The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
This document summarizes a study on the effect of chromium content on the microstructure and wear resistance of Fe-Cr-C hard facing layers. Hard facing layers containing various amounts of chromium were deposited on mild steel using shielded metal arc welding. Testing found that microstructure consisted of primary (Cr, Fe)7C3 carbides and eutectic phases. Higher chromium content refined the carbides. Wear resistance testing found that higher chromium, carbon, and silicon content resulted in higher hardness and less wear. Electrode I, with higher amounts of these elements, exhibited less wear than Electrode II. In conclusion, chromium content significantly affects microstructure and wear resistance, with higher chromium improving hardness and wear performance of Fe
Influence of volume fraction, size, cracking, clustering of particulates and ...eSAT Journals
Abstract
The objective of this study is to examine the influence of volume fraction, size of particulates, formation of precipitates at the
matrix/particle interface, particle cracking, voids/porosity, and clustering of particulates on the strength and stiffness of
6063/SiCp metal matrix composites. Tensile strength and stiffness increase with an increase in the volume fraction of SiC
particulates. The tensile strength and stiffness decrease with increase in size of the particulates, presence of porosity, clustering,
and particle cracking. Formation of particulate clusters is more prominent in the composites having very small-reinforced
particulates. Mg2Si compound is likely to precipitate at the matrix/particle interfaces of 6063/SiC composite.
Keywords: 6063, SiC, clustering, cracking, porosity, clustering
The document analyzes the mechanical properties of carbides in three commercial cold work tool steels using nanoindentation techniques. It finds that nanoindentation can effectively measure the hardness, elastic modulus, and fracture toughness of micron-sized carbides. Each tool steel contains two types of primary carbides ("hard" and "soft") that differ in morphology, chemical composition, and mechanical properties, with hard carbides generally having higher hardness and fracture toughness. Fracture toughness is also found to depend on carbide orientation in one of the tool steels.
This document describes the characterization and fabrication of an Al6063-Si metal matrix composite. Aluminum 6063 alloy was selected as the matrix material due to its light weight and strength. Silicon particles ranging from 5-8 wt% were used as reinforcement. The composites were produced using stir casting, where the matrix material was melted and silicon was added and stirred in. Hardness and tensile tests were performed according to standards. Results showed that hardness and tensile strength increased with higher silicon content, with the 8 wt% composite performing best. Microstructure analysis showed good dispersion of the reinforcement in the matrix.
This document summarizes a research article from the International Journal of Mechanical Engineering and Technology that studied the microstructure and mechanical properties of mild steel-copper joints created through friction welding. Key findings include:
1) Hardness tests found the weld interface had higher hardness than the base metals, with mild steel hardness increasing towards the heat affected zone and copper increasing slightly at the interface.
2) Tensile testing showed welded joints had lower strength than the base metals, failing in the reaction layer formed at the copper side near the interface.
3) Microstructural analysis found that at high rotational speeds, surface irregularities were smoothed and full bonding occurred at the interface, while low speeds allowed imp
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effect of steel ratio and mineral admixtures on crushing load of short columnseSAT Journals
of type of lateral reinforcement as a confining material and also the
effect of mineral admixtures on compressive strength of concrete in the column composite. For this, the work is carried out in two
phases. In the first phase, Short columns were casted by varying volumetric ratio and spacing of lateral reinforcement. The effect
of spacing, volumetric ratio on ultimate load carrying capacity of short columns is studied. And in the second phase, Short
columns with different types of mineral admixtures like fly ash and GGBS are developed. All the columns were tested in the
Universal Testing Machine of 1000 kN capacity. The effect of these admixtures on ultimate load capacity of short columns is
studied. Also, modes of failures, crack pattern, stress-strain patterns are also studied in both stages. The test results indicate that
with increase in volumetric ratio of steel, the strength and ductility of column increases and the columns in which 20% GGBS is
replaced shows high strength. From the modes of failure it is observed that the short columns shows brittle fracture and zone of
rupture is observed at top and bottom ends of the columns and this zone of rupture is decreases with the decrease in spacing of
ties. The spacing of ties is strongly influencing zone of rupture in all type of columns is observed in this study.
Keywords: Short Column, Volumetric Ratio, Fly Ash, GGBS, Mode of Failure
Characterization of Multiaxial Cold Rolled Al6061theijes
The document summarizes a study that characterized the effects of multiaxial cold rolling on an Al6061 alloy. Room temperature tensile tests and hardness tests were performed on samples rolled to 10%, 20%, and 40% reduction. Microstructural analysis also was conducted. The results showed that with increasing reduction, the alloy's grain structure became finer, tensile strength and hardness increased significantly, and the alloy could withstand rolling up to 50% reduction without cracking. The alloy's properties and microstructure were altered in a way that increased strength for engineering applications.
This document summarizes a study on the effect of chromium content on the microstructure and wear resistance of Fe-Cr-C hard facing layers. Hard facing layers containing various amounts of chromium were deposited on mild steel using shielded metal arc welding. Testing found that microstructure consisted of primary (Cr, Fe)7C3 carbides and eutectic phases. Higher chromium content refined the carbides. Wear resistance testing found that higher chromium, carbon, and silicon content resulted in higher hardness and less wear. Electrode I, with higher amounts of these elements, exhibited less wear than Electrode II. In conclusion, chromium content significantly affects microstructure and wear resistance, with higher chromium improving hardness and wear performance of Fe
Influence of volume fraction, size, cracking, clustering of particulates and ...eSAT Journals
Abstract
The objective of this study is to examine the influence of volume fraction, size of particulates, formation of precipitates at the
matrix/particle interface, particle cracking, voids/porosity, and clustering of particulates on the strength and stiffness of
6063/SiCp metal matrix composites. Tensile strength and stiffness increase with an increase in the volume fraction of SiC
particulates. The tensile strength and stiffness decrease with increase in size of the particulates, presence of porosity, clustering,
and particle cracking. Formation of particulate clusters is more prominent in the composites having very small-reinforced
particulates. Mg2Si compound is likely to precipitate at the matrix/particle interfaces of 6063/SiC composite.
Keywords: 6063, SiC, clustering, cracking, porosity, clustering
The document analyzes the mechanical properties of carbides in three commercial cold work tool steels using nanoindentation techniques. It finds that nanoindentation can effectively measure the hardness, elastic modulus, and fracture toughness of micron-sized carbides. Each tool steel contains two types of primary carbides ("hard" and "soft") that differ in morphology, chemical composition, and mechanical properties, with hard carbides generally having higher hardness and fracture toughness. Fracture toughness is also found to depend on carbide orientation in one of the tool steels.
This document describes the characterization and fabrication of an Al6063-Si metal matrix composite. Aluminum 6063 alloy was selected as the matrix material due to its light weight and strength. Silicon particles ranging from 5-8 wt% were used as reinforcement. The composites were produced using stir casting, where the matrix material was melted and silicon was added and stirred in. Hardness and tensile tests were performed according to standards. Results showed that hardness and tensile strength increased with higher silicon content, with the 8 wt% composite performing best. Microstructure analysis showed good dispersion of the reinforcement in the matrix.
This document summarizes a research article from the International Journal of Mechanical Engineering and Technology that studied the microstructure and mechanical properties of mild steel-copper joints created through friction welding. Key findings include:
1) Hardness tests found the weld interface had higher hardness than the base metals, with mild steel hardness increasing towards the heat affected zone and copper increasing slightly at the interface.
2) Tensile testing showed welded joints had lower strength than the base metals, failing in the reaction layer formed at the copper side near the interface.
3) Microstructural analysis found that at high rotational speeds, surface irregularities were smoothed and full bonding occurred at the interface, while low speeds allowed imp
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effect of steel ratio and mineral admixtures on crushing load of short columnseSAT Journals
of type of lateral reinforcement as a confining material and also the
effect of mineral admixtures on compressive strength of concrete in the column composite. For this, the work is carried out in two
phases. In the first phase, Short columns were casted by varying volumetric ratio and spacing of lateral reinforcement. The effect
of spacing, volumetric ratio on ultimate load carrying capacity of short columns is studied. And in the second phase, Short
columns with different types of mineral admixtures like fly ash and GGBS are developed. All the columns were tested in the
Universal Testing Machine of 1000 kN capacity. The effect of these admixtures on ultimate load capacity of short columns is
studied. Also, modes of failures, crack pattern, stress-strain patterns are also studied in both stages. The test results indicate that
with increase in volumetric ratio of steel, the strength and ductility of column increases and the columns in which 20% GGBS is
replaced shows high strength. From the modes of failure it is observed that the short columns shows brittle fracture and zone of
rupture is observed at top and bottom ends of the columns and this zone of rupture is decreases with the decrease in spacing of
ties. The spacing of ties is strongly influencing zone of rupture in all type of columns is observed in this study.
Keywords: Short Column, Volumetric Ratio, Fly Ash, GGBS, Mode of Failure
Characterization of Multiaxial Cold Rolled Al6061theijes
The document summarizes a study that characterized the effects of multiaxial cold rolling on an Al6061 alloy. Room temperature tensile tests and hardness tests were performed on samples rolled to 10%, 20%, and 40% reduction. Microstructural analysis also was conducted. The results showed that with increasing reduction, the alloy's grain structure became finer, tensile strength and hardness increased significantly, and the alloy could withstand rolling up to 50% reduction without cracking. The alloy's properties and microstructure were altered in a way that increased strength for engineering applications.
