Dr. S.Senthil Murugan | Rajalakshmi Engineering College (original) (raw)
Papers by Dr. S.Senthil Murugan
This study investigates the processing and analysis of laser-welded Hastelloy X (HX) alloy joints... more This study investigates the processing and analysis of laser-welded Hastelloy X (HX) alloy joints, which are widely used in high-temperature aerospace and nuclear applications. Laser beam welding (LBW) experiments were conducted on HX base metal using a CO₂ laser, following an L9 Orthogonal Array (OA) experimental matrix. Variables included laser power, focal length, and welding speed. ASTM-standard testing showed that weld bead characteristics and joint properties varied with parameters. The joint with 20 J/mm heat input achieved the highest tensile strength and ductility, with 93% efficiency. Microstructure and EBSD analyses revealed grain elongation and refinement in the weld zone (WZ). The corrosion behaviour of the joints was assessed using potentiostatic polarization, with corrosion rates ranging from 7.4 × 10⁻ 3 to 8.6 × 10⁻ 5 mm/ year. The joint with 25 J/mm heat input exhibited the highest corrosion resistance. Consequently, a dry sliding wear test was conducted on that sample, varying applied load, sliding distance, and sliding velocity as per the L9 OA matrix. Results indicated that the wear test (30 N, 1.0 m/s, and 1000 m) had the highest coefficient of friction (COF), while the wear test (50 N, 2.0 m/s, and 1500 m) showed the greatest wear loss. Increased wear rate correlated with higher load and sliding distance, with weld speed affecting joint strength and laser power influencing corrosion and wear properties. Field emission scanning electron microscopy (FESEM) revealed grain boundary effects, corrosion pits from localized corrosion, and wear tracks with surface irregularities on the worn weld surfaces.
This study aims to develop hybrid polymer laminate (HPL) structure utilizing the 3D printing fuse... more This study aims to develop hybrid polymer laminate (HPL) structure utilizing the 3D printing fused filament fabrication (FFF) method and analyze the printing process. The HPL plates were fabricated using PETG and nylon 66 thermoplastic polymers at varying infill densities, printing speeds, and layer thicknesses. The experimental setup followed a fixed matrix based on the L9 orthogonal array (OA). Each HPL consisted of a bottom layer printed with nylon 66, with PETG layers sandwiched on top. Subsequently, the samples underwent testing using a UTM m/c to assess their tensile and flexural strength, as well as printing efficiency. Warping was observed on the printed samples, with a maximum tensile strength of 27 MPa and flexural strength of 14.5 MPa recorded. Notably, different strength values were observed when altering printing parameters. While the printing process was successful, the resulting HPL exhibited slightly lower strength compared to PETG or nylon 66 filaments. The study achieved a maximum printing efficiency of 90% (η), with the layer thickness parameter significantly impacting tensile properties. These findings offer valuable insights and required for various industrial applications, including wind turbines, electronics, automotive, and aeronautics. Significant Statement HPL structure has several significant advantages and applications. This innovative approach combines the benefits of both hybrid polymers and 3D printing technology to create structures with different properties and functionalities. The developed laminates have lightweight and high strength, customizable materials properties, reduced material waste, and design flexibility.
Journal of The Institution of Engineers (India): Series D
Composite sandwich panels are known to possess high specific mechanical strength and impact resis... more Composite sandwich panels are known to possess high specific mechanical strength and impact resistance. The low-velocity impact test is performed to assess the impact resistance, damage tolerance, and strength of panels. Generally, it is difficult to calculate the damaged area induced by the impact test on the panels by visual inspection method on account of their colour visibility and irregular shapes. In this study, a novel method based on the digital image analysis technique combined with MATLAB programming is proposed to calculate the exact damage areas and can check its severity economically, and without any robust instrumentation. The results are compared with that of the visual inspection technique and confirmed that the proposed method was an effective tool for the evaluation of exact impact damage areas.
Advances in Materials Science and Engineering
Metal matrix composites (MMCs) and their hybrid combinations are widely incorporated in research ... more Metal matrix composites (MMCs) and their hybrid combinations are widely incorporated in research due to their enhanced mechanical properties and wear resistance. In this work, an investigation is made to fabricate AA2024 matrix flyash and graphite-reinforced hybrid composite for industrial applications and determine its suitability by performing testing and characterization. Tensile properties and compressive strength, wear resistance, fracture toughness, impact energy, and the hardness of the composites are evaluated. A tensile strength maximum of 300 MPa was achieved. Furthermore, the thermal analysis of a disc brake of this hybrid composite is performed using SOLIDWORKS software to identify the temperature distribution up to 469°K. The addition of flyash reinforcement shows the changes in properties with weight reduction. Although the content of graphite particles shows a deterioration in mechanical properties, it acts as a lubricant and reduces wear by friction and friction betw...
