This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
Presentation on Carburizing (Heat Treatment Process).
Presented To,
Engr. Ubaid-ur-Rehman Ghouri, Department of Industrial & Manufacturing Engineering, UET Lahore (RCET Campus).
Presented By,
Muhammad Zeeshan
Zahid Mehmood
Ali Iqbal
Muhammad Waqas
1. Carbon steels are classified as mild, medium, and high carbon based on their carbon content ranging from 0.05% to 1.5%. Mild steels contain up to 0.3% carbon, medium steels contain 0.3-0.7% carbon, and high carbon steels contain 0.7-1.5% carbon.
2. Alloy steels contain additional alloying elements added in amounts exceeding 1% to improve properties such as strength, corrosion resistance, and hardenability. Common alloying elements include chromium, nickel, molybdenum, and vanadium.
3. Stainless steels contain a minimum of 11.5% chromium which
Heat treatment methods are used to strengthen stainless steel and modify its properties. Annealing involves heating stainless steel above 1010°C to recrystallize the metal and remove stresses from cold working. Quench annealing involves rapidly cooling the steel to prevent sensitization. Martensitic stainless steels are hardened using austenitizing between 980-1010°C, followed by quenching and tempering to achieve hardness without cracking. Stress relieving and annealing techniques are used after welding to reduce residual stresses. Physical vapor deposition can be used to deposit hard titanium nitride coatings on stainless steel for surface hardening.
Tool steels are high-quality alloy steels developed for shaping other materials. They contain carbon from 0.1-1.6% along with alloying elements like chromium, molybdenum, and vanadium. Tool steels offer better durability, strength, corrosion resistance, and temperature stability compared to other construction steels. They are used in applications involving forming, extrusion, and plastic molding. The document then discusses different types of tool steels categorized based on their intended use and hardening properties.
Dual phase steels are microstructurally composed of 75-85% ferrite with the remainder being martensite, bainite, and retained austenite. They are processed through thermomechanical treatments to achieve better formability than ferrite-pearlite steels of similar strength. Dual phase steels work harden rapidly at low strains, have low yield strength but high ultimate tensile strength. They were initially developed in the 1960s but further improved in the 1970s for automotive applications requiring increased strength and fuel efficiency. Processing methods like continuous annealing, batch annealing, and as-rolled techniques are used to control the microstructure and resulting mechanical properties.
The document discusses various heat treatment processes used to alter the properties of metals and alloys. It describes processes like normalizing, annealing, hardening, and tempering. Normalizing involves heating above the critical temperature and air cooling to refine grains. Annealing fully softens metals by heating above the critical temperature and slow cooling. Hardening involves heating above the critical temperature and quenching in water or oil to form martensite. Tempering reduces the brittleness of hardened steel by reheating below the critical temperature.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
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Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
Presentation on Carburizing (Heat Treatment Process).
Presented To,
Engr. Ubaid-ur-Rehman Ghouri, Department of Industrial & Manufacturing Engineering, UET Lahore (RCET Campus).
Presented By,
Muhammad Zeeshan
Zahid Mehmood
Ali Iqbal
Muhammad Waqas
1. Carbon steels are classified as mild, medium, and high carbon based on their carbon content ranging from 0.05% to 1.5%. Mild steels contain up to 0.3% carbon, medium steels contain 0.3-0.7% carbon, and high carbon steels contain 0.7-1.5% carbon.
2. Alloy steels contain additional alloying elements added in amounts exceeding 1% to improve properties such as strength, corrosion resistance, and hardenability. Common alloying elements include chromium, nickel, molybdenum, and vanadium.
3. Stainless steels contain a minimum of 11.5% chromium which
Heat treatment methods are used to strengthen stainless steel and modify its properties. Annealing involves heating stainless steel above 1010°C to recrystallize the metal and remove stresses from cold working. Quench annealing involves rapidly cooling the steel to prevent sensitization. Martensitic stainless steels are hardened using austenitizing between 980-1010°C, followed by quenching and tempering to achieve hardness without cracking. Stress relieving and annealing techniques are used after welding to reduce residual stresses. Physical vapor deposition can be used to deposit hard titanium nitride coatings on stainless steel for surface hardening.
Tool steels are high-quality alloy steels developed for shaping other materials. They contain carbon from 0.1-1.6% along with alloying elements like chromium, molybdenum, and vanadium. Tool steels offer better durability, strength, corrosion resistance, and temperature stability compared to other construction steels. They are used in applications involving forming, extrusion, and plastic molding. The document then discusses different types of tool steels categorized based on their intended use and hardening properties.
Dual phase steels are microstructurally composed of 75-85% ferrite with the remainder being martensite, bainite, and retained austenite. They are processed through thermomechanical treatments to achieve better formability than ferrite-pearlite steels of similar strength. Dual phase steels work harden rapidly at low strains, have low yield strength but high ultimate tensile strength. They were initially developed in the 1960s but further improved in the 1970s for automotive applications requiring increased strength and fuel efficiency. Processing methods like continuous annealing, batch annealing, and as-rolled techniques are used to control the microstructure and resulting mechanical properties.
The document discusses various heat treatment processes used to alter the properties of metals and alloys. It describes processes like normalizing, annealing, hardening, and tempering. Normalizing involves heating above the critical temperature and air cooling to refine grains. Annealing fully softens metals by heating above the critical temperature and slow cooling. Hardening involves heating above the critical temperature and quenching in water or oil to form martensite. Tempering reduces the brittleness of hardened steel by reheating below the critical temperature.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
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The document discusses various types of steel and factors that influence weldability. It covers the classification of plain carbon steels based on carbon content. It also discusses alloy steels and how elements like carbon, manganese, molybdenum, and chromium influence the properties of steel. The document further summarizes different types of cracks that can occur during welding like hydrogen cracking, solidification cracking, and lamellar tearing. It explains the factors that contribute to these cracks and measures to prevent them.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
The document discusses different types of carbon and alloy steels. It begins with an introduction to carbon steels, outlining their classification and composition limits. It then discusses alloy steels, explaining that alloying elements are added to improve properties over plain carbon steel. Alloy steels are classified as low, medium, and high alloy steels. High alloy steels include stainless steels. The document explores various stainless steel types and how alloying elements affect their microstructure. In particular, it examines how elements can expand or contract the gamma phase field. Finally, it briefly discusses tool steels and their classification system.
This document discusses aluminum alloys. It describes the different alloying elements used in aluminum alloys and their effects, including copper, manganese, silicon, magnesium, zinc, and others. It discusses the properties and applications of various common aluminum alloy series, including 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, and 7xxx. It also covers casting aluminum alloys and the Russian standard classification system. In summary, it provides an overview of the composition, properties, and uses of the major types of wrought and casting aluminum alloys.
This document discusses factors that affect castability, including metal properties, casting process characteristics, and mold design geometry. Metal properties like viscosity, surface tension, inclusions, freezing zone, melting point, and slag formation can impact castability. Characteristics of the casting process such as pouring temperature, degree of superheat, pouring rate, heat transfer, solidification time, mold material, and mold design are also important. Proper mold geometry including uniform sections, rounded corners, consistent wall thicknesses, and gradual changes in thickness improve castability. The design of the gating system including the cup, sprue, sprue well, runners, and gates is also crucial to deliver molten metal to the mold cavity efficiently and minimize defects
This document discusses welding metallurgy and basic metallurgical concepts relevant to welding. It covers topics like crystalline structures of metals, phase transformations, alloying effects, microstructures like ferrite, pearlite, and martensite, and the influence of cooling rate on microstructure. It also discusses the heat affected zone and issues that can arise from changes in composition and cooling rate near the weld interface.
This document discusses the classification of steels. It begins by defining steel as an alloy of iron and 0.008-2% carbon. Steels are then classified based on their carbon content as low carbon (<0.3% C), medium carbon (0.3-0.6% C), or high carbon (0.6-2% C). Additional classifications include the amount and type of alloying elements, deoxidation method during manufacturing (rimmed, killed, semi-killed), grain structure, manufacturing process, depth of hardening, and intended form and use. Alloying elements are added to plain steels to enhance properties like strength, hardness, toughness, wear resistance, and corrosion resistance.
This document discusses the process of continuous casting of steel. It begins with an overview of steel composition and the continuous casting process, which solidifies molten metal directly into final form. Most metals are produced this way, including over 500 million tons of steel annually worldwide. The document then describes the steelmaking processes of basic oxygen furnaces and electric arc furnaces that prepare the molten steel. It focuses on the design, functions, and importance of tundishes in continuous casting, which hold molten steel and facilitate inclusion removal before casting. Key aspects of tundish design like features, insulation, nozzle placement, and refractory lining application are explained.
The document discusses various types of engineering materials including metals and their classification. It begins by introducing metallic materials and their properties. It then discusses the two main categories of metals - ferrous and non-ferrous metals. Ferrous metals contain iron while non-ferrous metals do not. The document further discusses various ferrous metals like steel and its alloys. It also discusses common non-ferrous metals like aluminum, zinc and copper. The classification of materials into ferrous and non-ferrous is described. Mechanical properties testing methods like tensile testing and hardness testing are also summarized.
