This document discusses a preliminary study on the cladding process for gray cast iron substrates. It provides background information on cladding, including that it is a deposition process used to improve substrate properties by depositing filler material in layers. Gas metal arc welding is discussed as a common cladding method. Process parameters for GMAW cladding are described, including current, voltage, and travel speed. Challenges of cladding gray cast iron due to its brittle microstructure are addressed. Nickel-based filler materials are proposed to address these challenges by preventing cracking during thermal cycling.
Synthesis, characterization and mechanical behavior of nickel coated graphite...eSAT Journals
Abstract In this paper we are going to describe the characterization and mechanical behavior of the Nickel Coated Graphite (NCG) particle reinforced Al6061 metal matrix composite. Many a times, the composites fail to answer the question or fail to serve the purpose for which it is fabricated to. This is due to the less wetting nature between the reinforcement and the matrix and the impossibility of higher percentage of reinforcement addition in to the matrix. However, metal coated reinforcements have been able to overcome these limitations to a very extent. NCG particles reinforced Al6061 matrix with various weight percentages were fabricated by Squeeze casting method. Samples of 0, 5 and 10 wt% reinforcement addition were synthesized and characterized. Finally some useful conclusions were made. Keywords: Metal Coated Reinforcement; Nickel Coated Graphite; Squeeze Casting; Wetting.
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
Synthesis, characterization and mechanical behavior of nickel coated graphite...eSAT Journals
Abstract In this paper we are going to describe the characterization and mechanical behavior of the Nickel Coated Graphite (NCG) particle reinforced Al6061 metal matrix composite. Many a times, the composites fail to answer the question or fail to serve the purpose for which it is fabricated to. This is due to the less wetting nature between the reinforcement and the matrix and the impossibility of higher percentage of reinforcement addition in to the matrix. However, metal coated reinforcements have been able to overcome these limitations to a very extent. NCG particles reinforced Al6061 matrix with various weight percentages were fabricated by Squeeze casting method. Samples of 0, 5 and 10 wt% reinforcement addition were synthesized and characterized. Finally some useful conclusions were made. Keywords: Metal Coated Reinforcement; Nickel Coated Graphite; Squeeze Casting; Wetting.
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
Determination of flux consumption when reuse of slag as flux in submerged arc...IJESM JOURNAL
The Objectives of this research is to study the effect of mixture of reused and new flux on chemical composition in weld metal of Submerged Arc Welding process (SAW). Slag generated during submerged arc welding has been recycled by mixing varying percentages of crushed slag with fresh flux to use in subsequent runs. Slag generated during submerged arc welding is normally thrown away as a waste. This poses the problem of storage, disposal, and environmental pollution and needs landfill space apart from exhaust of non-renewable resources. Reusing of slag will not only solve these problems but also be economical. In the present work an attempt has been made to use the submerged arc welding slag as flux in the same submerged arc welding process. Fused slag was crusher to the desired particle size as that of the original flux. The process is characterized by the use of granular flux blanket that covers the molten weld pool during operation. Protection through atmospheric contamination of the weld bead and slower cooling rate, achieved by this arrangement can enhance mechanical properties of the weldment. Selection of process parameters has great influence on the quality of a welded connection.
Mechanical Behaviour of AA 6061-Ca2SiO3 Compositeijtsrd
The advantage of composite materials over non alloy virgin metals has been on the front burner in the engineering materials sphere. To this ends, various reinforcement materials are constantly been mixed with metal matrix to form new composite materials. Ca2SiO3 is a ceramic material which finds application in medicine, heat and noise insulation, acid remediation, cement production etc. since it possesses qualities needed for the formation of composites, and is largely not researched on, this study aimed to characterize the mechanical properties of the AA 6061 Ca2SiO3 composite for different composition of percentage mix, and to establish a model that would predict the UTS for known values of percentage mix and load. Result of the study shows that 6 Ca2SiO3 - 94 AA 6061 and 24 Ca2SiO3 - 76 AA 6061 possessed the highest modulus of elasticity and are stiffer while 2 Ca2SiO3 - 98 AA 6061 mix had the lowest modulus of elasticity, and is more ductile than other composition mix. Also, it was observed that addition of Ca2SiO3 to AA 6061 T4 greatly improves its mechanical properties and96.43 of the variations in stress experienced by various percentage composition of the composite mix can be explained by the developed model. B. C. Chukwudi | B. M. Ogunedo "Mechanical Behaviour of AA 6061-Ca2SiO3 Composite" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-5 | Issue-6 , October 2021, URL: https://www.ijtsrd.com/papers/ijtsrd47596.pdf Paper URL : https://www.ijtsrd.com/engineering/mechanical-engineering/47596/mechanical-behaviour-of-aa-6061-ca2sio3-composite/b-c-chukwudi
Alternative Joining Methods in Car Body Productiontheijes
The optimization of a car body in terms of cost can be achieved by using different materials in various positions of the car in order to utilize specific properties of each different material. The paper deals with the methods of mechanical joining used in car body production as alternatives to the most used conventional resistance spot welding. Load-bearing capacities of the joints made by mechanical joining and resistance spot welding of various materials used in car body structures are compared. The mechanical joining is mainly used to join material with various thicknesses, mechanical properties, surface coatings, even ferrous or non-ferrous metals.
