manu sam | Amrita Vishwa Vidyapeetham (original) (raw)
Papers by manu sam
Silicon, 2020
This research compares the reciprocating tribo-mechanical behaviour of functionally graded A333 (... more This research compares the reciprocating tribo-mechanical behaviour of functionally graded A333 (Al-9Si-3Cu) alloy, Al-9Si-3Cu/6wt%B4C mono-composite and Al-9Si-3Cu/6wt%B4C/4wt%TiB2 hybrid-composite. Cylindrical test samples of both alloy and composites were horizontal centrifuge cast. Metallography of alloy revealed grain refinement and throughout presence of B4C particles along the cross-section of both functionally graded composites. Whereas, a rising gradient of TiB2 particles were observed towards the outer zone of hybrid composite. Comparative analysis on micro-hardness and tensile strength, revealed an improvement of 37.4% and 17.6% respectively for outer hybrid-composite; 22.6%, and 12.2% respectively for outer mono-composite with respect to alloy. Reciprocating wear analysis confirmed superior anti-wearing at outer hybrid-composite. Worn morphological analysis confirmed predominant delamination wear mechanism for outer zones of alloy, mono and hybrid composites. Abrasive, a...
Journal of Manufacturing Processes
International Journal of Automotive and Mechanical Engineering
Functionally graded material containing LM13 aluminium alloy as matrix and alumina as reinforceme... more Functionally graded material containing LM13 aluminium alloy as matrix and alumina as reinforcement (10 wt. %) was fabricated (Φout150 × Φin90 × 100 mm) by centrifugal casting. Samples were machined from the cylindrical cast along its longitudinal axis. Variation in hardness along the radial cross-sectional wall revealed 33.7% improvement at the outer periphery due to higher presence of alumina. This zone was preferred for dry sliding wear experiments, designed based on Taguchi L27 orthogonal array by varying the process parameters like sliding velocity, sliding distance and load using pin-on-disc tribometer. Analysis of variance revealed velocity as most influential wear factor, next to load. An optimal condition to minimise adhesive wear was determined at a load of 15 N, sliding velocity of 3.5 m/s and sliding distance of 1250 m. Scanning electron microscope analysis on abraded surfaces showed formation of tribolayer at high velocities and delamination at high loads.
Journal of Central South University
Non lubricated slide performance of functional grade copper matrix composite, fabricated using ho... more Non lubricated slide performance of functional grade copper matrix composite, fabricated using horizontal centrifuge cast technique was investigated using pin-on-disc tribo-tester. Rate of wear and friction coefficient of the inner wall thickness of hollow cylindrical cast specimen was analyzed using Taguchi based L27 orthogonal array, where the percentage of graphite particles were observed higher. Variable process parameters those influenced the rate of wear directly or indirectly were: applied load (15, 25 and 35 N), slide velocity (1.5, 2.5 and 3.5 m/s) and slide distance (750, 1500 and 2250 m). Rate of wear and friction coefficient showed a proportional dependency with applied load and slide distance, whereas showing a decline during intermediate slide velocity. Signal-to-Noise ratio predicted the minimal tribo-condition, on ‘smaller-the-better’ basis. Analysis of Variance technique quantified the influence of affecting parameters, along with their interactions. Regression analysis was utilized for the validation of the experimental data. Micrographs and scanning electron microscopy exhibited the wear mechanisms and mechanically mixed layer formation during worn surfaces analysis.
Transactions of the Indian Institute of Metals
Al 6060 alloy was coated with TiO 2 by spray pyrolysis technique at 400°C using Titanium isopropo... more Al 6060 alloy was coated with TiO 2 by spray pyrolysis technique at 400°C using Titanium isopropoxide as precursor. The adhesion of the coating with the alloy was enhanced by annealing at 450°C for 1 h which increased the hardness by 50%. Dry sliding wear resistance was experimented based on Taguchi's L 27 array using pinon-disc tribometer by varying parameters such as applied load (15, 25 and 35 N), sliding distance (500, 1000 and 1500 m) and sliding velocity (1.5, 2.5 and 3.5 m/s). Analysis of Variance predicted the major influence by load, followed by velocity and distance. Trend depicted an increase in wear rate with load and distance, whereas with velocity it decreased initially and then increased. Optimum condition for maximum wear resistance was determined from the Signal-to-Noise ratio. Experimental results were validated using regression equation with an error less than 3%. Scanning Electron Microscope analysis of the worn surfaces had revealed more defoilage and lay-off as the applied load was increased.