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
High velocity oxy fuel (HVOF) is a thermal surface alteration method which improves or restores t... more High velocity oxy fuel (HVOF) is a thermal surface alteration method which improves or restores the surface morphology or dimensions of a component, therefore extending equipment life by considerably enhancing erosion and abrasion resistance, as well as corrosion control. Using a high-temperature, relatively high stream materials are sprayed onto the surface, resulting in a thick spray coating that may be ground to a very high surface polish. The HVOF coating process permits the application of various coating materials to generate a coating with extraordinary hardness, excellent adherence to the substrate, and significant abrasion resistance and cathodic protection. In this study, some of the recent researches carried out using HVOF techniques and the research finding are explored
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
This paper describes the fundamental needs of the centrifugal casting (CC) process. It is widely ... more This paper describes the fundamental needs of the centrifugal casting (CC) process. It is widely popular in foundries because of its simplicity and characteristics. CC is called as if the casting is produced with the help of the centrifugal force developed by the mould rotation. The true centrifugal casting (TCC) process is suitable for making hollow pipes, in which the centrifugal force provides good adhesion of molten metal on the mould's wall. From the literature, CC is a method for the production of bulk functionally graded materials (FGMs). Many kinds of research have been done on the CC process and some of the results have been discussed here. In the case of FGMs by CC, the gradation of harder particles with higher density was found in the outer region because of the centrifugal force, according to this gradation and the transition of materials, the mechanical and wear properties are changed from one place to another place along the specimen. For this phenomenon, the CC process is suitable for the production of automobile components. This paper provides the baseline knowledge about CC in classification, process variables and the characterisation, advantages and applications, and CC uses in research.
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
Polluting railway tracks causes a lot of problems to both environment and human beings. One of th... more Polluting railway tracks causes a lot of problems to both environment and human beings. One of the main problems in the railway is the wastages that are put by the passengers on the railway track. These wastages are collected from railway tracks by manual. Besides, it is also dangerous to work on the track. So, a special simple and innovative product are needed for collecting the scraps or wastes thrown nearby the railway track. This paper is to discuss the fabrication of a model to collect the wastage materials on the railway track without any manual effort to facilitate the clean operation on track by the robust design of waste collecting vehicles. This device is simple in design and low-cost innovative concept to clean the track. This vehicle design is not only used in railway track cleaning, it can also be used in a home or road cleaning.
Materiali in tehnologije
Resistance spot welding (RSW) of dissimilar metals is an emerging trend in automobile industries ... more Resistance spot welding (RSW) of dissimilar metals is an emerging trend in automobile industries in the manufacture of passenger-vehicle bodies. It provides the material characteristics and advantages of both metals. In this research work, the influence of heat addition and maximum interface temperature in the RSW of austenitic stainless-steel sheets (AISI 304 and AISI 316L) is investigated by welding the specimens at various levels of welding current and weld time. The ultimate strength of the spot-welded joints is analyzed to evaluate the amount of heat utilization and the quality of spot welds, finite-element analysis, and macrostructural evaluations. The thermal distribution profile and stress-strain analysis on the welded specimens are carried out with the 3D finite-element model developed using ABAQUS V6.6 software through incremental electro-thermal-structural analysis. A maximum tensile shear failure strength of 253 MPa was obtained with a nugget diameter 6.55 mm and the hea...
Annals of Dunarea de Jos University of Galati Fascicle XII Welding Equipment and Technology
Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in t... more Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in the absence of pollution, smoke, fume, and IR radiation during welding than conventional welding technologies. In this paper, the joining of aluminium AA6063 and steel SS304 dissimilar metal is explained with different faying surfaces and their SEM images of weld interface (WI), joint quality, tensile and yield strength, and the axial shortening are evaluated and compared. The joint quality factor of the experiment faying surface modification ‘E3’ was the maximum and about >100% with 236 MPa strength. The axial shortening was also less than 27 mm. The joint with hemispherical faying surface showed ‘U’ shaped WI and the joint with taper faying surface showed ‘V’ shape WI. So, the cross-sectional area of WI can be increased and the strength also increased. FW yields very high strength, low-stress weld with no weld defects such as porosity, voids etc. Here, in most cases, the joint streng...
