

2022-05-24T19:11:00Z

Gcanzalo: Copied from old

[[Category: SOP]]

<big>Loss Prevention</big>
# Safety glasses should always be worn in the metallography labs
# Make sure the safety guard is active before cutting with the abrasive saw
# Do not allow the tensile bar fracture surface to directly contact anything that might damage the sample

<big>Procedure</big>
# To protect the fracture site, wrap electrical tape around the tensile bar at the end of the fracture site and pinch the end closed. Ensure that the tape is wrapped far enough away from the fracture surface so that the closed end does not contact the surface (Figure 1).
# Use an abrasive saw with Valcool coolant to cut the tensile bar ½ inch down from the fracture surface
# Carefully remove the tape at the end of the sectioned sample to expose the fractured surface
# Place absorbent pads on the bottom of a small beaker, fill the beaker with ethanol, and place the sample in the beaker, ensuring that the fracture surface is face up.
# Place the beaker and its contents in an ultrasonic cleaner for 10 minutes (Figure 2).
# Use tongs to remove the sample from the ethanol bath, and use compressed air to dry the sample
# Carbon coat the sample

[[File:Tensile Bar pic.jpg|thumb|left|Figure 1]] [[File:UlstrasonicClean.jpg|thumb|left|Figure 2]]

Sample Polishing and Preparation

2022-05-24T19:10:32Z

Gcanzalo: Copied from old

[[Category:SOP]]

# Mount specimen using standard procedure for the chosen mounting material, such as acrylic and Bakelite resins. Each material type requires separate steps for proper mounting, ask instructor or other MTU faculty for specifics.
# Apply low grit pad (usually 80-120 grit) to working wheel of a metallographic auto polishing machine
#* Make sure bad is correct type for sample, i.e. Ferrous vs. Non-Ferrous, and hard vs. soft
#* Most grit papers are Silicon Carbide. If the paper being used is not, be sure to make not of this for when the samples undergo whatever type of analysis they are needed for, as the polishing element may affect the analysis results.
# Load samples into auto polisher.
# Turn dial for sample pits until headless screw inside force column, visible through vertical slit on side of the column, reaches the second etched line from bottom of column rotator. Each line represents 10 newtons of applied force to the samples as they are grinded.
# Turn on water for the polisher to allow some lubrication while machine is running
# Turn on auto polisher and run until sample is sufficiently flat. (First run only)
#* For subsequent runs, run for specified amounts of time. Record time for each grit level.
#* Turn off water after each run finishes.
# Remove samples and clean.
#* Run under cold water and clean with small amount of soap.
#* Use cotton pads to wipe with. Do NOT use paper towels, as this may introduce micro scratches to sample when moving to lower grit pads.
#* After washing off soap, rinse with ethanol. Use hair dryer to evaporate ethanol and leave sample clear.
# Remove lower grit pad from work wheel and replace with higher grit.
#* Do not increase grit over double the first grit, i.e. Moving from 240 grit to 480 is okay, but jumping to 600 is not.
#* This rule of thumb can be bent if it is the first grit increase, but do not jump over 320 grit. This is the intermediate grit size that must be done before moving to the greater grit sizes.
# Repeat steps 3 through 8 until sample finishes with 1200 grit.
#* Pressures and run times may vary, depending on preference of user and/or quality of polishing after each run
# Take clean intermediate diamond polishing and apply 6 micron diamond polishing paste to pad. Use glove to spread paste across pad.
# Apply to work wheel and load samples
# Apply load of 20N and run machine for approximately 10 minutes.
#* If not polished enough, rerun for another 10 minutes, as needed
#* There should be no water used at this grit level. Water would wash away diamond paste.
# Repeat step 7.
# Remove pad from work wheel and save in personal storage for any later use.
# Repeat steps 10 through 14 for 3 and 1 micron diamond pastes, and 0.5 micron Colloidal Silica.
#* For Colloidal Silica, run time should only be about 90 seconds.
# Look at sample under optical microscope. If polished properly, few micro scratches should be visible. If not, re-run samples with 0.5 micron Colloidal Silica until satisfied with results.

Sample Epoxy Mounting

2022-05-24T19:10:04Z

Gcanzalo: Copied from old

[[Category: SOP]]

<big>Loss Prevention</big>
#Safety glasses should always be worn in the metallography labs
#Gloves should always be worn when working with chemicals

<big>Procedure</big>
#Use an abrasive saw with a water-soluble oil as a lubricant to cut the sample to be mounted.
#Clean the sample using ethanol and dry with compressed air
#Grab the mold and place the sample into the mold. Make sure to place the surface to be examined face down.
#Grab the epoxy resin and corresponding hardener. Read the directions on the resin container for the proper mixture of resin-hardener. (fig. 1) [[File:Epoxy2.jpg|thumb|right|Figure 1. Epoxy resin and corresponding hardener]]
#Place empty cup onto scale and tare
#Weigh out the required amount of resin and tare the scale
#Weigh out the hardener. If needed add a dab of color to the cup.
#Mix the resin and hardener for 5 minutes
#Pour the epoxy into the mold
#Allow molds to site for the amount of time specified on the resin container
#Remove the bottom cap of mold
#Place mold in the bench vise and tighten it down (fig. 2) [[File:Vice2.jpg|thumb|right|Figure 2. Mold tightened in the bench vise]]
#Use the metal rod and hammer to knock the sample out of the mold.

Rockwell Hardness Testing

2022-05-24T19:09:37Z

Gcanzalo: Copied from old

[[Category: SOP]]

<big><big>Loss Prevention</big></big>
# Do not place fingers under indenter
# Do not attempt to move the move the sample during indenting

<big><big>Setup </big></big>

# Preparation of the sample should begin by sanding two surfaces smooth down to ~500 grit. No more is necessary. [[File:Rockwell.png|right|frame|Rockwell Indenter]]
# Turn on the hardness tester by the switch in the back.
# Find the HRF hardness indenter, the 1/16" steel ball, and insert it into the tip holder. This secures via magnet (2).
## Adjust the mode on the indenter to HRF by turning the knob on the right to 60 kgf (3).
# Find the closest standard to the expected hardness value of your material.
# Load the calibration block onto the anvil. Turn the bottom wheel elevate the anvil until the indenter is near the standard (4).
## Find a position in the indenter that is away from other previous indents by 1.5 diameters
# Continue turning the wheel to elevate the standard until the indenter tip makes contact, slowly continue raising the standard until a firm click or beep is heard. Then stop.
# Allow the indent to take place. The machine will perform this automatically.
# When the indent is complete, as marked by the hardness being displayed on the front (1), lower the anvil and release the sample. If the measure is within the value of the standard you may continue.
## If the measured value is not within the range of the standard do not panic: Return the standard, exit the lab, and contact authorities immediately.

<big>Measurement</big>
# Find your sample and ensure it is of sufficient thickness. No less than 1/8".
# Ensure both sides are parallel and smooth.
# Place the sample on the anvil and raise the the anvil until it is just below the indenter tip.
# Slowly raise the anvil until contact is made and until a firm click or beep is heard from the machine. Release the wheel.
# Once the measure has finished record the value and lower the anvil. Repeat the process as needed.
# Upon completion: Turn off the machine, replace the cover.

Raman Spectroscopy

2022-05-24T19:09:09Z

Gcanzalo: Copied from old

[[Category: SOP]]
== Loss Prevention ==
* Wear the appropriate PPE when handling samples.
== Procedure ==
# Turn on machine.
# Calibrate the instrument. This must be done whenever the instrument is started.
# Load the sample under the laser. Orient the sample under the laser so an area of interest can be analyzed.
# Adjust the instrument parameters (laser filter, exposure time, spectrometer offset, wavenumber range).
# Set acquisition time and accumulated values to desired numbers.
# Save data.
# Remove sample and turn off laser and computer.

