Abstract: Metal matrix composites have been increasingly used
as materials for components in automotive and aerospace industries
because of their improved properties compared with non-reinforced
alloys. During machining the selection of appropriate machining
parameters to produce job for desired surface roughness is of great
concern considering the economy of manufacturing process. In this
study, a surface roughness prediction model using fuzzy logic is
developed for end milling of Al-SiCp metal matrix composite
component using carbide end mill cutter. The surface roughness is
modeled as a function of spindle speed (N), feed rate (f), depth of cut
(d) and the SiCp percentage (S). The predicted values surface
roughness is compared with experimental result. The model predicts
average percentage error as 4.56% and mean square error as 0.0729.
It is observed that surface roughness is most influenced by feed rate,
spindle speed and SiC percentage. Depth of cut has least influence.
Abstract: Ti-6Al-4V alloy has demonstrated a high strength to
weight ratio as well as good properties at high temperature. The
successful application of the alloy in some important areas depends
on suitable joining techniques. Friction welding has many
advantageous features to be chosen for joining Titanium alloys. The
present work investigates the feasibility of producing similar metal
joints of this Titanium alloy by rotary friction welding method. The
joints are produced at three different speeds and the performances of
the welded joints are evaluated by conducting microstructure studies,
Vickers Hardness and tensile tests at the joints. It is found that the
weld joints produced are sound and the ductile fractures in the tensile
weld specimens occur at locations away from the welded joints. It is
also found that a rotational speed of 1500 RPM can produce a very
good weld, with other parameters kept constant.
Abstract: In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis such as SEM, EDS and wet chemical analysis has been made in the Babbitt alloys and worn surfaces. Two type of babbitt materials: tinbase and lead-base babbitt was used. The benefits of thermally sprayed babbitt layers are completely clear especially in large bearings.
Abstract: Through a proper analysis of residual strain and stress
distributions obtained at the surface of high speed milled specimens
of AA 6082–T6 aluminium alloy, the performance of an improved
indentation method is evaluated. This method integrates a special
device of indentation to a universal measuring machine. The
mentioned device allows introducing elongated indents allowing to
diminish the absolute error of measurement. It must be noted that the
present method offers the great advantage of avoiding both the
specific equipment and highly qualified personnel, and their inherent
high costs. In this work, the cutting tool geometry and high speed
parameters are selected to introduce reduced plastic damage.
Through the variation of the depth of cut, the stability of the shapes
adopted by the residual strain and stress distributions is evaluated.
The results show that the strain and stress distributions remain
unchanged, compressive and small. Moreover, these distributions
reveal a similar asymmetry when the gradients corresponding to
conventional and climb cutting zones are compared.
Abstract: This study was aimed for investigating of
manufacturing high aluminum content Mg alloys using a horizontal
twin roll caster. Recently, weight saving has been key issues for lighter
transport equipments as well as electronic component parts. As
alternative materials to aluminum alloys, developing magnesium alloy
with higher strength has been expected. Normally high Aluminum
content Mg alloy has poor ductility and is difficult to be rolled because
of its high strength. However, twin roll casting process is suitable for
manufacturing wrought Mg alloys because materials can be cast
directly from molten metal. In this study, manufacturing of high
aluminum content magnesium alloy sheet using the roll casting
process has been carried out. Effects of manufacturing parameter, such
as roll velocity, pouring temperature and roll gap, on casting was
investigated. A microscopic observation of the crystals of cross section
of as cast strip as well as rolled strip was conducted.
Abstract: Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.
Abstract: In this study, we used shape memory alloys as
actuators to build a biomorphic robot which can imitate the motion of
an earthworm. The robot can be used to explore in a narrow space.
Therefore we chose shape memory alloys as actuators. Because of the
small deformation of a wire shape memory alloy, spiral shape memory
alloys are selected and installed both on the X axis and Y axis (each
axis having two shape memory alloys) to enable the biomorphic robot
to do reciprocating motion. By the mechanism we designed, the robot
can increase the distance as it moves in a duty cycle. In addition, two
shape memory alloys are added to the robot head for controlling right
and left turns. By sending pulses through the I/O card from the
controller, the signals are then amplified by a driver to heat the shape
memory alloys in order to make the SMA shrink to pull the mechanism
to move.
Abstract: The present article deals with a composite casting process that allows to produce bilayer AlSn6-Al strips based on the technique of horizontal continuous casting. In the first part experimental investigations on the production of a single layer AlSn6 strip are described. Afterwards essential results of basic compound casting trials using simple test specimen are presented to define the thermal conditions required for a metallurgical compound between the alloy AlSn6 and pure aluminium. Subsequently, numerical analyses are described. A finite element model was used to examine a continuous composite casting process. As a result of the simulations the main influencing parameters concerning the thermal conditions within the composite casting region could be pointed out. Finally, basic guidance is given for the design of an appropriate composite mould system.
