The Al 7075 alloy is a very useful material because of its mechanical properties i.e. low density, high strength, moderate ductility and toughness. Due to these properties, this alloy is mainly used for highly stressed structural parts. This material has a wide range of application such as aircraft fittings, gears and shafts, fuse parts, meter shafts and gear, missile parts , regulating valve parts, worm gears, keys and various other parts of commercial aircrafts and aerospace vehicles.
The document discusses Laminated Object Manufacturing (LOM), a type of solid rapid prototyping that uses lasers to create 3D models from layered materials. The LOM process involves adding and subtracting layers of material such as paper or plastic to build a part. Each thin layer is cut to shape using a CO2 laser before the next layer is added. LOM can produce models and prototypes quickly and cheaply from a variety of materials and is used to make scaled models, patterns for casting, and 3D printed objects for home use. However, LOM also has disadvantages like using unstable paper and producing smoke during cutting.
This document discusses laser beam machining (LBM), including:
- How lasers work by generating coherent, monochromatic light through stimulated emission.
- Common laser mediums like ruby, Nd:YAG, CO2, and their wavelengths.
- How laser light interacts with materials through absorption, melting, and vaporization.
- Key LBM process parameters like intensity, interaction time, and material properties.
- Applications of LBM like drilling, cutting, welding, and micro-machining.
- Centrifugal casting is a metal casting process that uses centrifugal force to form cylindrical parts by spinning a mold at high speeds. Molten metal is poured into the spinning mold and centrifugal force pushes the metal against the mold walls to form the casting shape.
- There are three main types of centrifugal casting: true centrifugal casting produces hollow castings using only centrifugal force without a core; semi-centrifugal casting uses a core to produce hollow cavities and is used for symmetrical parts; and centrifuging arranges small molds in a circle around a central axis to fill multiple molds simultaneously.
- Common applications include pipes, bearing bushes, cylinder liners, and pulleys. The process offers
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Electron beam machining (EBM) uses a focused beam of electrons to melt and vaporize small amounts of material. It was invented in 1952 and works by accelerating electrons in a vacuum chamber to generate a small, high-energy spot that precisely removes material through melting and vaporization. Key aspects of EBM include its ability to machine very small, high aspect ratio holes and its minimal heat affected zone. However, it requires expensive equipment and vacuum conditions.
The ceramic molding process involves making a mold from refractory ceramic materials that can withstand high temperatures. To make the mold, a slurry of silica grains, ethyl silicate, water, alcohol and a gelling agent is poured around a pattern. The mold is then fired to harden it and burn off unwanted materials, producing microcracks that allow permeability and collapsibility. Once assembled, the mold can be preheated and used to cast molten metals. Compared to investment casting, ceramic molds provide similar surface finish and intricacy but with reduced machining needs, shorter lead times, and ability to cast at various sizes and metals.
The document discusses Laminated Object Manufacturing (LOM), a type of solid rapid prototyping that uses lasers to create 3D models from layered materials. The LOM process involves adding and subtracting layers of material such as paper or plastic to build a part. Each thin layer is cut to shape using a CO2 laser before the next layer is added. LOM can produce models and prototypes quickly and cheaply from a variety of materials and is used to make scaled models, patterns for casting, and 3D printed objects for home use. However, LOM also has disadvantages like using unstable paper and producing smoke during cutting.
This document discusses laser beam machining (LBM), including:
- How lasers work by generating coherent, monochromatic light through stimulated emission.
- Common laser mediums like ruby, Nd:YAG, CO2, and their wavelengths.
- How laser light interacts with materials through absorption, melting, and vaporization.
- Key LBM process parameters like intensity, interaction time, and material properties.
- Applications of LBM like drilling, cutting, welding, and micro-machining.
- Centrifugal casting is a metal casting process that uses centrifugal force to form cylindrical parts by spinning a mold at high speeds. Molten metal is poured into the spinning mold and centrifugal force pushes the metal against the mold walls to form the casting shape.
- There are three main types of centrifugal casting: true centrifugal casting produces hollow castings using only centrifugal force without a core; semi-centrifugal casting uses a core to produce hollow cavities and is used for symmetrical parts; and centrifuging arranges small molds in a circle around a central axis to fill multiple molds simultaneously.
- Common applications include pipes, bearing bushes, cylinder liners, and pulleys. The process offers
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Electron beam machining (EBM) uses a focused beam of electrons to melt and vaporize small amounts of material. It was invented in 1952 and works by accelerating electrons in a vacuum chamber to generate a small, high-energy spot that precisely removes material through melting and vaporization. Key aspects of EBM include its ability to machine very small, high aspect ratio holes and its minimal heat affected zone. However, it requires expensive equipment and vacuum conditions.
The ceramic molding process involves making a mold from refractory ceramic materials that can withstand high temperatures. To make the mold, a slurry of silica grains, ethyl silicate, water, alcohol and a gelling agent is poured around a pattern. The mold is then fired to harden it and burn off unwanted materials, producing microcracks that allow permeability and collapsibility. Once assembled, the mold can be preheated and used to cast molten metals. Compared to investment casting, ceramic molds provide similar surface finish and intricacy but with reduced machining needs, shorter lead times, and ability to cast at various sizes and metals.
Various Non-conventional machining Processaman1312
The document provides information on various non-conventional machining processes. It begins by defining non-traditional manufacturing processes as those that remove material using mechanical, thermal, electrical, or chemical energy without sharp cutting tools. Extremely hard materials are difficult to machine with traditional processes. The document then discusses several non-traditional processes in detail, including abrasive jet machining (AJM), ultrasonic machining (USM), electrical discharge machining (EDM), and their working principles and applications.
This document discusses thixocasting, which is a near net shape forming process using partially melted alloys. It involves three main stages: 1) producing a pre-cast billet with a globular structure, 2) reheating the billet to the semi-solid casting temperature, and 3) pressing the billets into a die cavity to cast the component. Thixocasting allows for smooth filling of dies with minimal porosity and entrapped air. It produces fine, uniform microstructures and dimensions close to net shape, reducing machining needs. Common applications include automotive wheels, brake valves, disk brake callipers, and engine pistons.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
This document contains assignments for testing of materials course units 1 through 5. It includes questions related to the importance of material selection and testing, different types of material tests, mechanical tests, non-destructive tests, material characterization tests, and other tests such as thermal analysis and spectroscopy. Students are asked to explain topics like stages of test development, properties from bending tests, principles of hardness tests, and workings of various microscopy, spectroscopy, and thermal analysis techniques. They are also asked to discuss advantages, limitations and applications of different material tests.
Revolutionary and powerful technology with wide range of application.
The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance.
This document provides an overview of electrochemical machining (ECM). ECM is a non-conventional machining process that removes metal through an electrochemical process rather than adding it, as in electroplating. In ECM, a tool acts as the cathode and the workpiece the anode, with an electrolyte solution flowing between them. Metal is removed from the workpiece through an electrolysis process governed by Faraday's laws of electrolysis. ECM can machine complex internal and external geometries in hard metals and is well-suited for mass production. Key aspects of ECM covered include the power supply, electrolyte, tool, control system, and principles of operation. Applications and advantages, such as little
ME8073 Unconventional Machining Processes - By www.LearnEngineering.in.pdfnallak1
This document provides information on the subject ME 8073 Unconventional Machining Processes taught at engineering colleges. It includes the syllabus, lesson plan, unit summaries, and sample questions. The syllabus covers 5 units - mechanical energy based processes like abrasive jet machining, electrical energy based processes like EDM, chemical and electro-chemical energy based processes, and thermal energy based processes like laser beam machining. The lesson plan lists the topics covered in each unit along with the time allotted and reference books. Sample questions and answers are provided at the end for the introductory unit.
