This document summarizes an experimental study that analyzed the effects of flux cored arc welding (FCAW) process parameters on clad quality when duplex stainless steel is used to clad low carbon structural steel plates. Experiments were conducted using a central composite design with four welding parameters (current, speed, nozzle distance, angle) and responses (bead width, penetration, reinforcement, dilution). Mathematical models were developed to relate the parameters to the responses using multiple regression analysis. The models can help select welding parameters to achieve desired clad quality.
Research Inventy : International Journal of Engineering and Scienceinventy
Research 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.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steelijtsrd
Friction surface treatment is well established solid technology and is used for deposition, abrasion and corrosion protection coatings on rigid materials. This novel process has wide range of industrial applications, particularly in the field of reclamation and repair of damaged and worn engineering components. In this paper, present the prediction of tensile of friction surface treated tool steel using ANN for simulated results of friction surface treatment. This experiment was carried out to obtain tool steel coatings of low carbon steel parts by changing input process parameters such as friction pressure, rotational speed and welding speed. The simulation is performed by a 33 factor design that takes into account the maximum and minimum limits of the experimental work performed by the 23 factor design. Neural network structures, such as the Feed Forward Neural Network FFNN , were used to predict tensile tool steel sediments caused by friction. V. Pitchi Raju "ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steel" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29169.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29169/ann-model-based-calculation-of-tensile-of-friction-surfaced-tool-steel/v-pitchi-raju
Surface hybrid nanocomposites via friction stir processingmohammed noor
Friction stir Processing (FSP) is a new innovative technology developed based on the principle of Friction Stir Welding (FSW) technique.
In FSP, the ceramic particulates are reinforced into the base metal by adding it into the groove and Friction Stir Processing (FSP) is performed.
In this study, the aluminum alloy 6061 is chosen as the base metal, alumina and graphite Nano powder as reinforcement.
The process parameters such traverse speed of 64 mm/min and the tool rotational speed of 1060 rpm and tilt angle of 2deg were selected, The Friction Powder Processing was carried out on vertical milling machine.
New parameters such as powder type and number of passes were involved and we also study the effect of heat treatment.
The influence of FSP was checked using some tests such as the microstructure analysis that was carried out using optical microscope (OM) and the mechanical characteristics were analyzed using tensile test and hardness test.
The micrograph results revealed that powder particulates were evenly distributed in the stir zone and reduction in grain size also observed; the reason for the grain size reduction was stirring action of the FPP tool’s pin.
The tensile strength results showed a significant improvement in strength by a percent of
50% compared to base metal but when T6 heat treatment is applied, the tensile strength decreased.
Research Inventy : International Journal of Engineering and Scienceinventy
Research 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.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steelijtsrd
Friction surface treatment is well established solid technology and is used for deposition, abrasion and corrosion protection coatings on rigid materials. This novel process has wide range of industrial applications, particularly in the field of reclamation and repair of damaged and worn engineering components. In this paper, present the prediction of tensile of friction surface treated tool steel using ANN for simulated results of friction surface treatment. This experiment was carried out to obtain tool steel coatings of low carbon steel parts by changing input process parameters such as friction pressure, rotational speed and welding speed. The simulation is performed by a 33 factor design that takes into account the maximum and minimum limits of the experimental work performed by the 23 factor design. Neural network structures, such as the Feed Forward Neural Network FFNN , were used to predict tensile tool steel sediments caused by friction. V. Pitchi Raju "ANN Model Based Calculation of Tensile of Friction Surfaced Tool Steel" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29169.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29169/ann-model-based-calculation-of-tensile-of-friction-surfaced-tool-steel/v-pitchi-raju
Surface hybrid nanocomposites via friction stir processingmohammed noor
Friction stir Processing (FSP) is a new innovative technology developed based on the principle of Friction Stir Welding (FSW) technique.
In FSP, the ceramic particulates are reinforced into the base metal by adding it into the groove and Friction Stir Processing (FSP) is performed.