Pycnometer

2022-05-24T19:08:42Z

Gcanzalo: Copied from old

====This SOP is hosted on [https://www.appropedia.org/Pycnometer_:MOST#Operation_.26_Procedure Appropedia]====

[[Category:SOP]]

Power Hacksaw - General

2022-05-24T19:08:10Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Safety Precautions/Loss Prevention=
#Operator must be wearing safety glasses.
#Saw location requires operators to be wearing steel-toed boots and green coat.
#Do not operate saw without prior training.
=Standard Operation Procedure=
==Sample and Machine Set-Up==
#Briefly check machine for unsafe conditions: broken or loose blade, sharp or flammable metal scraps, E-STOP button.
#Secure sample in vice while saw is off.
#* The vice on this saw is a bit old and crooked. This makes securing smaller samples difficult. Use other pieces of metal or available guide to even out the vice while you are securing your sample.
#Make initial adjustments to both saw pressure and cutting fluid.
#*An operator can change the pressure of the blade during sawing with the dial shown in Figure 2 at the bottom of the page. If you know you are sawing a soft material, start at a pressure below “3”. If you are sawing a harder metal, start with the saw pressure at “3” and work up in pressure as needed.
#*The cutting fluid flow lever’s location can be seen in Figure 1. If you are sawing a soft material, please ensure that this is in the on position. This will help keep the blade from becoming gummed-up during use. Add more cutting fluid to saw by pouring water/lubricant mixture through one of the saw’s drains. Fluid should appear milky if it has an adequate amount of lubricant for sawing.
==Machine Operation==
#Turn on saw by turning the “ON/OFF” switch (Figure 1).
#The blade will begin moving once the “START” button is pressed. Guide the blade down until it meets your sample.
#*If your sample begins to shift in the vice at any point of sawing, press the “STOP” button immediately! A moving sample can cause the blade to snap!
#Move the cutting fluid nozzle so that the blade is lubricated.
#Adjust the saw pressure until you find the proper setting for your material. Pressure is optimal when each pass of the saw blade creates small shavings and not a curled, attached bit of material.
#The saw will stop automatically once it reaches the bottom of the sample. Stop the saw at anytime by pressing “STOP” as well.
#Raise the blade by holding down the “STOP” button.
#Turn off saw’s “ON/OFF” switch and remove sample.
#Vaccum/sweep up all shavings and appropriately dispose of them.

Peerless Power Hacksaw

2022-05-24T19:07:43Z

Gcanzalo: Copied from old

[[Category: SOP]]

=Saftey=
==Loss Prevention==
==PPE==

=Procedure=
==Startup==
#Check over the machine for unsafe conditions.
#Check that the coolant flows properly and is topped off
#Set your part in the vise in a safe manner. Ensure the part won’t slip while you cut. Place the part to have the most uniform amount of material while cutting.
#Turn on the machine with the black switch. {B}
#Control speed with silver knob. {C} Ensure the blade is not being overworked. (NOTE: The silver knob actually allows the blade to be lifted if turned all the way counterclockwise. So you should try to find the sweet spot where the blade starts moving downwards to start.) [[File:peerless_power_hacksaw1.jpg|150px|thumb|right|Image {A}]]

==Operation==
#Remember that at any point in the cut you can press either red button, (On the panel and under the blade) {A,B}, pulling the blade away from the part.
#Press the green button on either the control panel {B} or to the left of the blade {A}, beneath the cutting head, to start the blade. Begin your cut.
#Listen to the machine, if it sounds funny to you, use your instincts and stop the machine or slow down your cut.
#Once the cut is finished and the blade has stopped moving lift the saw with the rounded red button {B} until it is fully raised away from the part and take the part out.
#Never reach into the path of the moving blade! [[File:peerless_power_hacksaw2.jpg|150px|thumb|right|Image {B}]]

==Shutdown==
#Store with blade down to lower pressure on system in storage.
#Clean up the area [[File:peerless_power_hacksaw3.jpg|150px|thumb|right|Image {C}]]

Pandat Solidification and Crack Susceptibility (CSI) Simulation

2022-05-24T19:07:18Z

Gcanzalo: Copied from old

[[Category: SOP]]
== Summary ==
This SOP provides an example of how to perform a solidification simulation using the Pandat2020 software. Hot tearing or hot cracking is a serious defect occurred during welding and casting solidification. Crackingusually occurs at the end stage of solidification along grain boundaries. Prof Kou proposed a criterion to describe the crack susceptibility by using a crack susceptibility index (CSI). This principle has been applied in several Al alloy systems. An example of the process is described.

== Downloading Pandat Software ==
# Download Pandat2020 installation file from the link http://www.computherm.com/download/Pandat_2020_Setup.exe and run Pandat_2020_Setup.exe to install Pandat 2020 (including all modules) on your computer,
#Download PanEngine2020 from http://www.computherm.com/download/PanEngine_2020.zip to install PanEngine on your computer.

== Simulation for alloy solidification curve and hot cracking susceptibility index ==
=== '''Purpose''' ===
Hot tearing or hot cracking is a serious defect occurred in welding and
casting solidification. Cracking usually generated at the end stage of solidification
along grain boundaries. Prof. Kou [2005Kou] proposed a criterion to describe the crack
susceptibility by using a simple crack susceptibility index (CSI), which is the
maximum value of |dT/d(fs)1/2| at fs1/2 < 0.99. The CSI criterion has been successfully
applied in several Al alloy systems. In this example, users will learn how to perform
solidification simulation of an Al-Cu-Mg alloy and output the relationship of|dT/d(fs)1/2|
vs fs1/2 directly from Pandat, and thus determine the CSI value of the
alloy. Users will also learn to set extra output tables with some specified properties
and extra output plots from this example. Commercial database of PanAl.pdb
including the thermodynamic and mobility data is required to perform the calculation
of this example.

=== '''Module:''' PanSolidification ===
=== '''Database:''' PanAl2020_TH+MB.pdb; Al_Alloys.sdb ===
=== '''Calculation Method:''' ===
* Open Pandat2020, create and new workspace and select the PanSolidification module.
* Load PDB file PanAl2020_TH+MB through Database → Load TDB or PDB (Encrypted TDB) and select elements: Al, Cu, Mg.
* Load SDB file Al_Alloys.sdb through menu PanSolidification → Load SDB and select the available alloys: Al alloys.
* Set solidification simulation conditions shown in Figure 1 by selectiong the Solidification Simulation with Back Diffusion icon under PanSolidification on the menu bar. The alloy composition is Al5wt%Cu2wt%Mg. The cooling rate is 20K/s is set in Thermal History solidfying from 680C to 380C over 15 seconds. Temperature gradient is set at 10^-3C/um. Pay attention to the units when setting conditions.
[[File:Pandat Solidification conditions.jpg|thumb|Figure 1. Set up solidification conditions]]
* To output a table with the calculated values, click "Extra Outputs" in Figure 1, a new interface shown in Figure 2 will appear. Click the blue "+" symbol to pop out the Table editor shown in Figure 3 and create a new table. From this Table Editor, users can specify and type properties to output, such as sqrt(fs), -T//sqrt(fs) in this example. -T//sqrt(fs) refers to -dT/d(fs)1/2, as the syntax // means derivative in the Pandat software. Note that with this setting, a "generated" table will be created in addition to the Default table.
[[File:Pandat Extra Output Interface.jpg|thumb|Figure 2. Extra Output interface]]
[[File:Pandat Define Properties.jpg|thumb|Figure 3. Define properties in the extra output table]]
* Set "Extra Outputs Graph". Click on the "Graph" icon in "Set extra output" interface as shown in Figure 2, then click the blue "+" symbol to add an extra graph. An interface as shown in Figure 4 will appear. Select the "generated" table generated by the previous step. Drag sqrt(fs) from the left column to X axis in the right column; drag -T//sqrt(fs) from the left column to Y axis in the right column. Then click OK. Note that with this setting, a "graph" of -T//sqrt(fs) vs sqrt(fs) will be plotted automatically in addition to the Default graph.
[[File:Pandat Define Axes.jpg|thumb|Figure 4. Define the axes of the extra graph]]
* Additionally, to create a solidification curve for the alloy, generate another table by dragging fs in to the X axis column and T in to the Y axis column.
* Then Click OK to perform Solidification simulation.

==='''Post Calculation Output Plots'''===
* The Default plot, in Figure 5, presents the relationship of temperature vs fraction of solid (fs) or the solidifcation curve during solidification.
[[File:Pandat Default Plot.jpg|thumb|Figure 5. Default plot showing the relation between the temperature and fraction of solid]]
* The extra graph specified is plotted automatically and shown in Figure 6. The highest peak on this graph is representative of the maximum crack susceptibility index (CSI) and the fraction square root of the fraction solidified it occurs at. Note graphs can be edited and rescaled at this point.
[[File:Pandat Extra Plot.jpg|thumb|Figure 6. Extra plot specified by Extra Graph setting]]

Owl Video Conference

2022-05-24T19:06:56Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP for using the Owl device for video conferences. The Owl is an all-in-one conference device. It contains multiple cameras, including a 360 degree camera, spacial sound recognition, and audio speakers.

=Safety=
* Handle with care as there is thin fabric over the audio speakers on the sides of the device.
[[File:owl.png|The Owl has speakers on the sides and cameras on the top.|200px|thumb|right]]
* Avoid touching the lens cover at the top to prevent damage and scratches.

