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Bioreactor Controls-I01:28

Bioreactor Controls-I

Maintaining optimal conditions within fermenters is essential for maximizing microbial productivity and ensuring process efficiency. This lesson focuses on key parameters—temperature, foam, pH, carbon dioxide, oxygen, and pressure—and their precise measurement and control strategies in fermentation systems.Temperature ControlTemperature regulation is critical due to the exothermic nature of many fermentation processes. In small laboratory fermenters, temperature is commonly monitored using...
Bioreactor Controls-II01:18

Bioreactor Controls-II

In aerobic fermentations, oxygen is vital for microbial growth and metabolite production. Since air comprises only about 20% oxygen and the gas is poorly soluble in water—just 9 ppm at 20°C—supplying sufficient oxygen becomes a critical challenge, especially in high-demand processes like yeast growth or citric acid production. Even a fully saturated broth may offer only a few seconds of oxygen availability.To address this, sterile or scrubbed air is introduced into the fermentor via a sparger...

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Related Experiment Video

Updated: Jun 17, 2026

Experimental Multiscale Methodology for Predicting Material Fouling Resistance
09:13

Experimental Multiscale Methodology for Predicting Material Fouling Resistance

1.4K

In-Situ Monitoring and Control of Additive Friction Stir Deposition.

Evren Yasa1, Ozgur Poyraz1, Khoa Do1

  • 1Advanced Manufacturing Research Centre North-West, University of Sheffield, Blackburn BB2 7HP, UK.

Materials (Basel, Switzerland)
|April 24, 2025
PubMed
Summary

Additive friction stir deposition (AFSD) uses frictional heat to create solid parts. Monitoring process parameters like temperature and force, with or without PID control, is key to improving quality and managing residual stresses in aluminum alloys.

Keywords:
Al6061additive friction stir depositionadditive manufacturingprocess monitoringresidual stressestemperature evolution

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Additive friction stir deposition (AFSD) is a solid-state additive manufacturing (AM) method with high potential but limited technology readiness.
  • Optimizing process parameters and implementing closed-loop control are crucial for enhancing AFSD quality and addressing process variability.

Purpose of the Study:

  • To investigate the impact of process monitoring on AFSD of Al6061 aluminum alloy.
  • To compare AFSD outcomes with and without proportional-integral-derivative (PID) control.
  • To analyze thermal gradients, temperature/force fluctuations, and residual stresses.

Main Methods:

  • Utilized a sensor-based process monitoring setup to capture temperature, force, vibration, and sound data during AFSD.
  • Conducted experiments comparing AFSD with and without PID closed-loop control for the same parameter set.
  • Employed contour measurement techniques to evaluate residual stresses in the deposited parts.

Main Results:

  • Observed significant thermal gradients across the deposit and initial fluctuations in temperature and force that stabilized with increased height.
  • Demonstrated that process parameter variations can negatively impact deposit shape and quality.
  • Identified compressive residual stresses at the core and tensile stresses in the outer regions of the Al6061 deposits.

Conclusions:

  • Process monitoring and control are essential for achieving consistent quality in AFSD.
  • Understanding and managing thermal behavior and residual stresses are critical for successful AFSD applications.
  • PID control shows promise for improving the stability and predictability of the AFSD process.