International Journal of Advanced Science and Engineering, 2021
Friction welding, eco-friendly welding is widely popular for joining dissimilar joints. This soli... more Friction welding, eco-friendly welding is widely popular for joining dissimilar joints. This
solid-state welding process eliminates the smoke, fumes, fluxes caused by the fusion welding process. In
this work, the aluminium 6063 and stainless steel 304 was joined through rotary friction welding process
with flat faying surfaces as per Taguchi L9 orthogonal array with friction pressure (FP), upset pressure
(UP), and friction time (FT) were the major parameters and then the optimized parameters were identified
with grey relational analysis (GRA). The heat-affected zone during friction welding was narrow to 15-20
microns during the friction welding process; it improves the weld interface strength and showed good
bonding between the metals. The dissimilar weld joints were tested for axial shortening, tensile and yield
strengths, % elongation, peak load, and hardness along the weld zone. A maximum of 97% joint efficiency
was obtained for the 9th experiment with 18 MPa FP. The increase in FP also increases in tensile strength
of the dissimilar joint. Through this investigation, it is known that the axial shortening can be made within
the limit if we main the welding parameters.
International Journal of Advanced Science and Engineering
Journal of The Institution of Engineers (India): Series D
This paper discusses the fabrication of graphite-reinforced aluminium LM30 (A390) matrix composit... more This paper discusses the fabrication of graphite-reinforced aluminium LM30 (A390) matrix composite through gravity die casting and vertical centrifugal casting processes (VCC). The microstructures and the hardness of the cast specimen were characterized and presented here. The functionally graded composite (FGCs) processed through VCC showed the gradual transition of graphite and primary silicon from outer region to core region in microstructures. This was based on the gravity difference amongst the reinforcement and matrix during centrifugal casting. FGC is one of the potential engineering materials and has many applications in engineering industry. The microstructure of the gravity cast sample showed no gradual transitions but showed the uniform distribution of graphite reinforcement. The hardness of gravity cast samples showed a maximum of 130 HB. The hardness of FGC was measured from the outer periphery to the inner periphery. The results showed that the inner periphery had low hardness than that of inner periphery. Graphite particles reduced the hardness and increased the lubricating property of the composite. Gravity cast specimen showed greater hardness than that of VCC processed FGCs. Graphite particles had associated mostly with the primary silicon particles. Though the primary silicon particles are at inner, the graphite particles reduced the hardness.
Surface Review and Letters
Machining quality depends on numerous factors such as speed, feed rate, quality of the materials,... more Machining quality depends on numerous factors such as speed, feed rate, quality of the materials, the cutting fluids used and so on. The quality of machining components can also be improved by using appropriate cutting fluids. In this study, the three different types of eco-friendly cutting fluids based on coconut oil with nano boric acid particles were synthesized with nanoadditives and characterized during the lathe-turning operation of mild steel. The obtained results were compared between the dry/plain turning (without the cutting fluid) and the turning with the cutting fluids like coconut oil and mineral oil with nanoparticles. In industries, a wide variety of cutting fluids are used; however, most of these cutting fluids are made up of synthetic materials which may affect the environment significantly. Hence, it is essential to develop eco-friendly cutting fluids for environmental sustainability. Here, the cutting fluids were characterized by the morphological study on nanopar...
Journal of the Brazilian Society of Mechanical Sciences and Engineering
Joining of dissimilar alloys is demanded industrial applications and is effectively possible with... more Joining of dissimilar alloys is demanded industrial applications and is effectively possible with the friction welding (FW) process. In this work, SS304L alloy rods were electroplated with silver (Ag), nickel (Ni) and chromium (Cr) and joined with AA6063 at various upset pressures (UP) (18, 21, 24 MPa) through friction welding process. The interlayer produced by the electroplating process was considered as the third element between AA6063 and SS304L during the FW. The results obtained through weld microstructures, fracture images, energy-dispersive X-ray spectroscopy, tensile properties, joint efficiency, Vickers microhardness and Charpy V-notch test of the fabricated dissimilar joints are discussed here. Fracture study showed the dimple fracture. The maximum strength and axial shortening were obtained as 216 ± 8 MPa and 27 mm, respectively. Maximum joint efficiency was achieved for Cr interlayer as 105 ± 4% at 24 MPa UP, which also showed a 1.79 tensile-to-yield (TS/YS) ratio. UP of 24 MPa improved ductile nature of joint. Ag and Ni joints rendered poor elongation. FW of chromium-electroplated specimen gave maximum weld performance than that of others. Ag interlayer at 18 MPa UP showed good hardness. Maximum impact energy observed by Cr at 24 MPa UP was 35 J. The novelty of the work is to frictionally weld the dissimilar metals of ϕ12 mm rods with Ag, Ni, Cr interlayer at welding pressures in view of safety and energy consumption. There were the changes in the microstructure and mechanical properties of joints when the interlayers, UPs changed.