=Procedure=
# Position Owl in desired position (typically no more than 4 feet away from each person for best audio and visual quality)
# Plug the power supply into a nearby outlet
# Connect the OWL device to the computer via usb cable
# On computer, open preferred communication application
# On computer, while in chosen communication app, find "camera" and "microphone" settings and select "Owl" for both

Nanoindentation sample preparation for Al

2022-05-24T19:06:30Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP for the preparation of cast aluminum alloys samples for nanoindentation testing.

=Loss Prevention=
*Safety glasses are required to work in polishing labs at Michigan Technological University.
*Be mindful of the polishing machines. There are pinch points when moving the head and the grinding pads could cause abrasions.
*The air hose in the polishing lab is strictly for drying samples.
*EDM produces Ozone- keep machine closed during operation

=Procedure=
#Mark part with a marker where future cuts will be made
[[File:Autopolisher2.jpg|150px|thumb|right|Figure 1. Autopolisher in Polishing Lab]]
#Cut samples from part using edm (electrical discharge machining) to minimize subsurface deformations
#*Cutting settings
#**Current 3A
#**Voltage 4kV biased voltage
#**Feed rate .4mm per minute (speed through material)
#**Enter code (Gcode) to determine cut
#Mount the samples
#*[http://sop.mse.mtu.edu/index.php?title=Sample_Epoxy_Mounting See Sample Epoxy Mounting SOP]
#Grind the testing surface manually using 600-grit SiC paper (Hudson)
#*When the marking is gone, the epoxy layer should be removed (Roughly 5 minutes)
#*Lubricate disk with water
#Grind the testing surface using 800-grit SiC paper (Hudson)
#*Polish for 2 minutes with a pressure of 20N or 5lb
#*Lubricate disk with water
#Grind the surface using 1200-grit SiC paper (Hudson) using an auto-polisher(shown in figure 1) for 3 minutes with 20N load
#*Fully load the auto polisher (3 samples) to maintain an even force on the samples
#*Lubricate disk with water
#Polish samples with 3μm diamond paste polish for 10 minutes with a 20N load on a disc reserved for this purpose.
#*Use Red lube to lubricate the disk. '''Do not use water'''.
#*To apply diamond paste, Rub the paste into the disk with a '''gloved''' fingertip while the wheel spins around 100-200RPM.
[[File:100X .05um partA 1.jpg|150px|thumb|right|Figure 2. A380 aluminum with .05um polish under 100X magnification]]
#Polish samples with 1μm diamond paste polish for 10 minutes with a 20N load on a different disc reserved for this purpose.
#*Use Red lube to lubricate the disk. '''Do not use water'''.
#*To apply diamond paste, Rub the paste into the disk with a '''gloved''' fingertip while the wheel spins around 100-200RPM.
#Polish samples with .05μm Aluminum oxide polish for 5 minutes with a 40N load on a disc reserved for this purpose.
#Inspect surface under an optical microscope to ensure that the surface is well polished.
#*For nanoindenation, the testing area should be smooth under 100X magnification
#*If surface is too damaged, It needs to be resurfaced starting with the 600 grit paper

Nanoindentation

2022-05-24T19:05:58Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP for the nanindentation of High Pressure Die Cast(HPDC) aluminum samples

=Loss Prevention=
* Electromagnetic Actuator (Inforce 1000) costs $50,000 to replace
**Very sensitive. It only has a displacement range of 80μm after which is break.
**Be extremely careful to avoid bumping the actuator when working in and around the machine
*vibration isolation table and ballast plates
**The table has red pins that control whether or not it floats.
***ensure that the pins are out when the nanoindenter is working and avoid bumping the table to ensure optimal performance by the indenter.

=Procedure=
# Prepare samples by mounting and polishing them.
#*Subsurface damage can negatively impact test quality. Be sure that both the surface and subsurface of samples are free of damage
#*Sample should be very flat to ensure good results
#Open Environmental enclosure
#Remove specimen stage
#*In software first eject the stage and then remove.
#*The stage is secured in the machine with magnets. Apply steady, controlled force when working near the actuator.
#Mount 1 sample on stage .
#*Fused silica mount always stays on the stage as a control for the nanoindenter (the machine tests the fused silica before and after each set of indents).
#*The fused silica is used as a calibration at the start of the experiment.
#*Ensure that the sample surface is level with the 4 pillars on the corners of the stage.
#*Use screw pins to secure the sample mount in the stage
#Carefully place stage back into indenter
#Initiate software to load the stage.
#Use software and optical scope in the indenter to identify locations where experiments are to be run
#Test parameters and sizes vary.
#Select settings and set machine to run
#Most quality experiments will run over night, especially if the allowed thermal stability criteria is low

=Test Parameters=
Electromagnetic Actuator (Inforce 1000)
*Displacement range =

Mixture DOE in RStudio

2022-05-24T19:05:29Z

Gcanzalo: Copied from old

[[Category:SOP]]
==Loss Prevention==
*Check the surrounding area for possible trip hazards from computer wires and cords.
*Keep open drinks away from the work surface or computer components.
**A drink spilling could damage the electrical components of the computer.
*Keep food with crumbs away from the computer keyboard.
**Crumbs can get lodged in between keys, limiting functionalities.