In this study, the aluminum alloy 6061 is chosen as the base metal, alumina and graphite Nano powder as reinforcement.
The process parameters such traverse speed of 64 mm/min and the tool rotational speed of 1060 rpm and tilt angle of 2deg were selected, The Friction Powder Processing was carried out on vertical milling machine.
New parameters such as powder type and number of passes were involved and we also study the effect of heat treatment.
The influence of FSP was checked using some tests such as the microstructure analysis that was carried out using optical microscope (OM) and the mechanical characteristics were analyzed using tensile test and hardness test.
The micrograph results revealed that powder particulates were evenly distributed in the stir zone and reduction in grain size also observed; the reason for the grain size reduction was stirring action of the FPP tool’s pin.
The tensile strength results showed a significant improvement in strength by a percent of
50% compared to base metal but when T6 heat treatment is applied, the tensile strength decreased.
This is the presentation of my 8th semester project on Application of Artificial Neural Network in Friction Stir Processing. We have used AA5052. The presentation starts from the basics of Aluminium and FSP process and then first we predict the properties of Hardness, Roughness and Tensile strength using Minitab16 and then use Minitab16 to create dummy outputs which are fed into the ANN to train it.
EXPERIMENTAL INVESTIGATION AND MATERIAL CHARACTERIZATION OF A356 BASED COMPO...sathish sak
Recently friction stir processing (FSP) has emerged as an effective tool for enhancing sheet metal properties through microstructure modification. Significant grain refinement and homogenization can be achieved in a single FSP pass leading to improved formability, especially at elevated temperatures.
FSP is a solid-state process where the material within the processed zone undergoes intense plastic deformation resulting in dynamically recrystallized grain structure.
Most of the research conducted on FSP focuses on aluminum alloys. Despite the potential weight reduction that can be achieved using Titanium dioxide(B4C) alloys.
In this work, we examine the possibility of using FSP to modify the microstructure and properties of commercial A356-B4C alloy particles. The effect of various process parameters on thermal histories, resulting microstructure and properties to be investigated.
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
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
This is the presentation of my 8th semester project on Application of Artificial Neural Network in Friction Stir Processing. We have used AA5052. The presentation starts from the basics of Aluminium and FSP process and then first we predict the properties of Hardness, Roughness and Tensile strength using Minitab16 and then use Minitab16 to create dummy outputs which are fed into the ANN to train it.
EXPERIMENTAL INVESTIGATION AND MATERIAL CHARACTERIZATION OF A356 BASED COMPO...sathish sak
Recently friction stir processing (FSP) has emerged as an effective tool for enhancing sheet metal properties through microstructure modification. Significant grain refinement and homogenization can be achieved in a single FSP pass leading to improved formability, especially at elevated temperatures.
FSP is a solid-state process where the material within the processed zone undergoes intense plastic deformation resulting in dynamically recrystallized grain structure.
Most of the research conducted on FSP focuses on aluminum alloys. Despite the potential weight reduction that can be achieved using Titanium dioxide(B4C) alloys.
In this work, we examine the possibility of using FSP to modify the microstructure and properties of commercial A356-B4C alloy particles. The effect of various process parameters on thermal histories, resulting microstructure and properties to be investigated.
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
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Pla...IJERA Editor
Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based alloy Colmonoy on stainless steel plate by plasma transferred arc surfacing, are made and values of process parameters to produce optimal weld bead geometry are estimated. The experiments are conducted based on a five input process parameters and mathematical models are developed using multiple regression technique. The direct effects of input process parameters on weld bead geometry are discussed using graphs. Finally, optimization of the weld bead parameters, that is minimization of penetration and maximization of reinforcement and weld bead width, are made with a view to economize the input process parameters to achieve the desirable welding joint.
This paper details the application of Taguchi
techniques to determine the optimal process parameters for
submerged arc welding (SAW).The planned experiment work is
conducted in the semiautomatic submerged arc welding machine
and signal to noise ratios have been computed .the contribution of
each factor has been validated by analysis of variance(ANOVA).