The presentation covers various aspects of coating and deposition process in detail. The topics that are mainly covered in this PPT are
1) Type of Coating
2) Advantages and limitation for various coating process
3) Figures of various coating process
The document provides an overview of metal matrix composites (MMCs). It discusses that MMCs consist of a metal matrix reinforced with ceramic particles or fibers. The reinforcement improves the composite's properties over the unreinforced metal, such as increased strength and stiffness. The document also examines the important interfaces between the matrix and reinforcement, which influence the composite's performance. It describes various bonding mechanisms at the interface like mechanical, chemical, and diffusion bonding. Finally, the document outlines common processing techniques for fabricating MMCs, including powder metallurgy where metal powders are compacted and sintered to form the final composite material.
Diffusion welding is a solid state welding process that joins materials together without melting through the application of pressure and heat. It is commonly used to join refractory metals at temperatures just over half their normal melting point. Close tolerances and a protective atmosphere are required to accomplish the welding. The process is considered diffusion brazing when a filler material is placed between surfaces before joining. Diffusion bonding results from atomic diffusion and plastic deformation at the interface between surfaces. It is used for joining dissimilar metals and composites in applications like aerospace and nuclear industries.
Fabrication of metal matrix composites using stir casting methodAbhishekKumarSingh252
This document summarizes a project to fabricate metal-matrix composites using stir casting. The project aims to produce aluminum-silicon carbide (AlSiC) composites through stir casting to create strong, lightweight materials for use in industries like automotive and aerospace. Experiments are conducted by varying the composition of silicon carbide added to molten aluminum from 5-30% and stirring to ensure homogeneous mixing. The composites are then tested for properties like hardness and impact strength. The goal is to develop low-cost metal-matrix composite materials for industrial applications requiring high strength, stiffness, and other properties.
3D PRINTING - LIQUID AND SOLID BASED ADDITIVE MANUFACTURING S. Sathishkumar
This document provides information on liquid-based and solid-based additive manufacturing systems. It discusses stereolithography (SLA) and fused deposition modeling (FDM) in detail. SLA uses a laser to cure liquid resin layer-by-layer, and was the first commercialized AM process. FDM extrudes melted thermoplastics through a nozzle to build parts layer-by-layer. Both techniques can create prototypes, models, and some end-use parts, with SLA providing better accuracy and surface finish.
Recrystallization is the process in which deformed grains of the crystal structure are replaced by a new set of stress-free grains that nucleate and grow until all the original grains have been consumed. The process is accomplished by heating the material to temperatures above that of crystallization.
Friction-stir welding is an advanced solid-state joining process (the metal is not melted) which involves the use of a third body tool to join two facing surfaces. Heat is generated between the tool and material which leads to a very soft region near the FSW tool. It then mechanically intermixes the two pieces of metal at the place of the joint, then the softened metal (due to the elevated temperature) can be joined using mechanical pressure (which is applied by the tool), much like joining clay, or dough. It is primarily used on aluminium, and most often on extruded aluminium (non-heat treatable alloys), and on structures which need superior weld strength without a post weld heat treatment.
It was invented and experimentally proven at The Welding Institute UK in December 1991.
Powder metallurgy involves producing metal powders and using them to make parts. There are several methods for powder production, including mechanical, chemical, and physical methods. Mechanical methods involve milling or grinding metals into powders, while chemical methods reduce metal oxides using reducing agents. Physical methods like gas or water atomization involve spraying molten metal into a chamber to produce spherical powders. The properties of metal powders depend on factors like particle size, shape, density and flow characteristics, which influence the powder metallurgy process steps of mixing, compacting, and sintering to produce final parts.
Bearings support moving parts, such as shafts and spindles, of a machine or mechanism.
Bearings may be classed as
(i) Rolling contact (Ball and roller) bearings.
(ii) Plain bearings.
CANDU reactors were first developed in the 1950s-1960s in Canada as a partnership between government and private organizations. CANDU reactors use natural uranium fuel, pressurized heavy water as a moderator, and pressurized tubes to contain the fuel and coolant as it circulates. Key components include the pressurized fuel tubes, fuel elements, reactor core, steam generator, turbines, condenser, and cooling water. Neutrons are slowed by heavy water, heating it up which is then used to power the turbines and generate electricity. Control rods are used for start-up, shutdown, and regulating power during operation. Advantages include not requiring enriched fuel and low fuel consumption, while disadvantages include the high
Working of Laser beam machining process. Its one kind of non traditional or advanced manufacturing process.Production of laser beam and with the use of lasers how can material can be removed is to be explained over here...
The document discusses ultrasonic machining (USM), which uses high-frequency vibrations and an abrasive slurry to erode material. USM can machine hard and brittle materials by using a vibrating tool to drive abrasive particles against the workpiece. The document outlines the principles, components, process parameters, applications, and advantages/disadvantages of USM. It describes how the tool, transducer, abrasives, and other system parts work together to remove material through brittle fracture caused by abrasive particle impacts. Examples are given of complex features that can be machined using USM.
This document discusses time and resource constraints in the Indian construction industry. It begins with an introduction that provides background on the rapid growth of the Indian construction sector due to initiatives like Make in India. However, this growth has also increased risks and challenges related to project time and resource management. The document then outlines its various chapters which will examine definitions of time overruns, their causes, and resource constraints related to materials, manpower, equipment and financing. It aims to analyze these issues and provide recommendations to help deliver high quality construction projects on time and within resource limits in India.
This document is a 57-page independent project report submitted by Anuj Rawat to AIIM about challenges facing India's logistics sector and measures to overcome them, with a focus on controlled atmosphere storage. The report includes chapters on roads, railways, waterways/ports, warehousing, cold chain logistics, and conclusions. It discusses issues like high logistics costs in India, modal share of transportation, challenges specific to each mode, and government policies/initiatives to promote controlled atmosphere storage and cold chain infrastructure development.
Various Non-conventional machining Processaman1312
The document provides information on various non-conventional machining processes. It begins by defining non-traditional manufacturing processes as those that remove material using mechanical, thermal, electrical, or chemical energy without sharp cutting tools. Extremely hard materials are difficult to machine with traditional processes. The document then discusses several non-traditional processes in detail, including abrasive jet machining (AJM), ultrasonic machining (USM), electrical discharge machining (EDM), and their working principles and applications.
This document discusses thixocasting, which is a near net shape forming process using partially melted alloys. It involves three main stages: 1) producing a pre-cast billet with a globular structure, 2) reheating the billet to the semi-solid casting temperature, and 3) pressing the billets into a die cavity to cast the component. Thixocasting allows for smooth filling of dies with minimal porosity and entrapped air. It produces fine, uniform microstructures and dimensions close to net shape, reducing machining needs. Common applications include automotive wheels, brake valves, disk brake callipers, and engine pistons.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
This document contains assignments for testing of materials course units 1 through 5. It includes questions related to the importance of material selection and testing, different types of material tests, mechanical tests, non-destructive tests, material characterization tests, and other tests such as thermal analysis and spectroscopy. Students are asked to explain topics like stages of test development, properties from bending tests, principles of hardness tests, and workings of various microscopy, spectroscopy, and thermal analysis techniques. They are also asked to discuss advantages, limitations and applications of different material tests.