Journal of New Materials For Electrochemical Systems, 2020
This study discusses the dissimilar joining between AA6063 aluminium and AISI304L stainless steel... more This study discusses the dissimilar joining between AA6063 aluminium and AISI304L stainless steel of flat faying surfaces through a rotary friction welding process at different welding conditions as per L9 orthogonal array and the characterization of bimetal joints. The effect of welding parameters on the mechanical properties and the minimum level of welding conditions required for the metals joining were discussed. Bonding between the metals and the narrow heat-affected zone were observed from microscopy study. Energy dispersive x-ray analysis revealed the elements present at the weld interface and molybdenum formation. Fractography result on the tested specimens showed the dimple rupture during the fracture. The tensile test showed the plastic deformation near the weld joint for friction pressure 15 MPa and above. The maximum peak load and elongation of joint were around 12 kN and 12% respectively. 18 MPa friction pressure, 24 MPa upset pressure and 5 sec. friction time showed go...
International Journal of Modern Studies in Mechanical Engineering
The properties of metal matrix composite can be influenced by the reinforcement particles at diff... more The properties of metal matrix composite can be influenced by the reinforcement particles at different weight fractions of the composite. In this work, the hybrid composite, which consists of Al.6061 as matrix and fly ash&SiCP as the reinforcements, was processed by stir casting technique to studythe mechanical characterization and the effect of reinforcements (fly ash, SiCP)on the prepared composite. In addition, the study on the effect of input process parameters namely Wt.% of SiC, Stirring time and Stirring speed on the tensile and compressive strength is achieved by Taguchi method for predicting the better parameters that gives the highest tensile and compressive strength to the casting.The contribution ratio is obtained using analysis of variance.
Surface Review and Letters, 2020
This paper discusses the various joining methods with faying surface modifications used to join A... more This paper discusses the various joining methods with faying surface modifications used to join AA6063 and AISI304L dissimilar alloys by Rotary Friction Welding (RFW) process at different welding conditions mainly with friction pressure (FP), upset pressure (UP) and friction time (FT). This paper also studies the tensile behavior of the welded joints. The fabricated dissimilar joints were tested using universal testing machine against tensile load, and the mechanical properties of all 30 nos. of weld joints like elongation (%), strength coefficient ([Formula: see text]), strain hardening exponent ([Formula: see text]), strain hardening rate (TS/YS ratio), shear strength, etc. were calculated from the tensile testing results and plotted here with a standard error bar. Hollomon’s equation is considered here to study the stress and strain hardening relation and Von Mises yield criterion is considered for shear and yield stress correlation. Total elongation is also calculated from the i...
Archives of materials science and engineering, 2017
The interest in aluminum alloys is on account of their attractive properties and high strength to... more The interest in aluminum alloys is on account of their attractive properties and high strength to weight ratio. In marine environments aluminum alloys especially AA2014, exhibit low corrosion resistance. Micro arc oxidation (MAO), a novel technique, has gained popularity for synthesizing ceramic coatings by electrochemical treatment using an aqueous electrolyte on aluminum, magnesium, titanium and their alloys and it can be a method of improving corrosion resistance of aluminum alloys. In this study, a stable film is produced on the substrate of AA2014 aluminum alloy by MAO in an aqueous electrolyte having chemically treated with myristic acid. Corrosion properties of these treated and untreated surfaces are evaluated in freshly prepared 3.5% NaCl solution by potentiodynamic polarization test. The electrochemical measurements showed that the MAO treatment significantly reduced the corrosion current densities (Icorr) and simultaneously enhanced the corrosion potential (Ecorr) values ...
