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10. 1. Effect of Pin Profile on Microstructure and Mechanical Properties of Friction Stir Welded
AZ31B Magnesium Alloy
Piyush Gulati, Dinesh Kumar Shukla 1
2. Effect of Pulse Current Micro Plasma Arc Welding Parameters on Pitting Corrosion Rate of
AISI 316Ti Sheets in 3.5 N NaCl Medium
Kondapalli Siva Prasad 12
3. Recovery of Iron Values from Waste Iron Ore Slime
Jyolsna Jerin, Rajendra Kumar Rath, Anil Kumar 25
4. Recovery of Iron Values from Iron Ore Slimes using Reagents
Rajesh Chintala, R.K. Rath, Anil Kumar 32
5. Solidification Curve Analysis of Cylindrical Casting by FEM
Dharmesh Barodiya, M.D. Mahajan, Shaheen Beg Mughal 44
ContentsJournal of Materials Metallurgical Engineering

11. JoMME (2016) 1-11 © STM Journals 2016. All Rights Reserved Page 1
Journal of Materials Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print)
Volume 6, Issue 3
www.stmjournals.com
Effect of Pin Profile on Microstructure and Mechanical
Properties of Friction Stir Welded AZ31B Magnesium
Alloy
Piyush Gulati1,2,
*, Dinesh Kumar Shukla1
1
Department of Mechanical Engineering, Dr. B.R. Ambedkar National Institute of Technology,
Jalandhar, Punjab, India
2
School of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab, India
Abstract
Friction Stir Welding (FSW) is a solid state welding technique which was developed primarily
for joining soft metal alloys. The aim of the present work was to develop a defect free friction
stir joint of magnesium AZ31B sheets and to investigate the microstructural and mechanical
properties of the weld. Two types of tool pins namely cylindrical and truncated conical pin
profiled tools have been used to analyze its effect on the weld quality. Mechanical properties
of different zones were determined by Vickers hardness test and Impact energy absorption
test. Microstructure of the welded specimens was analyzed and mean grain size and grain
number were measured.
Keywords: Friction stir welding, grain size, mechanical properties, microstructure
INTRODUCTION
The main concern of automobile and aero
engine industry is to use lightweight materials
which would lead to increased efficiency, fuel
savings and reduction in emissions. This leads
to considerable attention on materials like
Aluminum and Magnesium.
Magnesium and its alloys are the lightest of all
metal alloys, one third in weight in
comparison to aluminum alloys, and also
possess good mechanical properties such as
high strength and stiffness and also good
machinability, therefore, is an excellent choice
for engineering applications when weight is a
critical design element [1–3]. However,
joining of magnesium alloys is a big
challenge, if done by conventional methods
such as GTAW, as it leads to defects like hot
cracks and porosity deteriorating joint’s
mechanical properties. These defects produced
by fusion welding processes can be overcome
by solid state joining processes [4–6].
Friction Stir welding (FSW) is a solid state
welding technique, which is capable of
producing defect free joints especially low
melting materials [7–9]. In FSW, a solid
rotating tool, harder than the workpiece, is
used to permanently join the plates. The tool
consisting of a shoulder and a pin is plunged at
a constant rotational speed and feed into the
joint line between two butted pieces of plate
material which are rigidly clamped and is
moved longitudinally at a constant welding
speed. The combined rotating and plunging
action of tool pin and shoulder produces
severe plastic deformation due to frictional
heat and hence produces a strong metallurgical
joint. The material flows in a stirring motion,
thereby elongating the grains and producing a
refined grain structure, which effectively
responds to this technique to improve the
strength and mechanical properties. Another
variant of Friction stir welding is Friction Stir
processing (FSP) is used to localized
refinement of grains by modifying material’s
microstructure [10]. Many researchers have
worked in the area of FSP studying the
thermo-mechanical process [11–17].