Revolutionary and powerful technology with wide range of application.
The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance.
This document provides an overview of electrochemical machining (ECM). ECM is a non-conventional machining process that removes metal through an electrochemical process rather than adding it, as in electroplating. In ECM, a tool acts as the cathode and the workpiece the anode, with an electrolyte solution flowing between them. Metal is removed from the workpiece through an electrolysis process governed by Faraday's laws of electrolysis. ECM can machine complex internal and external geometries in hard metals and is well-suited for mass production. Key aspects of ECM covered include the power supply, electrolyte, tool, control system, and principles of operation. Applications and advantages, such as little
ME8073 Unconventional Machining Processes - By www.LearnEngineering.in.pdfnallak1
This document provides information on the subject ME 8073 Unconventional Machining Processes taught at engineering colleges. It includes the syllabus, lesson plan, unit summaries, and sample questions. The syllabus covers 5 units - mechanical energy based processes like abrasive jet machining, electrical energy based processes like EDM, chemical and electro-chemical energy based processes, and thermal energy based processes like laser beam machining. The lesson plan lists the topics covered in each unit along with the time allotted and reference books. Sample questions and answers are provided at the end for the introductory unit.
The presentation covers various aspects of coating and deposition process in detail. The topics that are mainly covered in this PPT are
1) Type of Coating
2) Advantages and limitation for various coating process
3) Figures of various coating process
The document provides an overview of metal matrix composites (MMCs). It discusses that MMCs consist of a metal matrix reinforced with ceramic particles or fibers. The reinforcement improves the composite's properties over the unreinforced metal, such as increased strength and stiffness. The document also examines the important interfaces between the matrix and reinforcement, which influence the composite's performance. It describes various bonding mechanisms at the interface like mechanical, chemical, and diffusion bonding. Finally, the document outlines common processing techniques for fabricating MMCs, including powder metallurgy where metal powders are compacted and sintered to form the final composite material.
Diffusion welding is a solid state welding process that joins materials together without melting through the application of pressure and heat. It is commonly used to join refractory metals at temperatures just over half their normal melting point. Close tolerances and a protective atmosphere are required to accomplish the welding. The process is considered diffusion brazing when a filler material is placed between surfaces before joining. Diffusion bonding results from atomic diffusion and plastic deformation at the interface between surfaces. It is used for joining dissimilar metals and composites in applications like aerospace and nuclear industries.
Fabrication of metal matrix composites using stir casting methodAbhishekKumarSingh252
This document summarizes a project to fabricate metal-matrix composites using stir casting. The project aims to produce aluminum-silicon carbide (AlSiC) composites through stir casting to create strong, lightweight materials for use in industries like automotive and aerospace. Experiments are conducted by varying the composition of silicon carbide added to molten aluminum from 5-30% and stirring to ensure homogeneous mixing. The composites are then tested for properties like hardness and impact strength. The goal is to develop low-cost metal-matrix composite materials for industrial applications requiring high strength, stiffness, and other properties.
3D PRINTING - LIQUID AND SOLID BASED ADDITIVE MANUFACTURING S. Sathishkumar
This document provides information on liquid-based and solid-based additive manufacturing systems. It discusses stereolithography (SLA) and fused deposition modeling (FDM) in detail. SLA uses a laser to cure liquid resin layer-by-layer, and was the first commercialized AM process. FDM extrudes melted thermoplastics through a nozzle to build parts layer-by-layer. Both techniques can create prototypes, models, and some end-use parts, with SLA providing better accuracy and surface finish.
Recrystallization is the process in which deformed grains of the crystal structure are replaced by a new set of stress-free grains that nucleate and grow until all the original grains have been consumed. The process is accomplished by heating the material to temperatures above that of crystallization.
Friction-stir welding is an advanced solid-state joining process (the metal is not melted) which involves the use of a third body tool to join two facing surfaces. Heat is generated between the tool and material which leads to a very soft region near the FSW tool. It then mechanically intermixes the two pieces of metal at the place of the joint, then the softened metal (due to the elevated temperature) can be joined using mechanical pressure (which is applied by the tool), much like joining clay, or dough. It is primarily used on aluminium, and most often on extruded aluminium (non-heat treatable alloys), and on structures which need superior weld strength without a post weld heat treatment.
It was invented and experimentally proven at The Welding Institute UK in December 1991.
Powder metallurgy involves producing metal powders and using them to make parts. There are several methods for powder production, including mechanical, chemical, and physical methods. Mechanical methods involve milling or grinding metals into powders, while chemical methods reduce metal oxides using reducing agents. Physical methods like gas or water atomization involve spraying molten metal into a chamber to produce spherical powders. The properties of metal powders depend on factors like particle size, shape, density and flow characteristics, which influence the powder metallurgy process steps of mixing, compacting, and sintering to produce final parts.
Bearings support moving parts, such as shafts and spindles, of a machine or mechanism.
Bearings may be classed as
(i) Rolling contact (Ball and roller) bearings.
(ii) Plain bearings.
CANDU reactors were first developed in the 1950s-1960s in Canada as a partnership between government and private organizations. CANDU reactors use natural uranium fuel, pressurized heavy water as a moderator, and pressurized tubes to contain the fuel and coolant as it circulates. Key components include the pressurized fuel tubes, fuel elements, reactor core, steam generator, turbines, condenser, and cooling water. Neutrons are slowed by heavy water, heating it up which is then used to power the turbines and generate electricity. Control rods are used for start-up, shutdown, and regulating power during operation. Advantages include not requiring enriched fuel and low fuel consumption, while disadvantages include the high
Working of Laser beam machining process. Its one kind of non traditional or advanced manufacturing process.Production of laser beam and with the use of lasers how can material can be removed is to be explained over here...
The document discusses ultrasonic machining (USM), which uses high-frequency vibrations and an abrasive slurry to erode material. USM can machine hard and brittle materials by using a vibrating tool to drive abrasive particles against the workpiece. The document outlines the principles, components, process parameters, applications, and advantages/disadvantages of USM. It describes how the tool, transducer, abrasives, and other system parts work together to remove material through brittle fracture caused by abrasive particle impacts. Examples are given of complex features that can be machined using USM.
This document discusses time and resource constraints in the Indian construction industry. It begins with an introduction that provides background on the rapid growth of the Indian construction sector due to initiatives like Make in India. However, this growth has also increased risks and challenges related to project time and resource management. The document then outlines its various chapters which will examine definitions of time overruns, their causes, and resource constraints related to materials, manpower, equipment and financing. It aims to analyze these issues and provide recommendations to help deliver high quality construction projects on time and within resource limits in India.
This document is a 57-page independent project report submitted by Anuj Rawat to AIIM about challenges facing India's logistics sector and measures to overcome them, with a focus on controlled atmosphere storage. The report includes chapters on roads, railways, waterways/ports, warehousing, cold chain logistics, and conclusions. It discusses issues like high logistics costs in India, modal share of transportation, challenges specific to each mode, and government policies/initiatives to promote controlled atmosphere storage and cold chain infrastructure development.
