Abstract: The nickel-manganese (Ni-Mn) alloy coating prepared
from DC electrodeposition process in sulphamate bath was studied.
The effects of process parameters, such as current density and
electrolyte composition, on the cathodic current efficiency,
microstructure, internal stress and mechanical properties were
investigated. Because of its crucial effect on the application to the
electroforming of microelectronic components, the development of
low internal stress coating with high leveling power was emphasized.
It was found that both the coating’s manganese content and the
cathodic current efficiency increased with the raise in current density.
In addition, the internal stress of the deposited coating showed
compressive nature at low current densities while changed to tensile
one at higher current densities. Moreover, the metallographic
observation, X-ray diffraction measurement, and polarization curve
measurement were conducted. It was found that the Ni-Mn coating
consisted of nano-sized columnar grains and the maximum hardness of
the coating was associated with (111) preferred orientation in the
microstructure. The grain size was refined along with the increase in
the manganese content of the coating, which accordingly, raised its
hardness and resistance to annealing softening. In summary, the
Ni-Mn coating prepared at lower current density of 1-2 A/dm2 had low
internal stress, high leveling power, and better corrosion resistance.
Abstract: Zn alloy and composite coatings are widely used in
buildings and structures, automobile and fasteners industries to
protect steel component from corrosion. In this paper, Zn-Ni-Al2O3
nanocomposite coatings were electrodeposited on mild steel using a
novel sol enhanced electroplating method. In this method, transparent
Al2O3 sol was added into the acidic Zn-Ni bath to produced Zn-Ni-
Al2O3 nanocomposite coatings. The effect of alumina sol on the
electrodeposition process, and coating properties was investigated
using cyclic voltammetry, XRD, ESEM and Tafel test. Results from
XRD tests showed that the structure of all coatings was single γ-
Ni5Zn21 phase. Cyclic voltammetry results showed that the
electrodeposition overpotential was lower in the presence of alumina
sol in the bath, and caused the reduction potential of Zn-Ni to shift to
more positive values. Zn-Ni-Al2O3 nanocomposite coatings produced
more uniform and compact deposits, with fine grained microstructure
when compared to Zn-Ni coatings. The corrosion resistance of Zn-Ni
coatings was improved significantly by incorporation of alumina
nanoparticles into the coatings.
Abstract: Machining of hard materials is a recent technology for
direct production of work-pieces. The primary challenge in
machining these materials is selection of cutting tool inserts which
facilitates an extended tool life and high-precision machining of the
component. These materials are widely for making precision parts for
the aerospace industry. Nickel-based alloys are typically used in
extreme environment applications where a combination of strength,
corrosion resistance and oxidation resistance material characteristics
are required. The present paper reports the theoretical and
experimental investigations carried out to understand the influence of
machining parameters on the response parameters. Considering the
basic machining parameters (speed, feed and depth of cut) a study has
been conducted to observe their influence on material removal rate,
surface roughness, cutting forces and corresponding tool wear.
Experiments are designed and conducted with the help of Central
Composite Rotatable Design technique. The results reveals that for a
given range of process parameters, material removal rate is favorable
for higher depths of cut and low feed rate for cutting forces. Low feed
rates and high values of rotational speeds are suitable for better finish
and higher tool life.
Abstract: Composite materials, due to their unique properties
such as high strength to weight ratio, corrosion resistance, and impact
resistance have huge potential as structural materials in automotive,
construction and transportation applications. However, these
properties often come at higher cost owing to complex design
methods, difficult manufacturing processes and raw material cost.
Traditionally, tapered laminated composite structures are
manufactured using autoclave manufacturing process by ply drop off
technique. Autoclave manufacturing though very powerful suffers
from high capital investment and higher energy consumption. As per
the current trends in composite manufacturing, Out of Autoclave
(OoA) processes are looked as emerging technologies for
manufacturing the structural composite components for aerospace
and defense applications. However, there is a need for improvement
among these processes to make them reliable and consistent. In this
paper, feasibility of using out of autoclave process to manufacture the
variable thickness cantilever beam is discussed. The minimum weight
design for the composite beam is obtained using constant stress beam
concept by tailoring the thickness of the beam. Ply drop off
techniques was used to fabricate the variable thickness beam from
glass/epoxy prepregs. Experiments were conducted to measure
bending stresses along the span of the cantilever beam at different
intervals by applying the concentrated load at the free end.