In Friction stir welding, tool parameters such
as tool pin profile, shoulder diameter; pin
diameter and process parameters such as
rotational speed, welding speed and plunge
depth play a major role in producing defect

12. JoMME (2016) 12-24 © STM Journals 2016. All Rights Reserved Page 12
Journal of Materials Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print)
Volume 6, Issue 3
www.stmjournals.com
Effect of Pulse Current Micro Plasma Arc Welding
Parameters on Pitting Corrosion Rate of AISI 316Ti
Sheets in 3.5 N NaCl Medium
Kondapalli Siva Prasad*
Department of Mechanical Engineering, Anil Neerukonda Institute of Technology and Sciences,
Visakhapatnam, Andhra Pradesh, India
Abstract
Austenitic stainless steel sheets are used for fabrication of components, which require high
temperature resistance and corrosion resistance such as metal bellows used in expansion
joints in aircraft, aerospace and petroleum industries. When they are exposed to seawater
after welding they are subjected to corrosion as there are changes in properties of the base
metal after welding. The corrosion rate depends on the chemical composition of the base
metal and the nature of welding process adopted. Corrosion resistance of welded joints can be
improved by controlling the process parameters of the welding process. In the present work
Pulsed Current Micro Plasma Arc Welding (MPAW) is carried out on AISI 316Ti austenitic
stainless steel of 0.3 mm thick. Peak current, Base current, Pulse rate and Pulse width are
chosen as the input parameters and pitting corrosion rate of weldment in 3.5 N NaCl solution
is considered as output response. Pitting corrosion rate is computed using Linear Polarization
method from Tafel plots. Response Surface Method (RSM) is adopted by using Box-Behnken
Design and total 27 experiments are performed. Empirical relation between input and output
response is developed using statistical software and its adequacy is checked using Analysis of
Variance (ANOVA) at 95% confidence level. The main effect and interaction effect of input
parameters on output response are also studied.
Keywords: Plasma arc welding, austenitic stainless steel, pitting corrosion rate
INTRODUCTION
Austenitic Stainless Steel (ASS), being the
widest in use of all the stainless steel groups
finds application in the beverages industry,
petrochemical, petroleum, food processing and
textile industries amongst others. It has good
tensile strength, impact resistance and wear
resistance properties. In addition, it combines
these with excellent corrosion resistant
properties [1]. Welding is one of the most
employed methods of fabricating ASS
components. ASS is largely highly weldable;
the higher the carbon content, the harder the
SS and so the more difficult it is to weld. The
problem commonly encountered in welded
ASS joints is intergranular corrosion, pitting
and crevice corrosion in severe corrosion
environments. Weld metals of ASS may
undergo precipitation of (CrFe)23C6 at the
grain boundaries, thus depleting Cr and
making the SS weldment to be preferentially
susceptible to corrosion at the grain
boundaries. There may also be the
precipitation of the brittle sigma Fe-Cr phase
in their microstructure if they are exposed to
high temperatures for a certain length of time
as experienced during welding. High heat
input welding invariably leads to slow cooling.
During this slow cooling time, the temperature
range of 700–850°C stretches in time and with
it the greater formation of the sigma phase [2].
In Pulsed current MPAW process, the
interfuse of metals was produced by heating
them with an arc using a nonconsumable
electrode. It is widely used welding process
finds applications in welding hard to weld
metals such as aluminium, stainless steel,
magnesium and titanium [3]. The increased
use of automated welding urges the welding
procedures and selection of welding
parameters must be more specific for good
weld quality and precision with minimum cost
[4]. The bead geometry plays an important

13. JoMME (2016) 25-31 © STM Journals 2016. All Rights Reserved Page 25
Journal of Materials Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print)
Volume 6, Issue 3
www.stmjournals.com
Recovery of Iron Values from Waste Iron Ore Slime
Jyolsna Jerin1
, Rajendra Kumar Rath2
, Anil Kumar1,
*
1
National Institute of Foundry and Forge Technology, Ranchi, Jharkhand, India
2
CSIR-National Metallurgical Laboratory, Jamshedpur, Jharkhand, India
Abstract
Iron ore slime is a waste material generated after beneficiation of iron ores. Due to limited
iron ore resources and fast depleting of high-grade iron ore, iron ore producers are
emphasizing on recovery of iron values from iron ore slime. Different beneficiation techniques
such as hydrocyclone, Wet High Intensity Magnetic Separator (WHIMS), Dispersion-
flocculation, and Flotation are some options to recover the lost iron value from the waste. In
the present work, an attempt has been made, to beneficiate iron ore slime using Hydrocyclone,
WHIMS and dispersion-flocculation. Iron ore slime (-150 μm) was obtained after scrubbing
and wet screening of a low-grade iron ore assayed 42.7% Fe with 12.5% Al2O3 and 13.68%
SiO2. Size analysis revealed that 90% of the iron ore slime was having size less than 72 μm.
The isoelectric point of the iron ore slime was found to be at pH 4.21. The optimum condition
was applied for Hydrocyclone to obtain maximum recovery, i.e., 89.2%. The cyclone
underflow was enriched to 54.8% Fe with 45% recovery using WHIMS at current intensity of
2 Amp. Dispersion-flocculation could upgrade up to 47% Fe only. The nonmagnetic fraction
of WHIMS was upgraded from 37 to ~39% Fe using dispersion-flocculation under the
optimized condition.