Ferrous and Non-Ferrous Metals Production with Casting and Forging Ajjay Kumar Gupta
Ferrous and Non-Ferrous Metals Production with Casting and Forging (Aluminium Alloys, Copper Alloys, Magnesium Alloys, Welding and Joining Processes, ARC Welding Processes, Electrode coating, Spot Welding, Allied Processes, Electron Beam Welding, Structural Mills, Forging, Metal Casting processes, Foundry Processes, Tube Mills, Extrusion and Drawing, Surface cracking, Metallic Bond, Water Rinsing, Laser Welding, Projection Welding, Basic Oxygen Furnace, Ferrous Metals, Pig Iron, Manganese, Carbon, Alloy Steel, Wrought Iron )
In metallurgy, a non-ferrous metal is a metal, including alloys, that does not contain iron (ferrite) in appreciable amounts. Generally more expensive than ferrous metals, non-ferrous metals are used because of desirable properties such as low weight (e.g. aluminium), higher conductivity (e.g. copper), non-magnetic property or resistance to corrosion (e.g. zinc). Some non-ferrous materials are also used in the iron and steel industries.
Market Outlook
Global consumption of primary aluminium ingots during the period January to December 2015 (CY2015) increased to ~57.7 million metric tonnes (MMT) from ~54.3 MMT in CY2014, reflecting a growth rate of ~6.4%. However, consumption growth during H2CY2015 was lower, at ~4.2%. Primary aluminium demand during the second half was adversely impacted by consumption of the prevailing stock of semi-finished and finished products in the market. Consumption growth of primary aluminium metal remained at a similar level of ~4.2% in the first quarter of the current calendar year as well.
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106-E, Kamla Nagar, Opp. Spark Mall,
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Email: npcs.ei@gmail.com , info@entrepreneurindia.co
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How to Start Ferrous and Non-Ferrous Metal Processing Industry in India, Most Profitable Copper Production Business Ideas, Pig Iron Processing Projects, Small Scale Aluminium Manufacturing Projects, Starting a Non-Ferrous Metal Processing Business, How to Start a Ferrous and Non-Ferrous Metal Production Business, Ferrous Metals Based Small Scale Industries Projects, New small scale ideas in special welding processing industry, NPCS, Niir, Process technology books, Business consultancy, Business consultant, Project identification and selection, Preparation of Project Profiles, Startup, Business guidance, Business guidance to clients, Startup Project for Ferrous, Non-Ferrous Metals, Startup Project, Startup ideas, Project for startups, Startup project plan, Business start-up, Business Plan for a Startup Business, Great Opportunity for Startup, Small Start-up Business Project,
This document discusses plain carbon steel, which is an iron alloy containing a maximum of 1.5% carbon. It classifies plain carbon steels as low carbon (<0.25% C), medium carbon (0.3-0.6% C), or high carbon (0.6-2% C). Low carbon steel has good ductility but low strength, while high carbon steel has high strength but low ductility. Common impurities like silicon, manganese, sulfur, and phosphorus affect the properties. The document describes the microstructure and applications of each type of plain carbon steel.
The document discusses several tests used to evaluate hot cracking tendency in welds, including the Murex test, Houldcroft test, and Varestraint test.
The Murex test involves making a fillet weld between two plates and then rotating one plate during welding to induce strain. Cracking indicates higher susceptibility.
The Houldcroft test uses a "fishbone" shaped test piece with slots of increasing depth. A bead-on-plate weld is made and the length of cracking shows the material's resistance to solidification cracking at different strain levels.
The Varestraint test applies a bending load to induce plastic deformation in a plate as it is welded. The amount of strain
This document summarizes friction stir welding (FSW), including its working principle, microstructure analysis, tool design, process parameters, advantages, challenges, and applications. FSW is a solid state welding technique that uses a rotating tool to generate frictional heat and mechanically deform aluminum alloys below their melting point. It produces high quality welds with improved mechanical properties compared to fusion welding. Main applications are in shipbuilding, aerospace, and automotive industries.
Non-Metallic Inclusions in Steel Products
The document discusses non-metallic inclusions in steel products and methods for inclusion assessment, control, and modification. Small amounts of inclusions can significantly impact steel properties like strength and ductility. Inclusions originate from deoxidation reactions and refractory materials. Common inclusions are oxides, sulfides, and carbides. Inclusion size, morphology, distribution, and chemistry all influence steel properties. Inclusion control involves ladle shrouding, argon stirring, and tundish/mold flux design to prevent reoxidation. Calcium treatment is used to modify hard alumina inclusions into spherical calcium aluminate and calcium sulfide inclusions less likely to
Seam welding uses two rotating electrodes to create a continuous weld along a seam. It works on the same resistance heating principle as spot welding but produces a linear weld rather than discrete welds. The speed of the electrodes and current can be controlled to achieve different weld bead types. Seam welding is commonly used for leak-proof welding of fuel tanks, tin cans, and radiators. It has similar advantages and disadvantages to spot welding but is limited to straight or curved seams and risks current leakage through the welded region.
The document discusses nickel-based super alloys, including their properties, applications, common alloying elements, and weldability issues. Super alloys exhibit excellent mechanical strength and creep resistance at high temperatures due to their face-centered cubic crystal structure and alloying with nickel, cobalt, chromium, and other elements. Weldability problems with nickel alloys include hot cracking caused by sulfur and porosity caused by nitrogen, which require careful control of welding parameters.
This is the 5th in our weekly series overviewing the different grades of titanium. Ti-6Al-4V or Titanium Grade 5 is hands down the most utilized alloy of titanium world wide. Over fifty percent of the worlds usage of titanium consists of Ti 5. In this presentation, you will learn about the applications of Ti5 (and titanium) as well as the different product forms it commonly comes in and given resources on where to buy titanium or learn more about this amazing metal.
Take a look and share if you like what you see!
Heat treatment involves heating and cooling metals to alter their internal structure and properties. There are several heat treatment methods for carbon steels including annealing, normalizing, hardening, and tempering. Annealing involves heating steel to high temperatures and slowly cooling to relieve stresses and improve ductility. Normalizing also starts with heating above the critical point but involves air cooling to refine grain size. Hardening greatly increases hardness but causes brittleness, so tempering is used to relieve stresses and improve toughness through controlled reheating.
friction stir welding of aluminium alloymanishmitm
This document presents a study on the effect of friction stir welding on the mechanical properties and formability of thin aluminum blanks. It describes the experimental setup used, including the milling machine, fixture, backing plate, tools, and specimen. It details the experimental procedure and process parameters tested. Results are presented on hardness values, microhardness profiles, and limiting dome height tests of the welded samples. The conclusion is that hardness is higher on the advancing side of the weld due to more grain refinement, and that further tensile tests need to be done to fully analyze formability.
This document summarizes Mitchell Smith's undergraduate research project on friction stir welding of similar and dissimilar metal alloys. Smith conducted trial welds of aluminum alloys to understand the friction stir welding process and machine settings. Welds were made of similar aluminum alloys and dissimilar aluminum-copper alloys. Challenges included preventing separation of metal pieces during welding. Further tests are needed to characterize the welds and properties of the welded metals, including microstructural analysis, tensile tests, and impact tests. Continued research on welding nano-reinforced metals could expand applications of friction stir welding in fields like nuclear engineering.
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We connect Students who have an understanding of course material with Students who need help.
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# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
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The document discusses various types of steel and factors that influence weldability. It covers the classification of plain carbon steels based on carbon content. It also discusses alloy steels and how elements like carbon, manganese, molybdenum, and chromium influence the properties of steel. The document further summarizes different types of cracks that can occur during welding like hydrogen cracking, solidification cracking, and lamellar tearing. It explains the factors that contribute to these cracks and measures to prevent them.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
The document discusses different types of carbon and alloy steels. It begins with an introduction to carbon steels, outlining their classification and composition limits. It then discusses alloy steels, explaining that alloying elements are added to improve properties over plain carbon steel. Alloy steels are classified as low, medium, and high alloy steels. High alloy steels include stainless steels. The document explores various stainless steel types and how alloying elements affect their microstructure. In particular, it examines how elements can expand or contract the gamma phase field. Finally, it briefly discusses tool steels and their classification system.
This document discusses aluminum alloys. It describes the different alloying elements used in aluminum alloys and their effects, including copper, manganese, silicon, magnesium, zinc, and others. It discusses the properties and applications of various common aluminum alloy series, including 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, and 7xxx. It also covers casting aluminum alloys and the Russian standard classification system. In summary, it provides an overview of the composition, properties, and uses of the major types of wrought and casting aluminum alloys.
This document discusses factors that affect castability, including metal properties, casting process characteristics, and mold design geometry. Metal properties like viscosity, surface tension, inclusions, freezing zone, melting point, and slag formation can impact castability. Characteristics of the casting process such as pouring temperature, degree of superheat, pouring rate, heat transfer, solidification time, mold material, and mold design are also important. Proper mold geometry including uniform sections, rounded corners, consistent wall thicknesses, and gradual changes in thickness improve castability. The design of the gating system including the cup, sprue, sprue well, runners, and gates is also crucial to deliver molten metal to the mold cavity efficiently and minimize defects
This document discusses welding metallurgy and basic metallurgical concepts relevant to welding. It covers topics like crystalline structures of metals, phase transformations, alloying effects, microstructures like ferrite, pearlite, and martensite, and the influence of cooling rate on microstructure. It also discusses the heat affected zone and issues that can arise from changes in composition and cooling rate near the weld interface.