Experimental results showed that the stresses in the bean at different
intervals were constant. This proves the ability of OoA process to
manufacture the constant stress beam. Finite element model for the
constant stress beam was developed using commercial finite element
simulation software. It was observed that the simulation results
agreed very well with the experimental results and thus validated
design and manufacturing approach used.
Abstract: To develop AZ91D magnesium alloys with improved
properties, we have applied TiN and VN/TiN multilayer coatings
using DC magnetron sputter technique. Coating structure, surface
morphology, chemical bonding and corrosion resistance of coatings
were analyzed by x-ray diffraction (XRD), scanning electron
microscope (SEM), x-ray photoelectron spectroscopy (XPS), and
tafel extrapolation method, respectively. XPS analysis reveal that VN
overlayer reacts with oxygen at the VN/TiN interface and forms more
stable TiN layer. Morphological investigations and the corrosion
results show that VN/TiN multilayer thin film coatings are quite
effective to optimize the corrosion resistance of Mg alloys.
Abstract: Metal matrix composites (MMCs) attract considerable
attention as a result from its ability in providing a high strength, high
modulus, high toughness, high impact properties, improving wear
resistance and providing good corrosion resistance compared to
unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been
widely used in various industrial sectors such as in transportation,
domestic equipment, aerospace, military, construction, etc.
Aluminium silicon alloy is an MMC that had been reinforced with
aluminium nitrate (AlN) particle and become a new generation
material use in automotive and aerospace sector. The AlN is one of
the advance material that have a bright prospect in future since it has
features such as lightweight, high strength, high hardness and
stiffness quality. However, the high degree of ceramic particle
reinforcement and the irregular nature of the particles along the
matrix material that contribute to its low density is the main problem
which leads to difficulties in machining process. This paper examined
the tool wear when milling AlSi/AlN Metal Matrix Composite using
a TiB2 (Titanium diboride) coated carbide cutting tool. The volume
of the AlN reinforced particle was 10% and milling process was
carried out under dry cutting condition. The TiB2 coated carbide
insert parameters used were at the cutting speed of (230, 300 and
370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The
Sometech SV-35 video microscope system used to quantify of the
tool wear. The result shown that tool life span increasing with the
cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at
0.4mm) which constituted an optimum condition for longer tool life
lasted until 123.2 mins. Meanwhile, at medium cutting speed which
at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we
found that tool life span lasted until 119.86 mins while at low cutting
speed it lasted in 119.66 mins. High cutting speed will give the best
parameter in cutting AlSi/AlN MMCs material. The result will help
manufacturers in machining process of AlSi/AlN MMCs materials.
Abstract: Dissimilar joining of Titanium and Aluminum thin
sheets has potential applications in aerospace and automobile
industry which can reduce weight and cost and improve strength,
corrosion resistance and high temperature properties. However
successful welding of Titanium/Aluminium sheets is of challenge due
to differences in physical, chemical and metallurgical properties
between the two. This paper describes research results of Laser Beam
Welding (LBW) of Ti/Al thin sheets in which many researchers have
recently performed and critically reviewed from different
perspectives. Also some of notable works in the field of laser welding
with changes in mechanical properties, crack propagation, diffusion
behavior, chemical potential, interfacial reaction and the
microstructure are reported.
Abstract: The hydrogenated amorphous carbon films (α-C:H)
were deposited on p-type Si (100) substrates at different thicknesses by
radio frequency plasma enhanced chemical vapor deposition
technique (rf-PECVD). Raman spectra display asymmetric
diamond-like carbon (DLC) peaks, representative of the α-C:H films.
The decrease of intensity ID/IG ratios revealed the sp3 content arise at
different thicknesses of the α-C:H films. In terms of mechanical
properties, the high hardness and elastic modulus values showed the
elastic and plastic deformation behaviors related to sp3 content in
amorphous carbon films. Electrochemical properties showed that the
α-C:H films exhibited excellent corrosion resistance in air-saturated
3.5 wt.% NaCl solution for pH 2 at room temperature. Thickness
increasing affected the small sp2 clusters in matrix, restricting the
velocity transfer and exchange of electrons. The deposited α-C:H films
exhibited excellent mechanical properties and corrosion resistance.