Abstract: Magnesium alloy has been widely investigated as
biodegradable cardiovascular stent and bone implant. Its application
for biodegradable esophageal stenting remains unexplored. This
paper reports the biodegradation behaviors of AZ31 magnesium alloy
in artificial saliva and various types of beverage in vitro. Results
show that the magnesium ion release rate of AZ31 in artificial saliva
for a stent (2cm diameter, 10cm length at 50% stent surface
coverage) is 43 times lower than the daily allowance of human body
magnesium intakes. The degradation rates of AZ31 in different
beverages could also be significantly different. These results suggest
that the esophagus in nature is a less aggressive chemical
environment for degradation of magnesium alloys. The significant
difference in degradation rates of AZ31 in different beverages opens
new opportunities for development of degradation controllable
esophageal stent through customizing ingested beverages.
Abstract: Quaternary InxAlyGa1-x-yN semiconductors have
attracted much research interest because the use of this quaternary
offer the great flexibility in tailoring their band gap profile while
maintaining their lattice-matching and structural integrity. The
structural and optical properties of InxAlyGa1-x-yN alloys grown by
molecular beam epitaxy (MBE) is presented. The structural quality of
InxAlyGa1-x-yN layers was characterized using high-resolution X-ray
diffraction (HRXRD). The results confirm that the InxAlyGa1-x-yN
films had wurtzite structure and without phase separation. As the In
composition increases, the Bragg angle of the (0002) InxAlyGa1-x-yN
peak gradually decreases, indicating the increase in the lattice constant
c of the alloys. FWHM of (0002) InxAlyGa1-x-yN decreases with
increasing In composition from 0 to 0.04, that could indicate the
decrease of quality of the samples due to point defects leading to
non-uniformity of the epilayers. UV-VIS spectroscopy have been used
to study the energy band gap of InxAlyGa1-x-yN. As the indium (In)
compositions increases, the energy band gap decreases. However, for
InxAlyGa1-x-yN with In composition of 0.1, the band gap shows a
sudden increase in energy. This is probably due to local alloy
compositional fluctuations in the epilayer. The bowing parameter
which appears also to be very sensitive on In content is investigated
and obtained b = 50.08 for quaternary InxAlyGa1-x-yN alloys. From
photoluminescence (PL) measurement, green luminescence (GL)
appears at PL spectrum of InxAlyGa1-x-yN, emitted for all x at ~530 nm
and it become more pronounced as the In composition (x) increased,
which is believed cause by gallium vacancies and related to isolated
native defects.
Abstract: The fabrication of porous NiTi shape memory alloys (SMAs) from elemental powder compacts was conducted by selfpropagating high temperature synthesis (SHS). Effects of the preheating temperature and the chamber pressure on the combustion characteristics as well as the final morphology and the composition of products were studied. The samples with porosity between 56.4 and 59.0% under preheating temperature in the range of 200-300°C and Ar-gas chamber pressure of 138 and 201 kPa were obtained. The pore structures were found to be dissimilar only in the samples processed with different preheating temperature. The major phase in the porous product is NiTi with small amounts of secondary phases, NiTi2 and Ni4Ti3. The preheating temperature and the chamber pressure have very little effect on the phase constituent. While the combustion temperature of the sample was notably increased by increasing the preheating temperature, they were slightly changed by varying the chamber pressure.
Abstract: Greenhouse gases (GHG) emissions impose major
threat to global warming potential (GWP). Unfortunately
manufacturing sector is one of the major sources that contribute
towards the rapid increase in greenhouse gases (GHG) emissions. In
manufacturing sector electric power consumption is the major driver
that influences CO2 emission. Titanium alloys are widely utilized in
aerospace, automotive and petrochemical sectors because of their
high strength to weight ratio and corrosion resistance. Titanium
alloys are termed as difficult to cut materials because of their poor
machinability rating. The present study analyzes energy consumption
during cutting with reference to material removal rate (MRR).
Surface roughness was also measured in order to optimize energy
consumption.
Abstract: Equal Channel Angular Pressing (ECAP) is currently
being widely investigated because of its potential to produce ultrafine
grained microstructures in metals and alloys. A sound
knowledge of the plastic deformation and strain distribution is
necessary for understanding the relationships between strain
inhomogeneity and die geometry. Considerable research has been
reported on finite element analysis of this process, assuming threedimensional
plane strain condition. However, the two-dimensional
models are not suitable due to the geometry of the dies, especially in
cylindrical ones. In the present work, three-dimensional simulation of
ECAP process was carried out for six outer corner radii (sharp to 10
mm in steps of 2 mm), with channel angle 105¶Çü▒, for strain hardening
aluminium alloy (AA 6101) using ABAQUS/Standard software.
Strain inhomogeneity is presented and discussed for all cases. Pattern
of strain variation along selected radial lines in the body of the workpiece
is presented. It is found from the results that the outer corner
has a significant influence on the strain distribution in the body of
work-piece. Based on inhomogeneity and average strain criteria,
there is an optimum outer corner radius.