This document is a 57-page independent project report submitted by Anuj Rawat to AIIM about challenges facing India's logistics sector and measures to overcome them, with a focus on controlled atmosphere storage. The report includes chapters on roads, railways, waterways/ports, warehousing, cold chain logistics, and conclusions. It discusses issues like high logistics costs in India, modal share of transportation, challenges specific to each mode, and government policies/initiatives to promote controlled atmosphere storage and cold chain infrastructure development.
This document provides details about a summer internship project on the operation philosophy of a gas holder in a steel plant. It includes declarations, certificates of recommendation, acknowledgements, an abstract, table of contents, and the beginning of chapter 1 on the company profile. The internship was conducted at Tata Steel in Jamshedpur, India under the guidance of Mr. Shyam Manohar Pandey from June 23rd to August 17th, 2015. The project report is being submitted in partial fulfillment of requirements for a Bachelor of Technology degree.
This study was conducted at Kilang Minyak Sawit Kamunting Sdn. Bhd, Taiping to improve palm oil production by making improvements to the ripple mill machine. The ripple mill machine is part of the equipment in palm oil mills used to separate palm nut shells and kernels. The scope of the study was to examine the percentage efficiency of cracked shells and kernels. This percentage efficiency can be increased by improving the existing machine. According to the existing design of the ripple mill machine, the service life of the ripple rods was found to be short due to wear and tear. Parameters expected to affect the percentage efficiency of cracked palm nuts and shells and wear include optimum rotor speed, suitable distance between rotor and
The motivation behind the project and research is to present a new characteristic for temperature profile estimation in modelling of Rotary Friction Welding Process. For the first time, a unified model has been exhibited, with an implementation of phase transformation of similar and dissimilar materials and plastics too. The model was generated on ANSYS 15.0, thermal and structural modules were used to plot the temperature curve with which I make a compression. The curve for welding of dissimilar metals was analyzed with that of practical curves already acquired and then the effect of varying parameters on the welding of similar metals was studied.
This project report evaluates the design and fabrication of a miniature continuously variable transmission (CVT). CVTs allow the driving shaft to maintain a constant angular velocity over a range of output velocities, enabling the engine to operate at its most efficient revolutions per minute for different vehicle speeds to provide better fuel economy. The report discusses the history and working of CVTs, describes the components used and their design and construction details, and explains the power transmission process. It also discusses observations from the project and future prospects of CVTs.
The document provides a final report on a project aimed at improving flow and throughput in a Turbomachinery design job department. The report includes an abstract, acknowledgements, table of contents, and 7 main sections covering value stream mapping, a decision support tool, linear programming model, ARENA simulation, cost analysis, economics/project management, and conclusions/recommendations. The report was submitted by 6 students to Concordia University in fulfillment of an Industrial Engineering capstone project requirements. It focuses on applying lean product development concepts to assess current processes and develop tools to improve job prioritization, communication, and resource allocation at Pratt & Whitney Canada.
This report details a study on the fresh and hardened properties of normal strength self-compacting concrete (SCC). Mix designs were developed and tested to meet fresh concrete requirements for flowability, passing ability, and segregation resistance. The finalized mix was then evaluated for hardened properties like compressive, tensile, and flexural strength along with stress-strain behavior up to 14 days. The results provide insight into developing reliable normal strength SCC mixes and understanding their fresh and hardened characteristic properties.
This document is a project report on the design aspects of precast pretensioned U-girder bridges for metro rapid transit systems. U-girder bridges have advantages over traditional box girder bridges like reduced height, weight, and construction time, lowering overall project costs. The report analyzes the longitudinal behavior of a U-girder bridge under self-weight, superimposed dead, and live loads. It also examines the transverse behavior and calculates reinforcement requirements. Construction procedures for precasting U-girders are described. The report aims to optimize U-girder design for metro applications.
This document provides guidelines for energy efficient building design. It covers lighting, electric power and distribution, building envelope, air conditioning systems, and boiler and hot water systems. For lighting, it recommends efficient lamp types and design approaches to reduce energy use. It sets maximum power density limits for interior and exterior lighting. For other building systems, it provides requirements for equipment efficiency and design criteria to improve energy performance. The guidelines aim to reduce building energy use while maintaining occupant comfort.
“ALTERNATIVE SOLUTION OF ROBOT MACHINE BY APPLYING ROTARY MACHINE” Refrigeration industries, Book Publisher house, having such big pick & place robot arm machine .they are used to lift & rotate that deep freezer (product) from one place to another. We have found such problem of regularly failure & damage of product by this machine due to limitation of backless, tolerances & design limitation problem. So, we are tries to give alternate solution for this problem by giving alternate turn table m/which will perform the same task like the old machine. Hence, we give the sustainable & modified design of turn table m/c for pick & place robot arm m/c.
Here are the key points from the introduction:
- Directional drilling has become an important tool in developing oil and gas deposits.
- Controlled directional drilling enables producers to develop subsurface deposits that could not be reached economically by any other means.
- This module will cover topics that must be understood by directional drillers, including different types of wells and applications of directional drilling.
This is Ph.D. Thesis. The title reflects the work. Topologies and Controls for Optimal Energy Bifurcation in AC, DC, and Hybrid Microgrid. It will help to all the researchers work in this field
This document discusses dynamic soil-structure interaction for layered ground. It presents two methods, the constant scheme and linear scheme, for obtaining the acceleration unit-impulse response matrix used in analyzing dynamic soil-structure interaction problems. Three numerical examples are used to test the two schemes and compare their accuracy and computation time. The constant scheme provides high accuracy results but requires more computation time, while the linear scheme requires less time but introduces some errors. The linear scheme errors can be reduced by choosing appropriate parameters.
This document provides guidelines for the construction of steel deck projects. It describes various deck product types including composite floor deck, roof deck, cellular deck, and form deck. It provides details on their uses, profiles, finishes, and installation considerations. The document also covers topics like approved erection drawings, packaging, storage, safety procedures, damage prevention, and placing concrete.
This document is a summer intern project report submitted by Braj Kishor Sah to partially fulfill requirements for a Bachelor of Technology degree in Ceramic Engineering. It describes Sah's 8-week internship at Steel Authority of India Limited's Refractory Unit in Ramgarh, Jharkhand, India. The report includes sections on raw materials used, production processes, maintenance, hydraulics, purchasing, the laboratory, electrical systems, stores, and brick sizes manufactured at the facility.
This document is a dissertation submitted by Pratik Badgujar in partial fulfillment of the requirements for a Master's degree in Construction Management from Nottingham Trent University in September 2016. The dissertation aims to identify the causes and impacts of delays in the Indian construction industry. It includes an acknowledgement, abstract, table of contents, and 5 chapters that cover an introduction, literature review, research methodology, results and analysis, and conclusion. The document also cites references and includes appendices.
Case Study of Closely Spaced Intersections at the Junction of Jinnah & 7th Av...THEENTERTAINER3
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A PROJECT ON STUDY THE MECHANICAL BEHAVIOUR OF Al 7075 ALLOY BASED COMPOSITES BY COMPRESSION METHOD
1. A PROJECT ON
STUDY THE MECHANICAL BEHAVIOUR OF Al 7075
ALLOY BASED COMPOSITES BY COMPRESSION
METHOD
Project report submitted in partial fulfillment of the Requirements for the Award of the
Degree of B.Tech
In
Metallurgical Engineering
BY
JEETENDRAMAHARANA ,14MET039
Under the Esteemed Guidance of
Dr. R.GOVINDA RAO
Associate Professor
Department of Metallurgical Engineering
Gandhi Institute of Engineering and Technology
(Autonomous)
(Affiliated to BPUT, Rourkela)
Approved by AICTE- Accredited by NBA
Gunupur-765022
2018
2. Declaration
I declare that this written submission represents my ideas in my own words and where others'
ideas or words have been included, I have adequately cited and referenced the original
sources. I also declare that I have adhered to all principles of academic honesty and integrity
and have not misrepresented or fabricated or falsified any idea/data/fact/ source in my
submission. I understand that any violation of the above will be cause for disciplinary action
by the Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.