The results of the present investigation indicate that the welding
voltage is the most significant parameter that controls the bead
penetration as compared to other controlling parameters. The
contribution of voltage, current welding speed and nozzle-to-plate
distance have been found to be respectively: 60.8%, 9.86%,
3.54% and 13.8%. Optimum results have been obtained by using
26v, 475A at a trolley speed of 0.25 m/min and NPD of 16 mm.
Optimizing the process parameters of friction stir butt welded joint on alumi...eSAT Journals
Abstract This paper deals with Friction stir welding of AA6061-T6Aluminum Alloy by using H13 Tool at different rotational speeds and welding feeds &pin diameters. Experiments were conducted according to L9 Orthogonal array which was suggested by Taguchi. Optimum parameters for optimum Tensile strength, Hardness and ductility were found with the help of S/N ratios. Therefore optimization of input process parameter is required to achieve good quality of welding. In this experiment the effect of process parameters on welded joint was studied and optimizes the parameter by using Taguchi method for tensile strength, hardness, ductility. Assign the rank to each factor which are having more influence on the mean of tensile strength, hardness and ductility Keywords: FSW, Taguchi, DOE, Tensile Strength, Hardness, Ductility
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Similar to of flux cored arc welding process parameters ond duplex stainless steel clad quality (20)
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
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Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
2. T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239 231
Table 1
Chemical composition of base metal and filler wire used
Material Elements (wt.%)
C Si Mn P S Al Cr Mo Ni N2 Cu
IS: 2062 0.150 0.160 0.870 0.015 0.016 0.032 – – – – –
E2209T1-4/1 0.023 0.760 1.030 0.024 0.002 – 23.14 3.05 9.22 0.13 0.09
Fig. 1. Weld bead geometry.
• Good radiographic standard quality.
• Minimum electrode wastage.
This paper highlights an experimental study carried out
to analyse the effects of various FCAW process parameters
on important clad quality parameters in duplex stainless steel
cladding of low carbon structural steel plates. The experiments
were conducted based on four-factor five level central composite
rotatable design with full replications technique and mathemat-
ical models developed using multiple regression method. The
developed mathematical models have been checked for their
adequacy and significance.
2. Experimental work
The experiments were conducted using UNIMACRO 501C programmable
welding machine using DC electrode positive (DCEP). Test pieces of size
200 mm × 150 mm × 20 mmwerecutfromlowcarbonstructuralsteel(IS:2062)
plate and its surfaces were ground to remove oxide scale and dirt before cladding.
Flux cored duplex stainless steel welding wire (E2209T1-4/1) of 1.2 mm diam-
eter was used for depositing the weld beads. Chemical composition of the base
metal and welding wire is given in Table 1. CO2 gas at a constant flow rate of
18 L/min was used for shielding. The experimental setup used consisted of a
travelling carriage with a table for supporting the specimens. The carriage speed
wascontinuouslyadjustablefrom6 cm/minto72 cm/min.Theweldingtorchwas
held stationary in a frame mounted above the work table, and it was provided
with an attachment for both up and down movement and angular movement for
setting the required nozzle-to-plate distance and welding torch angle, respec-
tively. The experiments were conducted by laying three beads using stringer
bead technique with a constant overlap of 40%. An interpass temperature of
150 ◦C was maintained during all the cladding experiments. The experimental
setup is shown in Fig. 2.
Fig. 2. Experimental setup.
3. Experimental design procedure
The experimental design procedure used for this study is shown in Fig. 3
and important steps are briefly explained below.
3.1. Identification of factors and responses
The chosen factors were welding current (I), welding speed (S), nozzle-to-
plate distance (N), and welding torch angle (T). In this study, forehand welding
(push angle) technique was used. The chosen responses were weld bead width
(W), average depth of penetration (P), average height of reinforcement (R), and
percentage dilution (D). The chosen input and output parameters of FCAW are
shown in Fig. 4.