The effect of welding heat input and welding speed on microstructure of chrom...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
Effect of Sintering Temperature on Mechanical Properties of Aluminum Compositesijtsrd
Using Al, Al2O3 and SiC, different types of composites have been prepared in this experiment. Green compacts of Al composites were made at a compressing load of 1 ton and 2 ton respectively. These compacts were sintered at two different sintering temperatures of 400 °C and 450 °C in an oxygen free environment using muffle furnace for one hour followed by annealing process which took 12 hours. Sintered compacts were then sintered to micro structural examination and mechanical properties evaluation. Higher hardness has been attained for the composites containing 2.5 SiC. Attempts have been made to describe the influence of sintering temperature on the microstructure and properties of Al Al2O3 SiC composites. Samples are prepared of 100 Al, 97.5 Al 2.5 Al2O3, 92.5 Al 7.5 Al2O3, 95 Al 2.5 Al2O3 – 2.5 SiC, 92.5 Al 5 Al2O3 – 2.5 SiC, 95 Al – 5 Al2O3. The main objective of this experiment is to determine the factors that can increase hardness of Al composites. Mohd Quasim Khan ""Effect of Sintering Temperature on Mechanical Properties of Aluminum Composites"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd25073.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/25073/effect-of-sintering-temperature-on-mechanical-properties-of-aluminum-composites/mohd-quasim-khan
A review of effect of welding and post weld heat treatment on microstructure ...eSAT Journals
Abstract
Today getting high thermal efficiency in thermal and nuclear power plant is a big challenge. Many new material are developed. SA 335 grade 91 steel is modified high chrome-moly martenstitic steel. This material is having excellent toughness and high temperature creep strength. During welding, this material is having tremendous change in its microstructure and hence mechanical property. Many research works were done in this area. This paper discusses weld ability of P91 material. Effect of different welding process, type of filler wire, its chemical composition and type of flux is discussed in this paper. PWHT is necessary after welding of P91 steel. PWHT temperature and its duration affects phase transformation and mechanical properties of weld metal, HAZ and parent metal. Major focus is given on hardness, creep resistance and notch toughness.
Keywords - P91, Welding, Microstructure, Toughness, Creep, Hardness, PWHT
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Determination of flux consumption when reuse of slag as flux in submerged arc...IJESM JOURNAL
The Objectives of this research is to study the effect of mixture of reused and new flux on chemical composition in weld metal of Submerged Arc Welding process (SAW). Slag generated during submerged arc welding has been recycled by mixing varying percentages of crushed slag with fresh flux to use in subsequent runs. Slag generated during submerged arc welding is normally thrown away as a waste. This poses the problem of storage, disposal, and environmental pollution and needs landfill space apart from exhaust of non-renewable resources. Reusing of slag will not only solve these problems but also be economical. In the present work an attempt has been made to use the submerged arc welding slag as flux in the same submerged arc welding process. Fused slag was crusher to the desired particle size as that of the original flux. The process is characterized by the use of granular flux blanket that covers the molten weld pool during operation. Protection through atmospheric contamination of the weld bead and slower cooling rate, achieved by this arrangement can enhance mechanical properties of the weldment. Selection of process parameters has great influence on the quality of a welded connection.
Mechanical Behaviour of AA 6061-Ca2SiO3 Compositeijtsrd
The advantage of composite materials over non alloy virgin metals has been on the front burner in the engineering materials sphere. To this ends, various reinforcement materials are constantly been mixed with metal matrix to form new composite materials. Ca2SiO3 is a ceramic material which finds application in medicine, heat and noise insulation, acid remediation, cement production etc. since it possesses qualities needed for the formation of composites, and is largely not researched on, this study aimed to characterize the mechanical properties of the AA 6061 Ca2SiO3 composite for different composition of percentage mix, and to establish a model that would predict the UTS for known values of percentage mix and load. Result of the study shows that 6 Ca2SiO3 - 94 AA 6061 and 24 Ca2SiO3 - 76 AA 6061 possessed the highest modulus of elasticity and are stiffer while 2 Ca2SiO3 - 98 AA 6061 mix had the lowest modulus of elasticity, and is more ductile than other composition mix. Also, it was observed that addition of Ca2SiO3 to AA 6061 T4 greatly improves its mechanical properties and96.43 of the variations in stress experienced by various percentage composition of the composite mix can be explained by the developed model. B. C. Chukwudi | B. M. Ogunedo "Mechanical Behaviour of AA 6061-Ca2SiO3 Composite" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-5 | Issue-6 , October 2021, URL: https://www.ijtsrd.com/papers/ijtsrd47596.pdf Paper URL : https://www.ijtsrd.com/engineering/mechanical-engineering/47596/mechanical-behaviour-of-aa-6061-ca2sio3-composite/b-c-chukwudi
Alternative Joining Methods in Car Body Productiontheijes
The optimization of a car body in terms of cost can be achieved by using different materials in various positions of the car in order to utilize specific properties of each different material. The paper deals with the methods of mechanical joining used in car body production as alternatives to the most used conventional resistance spot welding. Load-bearing capacities of the joints made by mechanical joining and resistance spot welding of various materials used in car body structures are compared. The mechanical joining is mainly used to join material with various thicknesses, mechanical properties, surface coatings, even ferrous or non-ferrous metals.