==Procedure==
===Accessing RStudio on a campus Windows Computer===
#Press the circular power button on the computer tower
#*Circular button should have a green ring light up around it
#**If light appears as yellow or red, continue to click the power button until it has cycled to green.
#Click the rectangular power button on the monitor
#*The small dot light should flash green
#**If the light appears as yellow or red, continue to click the power button until it has cycled to green.
#The Windows log in screen should appear, enter your MTU ISO username and password
#In the bottom left corner of your computer screen there should be the windows icon: A set of four tetrahedrons arranged into a larger tetrahedron.Click this icon.
#Scroll down in the menu until you reach the letter "R"
#There should be a folder entitled "RStudio"
#*Click on the folder once to access the contents
#**The only content of the folder to appear should be the RStudio application
#Double click on the RStudio icon to launch the application
===Accessing RStudio using a remote Windows desktop===
#Open your computer
#Establish a VPN connection
#*Michigan Tech IT Has a support article for how to establish a VPN connection
#**https://michigantechit.teamdynamix.com/TDClient/KB/ArticleDet?ID=51483
#In the bottom left corner of your computer screen there should be the windows icon: A set of four tetrahedrons arranged into a larger tetrahedron.Next to this icon there should be a bar that says "Type here to search"
#In the box, begin to type "Remote Desktop Connection" until the application shortcut appears.
#Double click the link to the application to open it.
#Follow the instructions provided by Michigan Tech IT to complete the connection to a Michigan Tech Remote Desktop
#*Link to Michigan Tech IT Instructions: https://michigantechit.teamdynamix.com/TDClient/1801/Portal/KB/ArticleDet?ID=53387
#In the bottom left corner of your remote desktop window there should be the windows icon: A set of four tetrahedrons arranged into a larger tetrahedron.Click this icon.
#Scroll down in the menu until you reach the letter "R"
#There should be a folder entitled "RStudio"
#*Click on the folder once to access the contents
#**The only content of the folder to appear should be the RStudio application
#Double click on the RStudio icon to launch the application
===RStudio Setup===
====Setting Working Directory====
#Go to "Session" in the upper menu bar
#In the drop down list hover your cursor over the "Set Working Directory" list item
#*A new list should appear to the right of the "Set Working Directory" item
#In the new list select "Choose Directory"
#*File explorer will open
#Navigate to find your desired folder
#*This should be the folder you plan to do all of your RStudio work in, as Rstudio will not be able to find any programs referenced in your code that do not reside in the folder set as the working directory.
[[File:Working Directory.png|thumb|center|Menu path to take when attempting to set the working directory. ]]{{clear}}
====Starting a new file====
#Go to "File" in the upper menu
#Hover your cursor over "New File"
#*A New Menu should appear to the right of the "New File" option in the "File" drop down menu.
#In the new menu that appears select the "R Script" option
[[File:New File in RStudio.png|thumb|center|Menu path that must be taken when making a new script file]]{{clear}}
===Creating a Mixture DOE===
====Loading Packages====
#In the bottom right quadrant of the RStudio window select the "Packages" tab
#Click on the "Install" button in the top left of the "Packages" window
#*A small popup window will appear
#In the popup window type "mixexp" into the "Packages" textbox
#In the popup window click "Install"
#*Make sure "Install from:" is set to "Repository (CRAN)"
#*Make sure "Install dependencies" is checked
#*Don't change the "Install to Library:" drop down, this is automatically set to your current working directory
[[File:Packages Tab.png|thumb|center|This is the location of the packages tab in the RStudio window]]
[[File:Install Packages.png|thumb|center|This is where the Install button is in the Packages tab]]{{clear}}
[[File:Installing mixexp.png|thumb|center|These are the settings required in the popup window for installing the mixexp package]]{{clear}}
====Loading Functions====
#First you must the "mixturedesign.RData" file
#*Download it from the following shared google drive link: https://drive.google.com/open?id=1VnECw079iu8jT6NtNja5uJg4IkRkHPlB
#Move the file from your downloads folder to the folder you have selected as your working directory.
#In the upper right quadrant of the RStudio window, select the "Environment" tab.
#In the upper right corner of the "Environment" tab click on the icon that looks like a file folder with a green arrow coming out
#*This will open a finder window that says "Load Workspace" at the top.
#Navigate to your working directory folder
#Select the "mixturedesign.RData" file
#Click "Open" in the bottom right of the finder window
[[File:Environment Tab.png|thumb|center|This is where the environment tab in RStudio can be located]]{{clear}}
[[File:File Import.png|thumb|center|This is where you import files in RStudio]]{{clear}}
====Coding the DOE Design====
#Loading libraries
#*library(mixexp)
#Loading functions
#*load("mixturedesign.RData")
#Create an extreme vertices design
#*evdes<-Xvert(nfac=3,
#:::uc=c(5,6,7)/10.5,#upper limit
#:::lc=c(0,1,2)/10.5,# Lower limit
#:::axislabs=c("Oil","Water","Corn Starch")
#:::ndm=0,pseudo=FALSE)
#:DesignPoints(evdes, axislabs=c("Oil","Water","Corn Starch"), pseudo = TRUE)
#*In the example above:
#**3 is the number of factors, which for a mixture DOE is 3
#**5 is the upper limit for factor 1
#**6 is the upper limit for factor 2
#**7 is the upper limit for factor 3
#**0 is the lower limit for factor 1
#**1 is the lower limit for factor 2
#**2 is the lower limit for factor 3
#**Oil is the label for the first factor
#**Water is the label for the second factor
#**Cornstarch is the label for the third factor
#**10.5 is the sum of the upper and lower limits divided by 2
#Display extreme vertices DOE design points
#*evdes
#Change DOE points from the extreme vertices design from fractions to percents in terms of the data you plan to collect
#*DOEpercents<- round(evdes*10.5,3) #View fractions as percents
#**10.5 is the sum of the upper and lower limits divided by 2
#**3 is the number of factors
#Display the new DOE points in terms of the data you plan to collect
#*DOEpercent
====Acquire DOE Point Results====
#Evaluate the DOE points using whatever method desired
#*actual experiments
#*Thermocalc
#*etc.
====Coding to Acquire Mixture DOE Analysis====
#Enter the results into the same RStudio code directly after the previously stated line of code
#*laves<-c(1,2,3,4,5,6,7,8,9)
#*The way this code is set up you should have 9 data points to enter as results in the place of the 1-9 values above.
#*Ensure data is being entered in the same order as it appears vertically in the displayed DOEpercents
#Combine design and response data
#*evdoe<-data.frame(evdes,laves)
#Display results of combined design and response data
#*evdoe
#Create and analyze model
##Create model
##*quadratic=lm(laves ~ -1 + (x1+x2+x3)^2,data=evdoe)
##Add the ANOVA for the model
##*Anova(quadratic,type=2)
##View the regression equation
##*summary(quadratic)
#Begin to remove insignificant factors from model, until all remaining factors are significant
#*An example of a reduced model is shown below:
#**quadratic=lm(laves ~ -1 + (x1+x2+x3)^2,data=evdoe)
#*::Anova(quadratic,type=2)
#*::summary(reduced)
#*Refer to the pdf link shared below on how to determine if a factor is significant
#**https://drive.google.com/open?id=1mYM3kExqcv7yb1nyY1HapoE7D8ls63xc
#Produce the mixture plot
#*ModelPlot(reduced, dimensions = list(x1="x1",x2="x2",x3="x3"),
#*::contour=TRUE, fill=TRUE,
#*::axislabs=c("Oil", "Water", "Corn Starch"),
#*::cornerlabs = c("Oil", "Water", "Corn Starch"))
#*In this case:
#**Oil is the first factor
#**Water is the second factor
#**Corn Starch is the third factor
#Add constraints to the mixture plot
##Determine constraints
##*c(1.25,1.75)/10.5 #Factor 1
##:c(2.25,2.75)/10.5 #Factor 2
##:c(4.5,5.5)/10.5 #Factor 3
##*In this case:
##**The values in parenthesis are the points from your extreme vertices setup
##**The 10.5 is the sum of the max and min values divided by 2 (as used above)
#Show the whole region plotted with the limits
#*ModelPlot(reduced,dimensions = list(x1="x1",x2="x2",x3="x3"),
#*:::lim=c(0.14,0.19,0.25,0.31,0.50,0.61),
#*:::constraints=TRUE,
#*:::contour=TRUE, fill=TRUE,
#*:::axislabs=c("Oil", "Water", "Corn Starch"),
#*:::cornerlabs = c("Oil", "Water", "Corn Starch"))
#*In this case:
#**The values in parenthesis are the points from the determined constraints above
#**Oil is the first factor
#**Water is the second factor
#**Corn Starch is the third factor
#Show the plot of the results zoomed in on the region of interest
#*ModelPlot(reduced,dimensions = list(x1="x1",x2="x2",x3="x3"),
#*:::lim=c(0.14,0.19,0.25,0.31,0.50,0.61),
#*:::constraints=TRUE,
#*:::contour=TRUE, fill=TRUE,
#*:::axislabs=c("Oil", "Water", "Corn Starch"),
#*:::cornerlabs = c("Cu", "Mg", "Zn"),pseudo=TRUE)
#*In this case:
#**The values in parenthesis are the points from the determined constraints above
#**Oil is the first factor
#**Water is the second factor
#**Corn Starch is the third factor
====Mixture DOE Coding Resources====
*A sample code is linked below via google drive
**https://drive.google.com/open?id=1HwZ_R3uoYyJHCLEOgFnry2cfhYjlQssW
*Additional clarification and resources can be found in the power point linked below via google drive
**https://drive.google.com/open?id=13Vbl2Nn1Bf6L6Jk281OYOWAbDY65bOc2
==Summary of Linked Resources==
*[https://michigantechit.teamdynamix.com/TDClient/KB/ArticleDet?ID=51483 Setting up a VPN]
*[https://michigantechit.teamdynamix.com/TDClient/1801/Portal/KB/ArticleDet?ID=53387 Connect to Remote Desktop]
*[https://drive.google.com/open?id=1VnECw079iu8jT6NtNja5uJg4IkRkHPlB mixturedesign.RData file]
*[https://drive.google.com/open?id=1mYM3kExqcv7yb1nyY1HapoE7D8ls63xc Multi-factor ANOVA (Determining Significance)]
*[https://drive.google.com/open?id=1HwZ_R3uoYyJHCLEOgFnry2cfhYjlQssW Sample Mixture DOE Code]
*[https://drive.google.com/open?id=13Vbl2Nn1Bf6L6Jk281OYOWAbDY65bOc2 Mixture DOE background information slides]

Milling Graphite Crucibles

2022-05-24T19:05:00Z

Gcanzalo: Copied from old

[[Category: SOP]]

This page will document the procedure for milling graphite crucibles for use in Magnesium flammability testing or other testing where cheap, disposable, or custom sized crucibles are required. For the purposes of this SOP, assume 1" diameter round graphite bar crucibles that are 1" tall.

[[File:Horizontal_feeds.jpg|500px|left]]
{{clear}}

=Loss Prevention =
* Use of the mill in the pattern shop is restricted to those who have been trained and/or approved for use by Dale Dewald. All users must report to him before using this equipment
* A nuisance dust mask can be used, usually called a dust mask, but there are specific restrictions in place for use of these. If a dust mask is desired, contact Russ Stein to acquire one and receive proper instructions for EHSA compliance.
* Following this, there are no health hazards associated with milling graphite or graphite dust but many people experience a general discomfort with cleaning and removal of the dust from skin and clothing.
* Long hair must be tied and strings on clothing may not be worn during use of the mill.
* Safety glasses must be worn while in the pattern shop.
* Gloves may not be worn during use of the mill or other rotating tools.
* End mills are very sharp, handle them with care when changing tools.

=Procedure=
# Begin by cutting 1" long sections of 1" diameter graphite on the abrasive saw.
#* If coolant is used be sure the samples are thoroughly dried before milling or use. Refer to the Abrasive cut off saw SOP for use on this. Shorter samples
#* Shorter samples may be cut for smaller crucibles if desired.
# If needed, change out the collet and end mill to fit the size of your crucible.