3.2. Finding the limits of the process variables
The working ranges of all selected factors were fixed by conducting trial
runs. This was carried out by varying one of the factors while keeping the rest
of them at constant values [7]. The working range of each process parameters
was decided upon by inspecting the bead for a smooth appearance without any
visible defects such as surface porosity, undercut, etc. The upper limit of a factor
was coded as +2 and the lower limit was coded as −2. The coded values for
intermediate values were calculated using the following Eq. (1)
Xi =
2[2X − (Xmax + Xmin)]
Xmax − Xmin
(1)
Table 2
Welding parameters and their levels
Parameter Unit Notation Factor levels
−2 −1 0 +1 +2
Welding current A I 200 225 250 275 300
Welding speed cm/min S 20 30 40 50 60
Nozzle-to-plate distance mm N 22 24 26 28 30
Welding torch angle with reference to vertical ◦ T 20 15 10 05 00
3. 232 T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239
Fig. 3. Experimental design procedure.
Fig. 5. Typical cladded plate (Trial Nos. 14 and 29).
where Xi is the required coded value of a variable X, X the any value of the
variable from Xmin to Xmax, Xmin the lower limit of the variable and Xmax the
upper limit of the variable. The chosen levels of the selected process parameters
with their units and notations are given in Table 2.
3.3. Development of design matrix
The design matrix chosen to conduct the experiment was a central compos-
ite rotatable design. This design matrix [8] comprised of a full replication of
24 = (16) factorial design plus seven center points and eight star points which is
shown in Table 3. All welding variables at the intermediate levels (0) constituted
the center points and the combination of each welding variables at either its high-
est value (+2) or lowest value (−2) with other three variables of the intermediate
levels (0), constituted the star points. Thus the 31 experimental runs allowed the
estimation of the linear, quadratic and two-way interactive effects of the process
parameters on clad quality parameters.
3.4. Conducting the experiments as per the design matrix
The experiments were conducted at the Welding Engineering Research Cen-
tre in Coimbatore Institute of Technology, India. In this work, 31 deposits were
made using cladding condition corresponding to each treatment combination of
parameters shown in Table 3 at random. At the end of each run, settings for all
four parameters were disturbed and reset for the next deposit. This was essential
to introduce variability caused by errors in experimental settings [9]. A typical
cladded plate is shown in Fig. 5.
3.5. Recording the responses
To measure the weld bead geometry, transverse sections of each weld over-
lays were cut using power hacksaw from the mid-length position of the welds,
and the end faces were machined. Specimen end faces were polished and etched
using a 2% nital solution and the bead profiles were traced using a reflective type
optical profile projector at a magnification of 10 and then the bead dimensions
such as penetration, reinforcement and bead width were measured. The areas
of base metal melted and the weld metal forming reinforcement were measured
with the help of a digital planimeter and the percentage dilution was calcu-
lated. The measured weld bead dimensions and calculated percentage dilution
are given in Table 3.
Fig. 4. Chosen factors and responses for FCAW process.