This document discusses the classification of steels. It begins by defining steel as an alloy of iron and 0.008-2% carbon. Steels are then classified based on their carbon content as low carbon (<0.3% C), medium carbon (0.3-0.6% C), or high carbon (0.6-2% C). Additional classifications include the amount and type of alloying elements, deoxidation method during manufacturing (rimmed, killed, semi-killed), grain structure, manufacturing process, depth of hardening, and intended form and use. Alloying elements are added to plain steels to enhance properties like strength, hardness, toughness, wear resistance, and corrosion resistance.
This document discusses the process of continuous casting of steel. It begins with an overview of steel composition and the continuous casting process, which solidifies molten metal directly into final form. Most metals are produced this way, including over 500 million tons of steel annually worldwide. The document then describes the steelmaking processes of basic oxygen furnaces and electric arc furnaces that prepare the molten steel. It focuses on the design, functions, and importance of tundishes in continuous casting, which hold molten steel and facilitate inclusion removal before casting. Key aspects of tundish design like features, insulation, nozzle placement, and refractory lining application are explained.
The document discusses various types of engineering materials including metals and their classification. It begins by introducing metallic materials and their properties. It then discusses the two main categories of metals - ferrous and non-ferrous metals. Ferrous metals contain iron while non-ferrous metals do not. The document further discusses various ferrous metals like steel and its alloys. It also discusses common non-ferrous metals like aluminum, zinc and copper. The classification of materials into ferrous and non-ferrous is described. Mechanical properties testing methods like tensile testing and hardness testing are also summarized.
Ferrous and Non-Ferrous Metals Production with Casting and Forging Ajjay Kumar Gupta
Ferrous and Non-Ferrous Metals Production with Casting and Forging (Aluminium Alloys, Copper Alloys, Magnesium Alloys, Welding and Joining Processes, ARC Welding Processes, Electrode coating, Spot Welding, Allied Processes, Electron Beam Welding, Structural Mills, Forging, Metal Casting processes, Foundry Processes, Tube Mills, Extrusion and Drawing, Surface cracking, Metallic Bond, Water Rinsing, Laser Welding, Projection Welding, Basic Oxygen Furnace, Ferrous Metals, Pig Iron, Manganese, Carbon, Alloy Steel, Wrought Iron )
In metallurgy, a non-ferrous metal is a metal, including alloys, that does not contain iron (ferrite) in appreciable amounts. Generally more expensive than ferrous metals, non-ferrous metals are used because of desirable properties such as low weight (e.g. aluminium), higher conductivity (e.g. copper), non-magnetic property or resistance to corrosion (e.g. zinc). Some non-ferrous materials are also used in the iron and steel industries.
Market Outlook
Global consumption of primary aluminium ingots during the period January to December 2015 (CY2015) increased to ~57.7 million metric tonnes (MMT) from ~54.3 MMT in CY2014, reflecting a growth rate of ~6.4%. However, consumption growth during H2CY2015 was lower, at ~4.2%. Primary aluminium demand during the second half was adversely impacted by consumption of the prevailing stock of semi-finished and finished products in the market. Consumption growth of primary aluminium metal remained at a similar level of ~4.2% in the first quarter of the current calendar year as well.
See more
https://goo.gl/jZy2qv
https://goo.gl/fSIHG7
https://goo.gl/AAsBY5
Contact us:
Niir Project Consultancy Services
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
How to Start Ferrous and Non-Ferrous Metal Processing Industry in India, Most Profitable Copper Production Business Ideas, Pig Iron Processing Projects, Small Scale Aluminium Manufacturing Projects, Starting a Non-Ferrous Metal Processing Business, How to Start a Ferrous and Non-Ferrous Metal Production Business, Ferrous Metals Based Small Scale Industries Projects, New small scale ideas in special welding processing industry, NPCS, Niir, Process technology books, Business consultancy, Business consultant, Project identification and selection, Preparation of Project Profiles, Startup, Business guidance, Business guidance to clients, Startup Project for Ferrous, Non-Ferrous Metals, Startup Project, Startup ideas, Project for startups, Startup project plan, Business start-up, Business Plan for a Startup Business, Great Opportunity for Startup, Small Start-up Business Project,
This document discusses plain carbon steel, which is an iron alloy containing a maximum of 1.5% carbon. It classifies plain carbon steels as low carbon (<0.25% C), medium carbon (0.3-0.6% C), or high carbon (0.6-2% C). Low carbon steel has good ductility but low strength, while high carbon steel has high strength but low ductility. Common impurities like silicon, manganese, sulfur, and phosphorus affect the properties. The document describes the microstructure and applications of each type of plain carbon steel.
The document discusses several tests used to evaluate hot cracking tendency in welds, including the Murex test, Houldcroft test, and Varestraint test.
The Murex test involves making a fillet weld between two plates and then rotating one plate during welding to induce strain. Cracking indicates higher susceptibility.
The Houldcroft test uses a "fishbone" shaped test piece with slots of increasing depth. A bead-on-plate weld is made and the length of cracking shows the material's resistance to solidification cracking at different strain levels.
The Varestraint test applies a bending load to induce plastic deformation in a plate as it is welded. The amount of strain
This document summarizes friction stir welding (FSW), including its working principle, microstructure analysis, tool design, process parameters, advantages, challenges, and applications. FSW is a solid state welding technique that uses a rotating tool to generate frictional heat and mechanically deform aluminum alloys below their melting point. It produces high quality welds with improved mechanical properties compared to fusion welding. Main applications are in shipbuilding, aerospace, and automotive industries.
Non-Metallic Inclusions in Steel Products
The document discusses non-metallic inclusions in steel products and methods for inclusion assessment, control, and modification. Small amounts of inclusions can significantly impact steel properties like strength and ductility. Inclusions originate from deoxidation reactions and refractory materials. Common inclusions are oxides, sulfides, and carbides. Inclusion size, morphology, distribution, and chemistry all influence steel properties. Inclusion control involves ladle shrouding, argon stirring, and tundish/mold flux design to prevent reoxidation. Calcium treatment is used to modify hard alumina inclusions into spherical calcium aluminate and calcium sulfide inclusions less likely to
Seam welding uses two rotating electrodes to create a continuous weld along a seam. It works on the same resistance heating principle as spot welding but produces a linear weld rather than discrete welds. The speed of the electrodes and current can be controlled to achieve different weld bead types. Seam welding is commonly used for leak-proof welding of fuel tanks, tin cans, and radiators. It has similar advantages and disadvantages to spot welding but is limited to straight or curved seams and risks current leakage through the welded region.
The document discusses nickel-based super alloys, including their properties, applications, common alloying elements, and weldability issues. Super alloys exhibit excellent mechanical strength and creep resistance at high temperatures due to their face-centered cubic crystal structure and alloying with nickel, cobalt, chromium, and other elements. Weldability problems with nickel alloys include hot cracking caused by sulfur and porosity caused by nitrogen, which require careful control of welding parameters.
This is the 5th in our weekly series overviewing the different grades of titanium. Ti-6Al-4V or Titanium Grade 5 is hands down the most utilized alloy of titanium world wide. Over fifty percent of the worlds usage of titanium consists of Ti 5. In this presentation, you will learn about the applications of Ti5 (and titanium) as well as the different product forms it commonly comes in and given resources on where to buy titanium or learn more about this amazing metal.
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Heat treatment involves heating and cooling metals to alter their internal structure and properties. There are several heat treatment methods for carbon steels including annealing, normalizing, hardening, and tempering. Annealing involves heating steel to high temperatures and slowly cooling to relieve stresses and improve ductility. Normalizing also starts with heating above the critical point but involves air cooling to refine grain size. Hardening greatly increases hardness but causes brittleness, so tempering is used to relieve stresses and improve toughness through controlled reheating.
friction stir welding of aluminium alloymanishmitm
This document presents a study on the effect of friction stir welding on the mechanical properties and formability of thin aluminum blanks. It describes the experimental setup used, including the milling machine, fixture, backing plate, tools, and specimen. It details the experimental procedure and process parameters tested. Results are presented on hardness values, microhardness profiles, and limiting dome height tests of the welded samples. The conclusion is that hardness is higher on the advancing side of the weld due to more grain refinement, and that further tensile tests need to be done to fully analyze formability.
This document summarizes Mitchell Smith's undergraduate research project on friction stir welding of similar and dissimilar metal alloys. Smith conducted trial welds of aluminum alloys to understand the friction stir welding process and machine settings. Welds were made of similar aluminum alloys and dissimilar aluminum-copper alloys. Challenges included preventing separation of metal pieces during welding. Further tests are needed to characterize the welds and properties of the welded metals, including microstructural analysis, tensile tests, and impact tests. Continued research on welding nano-reinforced metals could expand applications of friction stir welding in fields like nuclear engineering.
Friction Stir Welding of Stainless SteelsNavneet Saini
Friction stir welding is a solid-state joining process that can be used to weld stainless steel. Some of the challenges of friction stir welding stainless steel include the tool wearing out more quickly due to the strength of steel, understanding the effects of phase transformations during welding, and optimizing the weld properties for the variety of steel compositions. Proper tool material selection is important to develop a tool that is strong and wear resistant at high temperatures during welding stainless steel. Analysis of the welded joint is also necessary to evaluate the feasibility of friction stir welding for an application compared to other joining processes.
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
- Aluminum is the most abundant metal in the Earth's crust and is a light-weight, non-toxic metal that can be easily machined or cast. It is strengthened through alloying with other metals.
- Aluminum is strong, corrosion resistant, conducts electricity and heat well, and is readily weldable. It provides greater strength than steel within a given weight budget.