Abstract: Al-Si-Mg-Ni(-Cu) alloys are widely used in the automotive industry. They have the advantage of low weight associated with low coefficient of thermal expansion and excellent mechanical properties – mainly at high temperatures. The corrosion resistance of these alloys in coastal area, particularly sea water, however is not yet known. In this investigation, electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization have been used to evaluate the corrosion resistance of Al-6Si-0.5Mg-2Ni (-2Cu) alloys in simulated sea water environments. The potentiodynamic polarization curves reveal that 2 wt% Cu content alloy (Alloy-2) is more prone to corrosion than the Cu free alloy (Alloy-1). But the EIS test results showed that corrosion resistance or charge transfer resistance (Rct) increases with the addition of Cu. Due to addition of Cu and thermal treatment, the magnitude of open circuit potential (OCP), corrosion potential (Ecorr) and pitting corrosion potential (Epit) of Al-6Si-0.5Mg-2Ni alloy in NaCl solution were shifted to the more noble direction.
Abstract: Biometallic materials are the most important materials for use in biomedical applications especially in manufacturing a variety of biological artificial replacements in a modern worlds, e.g. hip, knee or shoulder joints, due to their advanced characteristics. Titanium (Ti) and its alloys are used extensively in biomedical applications based on their high specific strength and excellent corrosion resistance. Beta-Ti alloys containing completely biocompatible elements are exceptionally prospective materials for manufacturing of bioimplants. They have superior mechanical, chemical and electrochemical properties for use as biomaterials. These biomaterials have the ability to introduce the most important property of biochemical compatibility which is low elastic modulus. This review examines current information on the recent developments in alloying elements leading to improvements of beta Ti alloys for use as biomaterials. Moreover, this paper focuses mainly on the evolution, evaluation and development of the modulus of elasticity as an effective factor on the performance of beta alloys.
Abstract: This research studies the electroplating of zinc coating
in the zinc chloride bath mixed with supercritical CO2. The sodium
fluoride (NaF) was used as the bath additive to change the structure
and property of the coating, and therefore the roughness and corrosion
resistance of the zinc coating was investigated. The surface
characterization was performed using optical microscope (OM), X-ray
diffractometer (XRD), and α-step profilometer. Moreover, the
potentiodynamic polarization measurement in 3% NaCl solution was
employed in the corrosion resistance evaluation. Because of the
emulsification of the electrolyte mixed in Sc-CO2, the electroplated
zinc produced the coating with smoother surface, smaller grain, better
throwing power and higher corrosion resistance. The main role played
by the NaF was to reduce the coating’s roughness and grain size. In
other words, the CO2 mixed with the electrolyte under the supercritical
condition performed the similar function as brighter and leveler in zinc
electroplating to enhance the throwing power and corrosion resistance
of the coating.
Abstract: Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Abstract: In this study, a plasma electrolytic oxidation (PEO) process was used to form titanium-aluminum oxide coating on aluminized steel. The present work was mainly to study the effects of treatment time of PEO process on properties of the titanium coating. A potentiodynamic polarization corrosion test was employed to investigate the corrosion resistance of the coating. The friction coefficient and wear resistance of the coating were studied by using pin-on-disc test. The thermal transfer behaviors of uncoated and PEO-coated aluminized steels were also studied. It could be seen that treatment time of PEO process significantly influenced the properties of the titanium oxide coating. Samples with a longer treatment time had a better performance for corrosion and wear protection. This paper demonstrated different treatment time could alter the surface behavior of the coating material.
Abstract: In the present study, two TRIP-assisted steels were designated as A (having no Cr and Cu content) and B (having higher Ni, Cr and Cu content) heat treated under different conditions, and the correlation between its heat treatment, microstructure and properties were investigated. Micro structural examination was carried out by optical microscope and scanning electron microscope after electrolytic etching. Non-destructive electrochemical and ultrasonic testing on two TRIP-assisted steels was used to find out corrosion and mechanical properties of different alter microstructure phase’s steels. Furthermore, micro structural studies accompanied by the evaluation of mechanical properties revealed that steels having martensite phases with higher corrosive and hardness value were less sound velocity and also steel’s microstructure having finer grains that was more grain boundary was less corrosion resistance. Steel containing more Cu, Ni and Cr was less corrosive compared to other steels having same processing or microstructure.
Abstract: Magnesium wastes are produced by many industrial activities. This waste problem is becoming a future problem for the world. Magnesium borates have many advantages such as; high corrosion resistance, heat resistance, high coefficient of elasticity and can also be used in the production of material against radiation. Addition, magnesium borates have great potential in sectors
including ceramic and detergents industry and superconducting materials.