4. T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239 233
Table 3
Design matrix and the observed values of clad quality parameters
Trial no. Design matrix Clad quality parameters
I S N T W (mm) P (mm) R (mm) D (%)
01 −1 −1 −1 −1 29.50 0.61 4.97 07.86
02 +1 −1 −1 −1 36.62 0.73 5.00 12.10
03 −1 +1 −1 −1 24.20 0.63 4.23 11.35
04 +1 +1 −1 −1 28.00 0.77 4.27 11.98
05 −1 −1 +1 −1 30.00 0.57 5.00 06.54
06 +1 −1 +1 −1 34.98 0.67 5.29 08.82
07 −1 +1 +1 −1 25.59 0.58 4.18 09.69
08 +1 +1 +1 −1 29.51 0.70 4.20 11.16
09 −1 −1 −1 +1 28.34 0.73 5.00 08.97
10 +1 −1 −1 +1 34.50 0.97 5.10 13.75
11 −1 +1 −1 +1 24.00 1.00 4.00 18.52
12 +1 +1 −1 +1 27.80 1.20 4.34 20.58
13 −1 −1 +1 +1 29.26 0.60 5.08 07.46
14 +1 −1 +1 +1 34.80 0.80 5.28 09.14
15 −1 +1 +1 +1 25.30 0.97 4.00 18.00
16 +1 +1 +1 +1 27.70 1.00 4.20 14.80
17 −2 0 0 0 20.15 0.40 3.98 05.86
18 +2 0 0 0 31.00 1.07 4.90 16.48
19 0 −2 0 0 39.53 0.70 5.68 05.31
20 0 +2 0 0 23.10 1.00 3.63 17.35
21 0 0 −2 0 25.10 0.83 4.32 11.71
22 0 0 +2 0 28.00 0.63 4.81 09.01
23 0 0 0 −2 30.20 0.56 4.17 10.54
24 0 0 0 +2 26.00 0.87 4.87 13.98
25 0 0 0 0 27.88 0.70 4.55 10.33
26 0 0 0 0 29.42 0.83 4.34 13.60
27 0 0 0 0 28.00 0.77 4.50 10.73
28 0 0 0 0 27.90 0.87 4.50 11.71
29 0 0 0 0 29.20 0.83 4.32 13.76
30 0 0 0 0 27.80 0.79 4.58 10.99
31 0 0 0 0 27.80 0.80 4.57 10.67
W, width; P, penetration; R, reinforcement; D, dilution %; I, welding current; S, welding speed; N, nozzle-to-plate distance; T, welding torch angle.
3.6. Development of mathematical models
The response function representing any of the clad quality parameters can
be expressed using Eq. (2)
Y = f(X1, X2, X3, X4) (2)
where Y is the response (e.g. weld bead width), X1 the welding current (I) (A),
X2 the welding speed (S) (cm/min), X3 the nozzle-to-plate-distance (N) (mm)
and, X4 the welding torch angle (T) (◦).
The second order response surface model [10] for the four selected factors
is given by Eq. (3)
Y = βo +
4
i=1
βiXi +
4
i=1
βiiX2
i +
4
i = 1
i<j
βijXiXj (3)
The above second order response surface model equation could be expressed as
follows:
Y = β0 + β1I + β2S + β3N + β4T + β11I2
+ β22S2
+ β33N2
+ β44T2
+β12IS + β13IN + β14IT + β23SN + β24ST + β34NT (4)
where β0 is the free term of the regression equation, the coefficients β1, β2, β3
and β4 are linear terms, the coefficients β11, β22, β33, and β44 the quadratic
terms, and the coefficients β12, β13, β14, β23, β24, and β34 the interaction
terms.
The values of the coefficients of the polynomial Eq. (4) were calculated [11]
using following Eqs. (5)–(8)
β0 = 0.142857 Y − 0.035714 (XiiY) (5)
βi = 0.041667 (XiY) (6)
βii = 0.03125 (XiiY) + 0.035714 (XiiY) − 0.035715 Y (7)
βij = 0.0625 (XijY) (8)
The coefficients were calculated using QA six sigma software (DOE-PCIV) and
the same was verified by using the software SYSTAT 10.2. After determining
the coefficients, the mathematical models were developed. The insignificant
coefficients were eliminated without affecting the accuracy of the developed
model by using t-test. This was done by back elimination technique, which is
available in QA six sigma software (DOE-PCIV) and the same was verified
by using the software SYSTAT 10.2. The significant coefficients are given in
Table 4. The final mathematical models were constructed by using only these
coefficients. The developed final models with welding variables in coded form
are given below.
Bead width (W) (mm) = 27.775 + 2.494I − 3.244S + 0.415N − 0.610T
−0.303I2 + 1.066S2 + 0.316T2 − 0.616IS.
Average depth of penetration (P) (mm) = 0.764 + 0.104I + 0.074S − 0.048N +
0.110T + 0.021S2 + 0.061ST.