IRJET- Investigation on Dissimilar Metal Welding of Stainless Steel 316 L and...IRJET Journal
The document investigates dissimilar metal welding of stainless steel 316L and mild steel A-2062 using gas tungsten arc welding (GTAW). Sixteen samples were prepared with variations in welding speed, current, and gas pressure based on a Taguchi experimental design. Tensile testing found ultimate tensile strengths ranging from 394 to 454 MPa. Microhardness was slightly higher than the base materials in the weld zone and heat-affected zone. Microstructure analysis was conducted on samples with the highest ultimate tensile strength, highest heat input, and lowest heat input. The depth of penetration averaged 5.8484 mm and bead width averaged 4.8243 mm across samples.
a survey on gas metal arc welding (gmaw) reviewNEERAJKUMAR1898
Gas metal arc welding (GMAW) is a common and cost-effective welding process that uses a continuous wire feed as an electrode. This document provides an overview of GMAW, including that it uses an electric arc between the wire electrode and workpiece to produce heat and join metals. The wire electrode is continuously fed into the weld pool and consumed, becoming the filler metal. The document discusses the different metal transfer modes in GMAW and that spray transfer mode is used for high productivity welding. It also reviews previous literature on optimizing GMAW parameters and microstructure for applications such as welding high-strength low-alloy steel.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, the aluminium metal matrix was reinforced with 1.5 wt. % of Al2O3 nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural examination conducted on the samples revealed a uniform distribution of alumina particulates. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load and the sliding velocity, with an unlubricated Multiple Tribo Tester. It was found that resistance to sliding wear improved considerably with the addition of alumina nano particles. Microscopic examinations of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear increases with increase in load and sliding velocity. Wear is more when load and speed are increased in steps. Delamination and abrasion are the dominating types of wear observed. Keywords: Sliding Wear, Al2O3, MMNC, Duralumin, Delamination and Abrasion.
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
Comparative Study on the High-Stress Abrasive Wear Behaviour of Zinc and Copp...IRJET Journal
This document presents a comparative study on the abrasive wear behavior of zinc-based and copper-based alloys. Pin-on-disc tests were conducted on samples of the two alloys under varying loads and sliding distances. The zinc-based alloy exhibited higher wear rates and friction coefficients than the copper-based alloy. Microstructural analysis found the zinc alloy had a dendritic structure with intermetallic phases, while the copper alloy contained copper and intermetallic compounds. Temperature and friction increased with load and sliding time for both alloys, with the zinc alloy experiencing higher temperatures and friction. The copper alloy showed better wear resistance overall.
Mechanism of Fracture in Friction Stir Processed Aluminium AlloyDr. Amarjeet Singh
Aluminium alloys are used for important
applications in reducing the weight of the component and
structure particularly associated with transport, marine,
and aerospace fields. Grain refinement by scandium (Sc)
addition can eliminate the casting defects and increase the
resistance to hot tearing for high strength aluminium alloys.
FSP for cast aluminium alloys have been focused and it has
great advantages including solid state microstructural
evolution, altering mechanical properties by optimizing
process parameters. These parameters are tool rotational
speeds (720, and 1000 rpm), traverse speeds (80, and 70
mm/min), and axial compressive force at 15 kN, etc. The
mechanical properties had been evaluated on FSPed
aluminium alloy with different microstructural conditions.
Fracture properties of aluminium alloys are very important
for industrial applications. Tensile and fracture toughness
properties were correlated to microstructural and
fractographic features of the aluminium alloys need to
explore their essential failure mechanisms.
This document summarizes a study on the effect of post-weld heat treatments on the tensile properties of gas tungsten arc welded AA2519-T87 aluminum alloy joints. Gas tungsten arc welding was used to join AA2519-T87 aluminum alloy plates. As-welded joints and joints subjected to artificial aging alone or solution heat treatment followed by artificial aging were evaluated. Microhardness and tensile properties including yield strength, tensile strength, and elongation were measured and compared. Solution heat treatment followed by artificial aging resulted in an 11.8% increase in tensile strength and improved joint efficiency from 66% to 74%, indicating post-weld heat treatments can effectively restore properties lost during
The document proposes optimizing the mechanical properties of AA1100 metal matrix composites (MMCs) through mixture design of experiments (DoE). AA1100 alloy will be reinforced with silicon, copper and magnesium particles via stir casting. Response variables like hardness and compressive strength will be measured. Mixture DoE will then be used to optimize compositional and process parameters like percentage of reinforcements, stirring speed and time to achieve the required mechanical property ranges for car bodies. The methodology involves preparing composite samples, testing them, and analyzing the results to optimize the formulation and processing of AA1100 MMCs.
Finite element analysis of aluminium alloys for their vibration characteristicseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Reducing Corrosion Rate by Welding DesignIJERD Editor
This document summarizes a study on reducing corrosion rates in steel through welding design. The researchers tested different welding groove designs (X, V, 1/2X, 1/2V) and preheating temperatures (400°C, 500°C, 600°C) on ferritic malleable iron samples. Testing found that X and V groove designs with 500°C and 600°C preheating had corrosion rates of 0.5-0.69% weight loss after 14 days, compared to 0.57-0.76% for 400°C preheating. Higher preheating reduced residual stresses which decreased corrosion. Residual stresses were 1.7 MPa for optimal X groove and 600°C
Influence of tensile behaviour of slab on the structural Behaviour of shear c...IJERD Editor
-A composite beam is composed of a steel beam and a slab connected by means of shear connectors
like studs installed on the top flange of the steel beam to form a structure behaving monolithically. This study
analyzes the effects of the tensile behavior of the slab on the structural behavior of the shear connection like slip
stiffness and maximum shear force in composite beams subjected to hogging moment. The results show that the
shear studs located in the crack-concentration zones due to large hogging moments sustain significantly smaller
shear force and slip stiffness than the other zones. Moreover, the reduction of the slip stiffness in the shear
connection appears also to be closely related to the change in the tensile strain of rebar according to the increase
of the load. Further experimental and analytical studies shall be conducted considering variables such as the
reinforcement ratio and the arrangement of shear connectors to achieve efficient design of the shear connection
in composite beams subjected to hogging moment.
This document summarizes research on the metallurgical behavior of AISI 304 steel butt welds under segregation. It discusses how solidification, microstructure development, and alloying element segregation influence properties. Rapid solidification during welding can result in fully austenitic or ferritic microstructures instead of duplex ones. Segregation of elements like chromium and molybdenum occurs due to the formation of dendrites and concentration gradients. This can lead to the precipitation of brittle intermetallic phases and cracking in the weld metal. The document analyzes the solidification modes, microstructures, segregation ratios, and mechanical effects for AISI 304 steel welds.
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, an aluminium metal matrix was reinforced with 1.5 wt. % of Al2O3 nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural examination conducted on the sample revealed a uniform distribution of alumina particulates. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load and the sliding velocity, with an unlubricated Multiple Tribo Tester. It was found that sliding wear resistance improved considerably with the addition of alumina nano particles. Microscopic examinations of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear increases with increase in load and sliding velocity. Delamination and abrasion are the dominating types of wear observed. Keywords: Sliding Wear, Al2O3, MMNC, Duralumin, Delamination and Abrasion.
Effect of pitch and nominal diameter on load distribution and efficiency in m...eSAT Journals
Abstract Lead screws are the devices which are used for power transmission or to have linear motion. It is theoretically assumed that applied load is evenly distributed among the thread pair in contact. However, practically it is observed that load is not uniformly distributed among threads. The first thread carries the maximum load and later the load on each thread reduces. Numerous studies have been carried out for analytical calculation of the load distribution using spring stiffness method. But these studies are for screw and nut combination. Not much study has been done to find load distribution on threads of a lead screw. The maximum load acting on one thread is an important parameter in lead screw design. The load decides the fatigue life of the screw and nut. To have better life of threads, the load distribution should be uniform to have fewer loads on single thread. The load is also important to know the deflection of thread which affects the positional accuracy of the lead screw drives. This paper focuses on analyzing mathematically the various thread parameters which affects the load distribution in threads and the corresponding effect on efficiency. The spring model method proposed in [1], [4] has different constant coefficient which are depending on thread geometry and material. If there are n numbers of threads in contact, there will be (n-1) number of equations in (n-1) unknowns. These are linear difference equations and can be solved by matrix elimination method. The results obtained from analytical solution are validated with the FEM (Finite Elements Method) results. Keywords: Lead Screws, Load Distribution, Thread Parameters, Efficiency, Linear Drives
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, the aluminium metal matrix was reinforced with 1.5 wt. % of alumina nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural investigation was conducted on the worn out samples. It showed uniform distribution of alumina particles in the matrix. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load (constant and step loads) and the sliding speed (constant and step speeds) using a Multiple Tribo Tester. It was found that resistance to sliding wear improved considerably with the addition of alumina nano particles. FESEM images of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear rate increases with increase in load and sliding velocity. Wear rate is more when load and speed are increased in steps. Delamination and abrasion are the dominating types of wear observed. Keywords: Wear rate, Al2O3, MMNC, Duralumin. Coefficient of friction.
A novel aluminum based nanocomposite with high strength and good ductilityHossein Ramezanalizadeh
This document summarizes a research study that fabricated an aluminum-based nanocomposite containing nano-sized Al3Mg2 reinforcing particles. Aluminum and Al3Mg2 powders were mechanically milled and mixed at different times, then hot extruded to consolidate. Testing showed the nanocomposite exhibited high strength and good ductility compared to conventional aluminum, with strength increasing with longer milling time up to 15 hours due to grain refinement and homogeneous particle distribution. The interface between aluminum and Al3Mg2 particles also improved with milling time. Transmission electron microscopy revealed a clean interface with intimate contact between phases.
THE JOINING OF THREE DISSIMILAR METALLIC ALLOYS BY A SINGLE-PASS FRICTION STI...sorayaomidi
This document summarizes research on joining three dissimilar metallic alloys (5083 aluminum alloy, 6061 aluminum alloy, and steel) using single-pass friction stir welding. The maximum joint efficiency achieved was 73% using a rotational speed of 900 rpm, welding speed of 20 mm/min, and a diffusion technique without direct contact between the welding tool and the steel surface. Microstructural analysis found an intermetallic reaction layer formed at the welded interfaces that enhanced joint strength. Tensile tests on the welded specimens found failures typically occurred on the 6061 aluminum alloy side. Diffusion welding without direct tool contact was found to be preferable to minimize wear and generated forces during the welding process when joining these dissimilar materials
This document presents a project on investigating the effect of low velocity impact and fatigue on woven glass fiber/epoxy polymer composite laminates. The objectives are to prepare 2mm thick laminates using hand layup, subject them to low velocity impact at different energy levels, and analyze the impact damage and reduction in fatigue life. The methodology involves impact testing laminates according to ASTM standards at varying heights, and conducting tension-tension fatigue tests on impacted and unimpacted laminates to determine the relationship between impact energy and number of failure cycles. Results and discussion will analyze force-time and force-displacement curves from impact testing and compare fatigue lives.