- Aluminum reaches its endurance limit sooner than steel in terms of flexure but has good flexural strength and rigidity. It is non-sparking and non-ferromagnetic.
Friction stir welding is a solid state welding process that uses a rotating pin tool to heat and plasticize materials being joined without melting them. It can weld various metals like aluminum, steel, magnesium, and aluminum-lithium alloys. Key parameters that control the weld include pin tool design, rotational and travel speeds, and applied force. Pin tool designs have evolved from simple cylindrical pins to features like flutes and threads that increase heat generation and material flow during welding. Friction stir welding offers benefits over fusion welding like reduced distortion and the ability to weld materials that are difficult to join through melting.
STRESS & STRAIN ANALYSIS IN FRICTION STIR WELDING WITH THE ANSYS TOOL(ppt)niajkumar
This document discusses stress and strain analysis of friction stir welding using ANSYS software. It describes friction stir welding as a solid-state welding technique that joins metals without filler material below the melting point. The document outlines the working process, parameters, objectives to analyze stresses in the welding process using ANSYS, and presents results on equivalent von-Mises stress and elastic strain from the predicted model. It concludes that friction stir welding produces stronger welds than other welding methods based on the stress analysis results.
This document provides an overview of friction stir welding (FSW), including its principles, setup, materials used, advantages, and applications. Some key points:
- FSW was invented in 1991 as a solid state welding process that generates frictional heat between a rotating tool and materials to be joined, below their melting points.
- It overcomes issues with conventional welding like distortion and defects, and enables welding of materials not possible with fusion welding.
- The FSW setup involves a cylindrical, shouldered tool with a probe that is rotated and plunged into materials to be joined. This generates frictional heat to plasticize the materials without melting.
- FSW produces high strength welds in a wide
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This document summarizes research on optimizing parameters for friction stir welding (FSW) of aluminum alloys. It first provides background on FSW and discusses how parameters like tool rotation speed, tilt angle, and travel speed affect weld strength. The document then reviews several other studies investigating these parameters. One study found that a tool rotation speed of 900 rpm, travel speed of 75 mm/min, and axial force of 3 kN produced the highest tensile strength for an aluminum alloy. Another identified tilt angle as the most influential parameter for weld strength. Finally, the document describes using the Taguchi method to optimize FSW parameters for aluminum alloy, identifying tilt angle as most significant. It concludes that tool rotation speed, travel
Experimental Investigations of Friction Stir Welding (FSW) on Al 6061 : A Cas...IRJET Journal
This document summarizes an experimental study on friction stir welding (FSW) of aluminum alloy 6061. The study used a milling machine to conduct FSW trials with different tool pin profiles at various welding parameters. Initial trials failed due to tool breakage. Failure analysis found the main causes were tool material, rpm, and tool profile/vibrations. Modifying the tool to a tapered, threaded pin profile and increasing rpm to 1200 led to a successful weld with tensile strength of 66MPa, demonstrating FSW is possible on conventional machine tools. The study explored using FSW to join common aluminum alloys for applications like automotive and construction.
Experimental Analysis to Optimize the Process Parameter of Friction Stir Weld...IRJET Journal
This document presents an experimental analysis to optimize the process parameters of friction stir welding (FSW) for aluminum alloy AA6082. The researchers conducted FSW experiments using different combinations of tool rotation speed, tilt angle, and welding speed. Tensile strength results of the welded joints were analyzed using Taguchi methods and particle swarm optimization to determine the optimal parameter settings. Specifically, a central composite design was used with three factors at three levels each to evaluate the effects of the FSW parameters on tensile strength. The goal of the research was to develop relationships between FSW variables and tensile/yield strength and identify the best settings for maximizing strength in single and multi-pass welds of AA6082 aluminum alloy.
This document presents an optimization study of friction stir welding process parameters for aluminum alloys to achieve maximum tensile strength. Experiments were conducted using Taguchi's design of experiments method to evaluate the effects of rotational speed, tool tilt angle, and travel speed on joint strength. Analysis of variance revealed that tool tilt angle was the most influential parameter, contributing 47.39% to tensile strength, followed by travel speed at 42.18%. The optimal parameters predicted were 1300 rpm rotational speed, 1° tool tilt angle, and 60 mm/min travel speed, which were expected to yield a maximum tensile strength of 285 MPa. Experimental validation of these optimal parameters produced a joint strength of 288 MPa, close to the predicted value.
Research Inventy : International Journal of Engineering and Scienceinventy
esearch Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Effect of various process parameters on friction stir welded jointeSAT Journals
Abstract Pure and ZnS added ADP (ammonium dihydrogen phosphate) single crystals have been grown at room temperature by the free evaporation method. A total of six crystals have been grown and characterized structurally, chemically, thermally, optically, mechanically and electrically by using the suitable standard methods. Results obtained indicate that the impurity molecules have entered into the ADP crystal matrix. ZnS addition is found to increase the SHG efficiency significantly. All the grown crystals exhibit good optical transmission in the entire visible region. Results of AC and DC electrical measurements indicate a normal dielectric behaviour for all the six crystals grown. The electrical parameters, viz., DC electrical conductivity, dielectric constant, dielectric loss factor and AC electrical conductivity are found to increase with the increase in temperature. The optical, mechanical and electrical parameters are found to vary nonlinearly with the impurity (ZnS) concentration. Keywords: ADP crystal, Crystal growth, Doped crystals, Physical properties, X-ray diffraction.
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
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
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 reviews the friction stir welding (FSW) process. FSW is a solid-state welding technique invented in 1991 that uses a rotating tool to generate heat and plasticize materials being joined, allowing them to bond without melting. It can weld materials like aluminum alloys that are difficult to weld using conventional fusion welding. The document discusses the principles of FSW, factors that affect weld microstructure and properties like tool parameters and heat flow, and summarizes several studies that examined the effects of FSW parameters and post-weld treatments on mechanical properties and microstructure of welded aluminum alloys.
This document summarizes research on optimizing friction stir welding (FSW) parameters using different tool profiles. It reviews several studies that investigated how tool geometry, rotational speed, feed rate, and depth of cut influence joint strength in FSW. The document also examines the effects of different tool profiles and heat treatments on the mechanical properties and microstructure of aluminum alloy welds. Overall, the research aims to weld two aluminum alloy plates using various tool profiles and optimize joint strength through parametric optimization of the FSW process.
EFFECT OF TiO2 NANOPARTICLES ON FRICTION STIR WELDED JOINTS OF AA8011 ALUMINI...IRJET Journal
This document discusses a study investigating the effect of TiO2 nanoparticles on friction stir welded joints of AA8011 aluminum alloy. AA8011 aluminum alloy plates were friction stir welded with TiO2 nanoparticles added to the weld groove before welding. Various welding parameters were varied to evaluate their effect on the mechanical properties and microstructure of the welded joints. Tensile tests, impact tests, and microhardness tests were performed on the welded joints and results were compared to published data. The maximum tensile strength and impact value obtained were 52.98 MPa and 5.0 joules, respectively, at a rotational speed of 1400 RPM and welding speed of 25mm/min.
Review paper on friction stir welding of various materialIRJET Journal
The document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. It discusses how FSW works, common materials welded, key process parameters like rotational speed and welding speed, and their effects on weld strength and microstructure. Several case studies are presented that examined how varying process parameters impacted tensile strength when welding materials like aluminum alloys, steel, and polymers. The conclusion states that FSW is well-suited for welding aluminum alloys and efforts are ongoing to weld higher-temperature materials and dissimilar metals using this technique.
Investigation and analysis of metallurgical and mechanical properties of aa11...Alexander Decker
1. The document investigates the mechanical and metallurgical properties of friction stir welded joints of AA1100 aluminum alloy fabricated at different tool rotational speeds and material positions.
2. Tensile tests, microhardness tests, and optical/SEM microscopy of the welds were used to evaluate the mechanical properties and microstructure of the joints.
3. The results showed that joints welded at 1200 rpm had the optimum properties, with smooth weld surfaces and good tensile strength, yield strength, and elongation. Microhardness was also highest at this welding condition.
This document summarizes a study that investigated the mechanical and metallurgical properties of friction stir welded AA1100 aluminum alloy joints. Different welding parameters were tested, including tool rotation speed (800-1400 rpm) and material positioning (advancing vs. retreating side). Microhardness, tensile, and fracture surface tests were used to evaluate the mechanical properties. Optical and SEM microscopy were used to analyze the microstructural evolution. The goal was to understand how processing parameters affect properties and defect development in similar AA1100 alloy joints.
Effect of Tool Rotation Speed on the Hardness of Welded Joints of Aluminium A...ijsrd.com
Aluminum alloys are used in engineering design for their light weight, high strength-to weight ratio, corrosion resistance, and relatively low cost. Aluminum is available in various compositions, including “pure†metal, alloys for casting, and alloys for the manufacture of wrought products wrought Alloys. Most aluminum alloys used for wrought products contain Less than 7 percent of alloying elements. By the regulation of the amount and type of elements added, the properties of the aluminum can be enhanced and its working characteristics improved. In this welding process we have study that two pieces of aluminum alloy (6063) were welded with the help of friction stir welding process and here in this welding process we have found that the microstructure of weld zone was characterized by dynamic recrastallization producing fine grain structure. The vickers hardness testing results obtained for welded specimens and we have observed that the hardness is increases and decreases on different parameters like tool rotation speed. But we have obtained that as the tool rotating speed is increases the hardness will aslo increases. Finally we obtained the max. hardness(Hv-40) on max. Tool rotation speed of (rpm-1800).