5. 234 T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239
Table 4
Estimated values of the significant coefficients of the models
Coefficient Clad quality parameters
W P R D
βo 27.775 0.764 4.535 11.702
β1 2.494 0.104 0.128 1.466
β2 −3.244 0.074 −0.475 2.730
β3 0.415 −0.048 0.054 −1.037
β4 −0.610 0.110 0.052 1.608
β11 −0.303 – – –
β22 1.066 0.021 0.053 –
β33 – – – –
β44 0.316 – – –
β12 −0.616 – – −0.751
β13 – – – −0.593
β14 – – – –
β23 – – −0.052 –
β24 – 0.061 – 1.482
β34 – – – –
Average height of reinforcement (R) (mm) = 4.535 + 0.128I − 0.475S +
0.054N + 0.052T + 0.053 S2 − 0.052SN.
Percentage dilution (D) = 11.702 + 1.466I + 2.730S − 1.037N + 1.608T −
0.751IS − 0.593IN + 1.482ST.
It was found that the reduced models are better than the full models because
the reduced models have higher values of R2 (adjusted) and lesser values of
standard error of estimates than that of full models. The values of R2 (adjusted)
and standard error of estimates for full and reduced models are given in
Table 5.
3.7. Checking the adequacy of the developed models
The adequacies of the developed models were tested using the analysis of
variance (ANOVA) technique [12]. As per this technique, if the calculated F-
ratio values for the developed models do not exceed the standard tabulated
values of F-ratio for a desired level of confidence (95%) and the calculated R-
ratio values of the developed models exceed the standard tabulated values of
R-ratio for a desired level of confidence (95%), then the models are said to be
adequate within the confidence limit. These conditions were satisfied for all the
developed models, which are given in Table 6. The validity of these models,
were again tested by drawing scatter diagrams as shown in Fig. 6a–d which
show the observed and predicted values of clad quality parameters.
3.8. Conducting the conformity test
Conformity tests were conducted using the same experimental setup to con-
firm the results of the experiment and demonstrate the reliability of the predicted
values. The conformity tests show the accuracy of the models developed, which
is above 96%. This is shown in Table 7.
4. Results and discussions
The models developed above can be used to predict the clad
qualityparametersbysubstitutingthecodedvaluesoftherespec-
tive process parameters. The responses calculated from these
models for each set of coded welding parameters are represented
in graphical form in Figs. 7–16. Also by substituting the values
of the desired clad quality parameters, the values of the process
parameters, in coded form can be obtained.
4.1. Direct effects of process parameters on clad quality
parameters
4.1.1. Direct effect of welding current (I) on clad quality
parameters
Fig. 7 shows all the clad quality parameters W, P, R, and
D increase with increase in welding current. This is due to the
increase in welding current density and the weight of wire fused
per unit of time [13]. Also with increase in welding current the
arc becomes stiffer and hotter which penetrates more deeply and
melting more base metal.
4.1.2. Direct effect of welding speed (S) on clad quality
parameters
From Fig. 8, it is evident that the clad quality parameters R
and W decrease with increase in welding speed but P and D
Table 5
Comparison of R2 values and standard error of estimates for full and reduced models
Clad quality parameter R2 values Standard error of estimates
Full models Reduced models Full models Reduced models
Width (W) 0.856 0.889 1.552 1.365
Penetration (P) 0.816 0.839 0.075 0.070
Reinforcement (R) 0.884 0.900 0.165 0.153
%Dilution (D) 0.793 0.836 1.707 1.515
Table 6
Analysis of variance for testing adequacy of the models
Parameter 1st order Terms 2nd order Terms Lack of fit Error terms F-ratio R-ratio Whether model is adequate
SS d.f. SS d.f. SS d.f. SS d.f.