In this study, using the starting materials of waste magnesium and H3BO3 the hydrothermal method was applied at a moderate
temperature of 70oC. Several mole ratios of waste magnesium to H3BO3 are selected as; 1:2, 1:4, 1:6, 1:8, 1:10. Reaction time was determined as 1 hour. After the synthesis, X-Ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FT-IR) techniques are applied to products. As a result the forms of mcallisterite “Mg2(B6O7(OH)6)2.9(H2O)”, admontite “MgO(B2O3)3.7(H2O)” and magnesium boron hydrate (MgO(B2O3)3.6(H2O)” are obtained.
Abstract: Polymer-like organic thin films were deposited on both
aluminum alloy type 6061 and glass substrates at room temperature by
Plasma Enhanced Chemical Vapor Deposition (PECVD) methodusing
benzene and hexamethyldisiloxane (HMDSO) as precursor materials.
The surface and physical properties of plasma-polymerized organic
thin films were investigated at different r.f. powers. The effects of
benzene/argon ratio on the properties of plasma polymerized benzene
films were also investigated. It is found that using benzene alone
results in a non-coherent and non-adherent powdery deposited
material. The chemical structure and surface properties of the asgrown
plasma polymerized thin films were analyzed on glass
substrates with FTIR and contact angle measurements. FTIR spectra
of benzene deposited film indicated that the benzene rings are
preserved when increasing benzene ratio and/or decreasing r.f.
powers. FTIR spectra of HMDSO deposited films indicated an
increase of the hydrogen concentration and a decrease of the oxygen
concentration with the increase of r.f. power. The contact angle (θ) of
the films prepared from benzene was found to increase by about 43%
as benzene ratio increases from 10% to 20%. θ was then found to
decrease to the original value (51°) when the benzene ratio increases
to 100%. The contact angle, θ, for both benzene and HMDSO
deposited films were found to increase with r.f. power. This signifies
that the plasma polymerized organic films have substantially low
surface energy as the r.f power increases. The corrosion resistance of
aluminum alloy substrate both bare and covered with plasma
polymerized thin films was carried out by potentiodynamic
polarization measurements in standard 3.5 wt. % NaCl solution at
room temperature. The results indicate that the benzene and HMDSO
deposited films are suitable for protection of the aluminum substrate
against corrosion. The changes in the processing parameters seem to
have a strong influence on the film protective ability. Surface
roughness of films deposited on aluminum alloy substrate was
investigated using scanning electron microscopy (SEM). The SEM
images indicate that the surface roughness of benzene deposited films
increase with decreasing the benzene ratio. SEM images of benzene
and HMDSO deposited films indicate that the surface roughness
decreases with increasing r.f. power. Studying the above parameters
indicate that the films produced are suitable for specific practical
applications.
Abstract: Waste problem is becoming a future problem all over the world. Magnesium wastes which can be used in recycling processes are produced by many industrial activities. Magnesium borates which have useful properties such as; high heat resistance, corrosion resistance, supermechanical strength, superinsulation, light weight, high coefficient of elasticity and so on. Addition, magnesium borates have great potential in the development of ceramic and detergents industry, whisker-reinforced composites, antiwear, and reducing friction additives.
In this study, using the starting materials of waste magnesium and H3BO3 the hydrothermal method was applied at a moderate temperature of 70oC with different reaction times. Several reaction times of waste magnesium to H3BO3 were selected as; 30, 60, 120, 240 minutes. After the synthesis, X-Ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FT-IR) techniques were applied to products. As a result, the forms of Admontite [MgO(B2O3)3.7(H2O)] and Mcallisterite [Mg2(B6O7(OH)6)2.9(H2O)] were synthesized.
Abstract: Titanium oxide films with different morphologies have for the first time been fabricated through hydrothermal reactions between a titanium substrate and iodine powder in water or ethanol. SEM revealed that iodine supported titanium (Ti-I2) surface shows different morphologies with variable treatment conditions. The mean surface roughness (Ra) was increased in the different groups. Use of surfactant has a role to increase the roughness of the film. The surface roughness was in the range of 0.15 μm-0.42 μm. Furthermore, the electrochemical examinations showed that the Ti-I2 surface fabricated in alcoholic medium has high corrosion resistance than in aqueous medium.
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: The localized corrosion behavior of laser surface
melted 304L austenitic stainless steel was studied by
potentiodynamic polarization test. The extent of improvement in
corrosion resistance was governed by the preferred orientation and
the percentage of delta ferrite present on the surface of the laser
melted sample. It was established by orientation imaging microscopy
that the highest pitting potential value was obtained when grains were
oriented in the most close- packed [101] direction compared to the
random distribution of the base metal and other laser surface melted
samples oriented in [001] direction. The sample with lower
percentage of ferrite had good pitting resistance.