Abstract: This study reports the preparation of soft magnetic
ribbons of Fe-based amorphous alloys using the single-roller melt-spinning technique. Ribbon width varied from 142 mm to 213
mm and, with a thickness of approximately 22 μm ± 2 μm. The microstructure and magnetic properties of the ribbons were
characterized by differential scanning calorimeter (DSC), X-ray diffraction (XRD), vibrating sample magnetometer (VSM), and electrical resistivity measurements (ERM). The amorphous material
properties dependence of the cooling rate and nozzle pressure have uneven surface in ribbon thicknesses are investigated. Magnetic
measurement results indicate that some region of the ribbon exhibits good magnetic properties, higher saturation induction and lower coercivity. However, due to the uneven surface of 213 mm wide
ribbon, the magnetic responses are not uniformly distributed. To
understand the transformer magnetic performances, this study analyzes the measurements of a three-phase 2 MVA amorphous-cored transformer. Experimental results confirm that the transformer with a
ribbon width of 142 mm has better magnetic properties in terms of lower core loss, exciting power, and audible noise.
Abstract: In this paper, the effect of bolt clamping force on the fatigue behavior of bolted single lap joints of aluminum alloy 2024- T3 have been studied using numerical finite element method. To do so, a three dimensional model according to the bolted single lap joint has been created and numerical analysis has been carried out using finite element based package. Then the stress distribution and also the slip amplitudes have been calculated in the critical regions and the outcome have been compared with the available experimental fatigue tests results. The numerical results show that in low applied clamping force, the fatigue failure of the specimens occur around the stress concentration location (the bolted hole edge) due to the tensile stresses and thus fatigue crack propagation, but with increase of the clamping force, the fatigue life increases and the cracks nucleate and propagate far from the hole edge because of fretting fatigue. In other words, with the further increase of clamping force value of the joint, the fatigue life reduces due to occurrence of the fretting fatigue in the critical location where the slip amplitude is within its critical occurs earlier.
Abstract: The psychological and physical trauma associated with the loss of a human limb can severely impact on the quality of life of an amputee rendering even the most basic of tasks very difficult. A prosthetic device can be of great benefit to the amputee in the performance of everyday human tasks. This paper outlines a proposed mechanical design of a 12 degree-of-freedom SMA actuated artificial hand. It is proposed that the SMA wires be embedded intrinsically within the hand structure which will allow for significant flexibility for use either as a prosthetic hand solution, or as part of a complete lower arm prosthetic solution. A modular approach is taken in the design facilitating ease of manufacture and assembly, and more importantly, also allows the end user to easily replace SMA wires in the event of failure. A biomimetric approach has been taken during the design process meaning that the artificial hand should replicate that of a human hand as far as is possible with due regard to functional requirements. The proposed design has been exposed to appropriate loading through the use of finite element analysis (FEA) to ensure that it is structurally sound. Theoretical analysis of the mechanical framework was also carried out to establish the limits of the angular displacement and velocity of the finger tip as well finger tip force generation. A combination of various polymers and Titanium, which are suitably lightweight, are proposed for the manufacture of the design.
Abstract: Laser beam forming is a novel technique developed for the joining of metallic components. In this study, an overview of the laser beam forming process, areas of application, the basic mechanisms of the laser beam forming process, some recent research
studies and the need to focus more research effort on improving the
laser-material interaction of laser beam forming of titanium and its
alloys are presented.
Abstract: The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.
Abstract: The hot deformation behavior of high strength low
alloy (HSLA) steels with different chemical compositions under hot
working conditions in the temperature range of 900 to 1100℃ and
strain rate range from 0.1 to 10 s-1 has been studied by performing a
series of hot compression tests. The dynamic materials model has been
employed for developing the processing maps, which show variation
of the efficiency of power dissipation with temperature and strain rate.
Also the Kumar-s model has been used for developing the instability
map, which shows variation of the instability for plastic deformation
with temperature and strain rate. The efficiency of power dissipation
increased with decreasing strain rate and increasing temperature in the
steel with higher Cr and Ti content. High efficiency of power
dissipation over 20 % was obtained at a finite strain level of 0.1 under
the conditions of strain rate lower than 1 s-1 and temperature higher
than 1050 ℃ . Plastic instability was expected in the regime of
temperatures lower than 1000 ℃ and strain rate lower than 0.3 s-1. Steel
with lower Cr and Ti contents showed high efficiency of power
dissipation at higher strain rate and lower temperature conditions.
Abstract: Manganese steel (Hadfield) is one of the important
alloys in industry due to its special properties. High work hardening
ability with appropriate toughness and ductility are the properties that
caused this alloy to be used in wear resistance parts and in high
strength condition. Heat treatment is the main process through which
the desired mechanical properties and microstructures are obtained in
Hadfield steel. In this study various heat treatment cycles, differing in
austenising temperature, time and quenching solution are applied. For
this purpose, the same samples of manganese steel was heat treated in
9 different cycles, and then the mechanical properties and
microstructures were investigated. Based on the results of the study,
the optimum heat treatment cycle was obtained.