# Remove the cap from the top of the mill to expose the drawbar. Using a suitable pair of pliars and the pivoting socket wrench. Loosen the drawbar sufficiently until it can be unthreaded from the collet by hand.
#* Be prepared to catch the collet and tool as they will fall out when the drawbar is removed. If they do not, a few light taps of the drawbar will release them.
[[File:Collet_and_Mill.jpg|500px|left]]
{{clear}}

# Insert your tool into the drawbar until the shoulder of the bit is covered. Replace the collet with the appropriate size and end mill. Insert them into the spindle and thread the drawbar into the collet.
[[File:Collet_in_spindle.jpg|500px|left]]
{{clear}}

# Tighten the drawbar with the pliars and wrench as before. Do not overtighten them. Milling graphite is a very lightweight procedure. Replace the cap covering the drawbar.
# Place your graphite into the vice on the table and align it with the right edge of the vice. Tighten it securely but be careful not to fracture the sample.
# Using table traverse wheels, align the end mill with the center of the graphite crucible. If the sample is not cut flat, a quick sanding or facing operation can be performed to fix this.
#* Lowering the tool to touch the sample face can ease the process of centering the tool on the workpiece.
[[File:Horizontal_feeds.jpg|500px|left]]
{{clear}}

# Once centered on the part, lower the tool to touch the surface of the graphite and note the head position on the scale. Your final cut depth will be an offset from this position.
# Position a portable vacuum hose so it can be held near the workpiece to collect dust as it is created.
# Clear all materials of the tool. Turn the mill on by turning the power to "FWD".
# Tighten the coarse vertical feed knob to engage the fine vertical feed. Begin lowering the tool head to the bottom workpiece using the fine vertical feed knob to the workpiece.
# Enter the workpiece at a slow but constant rate until the desired depth has been reached. This should be noted on the scale as the distance traveled will be equal to the depth of the crucible
#* A recommended floor thickness is 1/16" - 1/8". This is a total cutting distance of 7/8"
# Exit the workpiece by retracting the tool above the graphite crucible. Turn off the the tool by turning the power to "Off"
# A graphite crucible should be made. Repeat as necessary but alignment does not need to be repeated once done for the first time.
#* Holes may be drilled into the side of the crucible following a similar procedure if you wish to put thermocouples through it.

=Shutdown=
# Remove the crucible from the crucible if no further samples will be made.
# Remove and replace the collet and end mill from the machine. Return the collet to its respective holder and put into the drawer.
# Clean the area by vacuuming all graphite dust and sweeping that which has accumulated on the floor.

==If the Task has Subtasks, Use Subheadings==
* There may be instances where several tasks, each having multiple steps, are required to complete an overall larger task.
* Break the larger task into subtasks and separate subtasks by placing them under a subheading.
* Heading hierarchy is based on the number of equal (=) signs at the start and end of a line. Click the Edit tab and view the contents of this page for an example.

=Formatting Text and Images=
* [https://www.mediawiki.org/wiki/Help:Formatting See mediawiki formatting help] for detailed formatting information.
* [https://www.mediawiki.org/wiki/Help:Images See mediawiki images help] for detailed image formatting information.

Milk and Vinegar Kitchen Polymer

2022-05-24T19:04:35Z

Gcanzalo: Copied from old

[[Category: SOP]]

=Safety=
*Pot is hot, use handle.

=Making the Polymer=
# Put milk in an appropriately sized pot.
# Heat over medium-high heat until milk begins to steam.
# Take pot off the heat.
# add vinegar or lemon juice while gently stirring the milk.
# Once the mixture starts to curd, stir for an additional minute.
#* [[File:E.png|100px|thumb|left]]{{clear}}
# Pour the curds into a strainer.
#* Let sit for five minutes.
# Compact the curds into a clump.
# Place in a large bowl.
# Fill the bowl with vinegar until the clump is submerged.
#*[[File:D.png|100px|thumb|left]]{{clear}}
# Let sit for one hour.
#* This is to make the final surface smoother.
# Pour the clump back into the strainer.
#* Let sit for an additional five minutes.
# Use paper towel to squish and absorb as much liquid out of the clump as possible.
#*[[File:F.png|100px|thumb|left]]{{clear}}
# Compact into a mold.
# Let sit in the mold until hard and dry.

=Standard Recipe=
* 1 cup of milk
* 4 teaspoons of vinegar or lemon juice
* This is enough to fill four ice cube pockets
* This takes about a week to dry after molded.

Mg Polishing & Etching

2022-05-24T19:04:05Z

Gcanzalo: Copied from old

[[Category: SOP]]

<big>Loss Prevention</big>
# Safety glasses should always be worn in the metallography labs
# Gloves should always be worn when working with chemicals
# Wear a respirator when working with powders

<big>Procedure</big>
# Place the sample face down on a cotton round in a beaker of ethanol and leave the beaker in the ultrasonic cleaner for five minutes, then dry with compressed air
# Secure 240 silicon carbide pad in the polisher and apply a load of 20 N to the sample, force adjustments are made by turning the wheel above the sample. The height of the bolt in the slot above the sample indicates the force applied (figure 1)
[[File:MgPolishingEtchingFigure1.jpg|thumb|Figure 1: Automatic Polisher]]
# Run polisher for 2 minutes with water constantly rinsing the pad, make sure the head is locked in place
# Remove sample and rinse with water, fold and throw away the polishing pad
# Repeat steps 2-4 with 320, 400, 600, and 800 polishing pads and 1 minute intervals
# Repeat step 1
# Polish the sample using a diamond pad with RedLube (Methanol Propylene Glycol) for 5 minutes, do not rinse the pad with water
# Repeat step 1
# Make a suspension of roughly ⅓ cup alumina powder in 20 fl oz water
# Polish the sample with a flocked pad for 5 minutes, keep the pad wet with the suspension. Do not add water except to rinse the basin
# Repeat step 1
# In the fume hood, use a cotton swab to apply a small amount of nital for several seconds
# Rinse the sample with water, then spray with ethanol and dry with a hair dryer

Metal Horizontal Bandsaw

2022-05-24T19:03:41Z

Gcanzalo: Copied from old

[[Category: SOP]]
The following is an SOP on using the Baileigh metal horizontal bandsaw (model BS-260M)

=Contacts=
* Russ Stein (restein@mtu.edu)
* Dale Dewald (dkdewald@mtu.edu)
* Tom Wood (tdwood@mtu.edu)

=Safety=
[[File:Protective cover.JPG| Figure 1. Adjustable saw blade cover.|150px|thumb|right]]
[[File:Saw with arrow.png| Figure 2. Book with cutting parameters for different materials.|150px|thumb|right]]
[[File:Cylinder with arrow.png| Figure 3. Adjustable hydraulic cylinder.|150px|thumb|right]]
Overall, this is a very safe bandsaw. However, any sharp moving equipment has the potential to create serious injury, so care should be taken when operating the bandsaw.
* Required PPE:
** Safety glasses
** Steel-toed boots
** Green jacket
* Never put your body in the path of the saw while the saw is turned on.
** The saw has a protective cover that can be moved with the provided Allen wrenches (figure 1). After loading the sample but before turning the saw on, loosen this cover and move it as far up the saw as possible without contacting the sample being cut. Then, re-tighten the cover. This minimizes the exposed blade length during cutting.
** Do not use gloves while using this rotating equipment.
* "Do not cut material harder than 350 Brinell (38 Rc). If you are not certain, go run a hardness test." Hard materials will dull the blade, break teeth off the blade, or snap the blade. A book below the bandsaw (figure 2) describes the proper blade types for cutting different materials. As students, we can not change the blade. Consult Russ, Dale, or Tom with any questions about cutting hard materials.
* Samples must be clearly clamped between the vice grips prior to starting the saw. This prevents the sample from being violently jolted off the table while being cut.
* The pressure applied by the blade during cutting is controlled by a spring in the control panel of the blade (do not touch this spring). The speed at which the blade drops during cutting is controlled by twisting the upper part of an adjustable hydraulic valve (figure 3). If too much pressure is applied while cutting a thin segment, the blade can dull or break. Thus, when cutting thin sections, reduce the speed at which the blade drops. The user can also manually easy the blade into a cut using the handle at the end of the saw (figure 3).
* Sharp metal shards may fly off of the blade during cutting. Thus, keep your body away from the piece being cut. A full-face shield could help prevent this.
* The part may be hot or sharp after cutting. Use caution prior to grabbing a cut piece.

=Procedure=
[[File:Control panel.JPG| Figure 4. Saw control panel.|250px|thumb|right]]
# Adjust protective grip to sample size prior to turning on the machine.
# Twist the large black switch on the lower-left of the control panel (figure 4) 90 degrees to turn the saw on.
# Set the proper cutting speed using the knob on the right of the control panel.
# Load the sample into the grip and position the saw correctly.
# Test the speed at which the saw falls. If needed, adjust the hydraulic cylinder accordingly.
# Using the handle to hold the blade off of the sample, use the green button to turn the saw on.
# Manually ease the saw blade into the cut. Never leave the saw unattended.
# The saw should automatically stop when the cut is complete. In case of emergency, press the red E-Stop to stop the saw.
# Use caution when grabbing cut pieces.
# Turn the saw off using the lower-left switch when complete.