The document discusses multi response optimization of friction stir welding (FSW) parameters for aluminum alloy AA6105 using the Taguchi method. It first provides background on welding processes including FSW. It then discusses factors that affect FSW quality like rotational speed, welding speed, and tilt angle. The document proposes using an L9 orthogonal array experiment with three control factors and mechanical properties and microstructure as response variables. The methodology involves conducting experiments, applying Taguchi analysis and ANOVA to optimize parameters for properties like tensile strength and hardness. The research aims to minimize defects and improve joint quality of AA6105. Equipment for FSW and response testing is also detailed.
This document summarizes a proposed system to detect and kill Aedes larvae using a hydrophone sensor and pesticides. The hydrophone would detect the sound waves produced by larvae in water storage tanks. When larvae are detected, the system would automatically release pesticides into the water to kill the larvae. The goal is to reduce effort and time spent detecting larvae compared to current methods, and help reduce dengue fever cases worldwide. The system is powered by solar panels to support green energy initiatives. It is hoped this new technology can help control dengue in many affected countries.
Automatic Park and retrieve assissted systems for automobiles using smartphonetheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
IRJET- Investigation on Dissimilar Metal Welding of Stainless Steel 316 L and...IRJET Journal
The document investigates dissimilar metal welding of stainless steel 316L and mild steel A-2062 using gas tungsten arc welding (GTAW). Sixteen samples were prepared with variations in welding speed, current, and gas pressure based on a Taguchi experimental design. Tensile testing found ultimate tensile strengths ranging from 394 to 454 MPa. Microhardness was slightly higher than the base materials in the weld zone and heat-affected zone. Microstructure analysis was conducted on samples with the highest ultimate tensile strength, highest heat input, and lowest heat input. The depth of penetration averaged 5.8484 mm and bead width averaged 4.8243 mm across samples.
a survey on gas metal arc welding (gmaw) reviewNEERAJKUMAR1898
Gas metal arc welding (GMAW) is a common and cost-effective welding process that uses a continuous wire feed as an electrode. This document provides an overview of GMAW, including that it uses an electric arc between the wire electrode and workpiece to produce heat and join metals. The wire electrode is continuously fed into the weld pool and consumed, becoming the filler metal. The document discusses the different metal transfer modes in GMAW and that spray transfer mode is used for high productivity welding. It also reviews previous literature on optimizing GMAW parameters and microstructure for applications such as welding high-strength low-alloy steel.
Studies On Fracture Toughness Behavior of Hybrid Aluminum Metal Matrix Compos...IJERA Editor
The limited mechanical properties of Al and its alloys adversely affect its applications in automobile and
aerospace industries. This remains one of the major concern in the fabrication to suit its application in recent
days. The main aim of the present work is to improve the fracture toughness of the Al matrix composite . A
composite with Al 6061 alloy as matrix and Zirconium Oxide as reinforcement is fabricated by stir casting
process. The specimens were prepared according to ASTM standards and fracture toughness, tensile and
hardness tests were performed and the properties were investigated. Zirconium oxide is selected as a
reinforcement because of its ability to influence the microstructure of the Al 6061 alloy to improve the fracture
toughness. The fracture toughness is highest at 6% reinforcement of ZrO2 and hardness is found to be more at
4% reinforcement
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, the aluminium metal matrix was reinforced with 1.5 wt. % of Al2O3 nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural examination conducted on the samples revealed a uniform distribution of alumina particulates. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load and the sliding velocity, with an unlubricated Multiple Tribo Tester. It was found that resistance to sliding wear improved considerably with the addition of alumina nano particles. Microscopic examinations of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear increases with increase in load and sliding velocity. Wear is more when load and speed are increased in steps. Delamination and abrasion are the dominating types of wear observed. Keywords: Sliding Wear, Al2O3, MMNC, Duralumin, Delamination and Abrasion.
1) Cast scandium added aluminum-magnesium alloy was friction stir welded and its tensile properties were examined.
2) The weld exhibited better mechanical properties than the base metal, with the weld nugget showing the highest strength.
3) Tensile testing showed that the global joint fractured in the base material and had slightly higher strength than the base metal, indicating that friction stir welding is suitable for joining this alloy.
Comparative Study on the High-Stress Abrasive Wear Behaviour of Zinc and Copp...IRJET Journal
This document presents a comparative study on the abrasive wear behavior of zinc-based and copper-based alloys. Pin-on-disc tests were conducted on samples of the two alloys under varying loads and sliding distances. The zinc-based alloy exhibited higher wear rates and friction coefficients than the copper-based alloy. Microstructural analysis found the zinc alloy had a dendritic structure with intermetallic phases, while the copper alloy contained copper and intermetallic compounds. Temperature and friction increased with load and sliding time for both alloys, with the zinc alloy experiencing higher temperatures and friction. The copper alloy showed better wear resistance overall.
Mechanism of Fracture in Friction Stir Processed Aluminium AlloyDr. Amarjeet Singh
Aluminium alloys are used for important
applications in reducing the weight of the component and
structure particularly associated with transport, marine,
and aerospace fields. Grain refinement by scandium (Sc)
addition can eliminate the casting defects and increase the
resistance to hot tearing for high strength aluminium alloys.
FSP for cast aluminium alloys have been focused and it has
great advantages including solid state microstructural
evolution, altering mechanical properties by optimizing
process parameters. These parameters are tool rotational
speeds (720, and 1000 rpm), traverse speeds (80, and 70
mm/min), and axial compressive force at 15 kN, etc. The
mechanical properties had been evaluated on FSPed
aluminium alloy with different microstructural conditions.
Fracture properties of aluminium alloys are very important
for industrial applications. Tensile and fracture toughness
properties were correlated to microstructural and
fractographic features of the aluminium alloys need to
explore their essential failure mechanisms.
This document summarizes a study on the effect of post-weld heat treatments on the tensile properties of gas tungsten arc welded AA2519-T87 aluminum alloy joints. Gas tungsten arc welding was used to join AA2519-T87 aluminum alloy plates. As-welded joints and joints subjected to artificial aging alone or solution heat treatment followed by artificial aging were evaluated. Microhardness and tensile properties including yield strength, tensile strength, and elongation were measured and compared. Solution heat treatment followed by artificial aging resulted in an 11.8% increase in tensile strength and improved joint efficiency from 66% to 74%, indicating post-weld heat treatments can effectively restore properties lost during
The document proposes optimizing the mechanical properties of AA1100 metal matrix composites (MMCs) through mixture design of experiments (DoE). AA1100 alloy will be reinforced with silicon, copper and magnesium particles via stir casting. Response variables like hardness and compressive strength will be measured. Mixture DoE will then be used to optimize compositional and process parameters like percentage of reinforcements, stirring speed and time to achieve the required mechanical property ranges for car bodies. The methodology involves preparing composite samples, testing them, and analyzing the results to optimize the formulation and processing of AA1100 MMCs.
Finite element analysis of aluminium alloys for their vibration characteristicseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Reducing Corrosion Rate by Welding DesignIJERD Editor
This document summarizes a study on reducing corrosion rates in steel through welding design. The researchers tested different welding groove designs (X, V, 1/2X, 1/2V) and preheating temperatures (400°C, 500°C, 600°C) on ferritic malleable iron samples. Testing found that X and V groove designs with 500°C and 600°C preheating had corrosion rates of 0.5-0.69% weight loss after 14 days, compared to 0.57-0.76% for 400°C preheating. Higher preheating reduced residual stresses which decreased corrosion. Residual stresses were 1.7 MPa for optimal X groove and 600°C
Influence of tensile behaviour of slab on the structural Behaviour of shear c...IJERD Editor
-A composite beam is composed of a steel beam and a slab connected by means of shear connectors
like studs installed on the top flange of the steel beam to form a structure behaving monolithically. This study
analyzes the effects of the tensile behavior of the slab on the structural behavior of the shear connection like slip
stiffness and maximum shear force in composite beams subjected to hogging moment. The results show that the
shear studs located in the crack-concentration zones due to large hogging moments sustain significantly smaller
shear force and slip stiffness than the other zones. Moreover, the reduction of the slip stiffness in the shear
connection appears also to be closely related to the change in the tensile strain of rebar according to the increase
of the load. Further experimental and analytical studies shall be conducted considering variables such as the
reinforcement ratio and the arrangement of shear connectors to achieve efficient design of the shear connection
in composite beams subjected to hogging moment.
This document summarizes research on the metallurgical behavior of AISI 304 steel butt welds under segregation. It discusses how solidification, microstructure development, and alloying element segregation influence properties. Rapid solidification during welding can result in fully austenitic or ferritic microstructures instead of duplex ones. Segregation of elements like chromium and molybdenum occurs due to the formation of dendrites and concentration gradients. This can lead to the precipitation of brittle intermetallic phases and cracking in the weld metal. The document analyzes the solidification modes, microstructures, segregation ratios, and mechanical effects for AISI 304 steel welds.
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, an aluminium metal matrix was reinforced with 1.5 wt. % of Al2O3 nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural examination conducted on the sample revealed a uniform distribution of alumina particulates. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load and the sliding velocity, with an unlubricated Multiple Tribo Tester. It was found that sliding wear resistance improved considerably with the addition of alumina nano particles. Microscopic examinations of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear increases with increase in load and sliding velocity. Delamination and abrasion are the dominating types of wear observed. Keywords: Sliding Wear, Al2O3, MMNC, Duralumin, Delamination and Abrasion.