A review paper on friction stir welding process parametersIJARIIT
Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI (The Welding Institute), and the first patent
applications were filed in the UK in December 1991. Initially, the process was regarded as a “laboratory” curiosity, but it soon
became clear that FSW offers numerous benefits in the fabrication of aluminum products. Friction Stir Welding (FSW) has
become a major joining process in the aerospace, railway and ship building industries especially in the fabrication of aluminum
alloys. The process uses a spinning non-consumable tool to generate frictional heat in the work piece. Worldwide, there are now
over 135 licensees of FSW and new techniques and applications are being developed daily. This paper looks at the review, on
friction stir welding process, various welding variables like tool rotation, transverse speed, tool tilt, plunge depth and tool design,
for the welding of aluminum alloys or various dissimilar alloys. Applications, future aspects, and several key problems are also
described.
The document presents a project review of microstructural testing of friction stir welded aluminum alloys 7075 and 5052. Key points:
- The project investigated the microstructure, microhardness, and residual stresses of friction stir welded 7075 and 5052 aluminum alloys.
- Testing included tensile testing, hardness testing, and optical microscopy to analyze the mechanical properties and microstructure of the welded joints.
- Results found the weld nugget zone had lower microhardness than the base material, and that higher tool rotational speeds resulted in lower microhardness values. Tensile testing also showed welded specimens had lower strength than unwelded specimens.
Effect of Process Parameters of Friction Stir Welded Joint for Similar Alumin...IJERA Editor
This document discusses optimizing the process parameters for friction stir welding (FSW) of similar aluminum alloy H30. Experiments were conducted using a Taguchi L9 orthogonal array with rotational speed, travel speed, and axial force as parameters. Tensile tests found strengths ranged from 32-80 MPa. Analysis of variance and signal-to-noise ratios identified axial force as the most significant parameter, with a strength-optimized level of 6000N. Rotational speed of 1600 RPM and travel speed of 20 mm/min also improved strength. The study aims to determine optimum parameters for high strength FSW joints of aluminum alloy H30.
Effect of Process Parameters of Friction Stir Welded Joint for Similar Alumin...IJERA Editor
This document discusses optimizing the process parameters for friction stir welding (FSW) of similar aluminum alloy H30 joints. Experiments were conducted using a Taguchi L9 orthogonal array with rotational speed, travel speed, and axial force as parameters. Tensile tests showed that maximum strength was achieved at 1600 RPM, 20 mm/min travel speed, and 6000N axial force. Analysis of variance identified axial force as the most significant parameter. The study aims to determine optimum parameters for high joint strength using Taguchi methodology.
Similar to FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEW (20)
Submission Deadline: 30th September 2022
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Expected Date of Dispatch of Printed Journal: 5th October 2022
MODELING AND ANALYSIS OF SURFACE ROUGHNESS AND WHITE LATER THICKNESS IN WIRE-...IAEME Publication
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The study explores the reasons for a transgender to become entrepreneurs. In this study transgender entrepreneur was taken as independent variable and reasons to become as dependent variable. Data were collected through a structured questionnaire containing a five point Likert Scale. The study examined the data of 30 transgender entrepreneurs in Salem Municipal Corporation of Tamil Nadu State, India. Simple Random sampling technique was used. Garrett Ranking Technique (Percentile Position, Mean Scores) was used as the analysis for the present study to identify the top 13 stimulus factors for establishment of trans entrepreneurial venture. Economic advancement of a nation is governed upon the upshot of a resolute entrepreneurial doings. The conception of entrepreneurship has stretched and materialized to the socially deflated uncharted sections of transgender community. Presently transgenders have smashed their stereotypes and are making recent headlines of achievements in various fields of our Indian society. The trans-community is gradually being observed in a new light and has been trying to achieve prospective growth in entrepreneurship. The findings of the research revealed that the optimistic changes are taking place to change affirmative societal outlook of the transgender for entrepreneurial ventureship. It also laid emphasis on other transgenders to renovate their traditional living. The paper also highlights that legislators, supervisory body should endorse an impartial canons and reforms in Tamil Nadu Transgender Welfare Board Association.
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Since ages gender difference is always a debatable theme whether caused by nature, evolution or environment. The birth of a transgender is dreadful not only for the child but also for their parents. The pain of living in the wrong physique and treated as second class victimized citizen is outrageous and fully harboured with vicious baseless negative scruples. For so long, social exclusion had perpetuated inequality and deprivation experiencing ingrained malign stigma and besieged victims of crime or violence across their life spans. They are pushed into the murky way of life with a source of eternal disgust, bereft sexual potency and perennial fear. Although they are highly visible but very little is known about them. The common public needs to comprehend the ravaged arrogance on these insensitive souls and assist in integrating them into the mainstream by offering equal opportunity, treat with humanity and respect their dignity. Entrepreneurship in the current age is endorsing the gender fairness movement. Unstable careers and economic inadequacy had inclined one of the gender variant people called Transgender to become entrepreneurs. These tiny budding entrepreneurs resulted in economic transition by means of employment, free from the clutches of stereotype jobs, raised standard of living and handful of financial empowerment. Besides all these inhibitions, they were able to witness a platform for skill set development that ignited them to enter into entrepreneurial domain. This paper epitomizes skill sets involved in trans-entrepreneurs of Thoothukudi Municipal Corporation of Tamil Nadu State and is a groundbreaking determination to sightsee various skills incorporated and the impact on entrepreneurship.
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Living in 21st century in itself reminds all of us the necessity of police and its administration. As more and more we are entering into the modern society and culture, the more we require the services of the so called ‘Khaki Worthy’ men i.e., the police personnel. Whether we talk of Indian police or the other nation’s police, they all have the same recognition as they have in India. But as already mentioned, their services and requirements are different after the like 26th November, 2008 incidents, where they without saving their own lives has sacrificed themselves without any hitch and without caring about their respective family members and wards. In other words, they are like our heroes and mentors who can guide us from the darkness of fear, militancy, corruption and other dark sides of life and so on. Now the question arises, if Gandhi would have been alive today, what would have been his reaction/opinion to the police and its functioning? Would he have some thing different in his mind now what he had been in his mind before the partition or would he be going to start some Satyagraha in the form of some improvement in the functioning of the police administration? Really these questions or rather night mares can come to any one’s mind, when there is too much confusion is prevailing in our minds, when there is too much corruption in the society and when the polices working is also in the questioning because of one or the other case throughout the India. It is matter of great concern that we have to thing over our administration and our practical approach because the police personals are also like us, they are part and parcel of our society and among one of us, so why we all are pin pointing towards them.
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The goal of this study was to see how talent management affected employee retention in the selected IT organizations in Chennai. The fundamental issue was the difficulty to attract, hire, and retain talented personnel who perform well and the gap between supply and demand of talent acquisition and retaining them within the firms. The study's main goals were to determine the impact of talent management on employee retention in IT companies in Chennai, investigate talent management strategies that IT companies could use to improve talent acquisition, performance management, career planning and formulate retention strategies that the IT firms could use. The respondents were given a structured close-ended questionnaire with the 5 Point Likert Scale as part of the study's quantitative research design. The target population consisted of 289 IT professionals. The questionnaires were distributed and collected by the researcher directly. The Statistical Package for Social Sciences (SPSS) was used to collect and analyse the questionnaire responses. Hypotheses that were formulated for the various areas of the study were tested using a variety of statistical tests. The key findings of the study suggested that talent management had an impact on employee retention. The studies also found that there is a clear link between the implementation of talent management and retention measures. Management should provide enough training and development for employees, clarify job responsibilities, provide adequate remuneration packages, and recognise employees for exceptional performance.
ATTRITION IN THE IT INDUSTRY DURING COVID-19 PANDEMIC: LINKING EMOTIONAL INTE...IAEME Publication
Globally, Millions of dollars were spent by the organizations for employing skilled Information Technology (IT) professionals. It is costly to replace unskilled employees with IT professionals possessing technical skills and competencies that aid in interconnecting the business processes. The organization’s employment tactics were forced to alter by globalization along with technological innovations as they consistently diminish to remain lean, outsource to concentrate on core competencies along with restructuring/reallocate personnel to gather efficiency. As other jobs, organizations or professions have become reasonably more appropriate in a shifting employment landscape, the above alterations trigger both involuntary as well as voluntary turnover. The employee view on jobs is also afflicted by the COVID-19 pandemic along with the employee-driven labour market. So, having effective strategies is necessary to tackle the withdrawal rate of employees. By associating Emotional Intelligence (EI) along with Talent Management (TM) in the IT industry, the rise in attrition rate was analyzed in this study. Only 303 respondents were collected out of 350 participants to whom questionnaires were distributed. From the employees of IT organizations located in Bangalore (India), the data were congregated. A simple random sampling methodology was employed to congregate data as of the respondents. Generating the hypothesis along with testing is eventuated. The effect of EI and TM along with regression analysis between TM and EI was analyzed. The outcomes indicated that employee and Organizational Performance (OP) were elevated by effective EI along with TM.