This study investigates the processing and analysis of laser-welded Hastelloy X (HX) alloy joints... more This study investigates the processing and analysis of laser-welded Hastelloy X (HX) alloy joints, which are widely used in high-temperature aerospace and nuclear applications. Laser beam welding (LBW) experiments were conducted on HX base metal using a CO₂ laser, following an L9 Orthogonal Array (OA) experimental matrix. Variables included laser power, focal length, and welding speed. ASTM-standard testing showed that weld bead characteristics and joint properties varied with parameters. The joint with 20 J/mm heat input achieved the highest tensile strength and ductility, with 93% efficiency. Microstructure and EBSD analyses revealed grain elongation and refinement in the weld zone (WZ). The corrosion behaviour of the joints was assessed using potentiostatic polarization, with corrosion rates ranging from 7.4 × 10⁻ 3 to 8.6 × 10⁻ 5 mm/ year. The joint with 25 J/mm heat input exhibited the highest corrosion resistance. Consequently, a dry sliding wear test was conducted on that sample, varying applied load, sliding distance, and sliding velocity as per the L9 OA matrix. Results indicated that the wear test (30 N, 1.0 m/s, and 1000 m) had the highest coefficient of friction (COF), while the wear test (50 N, 2.0 m/s, and 1500 m) showed the greatest wear loss. Increased wear rate correlated with higher load and sliding distance, with weld speed affecting joint strength and laser power influencing corrosion and wear properties. Field emission scanning electron microscopy (FESEM) revealed grain boundary effects, corrosion pits from localized corrosion, and wear tracks with surface irregularities on the worn weld surfaces.
This study aims to develop hybrid polymer laminate (HPL) structure utilizing the 3D printing fuse... more This study aims to develop hybrid polymer laminate (HPL) structure utilizing the 3D printing fused filament fabrication (FFF) method and analyze the printing process. The HPL plates were fabricated using PETG and nylon 66 thermoplastic polymers at varying infill densities, printing speeds, and layer thicknesses. The experimental setup followed a fixed matrix based on the L9 orthogonal array (OA). Each HPL consisted of a bottom layer printed with nylon 66, with PETG layers sandwiched on top. Subsequently, the samples underwent testing using a UTM m/c to assess their tensile and flexural strength, as well as printing efficiency. Warping was observed on the printed samples, with a maximum tensile strength of 27 MPa and flexural strength of 14.5 MPa recorded. Notably, different strength values were observed when altering printing parameters. While the printing process was successful, the resulting HPL exhibited slightly lower strength compared to PETG or nylon 66 filaments. The study achieved a maximum printing efficiency of 90% (η), with the layer thickness parameter significantly impacting tensile properties. These findings offer valuable insights and required for various industrial applications, including wind turbines, electronics, automotive, and aeronautics. Significant Statement HPL structure has several significant advantages and applications. This innovative approach combines the benefits of both hybrid polymers and 3D printing technology to create structures with different properties and functionalities. The developed laminates have lightweight and high strength, customizable materials properties, reduced material waste, and design flexibility.
Journal of The Institution of Engineers (India): Series D
Composite sandwich panels are known to possess high specific mechanical strength and impact resis... more Composite sandwich panels are known to possess high specific mechanical strength and impact resistance. The low-velocity impact test is performed to assess the impact resistance, damage tolerance, and strength of panels. Generally, it is difficult to calculate the damaged area induced by the impact test on the panels by visual inspection method on account of their colour visibility and irregular shapes. In this study, a novel method based on the digital image analysis technique combined with MATLAB programming is proposed to calculate the exact damage areas and can check its severity economically, and without any robust instrumentation. The results are compared with that of the visual inspection technique and confirmed that the proposed method was an effective tool for the evaluation of exact impact damage areas.
Advances in Materials Science and Engineering
Metal matrix composites (MMCs) and their hybrid combinations are widely incorporated in research ... more Metal matrix composites (MMCs) and their hybrid combinations are widely incorporated in research due to their enhanced mechanical properties and wear resistance. In this work, an investigation is made to fabricate AA2024 matrix flyash and graphite-reinforced hybrid composite for industrial applications and determine its suitability by performing testing and characterization. Tensile properties and compressive strength, wear resistance, fracture toughness, impact energy, and the hardness of the composites are evaluated. A tensile strength maximum of 300 MPa was achieved. Furthermore, the thermal analysis of a disc brake of this hybrid composite is performed using SOLIDWORKS software to identify the temperature distribution up to 469°K. The addition of flyash reinforcement shows the changes in properties with weight reduction. Although the content of graphite particles shows a deterioration in mechanical properties, it acts as a lubricant and reduces wear by friction and friction betw...