J
EETANDRA MAHARANA 14MET039
Date:
3. Approval Sheet
This project report entitled “A PROJECT ON STUDY THE MECHANICAL
BEHAVIOUR OF Al 7075 ALLOY BASED COMPOSITE BY COMPRESSION
METHOD” by E.TIRUPATI, JEETENDRA MAHARANA, SONA KAMALESH PARIDA,
CHIRANJIBEE KUMAR MAHANTA is approved for the degree of Metallurgical
Engineering.
Examiners
________________________
________________________
________________________
Supervisor (s)
________________________
________________________
________________________
HOD, Metallurgical Engg.
________________________
Date :____________
Place:___________
4. ACKNOWLEDGEMENT
We would like to express our profound sense of gratitude to all for having helped us in
completing this dissertation. We would like to express our deep felt gratitude and sincere
thanks to our guide Dr.R Govinda Rao, Professor/ Associate professor/Assistant Professor,
Department of Metallurgical Engineering, Gandhi Institute of Engineering & Technology,
Gunupur for his skilful guidance, timely suggestions and encouragement in completing this
project.
We are highly obliged to our project coordinator Mr. Siva Raju, Professor, for having
extended his affable guidance, constant supervision and encouragement throughout the
progress of this project, which helped us to complete it within the stipulated time.
We would like to express our sincere thanks to Prof. (Dr.) Ajit KumarSenapati, Associate
Professor and Head of Department of Metallurgical Engineering, for providing the necessary
facilities for the successful completion of this work.
We wish to acknowledge the support received from our Principal, Dean and management
during the course of this project.
Last but not least, we wish to thank our Teaching& Non-teaching Staff, our parents
and all our friends for their constant moral support, co-operation and encouragement during
this period.
i
5. ABSTRACT
The Al 7075 alloy is a very useful material because of its mechanical properties i.e. low
density, high strength, moderate ductility and toughness. Due to these properties, this alloy is
mainly used for highly stressed structural parts. This material has a wide range of application
such as aircraft fittings, gears and shafts, fuse parts, meter shafts and gear, missile parts ,
regulating valve parts, worm gears, keys and various other parts of commercial aircrafts and
aerospace vehicles.
The main objective of our work is to improve the mechanical properties such as hardness,
Tensile strength, Compressive strength of Aluminum based Composite, and its relation with
processing of the Alumina particulate (Al2O3) as reinforced in Fly ash matrix. Aluminum
7075 alloy is chosen as matrix alloy, in which Aluminum is the base element. The work has
been proposed for Hardness test, Compression test and Tensile test.
Mechanical properties like Tensile test, Hardness test are conducted on Al 7075 reinforced
with Fly ash . These reinforcements provide comparatively high Strength and Hardness.
Ii
6. CONTENT
Title Page
ACKNOWNLEDGENENT............................................................................................. i
ABSTRACT...................................................................................................................... ii
LIST OF TABLES............................................................................................................ iii
LIST OF FIGURES.......................................................................................................... iv
CHAPTER -1:
1.1 INTRODUCTION.......................................................................................................1
CHAPTER- 2:
2. LITERATURE REVIEW................................................................................................2
2.1 CHARACTERSTICS....................................................................................................2
2.2 COMPOSITION OF Al 7075........................................................................................2
2.3 PROPERTIES OF Al 7075............................................................................................3
2.4 DEFINATION OF COMPOSITE.................................................................................3
2.5 CLASSIFICATION OF COMPOSITE.........................................................................4
2.6 ALUMINIUM –FLY ASH REINFORCED COMPOSITE..........................................5
2.7 FLY ASH.......................................................................................................................6
2.8 WHY FLY ASH.............................................................................................................7
CHAPTER-3:
3.1 EXPERIMENTAL WORK...........................................................................................8
3.2 HARDNESS TEST........................................................................................................9
3.3 TENSILE TEST............................................................................................................10-12
3.4 COMPRESSION TEST................................................................................................12
CHAPTER-4:
4.1 STRENGTHENING MECHANISM...........................................................................13
4.2 RECOVERY.................................................................................................................13
4.3 RECRYSTALLIZATION............................................................................................13
4.4 GRAIN GROWTH.......................................................................................................14
CHAPTER-5:
5.1 RESULT AND DISCUSSION....................................................................................15
5.2 COMPRESSION TEST RESULTS..............................................................................16-19
5.2.1 COMPOSITE.............................................................................................................16
5.2.2 PURE Al.....................................................................................................................17
7. 5.2.3 Al 6062.......................................................................................................................18
5.2.4 Al 7075.......................................................................................................................19
5.3 TENSILE TEST RESULTS.........................................................................................20-23
5.3.1 PURE Al....................................................................................................................20
5.3.2 Al 6061......................................................................................................................21
5.3.3 Al 7075......................................................................................................................22
5.3.4 COMPOSITE............................................................................................................23
5.4 HARDNESS TEST RESULTS....................................................................................24
5.5 MECHANICAL PROPERTIES..................................................................................24
CHAPTER-6:
CONCLUSION.................................................................................................................25
CHAPTER-7:
REFERENCES.................................................................................................................26
8. LIST OF TABLES
Table Title Page
1 Composition of Al 7075 2
2 Properties of Al 7075 3
3 Tensile test results of Pure Al 20
4 Tensile test results of Al 6061 21
5 Tensile test results of Al 7075 22
6 Tensile test results of Composite 23
7 Hardness test results 24
8 Mechanical properties 24
iii
9. LIST OF FIGURES
Figure Title Page
1 Microstructure of base alloy 7075 2
2 Fly ash 6
3 Laboratory stir casting set up 8
4 Hardness Before testing and After testing 9
5 BrinellHardnss Tester 10
6 Electronic Tensile Testing Machine10
7 Tensile Test Sample 11-12
8 Universial Testing Machine 12
9 Optical microstructure of different metals15
After compression test
10 Load vs. Displacement curve for different 16-19
metals After Compression test
11 Load vs. Displacement curve for different 20-23
metals After Tensile test
Iv
10. CHAPTER 1
1.INTRODUCTION
Conventional monolithic materials have limitations in achieving good combination of
strength, stiffness, toughness and density. To overcome these shortcomings and to meet the
ever increasing demand of modern daytechnology, composites are most promising materials
of recent interest. Metal composites possess significantlyimproved properties including high
specific strength, specific modulus, damping capacity and good wear resistance compared to
unreinforced alloys. There has been an increasing interest in composites containing low
density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash
is one of the most inexpensive and low density reinforcement available in large quantities as
solid waste by-product during combustion of coal in thermal power plants. Hence,
composites with fly ash as reinforcement are likely to overcome the cost barrier for wide
spread applications in automotive and small engine applications. It is therefore expected that
the incorporation of fly ash particles in aluminium alloy will promote yet another use of this
low-cost waste by-product and, at the same time, has the potential for conserving energy
intensive aluminium and thereby, reducing the cost of aluminium products.