Transactions of the Indian Institute of Metals
The research aims to fabricate LM25 alloy and composites reinforced with 15 wt% TiB 2 , 15 wt% Zr... more The research aims to fabricate LM25 alloy and composites reinforced with 15 wt% TiB 2 , 15 wt% ZrO 2 and 15 wt% WC using squeeze casting technique. The fabricated cylindrical castings were of dimensions 50 mm diameter and 150 mm length. Microstructural analysis revealed better distribution of reinforcement particles for each composite, which provided better hardness and tensile properties. Physical and wear properties were studied comparatively to understand the influence of reinforcements, and tungsten carbide (WC)-reinforced composites showed better performance. Fractographic analysis revealed ductile mode of failure for LM25 and a combination of ductile and brittle mode for its composites. Dry sliding performance of both alloy and composites was analysed under different sliding conditions of applied load (10-50 N), slide distance (500-2500 m) and slide velocity (1-5 m/s) using pin-on-disc tribometer. WC-reinforced composite improved resistance to wear by 70% compared to alloy. Wear analysis of composite using scanning electron microscope showed change in wear features from mild to severe at high loads. The developed LM25/WC composite was found to be most suitable for non-lubricated slide applications.
Journal of Materials Research and Technology
Abstract Functional grade composites Cu–10Sn–5Ni reinforced with 10 wt%SiC and 10 wt%Al 2 O 3 , r... more Abstract Functional grade composites Cu–10Sn–5Ni reinforced with 10 wt%SiC and 10 wt%Al 2 O 3 , respectively, and their alloy was developed through horizontal centrifuge cast technique. Sample composites and alloy were cast at cylindrical dimensions of Φ out 100 × Φ in 70 × 100 mm. They were later subjected to tribology analysis during non-lubricated sliding. Anti-wear performance variations at inner (0–8 mm) and outer (8–15 mm) wall thicknesses of both composites and alloy were experimented using pin-on-disc tribo-tester. Experimentation with increasingly varied parameters like load and slid distance showed a rising trend of wear and friction. This was observed while comparing between the least (10 N, 500 m) and highest (60 N, 3000 m) varied parameter; for both alloy and composites. Also, a proportional decline in coefficient of friction with increase in slid velocity was exhibited for both composites; whereas alloy showed a linear rise. Worn specimen analysis using scanning electron microscopy on both composites revealed Mechanically Mixed Layer formation at both zones. This caused reduction in friction coefficient at high velocity (6 m/s).
Materials Research Express
Materials Research Express
Particulate Science and Technology
ABSTRACT This study investigates the mechanical and tribological properties of a functionally gra... more ABSTRACT This study investigates the mechanical and tribological properties of a functionally graded Cu–Sn–Ni/Al2O3 metal matrix composite, synthesized using horizontal centrifugal casting technique with dimension Φout100 × Φin85 × 100 mm. The microstructure was examined along radial distances at 1, 8, and 13 mm from outer periphery. Specimens were tested for tensile strength from outer (1–8 mm) and inner zone (9–15 mm) of the casting and fractured surfaces were subjected to fractographic analysis. Wear resistance of inner layer was experimented using pin-on-disc tribometer based on Taguchi’s L27 orthogonal array using three variable process parameters, such as applied loads (10, 20, and 30 N), sliding velocities (1, 2, and 3 m/s), and distances (500, 1000, and 1500 m). Optimum parameters were determined for wear rate on “smaller-the-better” basis using signal-to-noise ratio. Analysis of variance predicted the effect of each influential parameter and their interactions. Results depict that wear rate increased with load and distance, forming phases such as Cu3Sn, Ni3Sn, Cu6Sn5, etc. Worn surfaces analysis using scanning electron microscope predicted the formation of mechanically mixed layers, showing a V-trend influence of velocity on wear. Thus, fabricated composite shows the replaceability of conventional leaded bearing materials with superior copper functionally graded composites having better wear characteristics.
Materials Research Express
Engineering Science and Technology, an International Journal
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
LM25 aluminum alloy reinforced with 10 wt% of TiB2, WC, and ZrO2 were squeeze cast to investigate... more LM25 aluminum alloy reinforced with 10 wt% of TiB2, WC, and ZrO2 were squeeze cast to investigate the effect of T6 heat treatment on tribo-mechanical properties. Among all, WC-reinforced composite achieved superior mechanical properties at the aging time of 8 h. Microstructural examination performed on all composites and alloy concluded that the presence of WC in T6 LM25 caused reduction of α-Al dendrite size, exhibiting superior properties for this composite. X-ray diffraction analysis conducted on alloy and WC-reinforced superior composite revealed formations of phases, which improved their mechanical properties. Energy-dispersive X-ray spectroscopy analysis quantified the actual intensity of WC presence in the superior composite along with its other constituents. Response surface methodology model developed for wear test of the superior composite involves parametric range like applied load (10–50 N), sliding velocity (1–4 m/s), and sliding distance (500–2500 m). Analysis of varia...