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
High velocity oxy fuel (HVOF) is a thermal surface alteration method which improves or restores t... more High velocity oxy fuel (HVOF) is a thermal surface alteration method which improves or restores the surface morphology or dimensions of a component, therefore extending equipment life by considerably enhancing erosion and abrasion resistance, as well as corrosion control. Using a high-temperature, relatively high stream materials are sprayed onto the surface, resulting in a thick spray coating that may be ground to a very high surface polish. The HVOF coating process permits the application of various coating materials to generate a coating with extraordinary hardness, excellent adherence to the substrate, and significant abrasion resistance and cathodic protection. In this study, some of the recent researches carried out using HVOF techniques and the research finding are explored
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
This paper describes the fundamental needs of the centrifugal casting (CC) process. It is widely ... more This paper describes the fundamental needs of the centrifugal casting (CC) process. It is widely popular in foundries because of its simplicity and characteristics. CC is called as if the casting is produced with the help of the centrifugal force developed by the mould rotation. The true centrifugal casting (TCC) process is suitable for making hollow pipes, in which the centrifugal force provides good adhesion of molten metal on the mould's wall. From the literature, CC is a method for the production of bulk functionally graded materials (FGMs). Many kinds of research have been done on the CC process and some of the results have been discussed here. In the case of FGMs by CC, the gradation of harder particles with higher density was found in the outer region because of the centrifugal force, according to this gradation and the transition of materials, the mechanical and wear properties are changed from one place to another place along the specimen. For this phenomenon, the CC process is suitable for the production of automobile components. This paper provides the baseline knowledge about CC in classification, process variables and the characterisation, advantages and applications, and CC uses in research.
Proceeding of 2nd International Colloquium on Computational & Experimental Mechanics (ICCEM 2021)
Polluting railway tracks causes a lot of problems to both environment and human beings. One of th... more Polluting railway tracks causes a lot of problems to both environment and human beings. One of the main problems in the railway is the wastages that are put by the passengers on the railway track. These wastages are collected from railway tracks by manual. Besides, it is also dangerous to work on the track. So, a special simple and innovative product are needed for collecting the scraps or wastes thrown nearby the railway track. This paper is to discuss the fabrication of a model to collect the wastage materials on the railway track without any manual effort to facilitate the clean operation on track by the robust design of waste collecting vehicles. This device is simple in design and low-cost innovative concept to clean the track. This vehicle design is not only used in railway track cleaning, it can also be used in a home or road cleaning.
Materiali in tehnologije
Resistance spot welding (RSW) of dissimilar metals is an emerging trend in automobile industries ... more Resistance spot welding (RSW) of dissimilar metals is an emerging trend in automobile industries in the manufacture of passenger-vehicle bodies. It provides the material characteristics and advantages of both metals. In this research work, the influence of heat addition and maximum interface temperature in the RSW of austenitic stainless-steel sheets (AISI 304 and AISI 316L) is investigated by welding the specimens at various levels of welding current and weld time. The ultimate strength of the spot-welded joints is analyzed to evaluate the amount of heat utilization and the quality of spot welds, finite-element analysis, and macrostructural evaluations. The thermal distribution profile and stress-strain analysis on the welded specimens are carried out with the 3D finite-element model developed using ABAQUS V6.6 software through incremental electro-thermal-structural analysis. A maximum tensile shear failure strength of 253 MPa was obtained with a nugget diameter 6.55 mm and the hea...
Annals of Dunarea de Jos University of Galati Fascicle XII Welding Equipment and Technology
Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in t... more Friction welding (FW) is cost-effective, efficient, occupational safer and also eco-friendly in the absence of pollution, smoke, fume, and IR radiation during welding than conventional welding technologies. In this paper, the joining of aluminium AA6063 and steel SS304 dissimilar metal is explained with different faying surfaces and their SEM images of weld interface (WI), joint quality, tensile and yield strength, and the axial shortening are evaluated and compared. The joint quality factor of the experiment faying surface modification ‘E3’ was the maximum and about >100% with 236 MPa strength. The axial shortening was also less than 27 mm. The joint with hemispherical faying surface showed ‘U’ shaped WI and the joint with taper faying surface showed ‘V’ shape WI. So, the cross-sectional area of WI can be increased and the strength also increased. FW yields very high strength, low-stress weld with no weld defects such as porosity, voids etc. Here, in most cases, the joint streng...