Keywords: Iron ore slime, recovery, Hydrocyclone, WHIMS and dispersion-flocculation
INTRODUCTION
World steel production is increasing steadily
over the years leading to increase in the
requirement of iron ore. According to
information published in the Indian Mineral
Yearbook, 2011–2012, the total iron ore
resource of the country is estimated to be
around 28.52 billion tonnes. This excludes
Banded Hematite Jasper (BHJ) and Banded
Hematite Quartzite (BHQ) deposits [1]. The
main iron ore deposits in India occur in the
eastern, central, and southern parts, for
example, Jharkhand, Orissa, Karnataka,
Chhattisgarh, and Goa. Generation of iron ore
slimes in India is estimated to be 10–25% by
weight of the total iron ore mined [1–4].
The iron ore values are lost to the tune of 15–
20 million tones every year. These slimes are
readily available in finer size typically
assaying 55–60% Fe [3]. These slimes are
dumped in the tailing ponds in the mine area
and cause environmental concern. Iron ore
slime is a waste generated after beneficiation
of iron ores. Due to limited iron ore resources
and depleting high-grade iron ore, iron ore
producers are emphasizing on recovery of iron
values from iron ore slimes. Generally,
physical beneficiation techniques such as
gravity, magnetic, flotation and selective-
flocculation for enriching the iron values from
slimes are employed.
Rath et al. studied dispersion-flocculation
experiments on individual samples of
hematite, quartz and kaolinite as a function of
different process parameters such as pH,
flocculation time and dosages of reagents.
They could find out a condition for selective
separation of hematite from quartz and
kaolinite and applied to ternary synthetic
mineral system [5].
Thella et al. conducted beneficiation on iron
ore slime using desliming and flotation. The
slime assayed 51% Fe. Classification of slimes
with two stage Hydrocyclone gives a
concentrate containing 61.99% Fe with Fe
recovery of 54.55% in Stage I. Concentrate
from Stage II Hydrocyclone contains 62.19%
Fe with Fe recovery of 47.45% with respect to
initial feed [6]. Manna et al. conducted

14. JoMME (2016) 32-43 © STM Journals 2016. All Rights Reserved Page 32
Journal of Materials Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print)
Volume 6, Issue 3
www.stmjournals.com
Recovery of Iron Values from Iron Ore Slimes using
Reagents
Rajesh Chintala1
, R.K. Rath2
, Anil Kumar1
1
National Institute of Foundry and Forge Technology, Hatia, Ranchi, Jharkhand, India
2
CSIR-National Metallurgical Laboratory, Jamshedpur, Jharkhand, India
Abstract
Mining wastes include waste generated during the extraction, beneficiation or processing of
minerals like iron ore fines, slimes and tailings. Approximately 10–20% of the raw material is
discarded as slimes in to slime ponds/tailing dams. Recovery of iron values from slimes result
in economic benefit by utilization of waste as a resource and minimizes the threat to the
environment. The iron ore slime is generally considered as waste due to its ultrafine nature
and its processing limitations. The chemical analysis of the present iron ore slime is 34.75%
Fe with 21.94% SiO2, and 14.4% Al2O3. This research work presents the route to size
enlargement of slime using reagents and enrichment of iron values by various beneficiation
techniques for the effective utilization of iron ore slime. Screen analysis revealed that 90% of
the particles are smaller than 80.15 µm. In the present investigation, the recovery of lost iron
values from iron ore slime waste was attempted using different beneficiation techniques like
Enhanced gravity separation (EGS) Falcon concentrator, Gravity separation by Mineral
separator and Vanner, and selective flocculation after treatment with various reagents.
Mineral separator generated a concentrate assaying 46.3% Fe with 56.2% recovery using
polyacrylamide flocculant at 90 sec collection time and similarly Vanner produced a
concentrate assaying 54.5% Fe with a recovery of 41.6% using CMC. From selective
flocculation studies, a concentrate assaying 45.3% Fe with 42.1 yield % was obtained using
modified corn starch at a settling time of 5 min, as starch facilitates the selective adsorption
on iron particles, which in turn leads to enhancement in selectivity and recovery.
Keywords: Iron ore slime, Tailing dams, Gravity, Enhanced gravity separator, Reagent
INTRODUCTION
India is bestowed with large and rich sources
of iron ore in terms of quantity and quality.
India occupies sixth position in iron ore
resource base and ranks fourth with respect to
world iron ore production [1]. The existing
reserves of hematite (averaging around 63%
Fe) are the only source of iron ore and as such,
these reserves may not last beyond 25–30
years at the present rate of consumption.