W 414.845 4 48.00 10 26.016 10 12.499 6 1.249 15.870 Adequate
P 0.732 4 0.010 10 0.073 10 0.018 6 2.477 20.149 Adequate
R 6.164 4 0.400 10 0.368 10 0.066 6 3.353 42.719 Adequate
D 318.38 4 56.142 10 34.20 10 12.24 6 1.677 13.119 Adequate
F-ratio (10, 6, 0.05) = 4.09; SS, sum of squares; R-ratio (14, 6, 0.05) = 3.96; d.f., degrees of freedom.
6. T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239 235
Table 7
Comparison of predicted and actual values of clad quality parameters
Process parameter in coded form Predicted values of clad quality parameters Actual values of clad quality parameters Error (%)
I S N T W P R D W P R D W P R D
−0.11 −0.22 0.09 −0.3 28.9 0.72 4.7 10.6 28.6 0.67 4.8 10.3 −1.04 −2.86 2.13 −2.80
−0.79 −0.35 0.94 1.02 27.3 0.72 4.8 10.3 27.7 0.71 4.6 10.2 1.47 −1.39 −4.17 −0.97
−0.66 0.03 0.90 1.03 26.3 0.77 4.6 11.5 26 0.78 4.7 11.8 −1.14 1.30 2.17 −2.61
%Error = actual value−predicted value
predicted value × 100.
Fig. 6. Scatter diagram of (a) weld bead width model; (b) depth of penetration model; (c) percentage dilution model; and (d) height of reinforcement model.
7. 236 T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239
Fig. 7. Effect of welding current on clad quality parameters.
increases with increase in welding speed. Decrease in R and W
can be obviously attributed to the reduced heat input per unit
length of weld bead as welding speed is increased and less filler
metal is applied per unit length of the weld [13]. The percentage
dilution of base metal in the pool increases with the increase
in welding speed, since the weight of deposited metal per unit
of length decreases with the cross section of the bead decreases
very little. With low welding speed the arc is almost vertical
and in this instance the weld pool cushions the effect of arc and
prevents deeper penetration.
4.1.3. Direct effect of nozzle-to-plate distance (N) on clad
quality parameters
It is evident from Fig. 9 that P and D decrease slightly
with increase in nozzle-to-plate distance but W and R increases
Fig. 8. Effect of welding speed on clad quality parameters.
Fig. 9. Effect of nozzle-to-plate distance on clad quality parameters.
with increase in nozzle-to-plate distance. Increase in nozzle-
to-plate distance increases the circuit resistance, which reduces
the welding current. This decrease of welding current reduces
the penetration of arc and hence reduces the dilution. With
increase in nozzle-to-plate distance the arc length is increased
hence the bead width is increased due to wider arc area at
the weld surface and this consequently increases the reinforce-
ment height because the same volume of filler metal is added
[14].
4.1.4. Direct effect of welding torch angle (T) on clad
quality parameters
From Fig. 10 R, P and D decrease with increase in weld-
ing torch angle but W increases with increase in welding torch
angle. The reason is when the angle is increased in fore-
hand welding the arc force pushes the weld metal forward, i.e.
Fig. 10. Effect of welding torch angle on clad quality parameters.
8. T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239 237
Fig. 11. Interaction effects of welding current and welding speed on bead width.
towards the cold metal, which reduces the penetration, reinforce-
ment and percentage dilution but width of the weld increases
[15].
4.2. Interaction effects of process parameters on clad
quality parameters
4.2.1. Interaction effects of welding current (I) and welding
speed (S) on bead width (W)
From Fig. 11 it is clear that the W increases with increase
in welding current. It also increases with decrease in welding
Fig. 12. Interaction effects of welding torch angle and welding speed on pene-
tration.
Fig. 13. Interaction effects of nozzle-to-plate distance and welding speed on
reinforcement.
speed. These effects are due to welding current having a pos-
itive effect but welding speed having negative effect on bead
width. The increasing trend of weld bead width with increase
in welding current decreases with the increase in welding
speed.