International Journal of Advanced Science and Engineering, 2021
Friction welding, eco-friendly welding is widely popular for joining dissimilar joints. This soli... more Friction welding, eco-friendly welding is widely popular for joining dissimilar joints. This
solid-state welding process eliminates the smoke, fumes, fluxes caused by the fusion welding process. In
this work, the aluminium 6063 and stainless steel 304 was joined through rotary friction welding process
with flat faying surfaces as per Taguchi L9 orthogonal array with friction pressure (FP), upset pressure
(UP), and friction time (FT) were the major parameters and then the optimized parameters were identified
with grey relational analysis (GRA). The heat-affected zone during friction welding was narrow to 15-20
microns during the friction welding process; it improves the weld interface strength and showed good
bonding between the metals. The dissimilar weld joints were tested for axial shortening, tensile and yield
strengths, % elongation, peak load, and hardness along the weld zone. A maximum of 97% joint efficiency
was obtained for the 9th experiment with 18 MPa FP. The increase in FP also increases in tensile strength
of the dissimilar joint. Through this investigation, it is known that the axial shortening can be made within
the limit if we main the welding parameters.
International Journal of Advanced Science and Engineering
Journal of The Institution of Engineers (India): Series D
This paper discusses the fabrication of graphite-reinforced aluminium LM30 (A390) matrix composit... more This paper discusses the fabrication of graphite-reinforced aluminium LM30 (A390) matrix composite through gravity die casting and vertical centrifugal casting processes (VCC). The microstructures and the hardness of the cast specimen were characterized and presented here. The functionally graded composite (FGCs) processed through VCC showed the gradual transition of graphite and primary silicon from outer region to core region in microstructures. This was based on the gravity difference amongst the reinforcement and matrix during centrifugal casting. FGC is one of the potential engineering materials and has many applications in engineering industry. The microstructure of the gravity cast sample showed no gradual transitions but showed the uniform distribution of graphite reinforcement. The hardness of gravity cast samples showed a maximum of 130 HB. The hardness of FGC was measured from the outer periphery to the inner periphery. The results showed that the inner periphery had low hardness than that of inner periphery. Graphite particles reduced the hardness and increased the lubricating property of the composite. Gravity cast specimen showed greater hardness than that of VCC processed FGCs. Graphite particles had associated mostly with the primary silicon particles. Though the primary silicon particles are at inner, the graphite particles reduced the hardness.
Surface Review and Letters
Machining quality depends on numerous factors such as speed, feed rate, quality of the materials,... more Machining quality depends on numerous factors such as speed, feed rate, quality of the materials, the cutting fluids used and so on. The quality of machining components can also be improved by using appropriate cutting fluids. In this study, the three different types of eco-friendly cutting fluids based on coconut oil with nano boric acid particles were synthesized with nanoadditives and characterized during the lathe-turning operation of mild steel. The obtained results were compared between the dry/plain turning (without the cutting fluid) and the turning with the cutting fluids like coconut oil and mineral oil with nanoparticles. In industries, a wide variety of cutting fluids are used; however, most of these cutting fluids are made up of synthetic materials which may affect the environment significantly. Hence, it is essential to develop eco-friendly cutting fluids for environmental sustainability. Here, the cutting fluids were characterized by the morphological study on nanopar...
Journal of the Brazilian Society of Mechanical Sciences and Engineering
Joining of dissimilar alloys is demanded industrial applications and is effectively possible with... more Joining of dissimilar alloys is demanded industrial applications and is effectively possible with the friction welding (FW) process. In this work, SS304L alloy rods were electroplated with silver (Ag), nickel (Ni) and chromium (Cr) and joined with AA6063 at various upset pressures (UP) (18, 21, 24 MPa) through friction welding process. The interlayer produced by the electroplating process was considered as the third element between AA6063 and SS304L during the FW. The results obtained through weld microstructures, fracture images, energy-dispersive X-ray spectroscopy, tensile properties, joint efficiency, Vickers microhardness and Charpy V-notch test of the fabricated dissimilar joints are discussed here. Fracture study showed the dimple fracture. The maximum strength and axial shortening were obtained as 216 ± 8 MPa and 27 mm, respectively. Maximum joint efficiency was achieved for Cr interlayer as 105 ± 4% at 24 MPa UP, which also showed a 1.79 tensile-to-yield (TS/YS) ratio. UP of 24 MPa improved ductile nature of joint. Ag and Ni joints rendered poor elongation. FW of chromium-electroplated specimen gave maximum weld performance than that of others. Ag interlayer at 18 MPa UP showed good hardness. Maximum impact energy observed by Cr at 24 MPa UP was 35 J. The novelty of the work is to frictionally weld the dissimilar metals of ϕ12 mm rods with Ag, Ni, Cr interlayer at welding pressures in view of safety and energy consumption. There were the changes in the microstructure and mechanical properties of joints when the interlayers, UPs changed.