Macro-etching WAAM steel

2022-05-24T19:03:13Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP on the macro-etching of WAA-manufactured steel samples. Macro-etching enables viewing of a material's macrostructure, including grains, weld beads, composition gradients, and other information. There are several methods of macro-etching; this page will cover the use of hydrochloric acid.

=Loss Prevention=
* In keeping with safety principles for all laboratory spaces, safety glasses must be worn at all times.
* Ensure that the fume hood is operating prior to the use of any solvents or acids. This is done by pressing the green "START" button at the top of the control bank at the right side of each fume hood.
* Hydrochloric Acid (HCl) is corrosive and must be used with caution. Users are required to wear lab coats (available on the wall to the left of the fume hoods in M&M U108) and nitrile gloves (found on the counter to the right of the fume hoods). Use tongs to handle samples that have been in contact with acid.
* Do not touch the face or eyes at any time during this procedure, until gloves have been removed and hands have been thoroughly washed.
* To avoid splashing of acid, pour into any required glassware in a slow and controlled manner. Clean up all spills and drops. Neutralize any excess acid with the use of an appropriate base. The resulting mixture must be washed down the drain in the sink under the fume hood. Following this, run cold water down the drain for a few minutes to dilute the waste material.
* A hot plate is required for this procedure. Ensure that the plate is cool prior to use. Check that the red light above the power control knob is off, then hold the back of your hand near the surface of the plate, at a safe distance. If the plate is hot, wait until it is fully cooled before use. Do not touch the plate during operation. Use tongs to handle any samples that have been heated. Remember to turn off the hot plate when the procedure is complete.
*Use a thermometer, located by the sink beside the auto-polishers in M&M U108, to test the temperature of any solutions used in the procedure.

=Procedure=
# Polish samples down to 1200 grit. The SOP for sample polishing can be found [http://sop.mse.mtu.edu/index.php?title=Polishing_and_etching_procedure_for_WAAM_steel here]. Samples may be too large to mount for use on the auto-polishers - if this is the case, the hand-polishing tables offer an acceptable substitute.
#* Thoroughly clean samples with soapy water, followed by ethanol. Dry samples using the hair dryer prior to immersing in HCl.
# Prepare a solution of 50% HCl and 50% water, using a volume sufficient for the samples' surfaces of interest to be fully immersed. This must be done under the fume hood, while it is running.
#* Pour water into the required glassware first, to avoid boiling of water when added to acid.
#* Constantly stir the mixture while adding acid, to ensure uniform dissolution and controlled mixing.
# Place the vessel on the hot plate and turn on the control knob. Monitor the solution with a thermometer until it reaches 70 degrees Celsius. Then, turn the control knob to the "3" position; this is sufficient power to maintain the required temperature for etching.
# Slowly immerse samples into the heated acid solution. The surfaces of the steel will effervesce throughout the procedure. Leave the samples in solution for 15 minutes, while monitoring the temperature.
# Carefully remove the samples from the acid bath, one at a time. Each sample must be promptly and thoroughly rinsed with cold water, then cleaned with ethanol and dried. Place samples away from the fume hood.
# Turn off the hot plate and allow the solution to reach room temperature. Remove the vessel from the hot plate.
# SLOWLY add a base (NaOH or NaHCO3 are acceptable) to the vessel of acid solution. Proceed until the solution stops bubbling. Stir consistently. Turn on the cold water and slowly pour the neutralized solution down the drain. Rinse the vessel thoroughly with water. Once all glassware, tongs, thermometers, etc. are cleaned, allow the water to run for several minutes to dilute the solution poured down the drain.
# Remove nitrile gloves and dispose of in a garbage can. Place all glassware on the racks by the auto-polishers to dry.

M&M 329 Metal 3D Printers

2022-05-24T19:02:48Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Loss Prevention=
These Metal 3D printers have a bright arc flash and produce hot material that should not be touched by hand. The material should be given sufficient time to cool before removing from the machine with insulating gloves (i.e. welding gloves). An auto darkening eye protection device should be worn during all times when the printer is operating. The printer also is motion controlled equipment that has pinch points and various moving parts. Always stand and keep hands clear when operating. Use Machine Lockout-Tagout procedures if necessary.

Lower Convection Furnace

2022-05-24T19:02:18Z

Gcanzalo: Copied from old

[[Category: SOP]]
The following is an SOP on using the lower convection furnace in the deformation lab. This furnace is often used for pre-heating extrusion tooling and billets.

=Contacts=
* Russ Stein (restein@mtu.edu)
* Dale Dewald (dkdewald@mtu.edu)
* Tom Wood (tdwood@mtu.edu)

=Safety=
* PPE:
** Required:
*** Safety glasses
*** Steel-toed boots
*** Green jacket
*** Gloves rated to the proper temperature
** Recommended based on temperature:
*** Full-face shield (for medium-to-high temperatures)
*** Silver jacket and spats (for high temperatures)
* PPE should be your last defense. All hot metal should be grasped with tongues, not gloves. Make sure the area is clear prior to opening the furnace or moving hot metal.
* When unloading hot metal, turn the furnace off before opening the door. This will reduce the heat in the air pumped through the furnace.
* The furnace measures temperatures in Fahrenheit. Be careful not to melt anything. Pure aluminum melts at 1,221°F, but alloys can melt lower.
* The samples being heated should not be in contact with the furnace wall, ceiling, or floor. They can be supported on ceramic blocks or aluminum profiles with an aluminum plate on top of them.
* Be advised that the furnaces temperature is often different than the metal temperature. A thermocouple touching the metal is the best way to read metal temperature.
* A quench pool is by the rollers at the end of the extrusion press. Be careful of steam when quenching hot metal.

=Procedure=
[[File:Closed_furncae.JPG| Figure 1. Closed furnace and control panel.|250px|thumb|right]]
[[File:Open_furnace.JPG| Figure 2. Open furnace with aluminum billets on top of an aluminum base plate and old profiles.|250px|thumb|right]]
# Use the arrows on the lower temperature panel to set the furnace to the proper temperature. Press the lower-left start button and close the door.
# When ready to unload samples, turn off the furnace with the lower-right red button. Make sure the area is clear before opening the furnace.

Laser Engraving UP Bottle Openers

2022-05-24T19:01:45Z

Gcanzalo: Copied from old

[[Category: SOP]]

Laser Engraving UP Bottle Openers

=Safety and Loss Prevention=
#When operating laser, wear TINTED safety glasses if observing etching process.
#Turn on fume hood where laser is located when operating.

=Overview=
This section is just to give you a general idea of how the laser engraving process will work.

*The laser engraver has two settings: scan and cut. Scanning etches an image file onto a surface by moving the laser back and forth relatively fast. Cutting will cut a specified path through a material at a slower speed.
*Never use greater than 66% power while using the engraver. This is crucial to preserve our laser tube.
*Before engraving any openers, you will have to make a cardboard “stencil” that will hold the openers in place while they scan. So when you head to the laser engraving lab, bring a few deconstructed cardboard boxes!
*Laser speed and power greatly affect how clear/sharp your scan images are and how well it may cut a material. You may have to “dial in” these settings as you go to ensure the product is turning out as it should be. Russ has practice bottle openers for you to use while getting used to the machine and program! Etch over the old designs to practice your new ones.
*This SOP has a lot of little, odd things that need to be followed for everything to run smoothly. Try to follow them the best as possible to keep frustration and wasting openers to a minimum.

=Standard Operating Procedure=
==Download Software==
#Download RDworksV8 software on to a laptop.
#*If you do not have a personal laptop, you will need to rent on from IT. Make sure you have admin access to laptop prior to attempting download.
#A zip extractor will need to be used to open application. The YouTube video below shows the specific steps a user will need to take to properly install RDWorks.
#*https://www.youtube.com/watch?v=9Cc62jzHdGM
==Engraving Process Outline==
These next parts are very important and takes some finessing. Below are the following steps that are recommended to take to start efficiently and correctly engraving bottle openers for the first time.

#Make a practice file on RDWorks that only has one front and one back.
#*You will end up running this file multiple times to scale and align your SCANNED images properly within cut paths.
#Prepare a cardboard stencil that will only be used for one front and back to check scan image alignment.
#*This means you can use a smaller piece of cardboard than what you will need when engraving multiple at once.
#Practice aligning your scan image and what power levels are best on practice openers Russ has.
#Once you have a project file that produces quality scans, use that same file to make a grid of many UP front and backs to be engraved.
#Create a larger cardboard stencil that is large enough for number of UPs you are engraving.
#Run engraving program as many times as needed with large stencil and fresh bottle openers until desired quantity is made.