Effect of pitch and nominal diameter on load distribution and efficiency in m...eSAT Journals
Abstract Lead screws are the devices which are used for power transmission or to have linear motion. It is theoretically assumed that applied load is evenly distributed among the thread pair in contact. However, practically it is observed that load is not uniformly distributed among threads. The first thread carries the maximum load and later the load on each thread reduces. Numerous studies have been carried out for analytical calculation of the load distribution using spring stiffness method. But these studies are for screw and nut combination. Not much study has been done to find load distribution on threads of a lead screw. The maximum load acting on one thread is an important parameter in lead screw design. The load decides the fatigue life of the screw and nut. To have better life of threads, the load distribution should be uniform to have fewer loads on single thread. The load is also important to know the deflection of thread which affects the positional accuracy of the lead screw drives. This paper focuses on analyzing mathematically the various thread parameters which affects the load distribution in threads and the corresponding effect on efficiency. The spring model method proposed in [1], [4] has different constant coefficient which are depending on thread geometry and material. If there are n numbers of threads in contact, there will be (n-1) number of equations in (n-1) unknowns. These are linear difference equations and can be solved by matrix elimination method. The results obtained from analytical solution are validated with the FEM (Finite Elements Method) results. Keywords: Lead Screws, Load Distribution, Thread Parameters, Efficiency, Linear Drives
Wear characteristics of pure aluminium, al alloy & al-alumina metal mtrix...eSAT Journals
Abstract In this report, the aluminium metal matrix was reinforced with 1.5 wt. % of alumina nano particles using non-contact cavitation method to prepare the metal matrix nano composite. Microstructural investigation was conducted on the worn out samples. It showed uniform distribution of alumina particles in the matrix. Sliding wear behavior of the as-cast MMNC was studied in dry condition, under different test conditions by varying the load (constant and step loads) and the sliding speed (constant and step speeds) using a Multiple Tribo Tester. It was found that resistance to sliding wear improved considerably with the addition of alumina nano particles. FESEM images of the worn out surfaces of pure Al, Al-alloy (duralumin) and MMNC reveal that the MMNC has greater resistance to sliding wear compared to pure aluminium and duralumin. Wear rate increases with increase in load and sliding velocity. Wear rate is more when load and speed are increased in steps. Delamination and abrasion are the dominating types of wear observed. Keywords: Wear rate, Al2O3, MMNC, Duralumin. Coefficient of friction.
A novel aluminum based nanocomposite with high strength and good ductilityHossein Ramezanalizadeh
This document summarizes a research study that fabricated an aluminum-based nanocomposite containing nano-sized Al3Mg2 reinforcing particles. Aluminum and Al3Mg2 powders were mechanically milled and mixed at different times, then hot extruded to consolidate. Testing showed the nanocomposite exhibited high strength and good ductility compared to conventional aluminum, with strength increasing with longer milling time up to 15 hours due to grain refinement and homogeneous particle distribution. The interface between aluminum and Al3Mg2 particles also improved with milling time. Transmission electron microscopy revealed a clean interface with intimate contact between phases.
THE JOINING OF THREE DISSIMILAR METALLIC ALLOYS BY A SINGLE-PASS FRICTION STI...sorayaomidi
This document summarizes research on joining three dissimilar metallic alloys (5083 aluminum alloy, 6061 aluminum alloy, and steel) using single-pass friction stir welding. The maximum joint efficiency achieved was 73% using a rotational speed of 900 rpm, welding speed of 20 mm/min, and a diffusion technique without direct contact between the welding tool and the steel surface. Microstructural analysis found an intermetallic reaction layer formed at the welded interfaces that enhanced joint strength. Tensile tests on the welded specimens found failures typically occurred on the 6061 aluminum alloy side. Diffusion welding without direct tool contact was found to be preferable to minimize wear and generated forces during the welding process when joining these dissimilar materials
This document presents a project on investigating the effect of low velocity impact and fatigue on woven glass fiber/epoxy polymer composite laminates. The objectives are to prepare 2mm thick laminates using hand layup, subject them to low velocity impact at different energy levels, and analyze the impact damage and reduction in fatigue life. The methodology involves impact testing laminates according to ASTM standards at varying heights, and conducting tension-tension fatigue tests on impacted and unimpacted laminates to determine the relationship between impact energy and number of failure cycles. Results and discussion will analyze force-time and force-displacement curves from impact testing and compare fatigue lives.
The document discusses multi response optimization of friction stir welding (FSW) parameters for aluminum alloy AA6105 using the Taguchi method. It first provides background on welding processes including FSW. It then discusses factors that affect FSW quality like rotational speed, welding speed, and tilt angle. The document proposes using an L9 orthogonal array experiment with three control factors and mechanical properties and microstructure as response variables. The methodology involves conducting experiments, applying Taguchi analysis and ANOVA to optimize parameters for properties like tensile strength and hardness. The research aims to minimize defects and improve joint quality of AA6105. Equipment for FSW and response testing is also detailed.
This document summarizes a proposed system to detect and kill Aedes larvae using a hydrophone sensor and pesticides. The hydrophone would detect the sound waves produced by larvae in water storage tanks. When larvae are detected, the system would automatically release pesticides into the water to kill the larvae. The goal is to reduce effort and time spent detecting larvae compared to current methods, and help reduce dengue fever cases worldwide. The system is powered by solar panels to support green energy initiatives. It is hoped this new technology can help control dengue in many affected countries.
Automatic Park and retrieve assissted systems for automobiles using smartphonetheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
Quality Evaluation Of Complementary Food Formulated From Moringa Oleifera Lea...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
Consumer Knowledge Of Food Labels Of Low Income Female Workers In Michael Okp...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Comparison of Ordinary Least Square Regression and Geographically Weighted Re...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
Robotic assistance for the visually impaired and elderly peopletheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Machining Of an Aluminum Metal Matrix Composite Using Tungsten Carbide Insertstheijes
This document summarizes an experiment that analyzed the effect of machining parameters on surface roughness, cutting temperature, and forces when turning an aluminum metal matrix composite (MMC) with tungsten carbide inserts. The MMC was fabricated via stir casting and machined using different cutting speeds, feeds, and depths of cut. Results showed that surface roughness decreased with increasing speed and decreasing feed and depth of cut. Cutting temperature was highest at medium speeds and feeds. Aluminum inserts produced better surface finish and lower temperatures than steel inserts but steel inserts generated lower cutting forces. The experiment aimed to determine optimal machining parameters for the composite.
Challenges to the Implementation of Information Technology Risk Management an...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Feasible Interfacing and Programming of Industrial Control Technology Unit wi...theijes
This document discusses the interfacing and programming of an industrial control technology unit with PLCs and robots. It begins with an abstract that describes how the unit assembles components using sensors, actuators, and a PLC for control. A PLC program is presented to control the unit and interface it with a 6-axis robot for workpiece transfer using a pneumatic gripper. The document then reviews literature on using PLCs compared to microprocessors for industrial control. It presents the project requirements, software used, and PLC and robot programming methods. The conclusion discusses the benefits of PLCs for industrial control and their interfacing with robots.
Implementation of Stronger S-Box for Advanced Encryption Standardtheijes
This document describes the implementation of a stronger S-box for the Advanced Encryption Standard (AES) using combinational logic. It presents a two-stage pipelined combinational logic based S-box that has smaller area and higher throughput compared to traditional ROM-based implementations. The S-box construction methodology decomposes arithmetic in GF(28) fields into lower order GF(2^2) and GF(2) fields. Equations for addition, squaring, multiplication and inversion in these composite fields are derived. Simulation results show encryption and decryption working as intended. Synthesis results indicate lower device utilization compared to ROM implementations.
Statistical Analysis of Factors Affecting the Dry Sliding Wear Behaviour of A...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
Assessing the impact of community development efforts in the nigeria`s state ...theijes
The document analyzes community development efforts in Nigeria's Zamfara state. It discusses how various state governments, including Zamfara, have implemented programs like the Community and Social Development Project and Community Driven Development initiative to mobilize rural communities and address poverty. The summary evaluates the impact of these efforts in Zamfara. It finds that they have: 1) promoted peace and harmony; 2) empowered communities and improved access to services; and 3) strengthened partnerships between local governments and communities to enhance human development. The document concludes that engaging and involving local communities early in the process is critical for effective community development.
Parametric Optimization of Wire Electrical Discharge Machining (WEDM) Process...theijes
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
Adaptive Optimization of Cloud Security Resource Dispatching SFLA Algorithmtheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Two Level Auditing Architecture to Maintain Consistent In Cloudtheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
Design of Banking Security System Using Mems And Rfid Technologytheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Design and Construction of a Simple and Reliable Temperature Control Viscomet...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Study on Gas Metal Arc Welding in S235 SteelIRJET Journal
The document studies gas metal arc welding (GMAW) of S235 high-strength steel. Samples of S235 steel were butt welded using GMAW with varying parameters like current, voltage, welding speed, and wire feed. The welded samples were tested for tensile strength, yield strength, hardness, and microstructure. The results showed that sample 3 with 21.9V current, 170A, and 70mm/min welding speed achieved the highest tensile strength of 560MPa and yield strength of 488MPa. Sample 5 with 21.3V, 150A, and 60mm/min achieved the highest hardness of 87. Microstructural analysis found samples 3 and 5 had the best grain structure
This study investigated the effect of three iron-based hardfacing electrodes - Hard Alloy 400, Hardloy III, and Hardloy V - on the properties of stainless steel when applied using shielded metal arc welding. Single and double layers of each electrode were deposited. Microhardness, wear resistance, and microstructure of the samples were then analyzed. Microhardness was found to increase by 1.7x, 2x, and 2.4x for the three electrodes respectively. Wear resistance improved by 29%, 60%, and 66% respectively. Microstructure analysis revealed that Hardloy V samples had the finest and most uniform grain structure, corresponding to the highest hardness and lowest wear rate. In conclusion, Hardloy V electrode
Effect of Process Parameters and Nano particles on Friction Stir Welding of D...IRJET Journal
This document summarizes research on friction stir welding (FSW) of dissimilar aluminum alloys. It discusses how FSW is used to join materials like aluminum and challenges in joining dissimilar materials, such as formation of brittle intermetallic compounds with different properties. The document reviews studies on FSW of aluminum alloys with additions of nanoparticles like silicon carbide to improve mechanical properties. It also examines work on using probeless tools to repair defects in friction stir welds of aluminum and copper.