Journal of New Materials For Electrochemical Systems, 2020
This study discusses the dissimilar joining between AA6063 aluminium and AISI304L stainless steel... more This study discusses the dissimilar joining between AA6063 aluminium and AISI304L stainless steel of flat faying surfaces through a rotary friction welding process at different welding conditions as per L9 orthogonal array and the characterization of bimetal joints. The effect of welding parameters on the mechanical properties and the minimum level of welding conditions required for the metals joining were discussed. Bonding between the metals and the narrow heat-affected zone were observed from microscopy study. Energy dispersive x-ray analysis revealed the elements present at the weld interface and molybdenum formation. Fractography result on the tested specimens showed the dimple rupture during the fracture. The tensile test showed the plastic deformation near the weld joint for friction pressure 15 MPa and above. The maximum peak load and elongation of joint were around 12 kN and 12% respectively. 18 MPa friction pressure, 24 MPa upset pressure and 5 sec. friction time showed go...
International Journal of Modern Studies in Mechanical Engineering
The properties of metal matrix composite can be influenced by the reinforcement particles at diff... more The properties of metal matrix composite can be influenced by the reinforcement particles at different weight fractions of the composite. In this work, the hybrid composite, which consists of Al.6061 as matrix and fly ash&SiCP as the reinforcements, was processed by stir casting technique to studythe mechanical characterization and the effect of reinforcements (fly ash, SiCP)on the prepared composite. In addition, the study on the effect of input process parameters namely Wt.% of SiC, Stirring time and Stirring speed on the tensile and compressive strength is achieved by Taguchi method for predicting the better parameters that gives the highest tensile and compressive strength to the casting.The contribution ratio is obtained using analysis of variance.
Surface Review and Letters, 2020
This paper discusses the various joining methods with faying surface modifications used to join A... more This paper discusses the various joining methods with faying surface modifications used to join AA6063 and AISI304L dissimilar alloys by Rotary Friction Welding (RFW) process at different welding conditions mainly with friction pressure (FP), upset pressure (UP) and friction time (FT). This paper also studies the tensile behavior of the welded joints. The fabricated dissimilar joints were tested using universal testing machine against tensile load, and the mechanical properties of all 30 nos. of weld joints like elongation (%), strength coefficient ([Formula: see text]), strain hardening exponent ([Formula: see text]), strain hardening rate (TS/YS ratio), shear strength, etc. were calculated from the tensile testing results and plotted here with a standard error bar. Hollomon’s equation is considered here to study the stress and strain hardening relation and Von Mises yield criterion is considered for shear and yield stress correlation. Total elongation is also calculated from the i...
Archives of materials science and engineering, 2017
The interest in aluminum alloys is on account of their attractive properties and high strength to... more The interest in aluminum alloys is on account of their attractive properties and high strength to weight ratio. In marine environments aluminum alloys especially AA2014, exhibit low corrosion resistance. Micro arc oxidation (MAO), a novel technique, has gained popularity for synthesizing ceramic coatings by electrochemical treatment using an aqueous electrolyte on aluminum, magnesium, titanium and their alloys and it can be a method of improving corrosion resistance of aluminum alloys. In this study, a stable film is produced on the substrate of AA2014 aluminum alloy by MAO in an aqueous electrolyte having chemically treated with myristic acid. Corrosion properties of these treated and untreated surfaces are evaluated in freshly prepared 3.5% NaCl solution by potentiodynamic polarization test. The electrochemical measurements showed that the MAO treatment significantly reduced the corrosion current densities (Icorr) and simultaneously enhanced the corrosion potential (Ecorr) values ...