4.2.2. Interaction effects of welding torch angle (T) and
welding speed (S) on average depth of penetration (P)
Fig. 12 shows that the P decreases with increase in welding
torch angle. This decreasing trend of P with increase in welding
torch angle gradually decreases with decrease in welding speed.
Fig. 14. Interaction effects of welding current and welding speed on percentage
dilution.
9. 238 T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239
Fig. 15. Interaction effects of nozzle-to-plate distance and welding current on
percentage dilution.
This is because welding torch angle has negative effect and
welding speed has positive effect on penetration.
4.2.3. Interaction effects of nozzle-to-plate distance (N) and
welding speed (S) on average height of reinforcement (R)
From Fig. 13, it is evident that R increases with the increase in
nozzle-to-plate distance when welding speed is from 20 cm/min
to 50 cm/min and the rate of increase in R also decreases with
the increase in welding speed. But when welding speed is at
60 cm/min, R decreases with increase in nozzle-to-plate dis-
tance.
Fig. 16. Interaction effects of welding speed and welding torch angle on per-
centage dilution.
4.2.4. Interaction effects of welding current (I) and welding
speed (S) on percentage dilution (D)
From Fig. 14, it is clear that D increases with increase in weld-
ing current for all values of welding speed. But this increasing
trend of D with the increase in welding current decreases grad-
ually with the decrease in welding speed. These effects occur
because both welding current and welding speed have a positive
effect on percentage dilution.
4.2.5. Interaction effects of welding current (I) and
nozzle-to-plate distance (N) on percentage dilution (D)
From Fig. 15, it is clear that D decreases with increase in
nozzle-to-plate distance for all values of welding current. But
this decreasing trend of D with the increase in nozzle-to-plate
distance decreases gradually with decrease in welding current.
These effects occur because welding current has a positive effect
whereas nozzle-to-plate distance has a negative effect on D.
4.2.6. Interaction effects of welding torch angle (T) and
welding speed (S) on percentage dilution (D)
From Fig. 16, it is evident that D decreases with the increase
in welding torch angle when welding speed is from 30 cm/min
to 60 cm/min and the rate of decrease in D also increases with
increase in welding speed from 30 cm/min. But when welding
speed is 20 cm/min D increases with the increase in welding
torch angle.
5. Conclusions
• Afivelevelfourfactorfullfactorialdesignmatrixbasedonthe
central composite rotatable design technique can be used for
the development of mathematical models to predict the clad
quality parameters for duplex stainless steel cladding using
FCAW.
• Dilution increases with the rise in welding current and weld-
ing speed and decreases with the rise in nozzle-to-plate dis-
tance and welding torch angle.
• Reinforcement increases with the rise in welding current and
nozzle-to-platedistanceanddecreaseswiththeriseinwelding
speed and welding torch angle.
• Weld bead width increases with the rise in welding cur-
rent, nozzle-to-plate distance and welding torch angle and
decreases with the rise in welding speed.
• Penetration increases with the rise in welding current and
welding speed and decreases with the rise in nozzle-to-plate
distance and welding torch angle.
• Bead width increases with the increase in welding current at
all levels of welding speed. But the rate of increase in bead
width with the increase in welding current decreases signifi-
cantly with the increase in welding speed.
• Increase in welding torch angle decreases penetration when
welding speed is high but penetration slightly increases with
the increase in welding torch angle when welding speed is
low.
• Percentage dilution decreases with the increase in nozzle-
to-plate distance at all levels of welding current. But the
rate of decrease in percentage dilution with the increase in
10. T. Kannan, N. Murugan / Journal of Materials Processing Technology 176 (2006) 230–239 239
nozzle-to-plate distance decreases significantly with decrease
in welding current.
Acknowledgements
The authors wish to thank M/S Bohler welding, Austria for
providing flux cored welding wire for this work. The finan-
cial support for this work from All India Council of Techni-
cal Education and University Grant Commission is gratefully
acknowledged. The authors also wish to thank the management
of Coimbatore Institute of Technology and Kumaraguru College
of Technology for having provided all the necessary facilities to
carryout this work.
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