Silicon, 2020
This research compares the reciprocating tribo-mechanical behaviour of functionally graded A333 (... more This research compares the reciprocating tribo-mechanical behaviour of functionally graded A333 (Al-9Si-3Cu) alloy, Al-9Si-3Cu/6wt%B4C mono-composite and Al-9Si-3Cu/6wt%B4C/4wt%TiB2 hybrid-composite. Cylindrical test samples of both alloy and composites were horizontal centrifuge cast. Metallography of alloy revealed grain refinement and throughout presence of B4C particles along the cross-section of both functionally graded composites. Whereas, a rising gradient of TiB2 particles were observed towards the outer zone of hybrid composite. Comparative analysis on micro-hardness and tensile strength, revealed an improvement of 37.4% and 17.6% respectively for outer hybrid-composite; 22.6%, and 12.2% respectively for outer mono-composite with respect to alloy. Reciprocating wear analysis confirmed superior anti-wearing at outer hybrid-composite. Worn morphological analysis confirmed predominant delamination wear mechanism for outer zones of alloy, mono and hybrid composites. Abrasive, a...
Journal of Manufacturing Processes
International Journal of Automotive and Mechanical Engineering
Functionally graded material containing LM13 aluminium alloy as matrix and alumina as reinforceme... more Functionally graded material containing LM13 aluminium alloy as matrix and alumina as reinforcement (10 wt. %) was fabricated (Φout150 × Φin90 × 100 mm) by centrifugal casting. Samples were machined from the cylindrical cast along its longitudinal axis. Variation in hardness along the radial cross-sectional wall revealed 33.7% improvement at the outer periphery due to higher presence of alumina. This zone was preferred for dry sliding wear experiments, designed based on Taguchi L27 orthogonal array by varying the process parameters like sliding velocity, sliding distance and load using pin-on-disc tribometer. Analysis of variance revealed velocity as most influential wear factor, next to load. An optimal condition to minimise adhesive wear was determined at a load of 15 N, sliding velocity of 3.5 m/s and sliding distance of 1250 m. Scanning electron microscope analysis on abraded surfaces showed formation of tribolayer at high velocities and delamination at high loads.
Journal of Central South University
Non lubricated slide performance of functional grade copper matrix composite, fabricated using ho... more Non lubricated slide performance of functional grade copper matrix composite, fabricated using horizontal centrifuge cast technique was investigated using pin-on-disc tribo-tester. Rate of wear and friction coefficient of the inner wall thickness of hollow cylindrical cast specimen was analyzed using Taguchi based L27 orthogonal array, where the percentage of graphite particles were observed higher. Variable process parameters those influenced the rate of wear directly or indirectly were: applied load (15, 25 and 35 N), slide velocity (1.5, 2.5 and 3.5 m/s) and slide distance (750, 1500 and 2250 m). Rate of wear and friction coefficient showed a proportional dependency with applied load and slide distance, whereas showing a decline during intermediate slide velocity. Signal-to-Noise ratio predicted the minimal tribo-condition, on ‘smaller-the-better’ basis. Analysis of Variance technique quantified the influence of affecting parameters, along with their interactions. Regression analysis was utilized for the validation of the experimental data. Micrographs and scanning electron microscopy exhibited the wear mechanisms and mechanically mixed layer formation during worn surfaces analysis.
Transactions of the Indian Institute of Metals
Al 6060 alloy was coated with TiO 2 by spray pyrolysis technique at 400°C using Titanium isopropo... more Al 6060 alloy was coated with TiO 2 by spray pyrolysis technique at 400°C using Titanium isopropoxide as precursor. The adhesion of the coating with the alloy was enhanced by annealing at 450°C for 1 h which increased the hardness by 50%. Dry sliding wear resistance was experimented based on Taguchi's L 27 array using pinon-disc tribometer by varying parameters such as applied load (15, 25 and 35 N), sliding distance (500, 1000 and 1500 m) and sliding velocity (1.5, 2.5 and 3.5 m/s). Analysis of Variance predicted the major influence by load, followed by velocity and distance. Trend depicted an increase in wear rate with load and distance, whereas with velocity it decreased initially and then increased. Optimum condition for maximum wear resistance was determined from the Signal-to-Noise ratio. Experimental results were validated using regression equation with an error less than 3%. Scanning Electron Microscope analysis of the worn surfaces had revealed more defoilage and lay-off as the applied load was increased.