IRJET- A Review on Microstructure and Mechanical Properties of Silicon Nitrid...IRJET Journal
1) The document discusses a review of the microstructure and mechanical properties of silicon nitride reinforced aluminum metal matrix composites (AMMCs) fabricated using stir casting.
2) Key findings from previous studies on AMMCs produced via different methods are summarized, focusing on the effects of processing parameters and reinforcement content and type on mechanical properties like tensile strength and hardness, as well as wear resistance.
3) The current study aims to investigate the microstructure and mechanical properties of AMMCs with aluminum oxide and silicon nitride reinforcements fabricated by stir casting and determine how properties vary with different cutting speeds and feeds during machining.
Development of Aluminium Metal Matrix Composite Using Stir Casting Methodtheijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
IRJET - Evaluate the Residual Stress Formation of DP600 During RSWIRJET Journal
This study evaluated residual stress formation in DP600 dual phase steel sheets during resistance spot welding (RSW) at different pressures and currents. Samples of DP600 steel were resistance spot welded at pressures of 3.5, 4.5, and 5.5 bar and currents of 4, 6, and 8 kA. Microstructure, hardness, and residual stress of the welded samples were then examined. Results showed that hardness was highest in the weld region due to martensite formation from the high cooling rates of RSW. Hardness increased with higher clamping pressure and current. Residual stress measurements found compressive residual stresses in the specimens, with the highest stresses found in the 5 kA-6 bar samples.
A Review on Friction Stir Welding of Similar and Dissimilar Aluminium AlloysIRJET Journal
This document provides a literature review on friction stir welding of similar and dissimilar aluminum alloys. It summarizes 18 research papers on the topic. The review finds that friction stir welding can produce high quality joints in aluminum alloys without defects like porosity or cracking. However, challenges remain in welding dissimilar alloys due to differences in mechanical properties and microstructure. Further research is needed to better understand material flow and optimize welding parameters for dissimilar aluminum alloy joints.
The Study of Flexural and Ultimate Behavior of Ferrocement Lightweight Beam b...IRJET Journal
1. The study examines the flexural and ultimate behavior of ferrocement lightweight beams using autoclaved aerated concrete (AAC) blocks.
2. Six beams were tested - three reinforced concrete beams and three ferrocement beams. Testing involved applying a single point load until failure and recording the first crack load, ultimate load, and deflections.
3. Test results found that ferrocement beams gave early warning of failure through initial cracking compared to sudden failure in reinforced concrete beams. Ferrocement beams also experienced greater deflections than reinforced concrete beams under the same loads.
This document summarizes a study that investigated the effects of different quenching media (brine solution, water, diesel oil, and air) on the impact strength of single-vee butt welded mild steel joints. Samples of mild steel were welded using a coated electrode and then heat treated at temperatures from 2000°C to 6000°C before being quenched in the different media. Impact testing found that quenching in brine solution resulted in the lowest average impact strength, while quenching in air produced the highest average impact strength. Overall, the results indicated that air was the best quenching medium for welded mild steel, followed by diesel oil, water, and brine solution, when considering impact
Corrosion Effects of Cr and Ni in Thermo-Mechanical Treated Steel Bar in Mari...IRJET Journal
This document summarizes a study on the corrosion effects of chromium and nickel in thermo-mechanically treated steel bars used in marine environments. Two different steel bars were tested - one containing copper, phosphorus, chromium, and nickel (Steel 1), and one containing just carbon, sulfur, and manganese (Steel 2). Tests were conducted to analyze the microstructure, mechanical properties, and corrosion resistance of the steel bars. The Steel 1 bar exhibited a composite microstructure and better balance of mechanical properties. Corrosion tests in salt water found that Steel 1 had a more noble free corrosion potential and lower corrosion current, indicating better corrosion resistance attributed to its alloying elements, which formed a denser rust layer. The
IRJET- Examination of Hardness Values for Ti-6Al-4V Welded Specimens and Micr...IRJET Journal
This document examines the hardness values and microstructural characterization of welded Ti-6Al-4V specimens. Hardness tests were conducted on different zones of welded specimens with different weld bead shapes. The fusion zone and heat-affected zone showed higher hardness than the base metal. Tensile tests revealed that specimens failed at the weld with a yield strength of 820 MPa and ultimate tensile strength of 890 MPa. Fractured surfaces were analyzed using scanning electron microscopy to understand failure modes. SEM images showed ductile failure with dimples in the base metal and no cracks in the welded region.
Studies on Al8081-B4C Metal Matrix Composites Fabricated by Stir Casting MethodIJMER
Aluminium MMCs are preferred in the fields of aerospace, military, automotive, marine and
in many other domestic applications. In the present work, an attempt has been made to develop and
study the, Mechanical properties of Al-8081/B4C reinforced aluminium metal matrix composites. The
composite was prepared by using Liquid Metallurgy Route (Stir Casting Technique). Liquid state has
some important advantages such as better matrix particle bonding, easier control of matrix structure,
simplicity, low cost of processing, nearer to net shape and wide selection of material. Al-8081 alloy
was taken as the base matrix to which B4C particulates are used as reinforcements. Al8081-B4C
composites were prepared by varying weight percentage of B4C i.e 0 to 6 %, in steps of two. The
objective is to study the effect of B4C particulates on mechanical properties such as ultimate tensile
strength, yield strength and hardness of Al8081 alloy composites. The results of this study revealed
that, as the B4C content was increased, there were significant increases in the ultimate tensile strength,
yield strength and hardness in the composites as compared to the base matrix
Performance of Armor Steel Gas Metal Arc Welded JointsIRJET Journal
This document discusses the performance of armor steel gas metal arc welded joints. It investigates welding Armox 500 T armor steel using the gas metal arc welding process with two different filler metals and joint configurations. The goal is to determine if the welded joints meet required tensile strength and absorbed energy standards. Results show that both single V-joint and single bevel joint configurations passed requirements, whether using carbon steel or austenitic stainless steel filler wire. Dilution was observed in single V joints and increased in single bevel joints. Increasing cooling rate improved strength and hardness near the weld. Both configurations also passed impact testing at -40°C. Corrosion rates of the welded joints were lower than the
REVIEW ON MECHANICAL PROPERTIES OF NON-ASBESTOS COMPOSITE MATERIAL USED IN BR...ijiert bestjournal
Metallic matrix composites are combinations of two or more different metals inter metallic compounds or second phases in which dispersed phases are embe dded within the metallic matrix. They are produced by controlling the morphologies of the constituents to achieve optimum combination of properties. Properties of the composites depend on the properti es of the constituent phases,their relative amount,and dispersed phase geometry including particle siz e,shape and orientation in the matrix. In this pap er,The mechanical properties,behaviour and micro stru ctural evolution of aluminium metal matrix metallic composites fabricated under various process conditi ons were investigated to understand their process- structure�property relations by optimization proces s. Addition of silicon carbide to aluminum has show n an increase in its mechanical properties.
Effect of Volume Fraction (Al2O3) on Tensile Strength of Aluminium 6061 by Va...IRJET Journal
This document reviews the effect of adding aluminum oxide (Al2O3) particles on the tensile strength of aluminum 6061 composites produced via stir casting. Stir casting is described as a common and cost-effective method for fabricating metal matrix composites. The key process parameters of stir casting that influence composite properties are identified as stirrer design and speed, temperature, time, and reinforcement concentration. Literature on aluminum metal matrix composites reinforced with Al2O3 and silicon carbide is summarized, finding that strength and hardness generally increase with higher reinforcement content, while ductility decreases. Adding Al2O3 to aluminum 6061 via stir casting was shown to improve tensile strength over the unreinforced alloy. The document concludes
Study of Pitting Corrosion Behavior of FSW weldments of AA6101- T6 Aluminium ...IJERA Editor
Friction Stir Welding (FSW) is a promising solid state joining process widely used generally for Al alloys,
especially in aerospace, marine and automobile applications. In present work, the microstructure and corrosion
behavior of friction stir welded AA6101 T6 Al alloy is studied. The friction stir welding was carried using
vertical milling machine with different tool rotational speeds and welding speeds. The microstructure at weld
nugget or stir zone (SN), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and base metal
were observed using optical microscopy. The corrosion tests of base alloy and welded joints were carried out in
3.5% NaCl solution at temperature of 30º C. Corrosion rate and emf were determined using cyclic polarization
measurement.
Evaluation of the Influence of the Welding Current on the Surface Quality of ...theijes
Welding is a metallurgical process; all aspects of a welding process can be more or less, related to metallurgy of the materials involved in welding,either base metal or electrodes. It is a rapid joining technique extensively used for joining thin assemblies in military and automotive applications. The resistance spot welding process bonds contacting metal surfaces via the heat obtained from resistance to an electrical current flow.Process parameters like welding current, time and pressure are closely controlled to obtain superior weld quality. Welding current is generally considered as a key factor affecting the weld quality. The paper deals with evaluation of welding current as the most important parameter of resistance spot welding on the surface quality of welded steel sheets.Various values of welding current were used in the experiments and consequently the marks of spot welded tips on the welded material surfaces were observed. Hot-dip galvanized steel sheets of H220PD and TRIP RAK 40/70 were used for resistance spot welding.
Investigation on Properties of Structural Steel Joints using Arc and MIG Weld...IRJET Journal
This document investigates the properties of structural steel joints welded using arc and MIG welding processes. Mild steel plates of varying thicknesses were welded using both processes. Samples from the welded joints underwent tensile testing, impact testing, hardness testing, and microscopic analysis to evaluate and compare the mechanical properties. The investigation found that MIG welding joints produced higher mechanical properties than arc welding joints when joining mild steel plates. V-shaped joints also performed better than square butt joints.