INFLUENCE OF TALENT MANAGEMENT PRACTICES ON ORGANIZATIONAL PERFORMANCE A STUD...IAEME Publication
By implementing talent management strategy, organizations would have the option to retain their skilled professionals while additionally working on their overall performance. It is the course of appropriately utilizing the ideal individuals, setting them up for future top positions, exploring and dealing with their performance, and holding them back from leaving the organization. It is employee performance that determines the success of every organization. The firm quickly obtains an upper hand over its rivals in the event that its employees having particular skills that cannot be duplicated by the competitors. Thus, firms are centred on creating successful talent management practices and processes to deal with the unique human resources. Firms are additionally endeavouring to keep their top/key staff since on the off chance that they leave; the whole store of information leaves the firm's hands. The study's objective was to determine the impact of talent management on organizational performance among the selected IT organizations in Chennai. The study recommends that talent management limitedly affects performance. On the off chance that this talent is appropriately management and implemented properly, organizations might benefit as much as possible from their maintained assets to support development and productivity, both monetarily and non-monetarily.
A STUDY OF VARIOUS TYPES OF LOANS OF SELECTED PUBLIC AND PRIVATE SECTOR BANKS...IAEME Publication
Banking regulations act of India, 1949 defines banking as “acceptance of deposits for the purpose of lending or investment from the public, repayment on demand or otherwise and withdrawable through cheques, drafts order or otherwise”, the major participants of the Indian financial system are commercial banks, the financial institution encompassing term lending institutions. Investments institutions, specialized financial institution and the state level development banks, non banking financial companies (NBFC) and other market intermediaries such has the stock brokers and money lenders are among the oldest of the certain variants of NBFC and the oldest market participants. The asset quality of banks is one of the most important indicators of their financial health. The Indian banking sector has been facing severe problems of increasing Non- Performing Assets (NPAs). The NPAs growth directly and indirectly affects the quality of assets and profitability of banks. It also shows the efficiency of banks credit risk management and the recovery effectiveness. NPA do not generate any income, whereas, the bank is required to make provisions for such as assets that why is a double edge weapon. This paper outlines the concept of quality of bank loans of different types like Housing, Agriculture and MSME loans in state Haryana of selected public and private sector banks. This study is highlighting problems associated with the role of commercial bank in financing Small and Medium Scale Enterprises (SME). The overall objective of the research was to assess the effect of the financing provisions existing for the setting up and operations of MSMEs in the country and to generate recommendations for more robust financing mechanisms for successful operation of the MSMEs, in turn understanding the impact of MSME loans on financial institutions due to NPA. There are many research conducted on the topic of Non- Performing Assets (NPA) Management, concerning particular bank, comparative study of public and private banks etc. In this paper the researcher is considering the aggregate data of selected public sector and private sector banks and attempts to compare the NPA of Housing, Agriculture and MSME loans in state Haryana of public and private sector banks. The tools used in the study are average and Anova test and variance. The findings reveal that NPA is common problem for both public and private sector banks and is associated with all types of loans either that is housing loans, agriculture loans and loans to SMES. NPAs of both public and private sector banks show the increasing trend. In 2010-11 GNPA of public and private sector were at same level it was 2% but after 2010-11 it increased in many fold and at present there is GNPA in some more than 15%. It shows the dark area of Indian banking sector.
EXPERIMENTAL STUDY OF MECHANICAL AND TRIBOLOGICAL RELATION OF NYLON/BaSO4 POL...IAEME Publication
An experiment conducted in this study found that BaSO4 changed Nylon 6's mechanical properties. By changing the weight ratios, BaSO4 was used to make Nylon 6. This Researcher looked into how hard Nylon-6/BaSO4 composites are and how well they wear. Experiments were done based on Taguchi design L9. Nylon-6/BaSO4 composites can be tested for their hardness number using a Rockwell hardness testing apparatus. On Nylon/BaSO4, the wear behavior was measured by a wear monitor, pinon-disc friction by varying reinforcement, sliding speed, and sliding distance, and the microstructure of the crack surfaces was observed by SEM. This study provides significant contributions to ultimate strength by increasing BaSO4 content up to 16% in the composites, and sliding speed contributes 72.45% to the wear rate
ROLE OF SOCIAL ENTREPRENEURSHIP IN RURAL DEVELOPMENT OF INDIA - PROBLEMS AND ...IAEME Publication
The majority of the population in India lives in villages. The village is the back bone of the country. Village or rural industries play an important role in the national economy, particularly in the rural development. Developing the rural economy is one of the key indicators towards a country’s success. Whether it be the need to look after the welfare of the farmers or invest in rural infrastructure, Governments have to ensure that rural development isn’t compromised. The economic development of our country largely depends on the progress of rural areas and the standard of living of rural masses. Village or rural industries play an important role in the national economy, particularly in the rural development. Rural entrepreneurship is based on stimulating local entrepreneurial talent and the subsequent growth of indigenous enterprises. It recognizes opportunity in the rural areas and accelerates a unique blend of resources either inside or outside of agriculture. Rural entrepreneurship brings an economic value to the rural sector by creating new methods of production, new markets, new products and generate employment opportunities thereby ensuring continuous rural development. Social Entrepreneurship has the direct and primary objective of serving the society along with the earning profits. So, social entrepreneurship is different from the economic entrepreneurship as its basic objective is not to earn profits but for providing innovative solutions to meet the society needs which are not taken care by majority of the entrepreneurs as they are in the business for profit making as a sole objective. So, the Social Entrepreneurs have the huge growth potential particularly in the developing countries like India where we have huge societal disparities in terms of the financial positions of the population. Still 22 percent of the Indian population is below the poverty line and also there is disparity among the rural & urban population in terms of families living under BPL. 25.7 percent of the rural population & 13.7 percent of the urban population is under BPL which clearly shows the disparity of the poor people in the rural and urban areas. The need to develop social entrepreneurship in agriculture is dictated by a large number of social problems. Such problems include low living standards, unemployment, and social tension. The reasons that led to the emergence of the practice of social entrepreneurship are the above factors. The research problem lays upon disclosing the importance of role of social entrepreneurship in rural development of India. The paper the tendencies of social entrepreneurship in India, to present successful examples of such business for providing recommendations how to improve situation in rural areas in terms of social entrepreneurship development. Indian government has made some steps towards development of social enterprises, social entrepreneurship, and social in- novation, but a lot remains to be improved.
OPTIMAL RECONFIGURATION OF POWER DISTRIBUTION RADIAL NETWORK USING HYBRID MET...IAEME Publication
Distribution system is a critical link between the electric power distributor and the consumers. Most of the distribution networks commonly used by the electric utility is the radial distribution network. However in this type of network, it has technical issues such as enormous power losses which affect the quality of the supply. Nowadays, the introduction of Distributed Generation (DG) units in the system help improve and support the voltage profile of the network as well as the performance of the system components through power loss mitigation. In this study network reconfiguration was done using two meta-heuristic algorithms Particle Swarm Optimization and Gravitational Search Algorithm (PSO-GSA) to enhance power quality and voltage profile in the system when simultaneously applied with the DG units. Backward/Forward Sweep Method was used in the load flow analysis and simulated using the MATLAB program. Five cases were considered in the Reconfiguration based on the contribution of DG units. The proposed method was tested using IEEE 33 bus system. Based on the results, there was a voltage profile improvement in the system from 0.9038 p.u. to 0.9594 p.u.. The integration of DG in the network also reduced power losses from 210.98 kW to 69.3963 kW. Simulated results are drawn to show the performance of each case.
APPLICATION OF FRUGAL APPROACH FOR PRODUCTIVITY IMPROVEMENT - A CASE STUDY OF...IAEME Publication
Manufacturing industries have witnessed an outburst in productivity. For productivity improvement manufacturing industries are taking various initiatives by using lean tools and techniques. However, in different manufacturing industries, frugal approach is applied in product design and services as a tool for improvement. Frugal approach contributed to prove less is more and seems indirectly contributing to improve productivity. Hence, there is need to understand status of frugal approach application in manufacturing industries. All manufacturing industries are trying hard and putting continuous efforts for competitive existence. For productivity improvements, manufacturing industries are coming up with different effective and efficient solutions in manufacturing processes and operations. To overcome current challenges, manufacturing industries have started using frugal approach in product design and services. For this study, methodology adopted with both primary and secondary sources of data. For primary source interview and observation technique is used and for secondary source review has done based on available literatures in website, printed magazines, manual etc. An attempt has made for understanding application of frugal approach with the study of manufacturing industry project. Manufacturing industry selected for this project study is Mahindra and Mahindra Ltd. This paper will help researcher to find the connections between the two concepts productivity improvement and frugal approach. This paper will help to understand significance of frugal approach for productivity improvement in manufacturing industry. This will also help to understand current scenario of frugal approach in manufacturing industry. In manufacturing industries various process are involved to deliver the final product. In the process of converting input in to output through manufacturing process productivity plays very critical role. Hence this study will help to evolve status of frugal approach in productivity improvement programme. The notion of frugal can be viewed as an approach towards productivity improvement in manufacturing industries.
A MULTIPLE – CHANNEL QUEUING MODELS ON FUZZY ENVIRONMENTIAEME Publication
In this paper, we investigated a queuing model of fuzzy environment-based a multiple channel queuing model (M/M/C) ( /FCFS) and study its performance under realistic conditions. It applies a nonagonal fuzzy number to analyse the relevant performance of a multiple channel queuing model (M/M/C) ( /FCFS). Based on the sub interval average ranking method for nonagonal fuzzy number, we convert fuzzy number to crisp one. Numerical results reveal that the efficiency of this method. Intuitively, the fuzzy environment adapts well to a multiple channel queuing models (M/M/C) ( /FCFS) are very well.