Hence, to meet the future and projected
requirement, additional domestic resources
like slimes and fines dumped elsewhere in
mines have to be utilized, which are available
in abundance [2]. In India most of the washing
plants located in mines generates lumps as
well as fines. During this process, a large
quantity about 18–25% of ROM of slime is
generated containing around 48–60% Fe
content, which are discarded as tailings [3].
According to the latest guidelines issued by
IBM, the cutoff grade for tailings is 45% [4].
This huge accumulation of slimes poses
environmental problems particularly during
rainy season when these fines get washed
away and affect the agricultural fields, water
bodies, removal of vegetation cover,
deforestation, land slope changes, increased
risk of erosion, water pollution and
contamination of agricultural goods and risk of
human health [5, 6]. The major iron ore mines
are located in the states of Jharkhand, Orissa,
Goa, Karnataka and Chhattisgarh [7]. Statistics
showed that the increase in 1% Fe in the
concentrate increases productivity of the hot
metal by 2% and reduced thereby coke and
limestone requirements by 1.8 and 0.9 %,
respectively [8]. As fines and slime forms
considerable part of iron ore resources, value
addition to the iron ore fines through
beneficiation is the need of the hour [9].
Generally, iron ore tailings contain substantial

15. JoMME (2016) 44-49 © STM Journals 2016. All Rights Reserved Page 44
Journal of Materials Metallurgical Engineering
ISSN: 2231-3818(online), ISSN: 2321-4236(print)
Volume 6, Issue 3
www.stmjournals.com
Solidification Curve Analysis of Cylindrical
Casting by FEM
Dharmesh Barodiya*, M.D. Mahajan, Shaheen Beg Mughal
Department of Industrial and Production Engineering,
Shri Govindram Seksaria Institute of Technology and Science, Indore, Madhya Pradesh, India
Abstract
In casting process, molten metal is solidified in mould cavity. Solidification process majorly
classify into three different sections: (i) liquefaction (ii) solidify (iii) after solidification. In all
three processes, one parameter which is called 'IHTC' (Intermediate Heat Transfer
Coefficient), is varies with time. IHTC coefficient depends on shape, size, type of casting etc.,
so, it is continuously varies with all dependent functions. So, establishment of IHTC value is a
very difficult task and hot cake between researchers. Various methods are available for
establishment of IHTC value, like inverse method. In this study we establish IHTC value via
inverse methodology. Solid cylinder of ADC 12 Material and sand casting process taken as
part of analysis. K-type thermocouple and Autonix temperature indicator are used for
temperature measurement. ADC 12 (Al alloys) material is used in various application such as
automotive transmission system, escalator steps barbeque covers, oil pumps. Pro cast is used
for simulation purpose. After complete experiment and simulation we are establishing IHTC
value which is 2000 w/m2-k.
Keywords: Sand casting, ADC 12, solid cylinder, K type thermocouple, Autonix temperature
indicator, Procast.
INTRODUCTION
Casting is a manufacturing process by which a
molten material is poured into a mold, allowed
to solidify in the mold box, and then cast out
or broken out to make a fabricated part.
Casting is used for making parts of convoluted
aspect that would be crucial or uneconomical
to make by other methods, such as cutting
from solid material (Campbell, 2002). This
solidification or heat is transferred by the
following equations:
Q=h (Tms–Tcs) (1)
Where, Q is heat flux, Tms is temperature of
mould surface, Tcs is temperature of casting
surface, and h is called intermediate heat
transfer coefficient [1].
LITERATURE REVIEW
As computer technology is becoming popular,
computer simulation of metal casting process
is becoming an accepted tool. With the help of
simulation, we can now produce virtual
casting without actually doing experimental
work. This saves time, material, manpower
and resources, and hence decrease cost of
product also. In this literature review, we
present the work done by analyzers in the area
of casting solidification simulation with the
help of finite element method. A metal casting
process is defined as a metal part produced by
pouring hot molten metal into a mould box
containing a cavity which has the desired
shape of the final product, and providing the
molten metal to solidify in the mold.
According to Taylor et al., 1959), copper was
the first metal to be cast; it was used for the
production of bells for large cathedrals at the
beginning of the 13th century. However, the
first authorized casting of aluminum was
produced in 1876.
The following researchers have used inverse
method to find out IHTC value. Kovačević et
al. generated a mathematical co-relation for
finding out IHTC value of Al alloy casting [2].
Choudhari et.al, (2013) concluded that IHTC
value depends on casting mould thickness and

16. conducted
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Energy Science/ /
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(JoMME)
Journal of Materials
MetallurgicalEngineering
September–December 2016
SJIF: 4.245
ISSN 2231-3818 (Online)
ISSN 2321-4236 (Print)