IRJET- Evolution of Tensile and Fracture Toughness Properties of Aluminum-707...IRJET Journal
This document summarizes an experimental study that investigated the tensile and fracture toughness properties of an aluminum-7075 alloy reinforced with zirconium silicate particulates. Specimens with various weight percentages (3%, 6%, 9%, 12%) of zirconium silicate reinforcement were fabricated using stir casting and tested according to ASTM standards. The results showed that the ultimate tensile strength and fracture toughness were improved with 9% zirconium silicate reinforcement but decreased at 12% reinforcement. The study aimed to determine the effect of zirconium silicate particulate reinforcement on the mechanical properties of aluminum-7075 alloy.
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The Effects of Welding Processes and Microstructure on 3 Body Abrasive Wear Resistances for Hardfacing Deposits
1. The International Journal Of Engineering And Science (IJES)
|| Volume || 3 || Issue || 12 || December - 2014 || Pages || 35-44||
ISSN (e): 2319 – 1813 ISSN (p): 2319 – 1805
www.theijes.com The IJES Page 35
The Effects of Welding Processes and Microstructure on 3 Body
Abrasive Wear Resistances for Hardfacing Deposits
Dr. K. M. Kenchi Reddy 1
And Dr. C. T. Jayadeva 2
1,
Professor, Department of Mechanical Engineering, Sri Krishna Institute of Technology, Bangalore, India.
2,
Professor, Department of Mechanical Engineering, Adichunchanagiri Institute of Technology, Chikmagalur,
India.
--------------------------------------------------ABSTRACT --------------------------------------------------------
Wear is the predominant factor that controls the life of any machine part. Metal parts often fail their intended
use not because they fracture and wear which causes them to lose dimension and functionally. Different
categories of wear exit, but most typical modes are abrasion,impact,Hardfacing is one of the most useful and
economic ways to improve the performance of components submitted to severe wear conditions. A study was
made to compare the microstructure and abrasion resistance of hardfacing alloys reinforced with primary
chromium carbides. The hardfacing alloys were deposited onto M.S. plate by shielded metal arc welding
(SMAW) process. Two different commercial hardfacing electrodes were employed to investigate the effect of the
microstructure. The abrasion tests were carried out in a dry sand-rubber wheel abrasion machine according to
the procedure A of ASTM G65 standard. Microstructure characterization and surface analysis were made using
optical and scanning electron microscope. The result shows that the wear resistance is determined by the size,
shape, distribution and chemical composition of the carbides, as well as by the matrix microstructure. The best
abrasion resistance was obtained in microstructure composed of chromium carbide alloy. Hardfacing is a
deposition of different metal over the parent metal to achieve required properties.
KEYWORDS: Abrasion resistance, Hardfacing alloys, Microstructure characterization, Wear mechanism,
welding.
---------------------------------------------------------------------------------------------------------------------------------------
Date of Submission: 03 December 2014 Date of Publication: 15 December 2014
---------------------------------------------------------------------------------------------------------------------------------------
I. INTRODUCTION
Hardfacing is also known as Hardsurfacing is the application e specialized alloys by means of welding
process to resist abrasion, corrosion, high temperature, or impact. Such an alloy may be deposited on the
surface, an edge, or merely the point of a part subject to wear. Hardfacing deposits can functionalize surfaces
and reclaim components by extending their service life. Hardfacing is a key technology to fulfill these
requirements and to apply different hardfacing alloys on the base metals. Hardfacing increases the service life of
a part and there by extend the life time of machinery equipment efficiently.Core components such as crushers
are exposed to heavy wear and require efficient surface protection measures to avoid costly downtimes and to
reduce costs for expensive spare parts. Hardfacing is a commonly employed method to improve surface
properties of agriculture tools, components for mining operation, soil preparation equipments and earth moving
equipments [1], [2]. This process has been also adopted across many industries such as Cement, Mining, Steel,
Petro-chemical, Power, Sugar cane and Food. An alloy is homogeneously deposits onto the surface of a soft
material by welding with the purpose of increasing loss in ductility and toughness of the substrate. A wide
variety of hardfacing alloys are commercially available for protection against wear. Deposits with a
microstructure composed by disperse carbides in austenite matrix are extensively used for abrasion applications
and are typically classified according to the expected hardness. Nevertheless, the abrasion resistance of a
hardfacing alloys depends on many other factors such as the type, shape and distribution of hard phases, as well
as the toughness and strain hardening behavior of the matrix[3].
Chromium-rich electrodes are widely used due to low cost and availability; however, more expensive
tungsten or vanadium-rich alloys offer better performance due to a good combination of hardness and
toughness. Complex carbides electrodes are also used; especially when abrasive wear is accompanied by other
wear mechanisms [4].Several welding techniques such as oxyacetylene gas welding (OAW), gas metal arc
welding (GMAW), shielded metal arc welding (SMAW) and submerged arc welding (SAW) can be used for
hardfacing. The most importance differences among these techniques lie in the welding efficiency, the weld
2. The Effects of Welding Processes and Microstructure…
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plate dilution and the manufacturing cost of welding consumables [5]. SMAW, for example, is commonly used
due to the low cost of electrodes and easier application. The present investigation aims to study two commercial
electrodes in terms of their chemical composition, microstructure, hardness and abrasive wear resistance.
II. EXPERIMENTAL PROCEDURE
Base Metal : The selection of base metal is very essential in deciding what alloy to use for hardfacing deposit.
Since welding procedure differs according to the base metal. Mild steel was selected as the base metal for the
study which composes the main elements of carbon, silicon, manganese, sulphur, and phosphorous. The
chemical composition is given in Table 1.
Hardfacing Alloys : In the study, two different commercial hardfacing alloys were used for overlaying. These
are basically iron – based alloys having varying amount of chromium, carbon, silicon and other alloying
elements as they are more suitable for shielded metal arc welding process. Chemical compositions of two
electrodes are presented in table 2.
Table 1: Chemical Composition of Base Metal (In Weight Percentage)
C Si Mn S P Fe
0.18 0.32 1.47 0.013 0.029 Bal
Table 2: Chemical Composition of Hardfacing Alloy (In Weight Percentages)
Electrode C Si Mn S P Cr Mo Ni V Fe
Hardfacing-1 0.33 0.28 1.15 0.014 0.025 2.22 - - - Bal
Hardfacing-2 0.1 0.38 1.51 0.024 0.03 2.15 0.745 1.09 0.103 Bal
Welding Conditions
The standard size of test specimens of 16 nos. with the dimensions of 250×100×12 mm was selected
for the experiment.
The following precautions are taken before hardfacing:
The electrodes are perfectly dried in the furnace and baked at 250°C one hour before the use
Area of the weld is properly cleaned
Preheated the hardfacing area to a minimum of 200°C
2.4 Machine specifications
Name: TORNADO MIG 630 Arc welding machine
Current: 100-630 A
Input Voltage: 415 V ± 10% / 50-60 Hz / 3 Phase
Machine Capacity: 50 KVA
2.5 Stages of Experiment
The experiment was carried out in three stages to investigate the effect of welding parameters
such as current, travel speed and voltage on hardfacing electrodes and the corresponding hardness was
determined by using Vickers hardness testing machine.
1) In first stage, voltage (V) and travel speed (S) were kept constant and current (A) was increased.
2) In second stage, voltage (V) and current (A) were kept constant and travel speed (S) was increased.
3) In third stage, current (A) and travel speed (S) were kept constant and voltage (V) was increased
III. RESULTS OF THE EXPERIMENT
Hardness test
The specimens were cut to a size of 100x30x12mm for hardness testing and were polished using
standard metallographic procedure. Hardness testing of different welding deposits was carried out in Vickers
hardness testing machine using SHIMADZU HMV-2000 Micro Hardness Tester, The load applied is 500 Gms,
dwell time is 13 Sec with a square base diamond pyramid of opposite face angle 136° ±0.5°. The test method
adopted is as per IS: 1501-2002. Micro hardness surveys were made on these specimens using Vickers hardness
tester along the direction of thickness from the top surface towards the base metal after every 0.5 mm. These
surface values are plotted in the form of a graph shown in figure 1. The results of the hardness survey of heat
affected zone (HAZ) samples for every 0.5mm depth indicate that the hardness values are more on the weld
surface and decrease towards the base metal and remain constant on the base metal. Based on welding
parameters such as current, travel speed and voltage the micro hardness surveys were made on the each
3. The Effects of Welding Processes and Microstructure…
www.theijes.com The IJES Page 37
specimens using Vickers hardness tester along the direction of thickness from the top surface towards the base
metal after every 0.5 mm are illustrated in the cumulative graph for all the 16 specimens are shown in figure 1
for comparison.
Figure1. Hardness survey of heat affected zone (HAZ) for 16 samples
Alloy (hardfacing 1) is the main martensitic with some kinds of austenite. Fine primary chromium
carbides are well distributed throughout the micro section. The hardness on the Weldment and HAZ towards the
base metal has been surveyed for every 0.5 mm depth and the values are plotted in figure 1. The chemistry of
the Fe/Cr carbides is reported for hypereutectic FeCrC alloys in literature to M7C3 structure [6-9]. The hardness
values of the ledeburitic matrix which are determined to about 500 HV 0.5 are close to previous investigations
from Fischer [10] and Buytoz [11]. Beside small and evenly distributed primary chromium carbide at a volume
content of approximately 5% can be detected which are supposed to be of major importance for increasing the
resistance against abrasion due to their high hardness. While observing the alloy of hardfacing 2 the constituents
of primary chromium carbides are not well distributed throughout the micro structure. After the dry sand
abrasion test comparisons were made between electrode 1 and electrode 2, the electrode 1 is more wear
resistance than electrode 2.