Transactions of the Indian Institute of Metals
The research aims to fabricate LM25 alloy and composites reinforced with 15 wt% TiB 2 , 15 wt% Zr... more The research aims to fabricate LM25 alloy and composites reinforced with 15 wt% TiB 2 , 15 wt% ZrO 2 and 15 wt% WC using squeeze casting technique. The fabricated cylindrical castings were of dimensions 50 mm diameter and 150 mm length. Microstructural analysis revealed better distribution of reinforcement particles for each composite, which provided better hardness and tensile properties. Physical and wear properties were studied comparatively to understand the influence of reinforcements, and tungsten carbide (WC)-reinforced composites showed better performance. Fractographic analysis revealed ductile mode of failure for LM25 and a combination of ductile and brittle mode for its composites. Dry sliding performance of both alloy and composites was analysed under different sliding conditions of applied load (10-50 N), slide distance (500-2500 m) and slide velocity (1-5 m/s) using pin-on-disc tribometer. WC-reinforced composite improved resistance to wear by 70% compared to alloy. Wear analysis of composite using scanning electron microscope showed change in wear features from mild to severe at high loads. The developed LM25/WC composite was found to be most suitable for non-lubricated slide applications.
Journal of Materials Research and Technology
Abstract Functional grade composites Cu–10Sn–5Ni reinforced with 10 wt%SiC and 10 wt%Al 2 O 3 , r... more Abstract Functional grade composites Cu–10Sn–5Ni reinforced with 10 wt%SiC and 10 wt%Al 2 O 3 , respectively, and their alloy was developed through horizontal centrifuge cast technique. Sample composites and alloy were cast at cylindrical dimensions of Φ out 100 × Φ in 70 × 100 mm. They were later subjected to tribology analysis during non-lubricated sliding. Anti-wear performance variations at inner (0–8 mm) and outer (8–15 mm) wall thicknesses of both composites and alloy were experimented using pin-on-disc tribo-tester. Experimentation with increasingly varied parameters like load and slid distance showed a rising trend of wear and friction. This was observed while comparing between the least (10 N, 500 m) and highest (60 N, 3000 m) varied parameter; for both alloy and composites. Also, a proportional decline in coefficient of friction with increase in slid velocity was exhibited for both composites; whereas alloy showed a linear rise. Worn specimen analysis using scanning electron microscopy on both composites revealed Mechanically Mixed Layer formation at both zones. This caused reduction in friction coefficient at high velocity (6 m/s).
Materials Research Express
Materials Research Express
Particulate Science and Technology
ABSTRACT This study investigates the mechanical and tribological properties of a functionally gra... more ABSTRACT This study investigates the mechanical and tribological properties of a functionally graded Cu–Sn–Ni/Al2O3 metal matrix composite, synthesized using horizontal centrifugal casting technique with dimension Φout100 × Φin85 × 100 mm. The microstructure was examined along radial distances at 1, 8, and 13 mm from outer periphery. Specimens were tested for tensile strength from outer (1–8 mm) and inner zone (9–15 mm) of the casting and fractured surfaces were subjected to fractographic analysis. Wear resistance of inner layer was experimented using pin-on-disc tribometer based on Taguchi’s L27 orthogonal array using three variable process parameters, such as applied loads (10, 20, and 30 N), sliding velocities (1, 2, and 3 m/s), and distances (500, 1000, and 1500 m). Optimum parameters were determined for wear rate on “smaller-the-better” basis using signal-to-noise ratio. Analysis of variance predicted the effect of each influential parameter and their interactions. Results depict that wear rate increased with load and distance, forming phases such as Cu3Sn, Ni3Sn, Cu6Sn5, etc. Worn surfaces analysis using scanning electron microscope predicted the formation of mechanically mixed layers, showing a V-trend influence of velocity on wear. Thus, fabricated composite shows the replaceability of conventional leaded bearing materials with superior copper functionally graded composites having better wear characteristics.
Materials Research Express
Engineering Science and Technology, an International Journal
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
LM25 aluminum alloy reinforced with 10 wt% of TiB2, WC, and ZrO2 were squeeze cast to investigate... more LM25 aluminum alloy reinforced with 10 wt% of TiB2, WC, and ZrO2 were squeeze cast to investigate the effect of T6 heat treatment on tribo-mechanical properties. Among all, WC-reinforced composite achieved superior mechanical properties at the aging time of 8 h. Microstructural examination performed on all composites and alloy concluded that the presence of WC in T6 LM25 caused reduction of α-Al dendrite size, exhibiting superior properties for this composite. X-ray diffraction analysis conducted on alloy and WC-reinforced superior composite revealed formations of phases, which improved their mechanical properties. Energy-dispersive X-ray spectroscopy analysis quantified the actual intensity of WC presence in the superior composite along with its other constituents. Response surface methodology model developed for wear test of the superior composite involves parametric range like applied load (10–50 N), sliding velocity (1–4 m/s), and sliding distance (500–2500 m). Analysis of varia...