Height and depth gauge linear metrology.pdfq30122000
Height gauges may also be used to measure the height of an object by using the underside of the scriber as the datum. The datum may be permanently fixed or the height gauge may have provision to adjust the scale, this is done by sliding the scale vertically along the body of the height gauge by turning a fine feed screw at the top of the gauge; then with the scriber set to the same level as the base, the scale can be matched to it. This adjustment allows different scribers or probes to be used, as well as adjusting for any errors in a damaged or resharpened probe.
Mechatronics is a multidisciplinary field that refers to the skill sets needed in the contemporary, advanced automated manufacturing industry. At the intersection of mechanics, electronics, and computing, mechatronics specialists create simpler, smarter systems. Mechatronics is an essential foundation for the expected growth in automation and manufacturing.
Mechatronics deals with robotics, control systems, and electro-mechanical systems.
Blood finder application project report (1).pdfKamal Acharya
Blood Finder is an emergency time app where a user can search for the blood banks as
well as the registered blood donors around Mumbai. This application also provide an
opportunity for the user of this application to become a registered donor for this user have
to enroll for the donor request from the application itself. If the admin wish to make user
a registered donor, with some of the formalities with the organization it can be done.
Specialization of this application is that the user will not have to register on sign-in for
searching the blood banks and blood donors it can be just done by installing the
application to the mobile.
The purpose of making this application is to save the user’s time for searching blood of
needed blood group during the time of the emergency.
This is an android application developed in Java and XML with the connectivity of
SQLite database. This application will provide most of basic functionality required for an
emergency time application. All the details of Blood banks and Blood donors are stored
in the database i.e. SQLite.
This application allowed the user to get all the information regarding blood banks and
blood donors such as Name, Number, Address, Blood Group, rather than searching it on
the different websites and wasting the precious time. This application is effective and
user friendly.
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Prediction of Electrical Energy Efficiency Using Information on Consumer's Ac...PriyankaKilaniya
Energy efficiency has been important since the latter part of the last century. The main object of this survey is to determine the energy efficiency knowledge among consumers. Two separate districts in Bangladesh are selected to conduct the survey on households and showrooms about the energy and seller also. The survey uses the data to find some regression equations from which it is easy to predict energy efficiency knowledge. The data is analyzed and calculated based on five important criteria. The initial target was to find some factors that help predict a person's energy efficiency knowledge. From the survey, it is found that the energy efficiency awareness among the people of our country is very low. Relationships between household energy use behaviors are estimated using a unique dataset of about 40 households and 20 showrooms in Bangladesh's Chapainawabganj and Bagerhat districts. Knowledge of energy consumption and energy efficiency technology options is found to be associated with household use of energy conservation practices. Household characteristics also influence household energy use behavior. Younger household cohorts are more likely to adopt energy-efficient technologies and energy conservation practices and place primary importance on energy saving for environmental reasons. Education also influences attitudes toward energy conservation in Bangladesh. Low-education households indicate they primarily save electricity for the environment while high-education households indicate they are motivated by environmental concerns.
Tools & Techniques for Commissioning and Maintaining PV Systems W-Animations ...Transcat
Join us for this solutions-based webinar on the tools and techniques for commissioning and maintaining PV Systems. In this session, we'll review the process of building and maintaining a solar array, starting with installation and commissioning, then reviewing operations and maintenance of the system. This course will review insulation resistance testing, I-V curve testing, earth-bond continuity, ground resistance testing, performance tests, visual inspections, ground and arc fault testing procedures, and power quality analysis.
Fluke Solar Application Specialist Will White is presenting on this engaging topic:
Will has worked in the renewable energy industry since 2005, first as an installer for a small east coast solar integrator before adding sales, design, and project management to his skillset. In 2022, Will joined Fluke as a solar application specialist, where he supports their renewable energy testing equipment like IV-curve tracers, electrical meters, and thermal imaging cameras. Experienced in wind power, solar thermal, energy storage, and all scales of PV, Will has primarily focused on residential and small commercial systems. He is passionate about implementing high-quality, code-compliant installation techniques.
Supermarket Management System Project Report.pdfKamal Acharya
Supermarket management is a stand-alone J2EE using Eclipse Juno program.
This project contains all the necessary required information about maintaining
the supermarket billing system.
The core idea of this project to minimize the paper work and centralize the
data. Here all the communication is taken in secure manner. That is, in this
application the information will be stored in client itself. For further security the
data base is stored in the back-end oracle and so no intruders can access it.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
Digital Twins Computer Networking Paper Presentation.pptxaryanpankaj78
A Digital Twin in computer networking is a virtual representation of a physical network, used to simulate, analyze, and optimize network performance and reliability. It leverages real-time data to enhance network management, predict issues, and improve decision-making processes.
2. N Ravinder Reddy and G Mohan Reddy
http://www.iaeme.com/IJMET/index.asp 74 editor@iaeme.com
INTRODUCTION
It is a method of solid phase welding, which allows a wide range of parts and
geometries to be welded are called Friction Stir Welding (FSW), was invented by W
Thomas and his colleagues at The Welding Institute (TWI), in 1991. The process
proves predominance for welding non-heat treatable to which the fusion welding
cannot be applied. Friction stir welding has a wide application potential in aerospace,
ship building, automobile and other manufacturing industries. Thus fundamental
studies on the weld mechanism, the relation between microstructure, mechanical
properties and process parameters have recently been started. Friction stir welding is a
relatively simple process as shown in Fig 1. In recent times, focus has been on
developing fast, efficient processes that are environment friendly to join two
dissimilar materials. The spotlight has been turned on Friction stir welding as a
joining technology capable of providing welds that do not have defects normally
associated with fusion welding processes. Friction stir welding (FSW) is a fairly
recent technique that utilizes a non consumable rotating welding tool to generate
frictional heat and plastic deformation at the welding location, thereby affecting the
formation of a joint while the material is in the solid state. The rotating tool is pushed
against the surface of two overlapping plates. The side of the weld for which the
rotating tool moves in the same direction as the traversing direction, is commonly
known as the advancing side, the other side, where tool rotation opposes the
traversing direction is known as the retreating side.
Figure 1 FSW Principle of Operation
LITERATURE
Arora et al. [1] states that computed temperatures for maximum shoulder diameter
are to the extent of high temperatures normally faced in FSW of AA 6061. Bhatt et al.
[2] studied consistent rotational speed of tool and tool of same geometry. Change in
the traverse speed of tool has total results on temperature and flow stress in FSW of
AA 7050-T7451 aluminium. Biswas et al. [3] have analyzed that concave shoulder
and conical pin were preferable to FSW of AA1100 to continue the diameter of the
tool pin so tiny as to present a wormhole defect.
Lienert et al. [4] viewed the suitability of FSW of steel to retain its tensile
characteristics. FSW of change of tough, HSLA and stainless steels could be possible.
The computed results of the analysis made by Nandan et al. [5] shows that significant
flow has an effect on movement of heat inside the work piece, the tool rotational and
linear movement and lack of symmetry of production of heat around the surface of the
tool pin.
3. Friction Stir Welding of Aluminium Alloys - A Review
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The system of FSW and the function of the tool in forming welds in aluminium
alloys 7020-T6 were gone into by Kumar et al. [6]. A tool having frustum pin of H13
as hard as 55 HRS was used by them. With a vertical milling machine they performed
experiments maintaining consistent welding characteristics which are 140 r.p.m. of
the speed of rotation, 80 mm/min of the speed of welding and the angle of tilt 2o
. It
was found by them that while the contact surface of the tool enhances, the defect of
the weld gets reduced. They further testified that in the initial part of welding, the
shoulder of the tool does not come in contact with the metal to the full extent as a
result of which the force around the axis will not be sufficient to generate heat. As
such the joint becomes imperfect. The point is that when contact surface between
shoulder and metal extends, the force of the axis also enhances. Which the force of
the metal will be confined to the cavity of the welds. It will generate enough heat and
hydrostatic power. This will ensure a weld that has no fault.
According to Oliver Lorrain et al. [7], threaded pins are used in industrial
application. In the initial stages there is a possibility of threaded tools becoming
unthreaded. This happens due to the wear of the tool when the toll is used for alloys of
a high melting point as well as aluminum alloys that are strengthened. They
conducted FSW tests with two variant pin profiles. The two pins are unthreaded with
or without level faces. The main idea of this experiment is to study the flow when
unthreaded pins are used to weld plates that are thin. To examine the flow of the
material welds with cross and longitudinal sections were studied with or without using
material marker. Both the threaded and unthreaded pins were observed to process the
same material flows. The material is placed in the advancing side in upper portion of
the weld which in the retreating side it is placed in the lower portion of the weld with
a rotating layer appearing around the tool. This study shows a very low vertical
movement towards the weld’s bottom due to the absence of threats. The force of the
plunge and the speed of the rotation affected the size of the zone controlled by the
shoulder. This can be diminished by the use of cylindrical frustum pin having flats.
Numerous studies on transfer of heat and flow of material during FSW were
made. Askari et al. [8] employed a 3D finite difference hydrodynamics code to
demonstrate the joining of geometry, production of heat and flow of plastic during the
process of FSW. The flow of material around the tool was initiated by Zhao [9].