A closed net or skeleton of brittle Fe/Cr carbides is clearly surrounds the primary dendrites. Higher
welding amperage, higher arc travel and higher voltage leads to decreasing hardness. Overall the chromium
carbides are irregularly distributed. There is a higher density of original carbides close to the fusion line,
whereas at the surface only rests of carbides are visible. BAIRD spectroscope is used to analyze the
microstructure of the specimens. Cross sections of the weld were polished and etched with kalling’s and Nital
2%. Different types of carbides present in the microstructures were first identified on the basis of their
morphologies and confirmed by micro hardness measurements. The wear resistance is in fact proportional
to the volume fraction in hypereutectoid Steels [12]. Furthermore, the original orientation of the colony and the
mean inter lamellar spacing have effects on wear resistance [13]. Several authors investigated that the
relationship between wear resistance and hardness is affected by microstructure [13, 14].
Wear resistance increased in the structural sequence from spheroidite to pearlite and from tempered
martensite to bainite [12, 15]. Microstructure shows pearlite with subsequent formation of interdendritic
carbides. However, the carbide content in the weld deposit made with welding parameters at current 200A,
travel speed 21.4cm/min and voltage 25V is higher than that with weld deposit made with welding parameters at
current 300A, travel speed 23.1 cm/min and voltage 25V for the same electrode. Furthermore coarser
microstructure are observed in weld deposit made with higher heat input at higher amperage current and travel
speed for the same electrode keeping more or less similar microstructural constituents. These microstructural
characteristics are also reflected in the hardness values. Higher amount of carbide and finer structure, in general
resulted in higher hardness, whereas lower hardness values were recorded in weld deposits with less amount of
carbides and coarser structure. Several Authors [16, 17] have suggested that abrasive wear resistance increases
in direct relationship with the volume of the hard constituent. It is interesting to note that weld deposits made
with high heat input with higher amperage of current for the same alloy system possess higher wear resistance.
Apparently one would expect lower wear resistance in the weld deposit made with high heat input, due to lower
hardness value. Alloy mainly martensitic with some islands of austenite. Chromium Carbides are well
distributed throughout the micro section (specimen 5, 8, 12). (Ledeburitic matrix).
4. The Effects of Welding Processes and Microstructure…
www.theijes.com The IJES Page 38
Major importance is an increasing resistance about abrasion due to their higher hardness and free from
defects. The distribution of hard phases in the specimen 7 is quite uniform. These is a higher density of original
carbides close to the fusion line, whereas at the surface only rests of carbides are visible. While observing the
microstructure of all the 16 specimens, specimen 3, 4 and 7 were having defects noticed through optical
microscope on the weld surface deposit. Specimen no. 3 which contains network of grain boundary cracks and
several blow holes. Specimen no. 4 having several blow holes observed within the weldment. Specimen no. 7
having microcracks within weldment.
Dry sand abrasive test : In the present study, sample of 75x26x6 mm size were used for testing as shown in
figure 2 as per ASTMG65 standards. Specimens were ground using surface grinder to make the surface flat.
Before the abrasive wear test all the specimens were cleaned with acetone and then weighed on an electronic
balance with an accuracy of ± 0.1 mg. The three-body abrasive wear tests were conducted using a dry
sand/rubber wheel abrasion tester as per ASTM G65-04 (2010) shown in figure 3. The sand particles of AFS
60 grade (figure 4) were used as abrasives and they were angular in shape with sharp edges. The sand particles
were sieved (size 200–250 µm), cleaned and dried in an oven for 6 h at 40 0
C. In this test, samples were held
against a rotating rubber wheel under the constant flow of abrasives in between the sample and the rubber
wheel under predetermined load.
Figure 2. Standard test specimen Figure 3. Dry sand/rubber wheel
(75×26×6 mm) abrasion Tester
Test conditions
Speed: 200 ± 5 rpm
Sample test duration: 15 and 30 min.
Abrasive: loose silica sand having particle size 200 - 250 µm
Load is kept constant at 130.5 N for all the samples. After each test, the samples were cleaned with acetone and
then weighed on the electronic balance. The wear loss was calculated as weight losses in Gms.
Figure 4. SEM picture of silica sand (200-250 µm)
5. The Effects of Welding Processes and Microstructure…
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Figure 5. Stages of abrasion; a) initial, b) middle and c) end of tests
In three-body abrasion, the sand particles behaved in one of the following ways. From free fall, the
sand particles gained energy from the rubber wheel (figure 5.a) and then struck the sample surface, which would
result in the formation of pits. Secondly, the abrasive particles were embedded in the rubber wheel, transforming
the three-body abrasion into multi-pass Two-body abrasion (figure 5.b). Thirdly, the particles roll at the
interface causing plastic deformation to the hardfaced alloy (figure 5.c). These stages are illustrated in figure
5.a-5.c respectively.
Wear is generally a complex process, which is influenced by the many system variables, such as
materials properties, environment and mode of loading. In this study, two Fe-Cr-C hardfaced alloys of different
composition and microstructure were investigated under three-body abrasion.Various researchers have been
demonstrated that the application of hardfaced alloy on cast iron/mild steel significantly increases the surface
hardness and results in increased resistance to abrasive wear [18-19], it has been shown in this work that the
hardness of two hardfaced alloys were very different, their wear loss were dissimilar under the same test
conditions. This indicates that the importance of microstructural parameters, such as the amount and size of the
carbides, weld parameters, toughness and type of phases in determining the wear resistance [20-22].
The development of Fe-Cr-C hardfacing has been based around the understanding that good wear
resistance is obtained with materials that have a high volume fraction of hard phases that are supported in a
tough matrix. Both hardfacing 1 (type 1 electrode) and hardfacing 2 (type 2 electrode) are composed of similar
phases; however, hardfacing 1 has a significantly larger amount of carbide phases than hardfacing 2.
Figure 6. Wear loss of weld sample Figure 7. Wear loss of weld samples
15 min 30 min
The wear resistance increases with increase in chromium, carbon and silicon present in the hardfaced
alloy 1. The experimental results are in agreement with those reported [23-24] on hardfacing alloys tested under
low stress against a rubber wheel. Meanwhile, decrease in the wear resistance with decreasing chromium,
carbon and silicon were observed in type 2 electrode and is in consistent with other published works.
6. The Effects of Welding Processes and Microstructure…
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The reduction of the wear resistance with type 2 electrode could be due to the fact that the surface
hardness was greatly reduced as compared to type 1 electrode. Higher hardness of samples increasing the
apparent contact area allows a large number of sand particles to encounter the interface and share the stress.
This, in turn, leads to a steady state or reduction in the wear rate.
The wear test results of the type 1 electrode deposited hardfaced alloy indicate that a better wear
performance. In type 2 electrode deposited hardfaced alloy, the wear resistance is poor compared to those
obtained for type 1 hardfacing alloys. In type 2 electrode deposited hardfaced alloys, the abrasion was
simultaneously initiated on the hard and soft phases of the weld material. In this situation, soft surface was
continuously exposed to the interface throughout the entire test. It can be clearly seen from figures 6 and 7, that
the presence of lower chromium and silicon in the interface increases the wear rate. On the other hand, in the
case of the rich chromium, and silicon, the abrasion started through contact with the hard phase. This
contributed to marginal damage and surface topography using atomic force microscopy (AFM) are shown in
figures as shown in Fig. 8 and 9 for type 1 electrode deposited samples (Samples 1 and 5).
Figure 8. AFM images for type 1 electrode deposited sample 1:
a) Before wear test and b) After wear test
Figure 9. AFM images for type 1 electrode deposited sample 5:
a) Before wear test and b) After wear test
Scanning probe microscopy constitutes a family of advanced techniques for surface analysis of
hardfaced alloys. Although scanning probe microscopy was invented first, the current progress in scanning
probe microscopy of metallic alloys for atomic force microscopy (AFM). Surface roughness of metallic alloys
affects the wear behaviour of hardfaced alloys. Therefore, in this work, before conducting the abrasive wear
tests, selected sample surface topography were examined using AFM and the surface images of the samples are
shown in figure 8 and 9 respectively.
7. The Effects of Welding Processes and Microstructure…
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The worn surface topography measured by AFM showed lower roughness values for type 1 electrode
deposited hardfaced alloys (sample 5) and AFM images are shown in figure 9 when compared to sample 1
(figure 8). From these data in can be concluded that the damage is relatively low in sample 5 than that of sample
1. Scanning electron micrographs and surface topography by AFM taken from worn surfaces of the type 1
electrode deposited samples give an idea about the particular mechanisms involved in the wear process. Under
the attack of irregular sand particles, the individual grains penetrate deeply into the surface of the sample
investigated, subsequently removing material from the surface by an extensive micro-ploughing
process.Mechanical properties influence the abrasive wear performance of a material. When considering the
properties individually, it has been found that the hardness played a main role in controlling the abrasive wear.
The compression strength could have a stronger influence on the abrasive wear property than the tensile strength
thereby the load is applied in the form of compression thereby pressing the specimen toward the sand particles
at the interface. This attracted the attention to explore the possibility of a correlation between the selected
mechanical properties and the wear loss of the hardfaced alloys.
Table 3 shows the wear loss as well as the hardness of all the samples. From the table it can be seen
that when considering the hardness alone, the wear resistance of all the hardfaced alloys tested, a better
correlation was obtained in the present work. The higher the hardness, the lower was the wear loss. From wear
testing data under various conditions of the parameters, it can be stated that type 1 electrode deposited hardfaced
alloys are more wear resistant than the type 2 electrode deposited hardfaced alloys. The work summarizes that
type 1 electrode deposited by considering optimum weld parameters i.e., current 200 Amps, travel speed of 21.3
cm/min and potential difference of 15 volts of hardfaced alloys has beneficial effect on the three-body wear as
well as on the hardness, thus re-emphasizing the fact that the introduction of rich Cr, C and Si in type 1
electrode has got the advantage of enhancing the properties.Will be less in wear and wear resistance is increase
from specimen 3 to 5. Also results indicate that the wear resistance increases with increasing hardness. The
wear loss will be 1.6075 grams for the specimen 1 which is at 377 HV0.5 is decreased by 0.6007 of the
specimen 5 which is hardness 418 HV. It is clearly observed both from wear results and microstructures. The
wear resistance increased by 62 percent by varying welding current and travel speed and keeping welding
parameter is constant. The structure and properties of weld metal varies with varying welding parameters.