Now the days the particulate reinforced aluminium composites are gaining importance
because of their lowcost with advantages like isotropic properties and the possibility of
secondary processing facilitating fabrication of secondary components. Cast aluminium
matrix particle reinforced composites have higher specific strength, specific modulus and
good wear resistance as compared to unreinforced alloys.
In the present work, fly-ash which mainly consists of refractory oxides like silica, alumina,
and iron oxides isused as reinforcing phase. Composite was produced with 10gm to40gm fly-
ash as reinforcing phase. Commercially pure aluminium was also melted and casted. Then
particle size and chemical composition analysis for fly-ash was done. Mechanical, physical
and grain properties of the composite were evaluated and compared with the commercially
pure aluminium. Mechanical properties of composites are affected by the size, shape and
volume fraction of the reinforcement, composite material and reaction at the interface.
11. CHAPTER 2
2. LITERATURE REVIEW
2.1 CHARACTERISTICS
7075 aluminum alloy is perfect for applications where high strength is essential and good
corrosion resistance is less important. It is known to have a high strength to weight ratio and
certain tempers offer decent resistance to stress-corrosion cracking. 7075 is able to match
most steel alloys in terms of strength.
(Fig 1: Microstructure of base alloy 7075)
2.2 COMPOSION OF Al 7075
Table-1 Composition of Al 7075
Material Weight %
Copper 1.53
Chromium 0.20
Magnesium 2.50
Zinc 5.45
Iron 0.20
Manganese 0.25
Silicon 0.30
Titanium 0.16
Aluminum Remaining
12. 2.3 PROPERTIES OF Al 7075
Table-2 Properties of Al 7075
Mechanical properties Values
Hardness – Brinell 94.95
Tensile yield strength 198.9MPa
Elongation at beak 5.40%
Modulus of Elasticity 71.7GPa
Poisson’s Ratio 0.33
Machinability 70%
Shear modulus 26.9GPa
Shear strength 331Mpa
2.4 Definition of composite material:
The composite material can be defined as the system of material consisting of a mixture of
combination of two or more micro constituents insoluble in each other and differing in form
and or in material composition .These materials can be prepared by putting two or more
dissimilar material in such way that they function mechanically as a single unit. The
properties of such materials differ from those of their constituents. These materials may have
a hard phase embedded in a soft phase or vice versa. Normally in the composite material have
a hard phase in the soft ductile matrix where the hard phase act as a reinforcing agent
increase the strength and modulus, and soft phase act as matrix material. The requirement for
satisfying the above mentioned condition is
a. The composite material has to be man-made
b. The composite material must be a combination of at least two chemically distinct
materials with an interface separating the components.
c. The properties of composite should be three dimensionally combined.
13. 2.5 Classification of Composites
On the basis of Matrix composite can be classified in the following groups:
a) Polymer-matrix composites (PMC)
The most common matrix materials for composites are polymeric. Polyester and viny esters
are the most widely used and least expensive polymer resins. These matrix materials are
basically used for fiber glass reinforced composites. For mutations of a large number resin
provide a wide range of properties for these materials .The epoxies are more expensive and in
addition to wide range of ranging commercials applications ,also find use in PMCs for
aerospace applications. The main disadvantages of PMCs are their low maximum working
temperature high coefficients of thermal expansion and hence dimensional instability and
sensitivity to radiation and moisture. The strength and stuffiness are low compared with
metals and ceramics.
b) Metal-matrix composites (MMC)
The matrix in these composites is a ductile metals .These composites can be used at higher
service temperature than their base metal counterparts. These reinforcements in these
materials may improve specific stuffiness specific strength, abrasion resistance, creep
resistance and dimensional stability. The MMCs is light in weight and resist wearand thermal
distortion, so it mainly used in automobile industry. Metal matrix composites are much more
expensive those PMCs and, therefore, their use is somewhat restricted. [9, 10]
c) Ceramic-matrix composites (CMC)
One of the main objectives in producing CMCs is to increase the toughness. Ceramics
materials are inherent resistants to oxidation and deterioration at elevated temperatures; were
it not for their disposition to brittle fracture, some of these materials would be idea candidates
for use in higher temperature and serve-stress applications, specifically for components in
automobile an air craft gas turbine engines .The developments of CMCs has lagged behind
mostly for remain reason, most processing route involve higher temperature and only
employed with high temperature reinforcements.
On the basics of reinforcement can be classified into three types:
a) Particle reinforced composites
Particulate reinforcements have dimensions that are approximately equal in all directions
.The shape of the reinforcing particles may be spherical, cubic, platelet or any regular or
irregular geometry. These composite can classified under two sub groups :
(i) Large particle composites
(ii) Dispersion strengthened composites
14. b) Fiber reinforced composites
A fibrous reinforcement is characterized by its length being much greater than its cross-
sectional dimension .However the ratio of length to the cross sectional dimension know as the
aspect ratio, can vary considerably .In single layer composite long fibers with high aspect
ratios give that are called continuous fiber reinforced composites whereas discontinuous fiber
reinforced composites are fabricated using short fibres of low aspect ratio .The orientation of
the discontinuous fibres may be random or preferred .The frequently encountered preferred
orientation in the case of continuous fibre composite is termed unidirectional and the
corresponding random situation can be approximated to by bidirectional woven
reinforcement.
2.6 Aluminium -fly ash particulate reinforced composite
M. Ramachandra K. Radhakrishna has worked on the Effect of reinforcement of fly ash on
sliding wear, slurry erosive wear and corrosive behavior of aluminium matrix composite. Al
(12 wt% Si) as matrix material and up to 15 wt% of fly ash particulatecomposite was
fabricated using the stir casting rote and came forward into following conclusions
Fly ash improves abrasive wear resistance (20-30%) of Al. and reduces the coefficient of
Friction.
Increase in normal load and sliding velocity increases magnitude of wear and frictional
force.Different wear mechanisms were studied under varying different parameter such as
normal load, % of fly ash content and sliding velocity.
Four different mechanisms are found that are abrasion, oxidation, delamination, thermal
softening and adhesion.Corrosion resistance of reinforced composite has decreased with
increase in flyash content.
Sudarshan, M.K. Surappa havesynthesized A356 Al–fly ash particle composites .They
studied mechanical properties and dry sliding wear and come into brief idea that
Fly ash with narrow size range (53–106μm) show better properties compared with the wider
size range (0.5–400μm) particles.
The damping capacity of composite increases with the increase in volume fraction of fly
ash.Fracture surface of composites show mixed mode (ductile and brittle) fracture.
The 6%of fly ash particles into A356 Al alloy shows low wear rates at low loads (10 and 20
N)while12% of fly ash reinforced composites show lower wear rates compared to the
unreinforced alloy in the load range 20–80 N.
15. The types of wear dominant in unreinforced alloy are adhesive wear, whereas abrasive wear
is predominant in composites. At higher load, subsurface delamination is the main
mechanism in both the alloy as well in composites.
R.Q. Guoa and P.K. Rohatgi, while studding the changes of chemical reaction between the Al
and the fly ash during synthesis or reheating of fly ash found out that
The chemical reactions do occur between the fly ash an Al melts. The SiO2and Fe2O3
present in the fly ash is reduced to Si and Fe .The melt oxidized to Al2O3.