Arbitrary Lagrangian-Eulerian procedures were used by Zhao with a moving mesh to
handle extreme plastic distortions around the rotating tool. Using commercial code
based fluid dynamic procedures, Colegrove and Shercliff [10] offered a 2D model to
study the flow of material around the welding tool.
O F Valero [11] made an attempt to identify the tensile characteristics of the joint
performed in different conditions of welding. This study showed the least tensile
strength and malleability at the lowest spindle speed for a specific traverse speed.
When the speed of the spindle extended, there was increase in strength and elongation
attaining the highest point before falling down due to high speed of rotation. In FSW
the speed of rotation and the input of heat increase simultaneously. Therefore the
speed of the tool rotation must be maximized to achieve the highest tensile of the
joints. When the speed of welding rises, the width of the exerted area and the value of
the maximum exertion go down. Then the area of the maximum exertion slowly
moves to the retreating side of the joint from its advancing side. The tensile strength
diminishes considerably as the speed of welding rises. The area which is softened is
narrower for higher speeds of welding than for lower speeds of welding. Therefore the
4. N Ravinder Reddy and G Mohan Reddy
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speed of welding must be maximized to obtain maximum tensile characteristics of the
FS joints.
Thomas et al. [12] explained the results of microstructure analyses, hardness
measurements and tensile tests of Friction stir welded sheets of two aluminium alloys
Al Mg4.5Mn0.7 (AA5083) and AlZn6Mg2Cu (AA7075). The macrostructures and
microstructures of FSW welds are similar to these produced by hot working. They
strongly depend on sheet thickness, as do also their tensile properties. The variation of
hardness through weld width is small in alloy AA5083 and more important in
AA7075. The strength of FSW welds in AA5083 and AA7075 6.0mm sheets are as
high as 100% and 72% respectively of parent material strength.
Z.H. Fu, et al. [13] investigated that Joining by FSW of aluminium is done at low
temperature that eliminates the major problem of conventional welding processes,
which must be performed under inert gas to present the dissolution of atmosphere
gases in the melted material of the joint.
Schmdt and Hattel [14] employed a commercial FE code, ABAQUS, to anticipate
an extreme plastic distortion in the process of FSW. To solve coupled
thermomechanical problems during the operations of FSW, Nandan et al. [15] prepard
a 3D visco-plastic finite element model.
Liu and Fuji [16] discovered that at a low fore of the axis, the shape of non-
symmetrical semi-circular units at the top of the weld surface shows mediocre
plasticization, through the combination of the material under the sway of the shoulder
of the tool, has a proper quality. The structure shear lips and flashes that is extremely
high on the advancing as well as retreating sides of the weld line rendering the metal
in the area of the weld too thin giving mediocre tensile characteristics, all due to
greater force. To prevent this, the force of the axis must be optimized so that optimum
tensile characterizes may be obtained.
According to Zaho et al [17] the profile of the pin exercises a crucial role in the
flow of the material and thus regulate the welding characteristics of the process of
FSW. FSW has a weld lump and flow contour almost round in structure. The flow
contour depends on the design of the tool as well as the characteristics and process of
welding.
Hidetoshi Fujii [18] studied the effect of the profile of the tool on the mechanical
characteristics and microstructures of welded aluminium plates that are 5mm thick.
He maintained that the simplest profile without threads and the ordinary profile with
threads along with triangular prism shaped profile be used for welding three types of
aluminium alloys. For 1050-H24 define to impairment is minimum and a columnar
tool without threads produces the weld with maximum mechanical characteristics. In
the case of 6061-T6 the power to resist impairment is minimum and the profile of the
tool has minimum effect on the microstructures and mechanical characteristics. If the
speed of rotation is as low as 600 rpm, the profile of the tool has no notable effect on
the microstructures and mechanical characteristics of the joints. P. Cavaliere [19]
analyzed the effect of processing characteristics on mechanical and microstructural
articles of AA 6056 joints formed by FSW. Many samples were procured by using
rotational speeds of 500, 800 and 1000 rpm and welding speeds of 40, 56 and 88
mm/min. The mechanical characteristics of the joints were assessed using micro
hardness (HV) and tests of tensility at room temperature.
Sato Y.S. et al. [20] worked on FSW of extremely fine grained Al alloy 1100
provided by stored roll bonding. Friction Stir Welding brought about a repetition of
very fine grains in the stir zone and little expansion of the very fine grains of the
5. Friction Stir Welding of Aluminium Alloys - A Review
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ARBed material at the outer surface of the stir zone. FSW has enormous hidden cuts
of toughness in the ARBed material, though the stir zone and TMAZ had few cuts of
toughness on account of active formation and retrieval. Subsequently, FSW efficiently
prohibited the softening in the ArBed alloy.
S. Benavides et al. [21] made a study of minimum temperature FSW of 2024
aluminium. They used active reformation of superfine equiaxed grain forms to make
possible super plastic impairment as the welding and unification mechanism.
2024 Al alloy was friction stir welded at an initial heat of 230°C and the
maximum heat of the weld zone was within 640°C. The remaining FSW zone grain
form had equiaxed fine grains having an identical size of nearly 0.8mm, all though
which could be compared with a central weld zone grain of nearly 10 mm in 2024 Al
FSW at an initial of 30°C, where the maximum heat was 330°C. A cut is obvious in
the softening close to the boundary of the weld one around the weld HAZ when the
heat is minimum through no similar softening exists in the weld zone contrary to the
room heat of the weld zone. It causes reversal of toughness in similar weld zones.
H.G. Salem [22] used friction stir technology to link actively reconstituted Al
alloy light sheets for structural parts fulfil the demand for generation and hardness of
macrostructures as well as microstructures. FSW at 1000 rpm speed of tool rotation
and 4.2 mm/s weld feeding rate were accomplished without grain growth. FSW in
created the fine equiaxed structure with high grain boundary angles.
Fonda R.W. et al. [23] made a study of the growth of grain structure at some stage
in friction stir welding. They observed that a stop action FSW was arranged in Al-Li
2195 to free in the active impairment area adjacent to FSW tool. An examination of a
plan view section of the weld shows important new information of evolution of the
structure of grain and the development of the texture near the FSW tool. Strips of
grain develop in front of the fully polished area showing divergent stabilities of the
earlier grain adjustments to the applied impairment. Polished sub-grains develop in
the area of impairment and slowly develop higher disorientations to bring about finer
grains as noticed near the tool. This area shows an fcc shear texture following
application of appropriate rotations. Thus in this weld the main process of purification
of grain is the subdivision caused by impairment and active retrieval processes. There
is no need to evoke an active restructuring process.
Liu G. et al. [24] studied the microstructural issues of FSW of 6061-T6 aluminium
and stated that LM and TEM were used to describe the microstructures in the FSW
area and compare these microstructures with the primary 6061-T6 aluminium alloy
plate which was about 0.65 cm in thickness. They calculated the profile of
microhardness stretching from work piece and through zone of the weld. They also
conducted many butt and assumed welds in stable plate divisions at the speeds of
rotation extending from 300 to 1000 rpm and traverse speeds of 0.15 to 0.25 cm/s.
The tempered carbon steel welding head pin was 0.63 cm in diameter and 58 cm/s
long. The main results that were obtained were that the FSW area in 6061-T6
aluminium was represented by an active and continuous restructuring of
microstructure. The particles in the next phase of the work piece are stirred into the
weld area where the remaining toughness varies from 55 VHN near the bottom of the
weld. These contracts with the toughness of the work piece varying from 85 and 100
VHN. The size of the weld area grain had an average of 10 μm as against 100 μm of
the work piece.
A constantly rotated non consumable cylindrical tool with a profiled probe is
transversely fed at a constant rate into a butt joint between two clamped parts of
6. N Ravinder Reddy and G Mohan Reddy
http://www.iaeme.com/IJMET/index.asp 78 editor@iaeme.com
butted material. The pin is slightly shorter than the width of the weld metal, with the
tool shoulder riding atop the work surface. Frictional heat is generated between the
wear resistant welding components and the work pieces. This heat, along with that
generated by the mechanical mixing process and the adiabatic heat within the
material, cause the stirred materials to soften without melting. As the pin is moved
forward, a special profile on its leading face forces plasticized material to the rear
where clamping force assists in a forged consolidation of the weld. This process of the
tool traversing along the weld line in a plasticized tubular shaft of metal results in
severe solid state deformation involving dynamic recrystallization of the base
material.
Metallurgical benefits: less distortion, high stability, fine microstructure
Environmental Benefits: Shielding gas not required
Energy Benefits: less energy required
MICROSTRUCTURE
Due to high plastic deformation and high temperature in the stirred zone during FSW
recrystallization and microstructure evolution occurs in stirred zone and precipitate
dissolution and coarsening within and around the stirred zone. On the basis of
microstructural characterization of grains and precipitates, three different zones,
Nugget (stirred) zone, thermo-mechanically affected zone (TMAZ), and heat affected
zone (HAZ) have been identified. The microstructural variations in different zones
have considerable effect on post weld mechanical properties
CONCLUSION
The friction stir welding is very recent trends in the manufacturing technology of
metal joining processes especially for aluminum alloys. It is found that many research
works are done on the aluminum alloys. Moreover various engineering industries will
not only give importance for aluminum and aluminum based alloys but also for mild
steel and its alloys. This paper highlights the principle of FSW and vital factors that
influence the quality of weld and the critical analysis realize the possible research
works on other than aluminum alloys such as mild steel etc.
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