Sample 1 shows ductile structure along with ferrite, which gives because of low current and travel speed of 23.1
cm/min. Whenthe current increase the structure will be hard and grain size will decrease both in weldment and
heat affected zone.
Table 3. Relation between hardness and abrasion resistance
Sample
Number
Load (N) Weight loss (g)
Hardness
(Hv0.5)
1 130.5 1.6075 377
2 130.5 1.3345 318
3 130.5 0.9861 380
4 130.5 0.638 417
5 130.5 0.6007 418
6 130.5 0.8454 356
7 130.5 1.0923 537
8 130.5 0.5934 390
9 130.5 0.9051 330
10 130.5 0.9698 416
11 130.5 0.9746 370
12 130.5 0.9205 406
13 130.5 1.1571 388
14 130.5 1.0576 377
15 130.5 0.9852 357
16 130.5 0.9506 401
The sample welded at 250A, 25V and 23.1 cm/min speed having more wear resistance compare to
sample 1 welded at 200A, 25V and 23.1 cm/min. Similarly sample 6, 7 and 13 shows large grain structure and
has low strength, hardness and low wear resistance. Hence more wear loss occurs on these samples. Samples 4,
5 and 8 shows small grain structure with hard micro constitutions and has high wear resistance. Hence, these
metals along with welding parameters are suitable for wear resistance applications. The HAZ is defined as the
area of base metal where the microstructure and material properties have been altered by the welding process.
The heat from the welding process and subsequent re-cooling causes these change from the weld interface to the
termination of the sensitizing temperature in the base metal.
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The extent and magnitude of property change depends primarily on the base material, the weld filler
metal, and the amount and concentration of heat input by the welding process. The thermal diffusivity of the
base material plays a large role if the diffusivity is high, the material cooling rate is high and the HAZ is
relatively small. Alternatively, a low diffusivity leads to slower cooling and a larger HAZ. The amount of heat
inputted by the welding process plays an important role as well, as processes high heat input and increase the
size of the HAZ. A heat affect zone structure of all samples shows more ferrite (white grain) than the coated
materials. The properties of these structures are ductile and low hardness.
IV. SCANNING ELECTRON MICROGRAPHS OF DIFFERENT WORN SURFACES
Scanning Electron Microscopy Analysis : The SEM photographs shown in figures 10, 11 and 12 reveals the
worn surfaces of specimens 1, 3 and 5 (table 3) after dry sand abrasion test. The worn out specimens consists of
low, medium and high abrasion resistance at the entry and exit. Examination of the wear scars indicate that
morphologies for all the samples were similar consisting of three zones, a short entrance and exit area and the
main wear zone in middle. At the entrance and exit zones where the pressure applied to the abrasive is lowest,
the damage morphologies were consistent with particle rolling. In the center of wear scar, parallel grooves were
formed, typical of particle sliding, a result of the higher pressure forcing abrasives into rubber wheel. The worn
surfaces are characterized by shallow continuous grooves and micro cuttings given in figures 10, 11and 12 (a &
b) respectively. Characterization of microstructure has been done with optical microscopy and scanning electron
microscopy. In the present research, quantitative analysis of the microstructure was carried out by the use of
intronic image C software. Quantitative wear characterization has been done by gravimetric mass loss of the
testing specimen during wear testing. Qualitative characterization of worn surfaces and worn edges has been
carried out by evaluating of macroscopic and cross section images and by SEM investigations. Typical micro
structures of weld deposits made with different electrodes have been shown and discussed.
Figure 10. Worn surface features of sample 1- (a) 15 min (b) 30 min
Figure 11. Worn surface features of sample 3- (a) 15 min (b) 30 min
Figure 12. Worn surface features of sample 5- (a) 15 min (b) 30 min
Abrasive wear resistance and mass removal mechanism
SEM microscopy of the worn surfaces of samples 1, 3 and 5 are shown in Figures 10, 11 and 12
respectively. Figure 10(a & b) shows the worn surface features of sample 1, where micro-ploughing and micro-
cutting are the main abrasive wear mechanisms. Figure 11 (a & b) shows the surface of sample 3, where micro-
cutting and wedge formation were the main abrasive mechanisms: this deposit presented lower abrasion
resistance. The worn surfaces of samples 1 and 3 clearly shows obvious evidence of cutting and ploughing
(Figure 10 and 11 ), however, no obvious plastic deformation can be found on the worn surface of sample 5
(Figure 12 (a) & (b)) although there are some slight traces of ploughing to be seen on the matrix area, these
cease when elements such as carbides are encountered, indicating that the silica and chromium elements
9. The Effects of Welding Processes and Microstructure…
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effectively stop the abrasive form cutting or ploughing into the surface layer during the wear process, thereby
noticeably lowering the wear loss. However, the grooves were not deeper than samples 1 and 3. This hardfacing
deposit presented higher abrasion resistance, because the large quantity of carbides rich in titanium, uniformly
distributed in the matrix, blocked the abrasive particles. Further, the resistance of silica, manganese and
chromium elements to the abrasive could be attributed to its higher hardness. Further observations of Figure 12
also provide evidence of cutting and cracking of the carbides. This is due to the hardness of the carbide groups
in the sample 5 being lower than that of abrasive SiO2. It is reasonable to believe that the wear resistance of the
materials will increase if the hardness of the hardfacing alloy is improved.
Analysis of Fractography of worn out specimens : The Fractography analysis has been done for low, medium
and high worn out specimens based on welding parameters such as current (200 and 300 A) and travel speed
(21.4 cm/min) after dry sand abrasion testing. Figures 10-12 shows the scanned electron fractography of
chromium hard faced with welding technology using varying welding current. All samples shows directional
solidification after welding chromium as hardfacing on low carbon steel specimens. Figure 10(a & b) reports
chromium hard faced mild steel using 200 ampere current but it shows more wear loss compared to other two
specimens and both sample shows a fair amount of scraches since the size of test sand is bigger and harder than
that of surface coatings. Similarly the figures 11 (a & b) shows the chromium hard faced mild steel using 200
ampere current and at normal running speed, indicated that more wear resistance compared to figure 10 (a & b).
Figure 12 (a & b) shows randomly distrbuted pits approximately 10 to 20 micrometer which is close to matrix.
Surface coating using 300 ampere and normal welding speed is decrease gradually as welding current increases.
The chromium plated using 300 ampere and at moderate travel speed shows the high wear resistance
compared other two samples. The rate of wear of chromium welded using 200 ampere and moderate speed
almost is twice than the other samples prepared using 300 ampere as shown in the figures 10 and 12
respectively. This wear loss is predicted through the fractography of rubber wheel abrasion test as shown in the
figure 10 and 12 (a & b) respectively. It is clearly indicated that, the wear track will be small and narrow
indicates there will be less in wear and wear resistance is increased from the specimen 8 & 5 respectively. Also,
results indicate that, the wear resistance increases with increasing hardness. The wear loss will be 1.6075 grams
for the specimen 1 which is at 377 HV 0.5 is decreased by 0.6007 of the specimen 5 which is hardness 418 HV
0.5. It is clearly observed both from wear results and fractography, the wear resistance is increased by 62% by
varying welding current and travel speed and keeping welding parameters is constant.
V. CONCLUSION AND FUTURE WORK
SEM photographs showing as weld dendritic structure of the Fe-Cr-C hardfacing alloy, eutectic
carbides, mapping elements Fe-Cr-C of austenite and eutectic carbide. Fractography analysis was conducted to
worn-out specimens of low medium and high abrasion resistance. Results showed that small and narrow wear
track clearly indicates there will be less in wear and the wear resistance increases with increasing hardness. It is
clear that a significant effect of primary carbides in the weld deposits leading to improved abrasive wear.
Microstructure plays an important role in the abrasive wear of the weld deposits, though a linear relationship
between wear resistance and hardness has been observed for similar microstructural characteristics,
microstructure having coarser carbide and less grain boundary area, possesses better wear resistance than
microstructure containing fine carbide and fine grain size resistance. ASTM G-65 is a reliable low stress
abrasion test to assess the performance of the hardfacing deposits used in actual service conditions.Results
reveal that weld metal chemistry, welding heat input and test duration have significant influence on abrasion
resistance. Hardness can be used as a predictor of wear resistance only for weld deposits having similar
microstructural characteristics.Wear resistance increases with increase in chromium, silicon and carbon content
of weld deposit as well as with increase in heat input.The hardness mainly depends on process parameters such
as welding current, speed of arc travel and voltage.
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1. Dr.K.M.Kenchi Reddy is born in Karnataka, India on 4thAugust 1961. He earned his
Undergraduate degree in Mechanical Engineering in 1986 from University of Mysore,
Karnataka, India, Postgraduate degree in Production Engineering and System Technology
from Mysore University in the year 1994 and Ph.D in Hardfacing on Mild Steel from
VTU, Belgaum, India in the year 2013. Presently working as Professor in the Department
of Mechanical Engineering, Sri Krishna Institute of Technology, Bangalore. He has
published 12 papers in National/ International conferences/journals. He is a Life Member
of Indian Society for Technical Education
2. Dr. C. T Jayadeva is born in Karnataka, India on 18th July 1963. He earned his
Undergraduate degree in Industrial and Production Engineering in 1986 from University
of Mysore, Karnataka, Postgraduate degree in Industrial Engineering from university of
Calicut, Kerala in the year 1993 and Ph, D in Quality Management from VTU, Belgaum,
India in the year 2008. He worked as Principal at Yagachi Institute of Technolgy, Hassan,
Karnataka and presently working as Professor in the Department of Mechanical
Engineering, AIT, Chikmaglur, Karnataka, He has published 24 papers in
National/International conferences/journals. He is a Life Member of Indian Society for
Technical Education.