2.7 FLY ASH
Fly ash is one of the residues generated in the combustion of coal. It is an industrial
byproduct recovered from the flue gas of coal burning electric power plants. Depending upon
the source and makeup of the coal being burned, the components of the fly ash produced vary
considerably, but all fly ash includes substantial amounts of silica (silicon dioxide, SiO2)
(both amorphous and crystalline) and lime (calcium oxide, CaO). In general, fly ash consists
of SiO2, Al2O3, and Fe2O3 as major constituents and oxides of Mg, Ca, Na, K etc. as minor
constituent. Fly ash particles are mostly spherical in shape and range from less than 1 μm to
100 μm with a specific surface area, typically between 250 and 600m2/kg. The specific
gravity of fly ash vary in the range of 0.6-2.8 gm/cc. Coal fly ash has many uses including as
a cement additive, in masonry blocks, as a concrete admixture, as a material in lightweight
alloys, as a concrete aggregate, in flow able fill materials, in roadway/runway construction, in
structural fill materials, as roofing granules, and in grouting. The largest application of fly ash
is in the cement and concrete industry, though, creative new uses for fly ash are being
actively sought like use of fly ash for the fabrication of MMCs.
(Figure 2: Fly Ash)
16. 2.8 WHY FLY ASH
1. The preference to use fly ash as a filler or reinforcement in metal and polymer matrices is
that fly ash is a byproduct of coal combustion, available in very large quantities at very low
costs since much of this is currently land filled. Currently, the use of manufactured glass
micro spheres has limited applications due mainly to their high cost of production. Therefore,
the material costs of composites can be reduced significantly by incorporating fly ash into the
matrices of polymers and metallic alloys.
2. The high electrical resistivity, low thermal conductivity and low density of fly-ash may be
helpful for making a light weight insulating composites.
3. Fly ash as a filler in Al casting reduces cost, decreases density and increase hardness,
stiffness, wear and abrasion resistance. It also improves the maintainability, damping
capacity, coefficient of friction etc. which are needed in various industries like automotive
etc.
4. As the production of Al is reduced by the utilization of fly ash. This reduces the generation
of green house gases as they are produced during the bauxite processing and alumina
reduction.
17. CHAPTER 3
3.1 EXPERIMENTAL WORK
Following steps are carried out in our experimental work
1. Material selection
2. Composite preparation
3. Testing
3.1 Hardness test
3.2 Tensile test
3.3 Compression test
Material selection
The Al 7075 alloy (matrix material), reinforcement Fly ash were used for fabrication of
MMCs, Al 7075,Al 6061 and pure Al.
Composite Preparation
The aluminum fly ash metal matrix composite was prepared by stir casting route. For this we
took pure aluminum and desired amount of fly ash particles. The fly ash particle was
preheated to 300ᵒC for three hour to remove moisture. Commercially pure aluminum was
melted in a resistance furnace. The melt temperature was raised up to 720ᵒC and then the melt
was stirred. The melt temperature was maintained 700ᵒC during addition of fly ash particles.
The melt with reinforced particulates were poured into the preheated permanent metalicmold.
The pouring temperature was maintained at 680ᵒC.The melt was then allow to solidify the
moulds. Magnesium and silicon were added to increase the wettability of fly ash particles.
(Fig 3 Laboratory stir casting set up)
18. 3.2 Hardness test
The Brinell hardness test method as used to determine Brinell hardness is defined in ASTM
E10. Most commonly it is used to test materials that have a structure that is too coarse or that
have a surface that is too rough to be tested using another test method.Brinell hardness is
determined by forcing a hard steel or carbide sphere of a specified diameter under a
specifiedload into the surface of a material and measuring the diameter of the indentation left
after the test. The Brinellhardness number, or simply the Brinell number, is obtained by
dividing the load used, in kilograms, by the actual surface area of the indentation, in square
millimeters. The result is a pressure measurement, but the units are rarely stated.
The BHN is calculated according to the following formula:
Where
BHN = the Brinell hardness number
P = the imposed load in kg
D = the diameter of the spherical indenter in mm
d= diameter of the resulting indenter impression in mm
Fig 4(a)Fig 4(b)
Fig 4(a) Before testing and (b) After testing
19. (Fig 5Brinell hardness tester)
3.3 Tensile test
Tensile testing, also known as tension testing, is a fundamental materials science test in
which a sample is subjected to uni-axial tension untill failure. The results from the test are
commonly used to select a material for an application, for quality control, and to predict how
a material will react under other types of forces. Properties that are directly measured via a
tensile test are ultimate tensile strength, maximum elongation & reduction in area. The tensile
specimens of diameter 6 mm and gauge length 37 mm were machined from the cast
composites with the gauge length of the specimen parallelto the longitudinal axis of the
castings.
Fig 6 Electronic Tensile Testing Machine (Tenson Meter )
21. Fig 7(e) After testing(composite)
3.4 Compression test
The compression test specimens were machined to have cylindrical shape with 10 mm
diameter and 10 mm height. Isothermal compression tests at constant strain rates and constant
temperatures were conducted. The maximum compression equivalent strain of 0.2 was
achieved in the test. Before beginning the test, the specimens were held in the die for some
minutes to allow the material to reach steady state. The temperature was measured using
thermocouples. Carbon powder was used as a lubricant to decrease the effect of friction and
barreling. The deformation temperature and strain rate were automatically controlled by the
machine control unit. Some specimens were subjected to the cold compression test at room
temperature and constant cross head speed. The specimens were subjected to this test to
investigate the anisotropy behavior by measuring the flow stress curve at room temperature,
and by measuring two perpendicular diameters on the specimen’s cross section.
( Fig 8 Universial testing machine)
22. CHAPTER 4
4.1 STRENGTHENING MECHANISM
a.Recovery
b.Recrystallization
c.Grain growth
4.2 RECOVERY
It is a low temperature phenomena which result in the restoration of physical properties.
In this region, no appreciable change in microstructure is observed.
The grains remain distorted and hence mechanical properties such as hardness, tensile
strength and ductility do not change appreciably.
Negligible effect on hardness.
Release internal stresses.
Reduce the number of dislocation.
However, due to heating, some imperfection like vacancies and interstitialcies exiting in the
slip bands may get eliminated.
During recovery, physical properties of the cold worked material are restored without any
observable change in microstructure.
There is some reduction, though not substantial, in dislocation density as well apart from
formation of dislocation configurations with low strain energies.
4.3 RECRYSTALLIZATION
In this region old distorted grains are replaced by new stress free grain, strain free grains by a
process of neucleation and growth This occurs by a recrystallization process.
The microstructure at the end of recrystallization process is very much similar to the original
structure i.e. similar to the structure prior to cold work.
The grains become equiaxed and the dislocation density gets reduced to a value
characteristics of strain free metal.
Due to change in microstructure, all the mechanical properties are changed and the internal
stresses are reduced.
It involves replacement of cold-worked structure by a new set of strain-free,approximately
equi-axed grains to replace all the deformed crystals.
The recrystallization temperature is strongly dependent on the purity of a material.
Pure materials may recrystallize around 0.3Tm, while impure materials may recrystallise
around 0.4Tm, where Tm is absolute melting temperature of the material.
23. 4.4GRAIN GROWTH
If a completely recrystallized material is heated to a higher temperature and kept for a longer
time at the annealing temperature, it will show that the size of the grain will increases.
It affects on the ductility of the material i.e. the ductility will be improved.
During this type of growth, some grains grow abnormally at the expense of the surrounding
recrystallized grains.