==Creating Project File==
#Open RDWorks and start a new project.
#Select the rectangle cut tool on the left side of the screen and define two long, thin rectangles along the left and top edge of the workspace.
#*This step is crucial for making sure your bottle opener stencil will align with the engraving area of the laser engraving machine.
#Import images that will be SCANNED first (MTU logo, Class of 20XX, ARC logo).
#*You may resize these images to fit within cut paths.
#Next, import images that will be cut (UP opener front and back shapes).
#*Do not resize these images or else they will not be true to the bottle opener’s actual size.
#Arrange the different file types so that they depict what you want to engrave.
#Drag a selection box over the UP stencils you made in the RDWorks workspace.
#Select the “Vertical Mirror” option on the left side of the screen. After doing so, the UPs and scan images should appear reversed/backwards.
#Rehighlight all of the UPs and move them so they are as close to the upper left corner as possible (but not overlapping the thin rectangles you defined in step #2.

At this point, you should make a cardboard stencil (directions in next three section) that is only for one front and one back of the UP. Use old openers Russ has to check scan image alignment and laser power/speed options. These are the steps that are tedious, but if done thoroughly and correctly will make engraving 20 openers at a time much easier in later steps.

#Once you have a project file with one front and back of the UP opener you are happy with, use the copy function to make multiple rows and columns of the scan and cut files.

Here is a short YouTube video that explains some of the basic functions RDWorks has for users to manipulate their project files. It is very helpful to watch this prior to your first time using the laser engraver: https://www.youtube.com/watch?v=9dz8w9rlrHc&t=615s .

==Laser Speed and Power Controls in RDWorks==
[[File:Que.jpg|Path que and settings chart in RDWorks program.|300px|thumb|right]] On the upper right-hand side of the RDWorks screen, you should see the contents of Figure __. This is where the user may manipulate the order that images are scanned/cut, the power of the laser, and the speed of the laser.

The upper-most chart in this section shows the path que for your project file. The cut/scan step at the top of this chart will be performed by the engraver first and then it will move down the list. For engraving bottle openers, make sure that all “CUT” actions are queued before “SCAN” actions.

There is a column in this chart titled “Output”; by double clicking this column next to a specific cut/scan action, it will change in between displaying “Yes” or “No”. When “Yes” is displayed, the laser engraver will execute the defined path and settings for that step. When “No” is displayed, the laser engraver will bypass that step of your project file.

Below the action que is a table where the user can change the laser power and speed for the individual steps in the que. Click on an individual step in the action que, and then change the appropriate settings in the settings chart to fit that specific step. Remember to never set the laser power to over 66%!

==Basic Engraver Operating==
#To turn on engraver, twist and pull-out E-STOP button located on the right of the engraver.
#Look at the display screen on the engraver when you first turn it on. Follow prompts to exit any previous programs that might have been left in que.
#Connect your laptop with RDWorks to the engraver via USB cable.
#Open engraving file you want to execute and click “Download” in the lower right-hand corner of the RDWorks screen. This should send your project file to the laser engraver.
#Set-up what you need to on the engraving bed (either a new cardboard stencil or switch out openers from already-made stencil).
#Press “Start/Pause” button on the engraver to begin program.
#Only open the engraver cover once your program has ended and the laser has returned to its original position in the upper right-hand corner.
#*Holding “Reset” will also make the laser return to its original position. Consider “Reset” as your cancel button.

==Stencil Set-Up==
This is the process to make a “stencil” to hold bottle openers while they are being engraved. Once you cut the stencil, you will remove the cardboard UP shapes it cut and replace them with the aluminum ones for engraving. Doing this correctly will ensure there are no physical alignment issues with the openers.

#Cut a piece of cardboard that will fit the engraving bed of the laser engraver. If only engraving a few openers at a time, you do not have to have a piece that covers the entire area.
#Open hood of engraver and place cardboard in the upper RIGHT-HAND corner of the engraving bed.
#Use painter’s tape to secure cardboard in place.
#Turn on engraver.
#Download RDWorks file you want to make a stencil for.
#*If just making a stencil, you should change the “Output” option in your path que for SCAN paths to display “No”. This way the engraver will only cut out the UPs from the cardboard and not scan the images onto them.
#*The “CUT” paths should have about 40% power for cutting cardboard.
#Start the engraver and let the program run through.
#Once complete, you will need to carefully remove the UPs from the stencil. THIS IS VERY IMPORTANT AND WILL SAVE YOU A LOT OF FRUSTRATION: the laser engraving bed can shift if leaned on or poked to hard. Once your stencil in cut, take great care to not shift the bed at all or else your alignment will be off on your next run. The best way to remove the cut UPs is to poke one end of an individual UP with a pencil or screwdriver so that the opposite end pops up a bit. Then, gently pull the UP up with your fingers and throw it away.

Now you have a stencil ready for new or practice openers to be set in. Be careful again to not shift the bed or else you will have to do this whole process over again. Simply drop the openers vertically into and empty slot; when removing, pull them straight up.

==Cut and Scan Path Settings After Stencil is Made==
Once you have your stencil made and you are ready to start doing practice or final engravings, please consider the following:
#Even though you will not be cutting anymore, DO NOT DELETE YOUR CUT PATHS! They help the machine “figure out” where it is supposed to go prior to engraving. Instead, change the power setting to 1% and the speed to 200 mm/s. This will cause the engraver to basically trace to outline of the rectangles and the UPs where it had previously cut.
#*Changing the CUT “Output” option at this point to “No” will cause your SCAN images to not be engraved in their aligned spot! This is why you should leave the “Output” on “Yes” and change the settings to the ones described above. It adds ~2 mins. To the processes but it necessary.
#After your cut paths are set to just trace, make sure your “Output” for scan paths are all set to “Yes”.
#Scanned images on Al turn out best at relatively high power and speed. To slow and to high of power will create fuzzy, unfocused images while too fast and too low of power will barely engrave enough material off for the image to show.
#*Try to find a sweet spot for power from 30% to 50% power and 120 mm/s to 145 mm/s for speed.

If things do not turn out right with some of the openers, it could be issues with coating thickness or opener height. Both of these factors can cause bad scan quality so don’t get frustrated in you get a few in a batch that look bad!

Ion Mill

2022-05-24T19:01:18Z

Gcanzalo: Copied from old

[[Category: SOP]]

The following is an SOP on using the ion mill. Since a good SOP is already written and commonly used by operators, it is attached here.

[[File:IonMill1of3.png|1000px]]
[[File:IonMill2of3.png|1000px]]
[[File:IonMill3of3.png|1000px]]

Inspire Extrude Extrusion Simulation

2022-05-24T19:00:39Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Standard Operating Procedure=
==Simulation Preparation==
===Extrusion Die===
To run an extrusion simulation in Altair Inspire Extrude (IE), you will need to have a CAD model of the die you wish to analyze. Your simulation is more likely to run successfully if you do the following things:
#Save the file the die’s model as a .stp file to be imported into Inspire Extrude.
#Create a folder in your Michigan Tech H-Drive (home drive) to save all die models and Inspire Extrude files.
#Ensure model is fully constrained to avoid meshing issues while modeling.
===Obtain Press & Process Information===
Below is the information prompted by IE to model an extrusion press that is not one of the pre-set presses. The values are for MTU’s Breda 550 Extrusion Press; if you wish to model a different press, you will have to obtain new information
Container Diameter: 3.7 inches
Maximum Billet Length: 10 inches
Minimum Billet Length: 2 inches
Maximum Ram Speed: 30 in/min
Maximum Extrusion Ration: 100:1
Maximum Exit Velocity: default
Max Taper per Length: 10C to 20C
Press Capacity: 550 tons
Dead Cycle Time: 60 seconds
==Running an Extrusion Simulation ==
[[File:InspireExtrudeToolBar.jpg|Figure 1 – “Extrusion” Tools avaible for Inspire Extrude users. |1600px|thumb|center]]

 
 