This occurs by rapid migration of grain boundaries of few of the primary recrystallized grains
with a results of formation of very large secondary grains.
The driving force for the grain growth is the reduction in the grain boundary surface energy.
24. CHAPTER 5
5.1 RSEULTS AND DISCUSSION
Optical microstructure of different metals
Fig 9(a)After compression(Al 7075) Fig 9(b)After compression(pure Al)
Fig 9(C)After compression(Al 6061)Fig 9(d)After compression(composite)
29. 5.3 Tensile test results
5.3.1 Pure Al
Table -3
High Limit : 19614 N Low Limit : 196 N
Cross Sec Area : 28.40 SQ MM Sample Length : 38.0 MM
Selected Load Cell : 20 KN Test Speed : 0.2 MM /MIN
Peak Load : 1588 N At Length : 6.3 MM Peak Disp. : 16.6 %
Break Load : 107 N At Length : 8.6 MM Break Disp. : 22.6 %
Ten/Cmp Stress : 55.9 N / SQ MM U.T.S. : 55.9 N / SQ MM
Fig 11(a) Stress vs. Strain
Fig 11(b) Load vs. Displacement
0
10
20
30
40
50
60
0.00 0.04 0.09 0.13 0.18 0.22
StressInN/Sq.MM
Strain
0
200
400
600
800
1000
1200
1400
1600
1800
0.00 1.70 3.40 5.10 6.80 8.50
LoadInN
Displacement In mm
30. 5.3.2Al 6061
Table-4
High Limit : 19614 N Low Limit : 196 N
Cross Sec Area : 28.40 SQ MM Sample Length : 38.0 MM
Selected Load Cell : 20 KN Test Speed : 0.2 MM /MIN
Peak Load : 5060 N At Length : 3MM Peak Disp. : 6.8 %
Break Load : 5060 N At Length : 3MM Break Disp. : 8.1 %
Ten/Cmp Stress : 178.2 N / SQ MM U.T.S. : 178.2 N / SQ MM
Fig 12(a) Stress vs. Strain
Fig 12(b) Load vs. Displacement
0
20
40
60
80
100
120
140
160
180
200
0.00 0.01 0.03 0.04 0.05 0.07
StressInN/Sq.MM
Strain
0
200
400
600
800
1000
1200
1400
1600
1800
0.00 1.70 3.40 5.10 6.80 8.50
LoadInN
Displacement In mm
31. 5.3.3Al 7075
Table-5
High Limit : 19614 N Low Limit : 196 N
Cross Sec Area : 28.40 SQ MM Sample Length : 37.0 MM
Selected Load Cell : 20 KN Test Speed : 0.2 MM /MIN
Peak Load : 5649 N At Length : 2.1 MM Peak Disp. : 5.7 %
Break Load : 5649 N At Length : 2.5 MM Break Disp. : 6.8 %
Ten/Cmp Stress : 198.9 N / SQ MM U.T.S. : 198.9 N / SQ MM
Fig 13(a) Stress vs. Strain
Fig 13(b) Load vs.Displacement
0
50
100
150
200
250
0.00 0.01 0.02 0.02 0.03 0.04
StressInN/Sq.MM
Strain
0
1000
2000
3000
4000
5000
6000
0.00 0.30 0.60 0.90 1.20 1.50
LoadInN
Displacement In mm
32. 5.3.4Composite
Table-6
High Limit : 19614 N Low Limit : 196 N
Cross Sec Area : 28.40 SQ MM Sample Length : 37.0 MM
Selected Load Cell : 20 KN Test Speed : 0.2 MM /MIN
Peak Load : 12004N At Length : 1.4 MM Peak Disp. : 3.7 %
Break Load : 10023 N At Length : 1.4 MM Break Disp. : 3.7 %
Ten/Cmp Stress : 422.7 N / SQ MM U.T.S. : 422.7 N / SQ MM
Fig 14(a) Stress vs. Strain
Fig 14(b)Load vs. Displacement
0
50
100
150
200
250
300
350
400
450
0.00 0.02 0.03 0.05 0.06 0.08
StressInN/Sq.MM
Strain
0
2000
4000
6000
8000
10000
12000
14000
0.00 0.60 1.20 1.80 2.40 3.00
LoadInN
Displacement In mm
33. 5.4 Hardness test
Table-7
Materials BHN
Pure Al 29.55
AL 6061 41.53
Al 7075 94.95
Composite 138.21
5.5 Mechanical Properties
Table-8
Sample Hardness Tensile length %of
Elongation
% of Reduction
In Area
Pure Al 29.55 55.9 18.42 11.55
Al 6061 41.53 178.2 13.51 10.52
Al 7075 94.95 198.9 5.40 5.12
Composite 138.21 422.7 2.70 2.63
34. CHAPTER 6
CONCLUSIONS
Here we successfully fabricated the Al 7075-Fly Ash with proper distribution of ash particles
all over the specimen. We have drawn various conclusions from the various calculations
based on the diff. experimental testes:
From the study it is concluded that we can use fly ash for the production of composites and
can turn industrial waste into industrial wealth. This can also solve the problem of storage
and disposal of fly ash
Addition of magnesium and silicon improves the wettability of fly ash with aluminium melt
and thus increases the retention of the fly ash in the composite
Hardness of commercially aluminium is increased from 95BHN to 138BHN with addition of
fly ash and magnesium.
The Ultimate tensile strength has improved with increase in fly ash content. Where as
ductility has decreased with increase in fly ash content.
The effect of increased reinforcement on the wear behavior of the MMCs is to increase the
wear resistance and reduce the coefficient of friction. The MMCs exhibited better wear
resistance due to its superior load bearing capacity
The density of the composites decreased with increasing ash content. Hence these light
weight composites can be used where weight of an object maters as like in the aero and space
industries.
From the above results we find the Composite having an good toughness, hardness, tensile
strength and alsohaving the low density comparatively alloys . So that these composites could
be used in those sectors where light weight and good mechanical properties are required as
like in automobile and space industries
35. CHAPTER 7
REFERENCES
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Composites for automotive and other engineering applications”, JOM, vol. 58, issue no.11,
pp.71-76,2006.
[2] RAO, J.BABU (2010):- “Development of light weight ALFA composites”, interntional
journal of engineering, science and technology.Vol.2,issue no.11, pp. 50-59, 2010.
[3] SHANMUGHASUNDARAM, P. (2011):- “Some studies on Aluminium- Fly Ash
composites fabricated by two step stir casting method”,european journal of scientific
research, vol. 63, issue no.2, pp. 204-218, 2011.
[4] MAHENDRA, K.V (2007):- Fabrication of Al-4.5% Cu alloy with Fly Ash Metal Matrix
Composites and its characteriszation”, materials science-poland, vol. 25, issue no.1, 2007.
[5] MOUTSATSOU, ANGELIKI (2009):- “Synthesis of Aluminium-based Metal Matrix
Composites (MMCs) with lignite fly ash as reinforcement material”, world of coal ash
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[6] CANUL, M.I. PECH (2010):- “The use of fly ash and rice-hull-ash in Al/Sicp
composites: a comparitive study of the corrosion and mechanical behavior”, vol. 15, issue no.
2, pp. 225-232, 2010.
[7] ITSKOS, GRIGORIOS (2011):- “Compaction of high- Ca fly ash-Al- and Al-alloy-
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tribological performance”, coal combustion and gasification products, vol. 3, pp. 75-82, 2011.