To begin a simulation, open your die’s .stp file into the program; it should appear in the program’s window. The ‘Open” command can be found in the “File” tab of the tool menu.
Like more Altair programs, setting up a simulation in IE is relatively straight forward if you work left to right across the top tool bar. This section will break down how to use and maneuver each IE tool bar icon.
===Orientation===
#Click on the “Orientation”.
#Use the axis to appears to assign the direction the metal should exit the die.
#*The positive z axis should align with this direction.
#Right click in an open area of the work screen and click the green checkmark to end task.
===Flow Volume===
#Click and drag to highlight your entire die model.
#Click on “Flow Volume”.
#* This will determine the space avaible in your die for metal to “flow” through during extrusion.
#* This step may not work if there are gaps in your die assembly
#Right click in an open area of the work screen and click the green checkmark to end task.
===Bearing===
#Hover over the “Bearing” icon until the _____ (____) is highlighted. Select this feature.
#Use your cursor to highlight the bearing surface on the flow volume shown in the workspace.
#After this, a small entry box should pop-up asking for the following information:
#*Bearing Length: enter the correct bearing length according to your die dimensions.
#*Profile Length: enter the length of extrusion you want the program to execute.
#Right click in an open area of the work screen and click the green checkmark to end task.
===Organize===
If your die has multiple parts, this step will be needed to help the program assign the different parts of your model. The avaible options are: .
===Billet===
#Click on the “Billet” icon; a pop-up menu should appear.
#Enter appropriate billet dimensions.
#*MTU uses 3.5’’ diameter billets.
#*DO NOT CLICK SKIN THICKNESS. You will have to restart your model.
#Right click in an open area of the work screen and click the green checkmark to end task.
===Materials===
Inspire Extrude has a large data base of avaible billet, die, and coolant materials. A SOP for how to add a custom material will be added here soon.
#Click on the “Materials” icon.
#The menu on the upper-left side of the pop-up screen will show which part of the extrusion you are currently selecting materials for (billet, die, or coolant). The menu on the lower-left side will show you what materials you have selected for each part; you can add or remove selections here by right clicking and pressing “Remove/Delete”.
#Click through material library to select your billet material.
#Click “Tool Material” in the upper left menu and then select your tool material.
#*MTU uses H13 tool steel for their dies.
#Right click on the coolant material in the lower-left menu; MTU’s foundry does not use a coolant for extrusions.
#Once all material settings are correct, press “Okay” to apply the settings.
===Press Data===
When you press “Press Data”, Inspire Extrude will show you three options: two pre-set presses and a “user” press. The “user” press is where you can create your own press to model with.
#Click the “Edit” button and enter in press specifications.
#Click “Apply”
#Make sure your new press data is selected and then click “Okay”.

Induction Hot Compression Testing

2022-05-24T19:00:09Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Safety Precautions/Loss Prevention=
#Operator must be wearing safety glasses in the mechanical testing lab.
#Do not wear loose jewelry around induction power source or coils.
#Do not operate the induction power system or mechanical testing frame without training.
#Heat resistant gloves must be worn when handling heated samples.
 
 
=Standard Operating Procedure=
==Compression Sample Preparation==
[[File:HCASTM.jpg|Figure 1 –ASTM E209-18 Hot Compression Sample |300px|thumb|right]]
#Machine compression samples that follow an ASTM standard.
##Surface smoothness is crucial for successful testing as friction should be minimized.
#All samples must be spray painted black for the IR temperature sensor to be able to detect them/
 
 
==Cooling System Set-Up==
#Ensure that the radiator has a sufficient supply of distilled water, there is a bucket on top of the radiator to refill it if needed.
#Ensure that the Supply and Return hoses are installed properly on the Induction Power Source and radiator.
#Ensure that the valve on the back of the radiator is opened. Turn on the radiation pump by pushing the green button located under the protective plastic film.
#Open the Hot and Cold water supply valves located downstream of the radiator.
#Check to make sure there are no leaks.
 
 
==Mechanical Test Frame Set-Up==
#Position the Induction Power Source such that the induction coil is between the Test Frame platens.
#Ensure that the Induction Power Source switch is in the off position.
#Put on some heat resistant gloves.
#Gently pull the Induction coil down to provide enough room to install the compression sample onto the platens using long tweezers.
#Ensure the Induction coil is not contacting any surfaces.
#Position the IR Temperature Sensor so that the laser is directed onto the compression sample, make sure the laser is NOT directed onto the coil.
#Ensure the IR Temperature Sensor is turned on and confirm a good temperature reading.
 
 
==Induction Power Source Set-Up==
#Plug in the Induction Power Source to the required power supply located next to the Mechanical Test Frame.
#Flip the Power Switch to the on position on the back of the Power Source.
#Set the Set Point to 20%.
 
 

==Running a Test==
#Open the MTS TestSuite software.
#Start a new test or open an existing test.
#Click on the Monitor tab and set desired parameters for testing.
#Bring Crosshead down until almost touching the compression sample by clicking the down arrow on the software. SET ZERO BY RIGHT CLICKING ON THE CROSSHEAD DISPLACEMENT OUTPUT AND CLICKING “Set output to zero”.
##NOTE: If compression samples have significantly different lengths, Crosshead zeroing will have to be performed for each different sized sample.
#Once Zero is set, raise the Crosshead to an inch above Zero by clicking the up arrow, ensure that the platens are clear of the Induction Coil.
#Turn on the Induction Coil Power Source by pressing the Start Button.
#Observe the temperature reading until it is 25C above desired testing temperature.

#Bring the Crosshead to Zero by clicking the Enter button next to the arrows.

#Turn off Induction Power Source as the plattens enter the induction coil.
#Once the Crosshead reaches Zero, click the Play button.
#The software will prompt you twice, click continue & cancel on the respective dialogue boxes.
#Wait for the test to run and observe the temperature.
#Raise the Crosshead an inch above Zero after the test is complete.
#Flip the Induction Power Source switch to the OFF position.
#Gently push down the induction coil and remove the compression sample with the long tweezers, the sample will be HOT.
#Quench the sample in a bowl of water.
#Name your Test run as desired.
 
 
==End of Testing Clean-Up==
#Allow water to circulate for at least 5 minutes after your last test.
#Perform the above operations in the opposite order starting with Induction Power Source

How to Make A Thermocouple

2022-05-24T18:59:41Z

Gcanzalo: Copied from old

[[Category: SOP]]

==Thermocouple Assembly==
#Obtain a k-type thermocouple wire.
#Separate the two ends such that the ends are not touching.
#Twist the two ends together such that the ends are barely being held together by the twist.
#Turn on the electrode instrument which will be used to weld the two wire ends together at the twist.
#Ensuring that you are ''NOT'' touching the metal wire place the twist on the electrode and push the button which uses an electric current to weld the wire ends at the twist.
#Weld the wires together so that there is a metal ball on the end which is about 1mm in diameter.
#Untwist the wires if part of the initial twist still is present to avoid short circuiting the thermocouple.

Hot Compression Testing

2022-05-24T18:59:11Z

Gcanzalo: Copied from old

[[Category: SOP]]
==Safety==
* Must wear appropriate PPE, including safety glasses
* Know where the emergency off button is
* Use appropriate fasteners on load frame
* Samples fragments may cause projectile hazards

==Procedure==
# Sign into the log book
# Turn on the computer and open the software Testworks 4.
# Attach the desired load cell (Futek 5000 lb) to the Instron 4206 Test Frame.
# Ensure that the load cell is connected to computer.
# Calibrate the load cell by selecting the correct calibration file.
# Measure the width, depth, and length of the sample using a caliper.
# Heat the sample in a furnace for a minimum of five minutes.
# Load the sample.
# Go to file and select “New Sample”.
# Zero the load, crosshead position and displacement channel.
# Press start (green arrow). (If test will not run, the motor may have to be reset. This is done by pressing the “Reset motor” button in the lower right hand corner of screen)
# A screen will appear asking for name, width, and depth of the sample. Input these parameters and press start test.
# Let the test run. Do not touch the machine while it is running.
# Once the test is done, remove the sample from the machine.
# The data can be exported by opening the file menu and selecting the export option. This creates a text file within the export folder that can be retrieved.
# Return crosshead to the starting height by pressing the yellow arrow when test is concluded.
# Repeat for every sample.

Green Sand Hardness Tester

2022-05-24T18:58:46Z

Gcanzalo: Copied from old

[[Category: SOP]]
=Safety Precautions/Loss Prevention=
#If using in foundry or deformation lab, please wear protective footwear, safety glasses, and a green foundry coat.

=Standard Operation Procedure=
==Tester Set-Up==
#Unscrew back panel of sand tester and insert batteries. Reattach back panel prior to use.
#Press the “Enter/Exit” button and wait for menu to appear on display.
#Press the right arrow button until the flashing cursor is below the number located on the left-hand side of the screen.
#Select the “Enter/Exit” button to change “Md” to “Wk” (should be displayed in the top left-hand corner).
==Taking a Measurement==
#Place the tester’s sensor flat on the surface of the sand being measured.
#Apply gentle pressure until the sensor has been pressed into the sand up to the marked black line on the sensor.
#Carefully remove tester from sand and a reading will appear on its display about 5 seconds after.
#Following use, please clean off outside of tester and remove batteries.