The effect of welding heat input and welding speed on microstructure of chrom...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
Effect of Sintering Temperature on Mechanical Properties of Aluminum Compositesijtsrd
Using Al, Al2O3 and SiC, different types of composites have been prepared in this experiment. Green compacts of Al composites were made at a compressing load of 1 ton and 2 ton respectively. These compacts were sintered at two different sintering temperatures of 400 °C and 450 °C in an oxygen free environment using muffle furnace for one hour followed by annealing process which took 12 hours. Sintered compacts were then sintered to micro structural examination and mechanical properties evaluation. Higher hardness has been attained for the composites containing 2.5 SiC. Attempts have been made to describe the influence of sintering temperature on the microstructure and properties of Al Al2O3 SiC composites. Samples are prepared of 100 Al, 97.5 Al 2.5 Al2O3, 92.5 Al 7.5 Al2O3, 95 Al 2.5 Al2O3 – 2.5 SiC, 92.5 Al 5 Al2O3 – 2.5 SiC, 95 Al – 5 Al2O3. The main objective of this experiment is to determine the factors that can increase hardness of Al composites. Mohd Quasim Khan ""Effect of Sintering Temperature on Mechanical Properties of Aluminum Composites"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd25073.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/25073/effect-of-sintering-temperature-on-mechanical-properties-of-aluminum-composites/mohd-quasim-khan
A review of effect of welding and post weld heat treatment on microstructure ...eSAT Journals
Abstract
Today getting high thermal efficiency in thermal and nuclear power plant is a big challenge. Many new material are developed. SA 335 grade 91 steel is modified high chrome-moly martenstitic steel. This material is having excellent toughness and high temperature creep strength. During welding, this material is having tremendous change in its microstructure and hence mechanical property. Many research works were done in this area. This paper discusses weld ability of P91 material. Effect of different welding process, type of filler wire, its chemical composition and type of flux is discussed in this paper. PWHT is necessary after welding of P91 steel. PWHT temperature and its duration affects phase transformation and mechanical properties of weld metal, HAZ and parent metal. Major focus is given on hardness, creep resistance and notch toughness.
Keywords - P91, Welding, Microstructure, Toughness, Creep, Hardness, PWHT
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Clinching as a Nonconventional Method to Join Drawing Quality Steel Sheetsijtsrd
The most common methods for joining the galvanized steel sheetsin automotive industry is resistance spot welding.These methods require some specific time-consuming pretreatment of joined materials and the protective layer is destroyed which lead to decreasing of corrosion resistance.Therefore, it is necessary to utilize the other joining methods. The contribution deals with analysis of properties of clinched joints. There were made samples with single press joint and various sheets orientation due to punch and die and also samples with double press joints. Deep drawing quality steels of U.S.SteelKošice, Ltd. productions of various thicknesses a quality were used. The steels are also used in automotive industry. Moreover carrying capacity of press joints was evaluated. Luboš Kašcák"Clinching as a Nonconventional Method to Join Drawing Quality Steel Sheets" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-1 , December 2017, URL: http://www.ijtsrd.com/papers/ijtsrd8243.pdf http://www.ijtsrd.com/other-scientific-research-area/other/8243/clinching-as-a-nonconventional-method-to-join-drawing-quality-steel-sheets/luboš-kašcák
Finite element simulation of hybrid welding process for welding 304 austeniti...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Finite element simulation of hybrid welding process for welding 304 austeniti...eSAT Journals
Abstract Although autogenous laser welding has many advantages over traditional welding methods in many applications, still the process has a main disadvantage of poor gap bridging capability, which limits its applicability for wider industrial use. Owing to this limiting factor, a great deal of research work was carried out to overcome this disadvantage by using Arc source with laser welding. The combination of laser and Arc (MIG/TIG) welding processes in a same process zone is known as Hybrid Welding. This process involves very high peak temperature and rapid change in thermal cycle both of which are difficult to measure in real time. In this dissertation work, a 3- dimensional finite element model was developed for the analysis of hybrid welding process. Ansys Parametric Design language (APDL) code was developed for the same. The FEA results were validated with experimental results showing good agreement. Hybrid welding Simulations were carried out for AISI 304 Austenitic stainless Steel plate. The effects of laser beam power, Arc Welding and torch angle on the weld-bead geometry i.e. penetration (DP), welded zone width (BW) were investigated. The experimental plan was based on three factor 5 level central composite rotatable design. Second order polynomial equations for predicting the weld-bead geometry were developed for bead width and depth of penetration. The results indicate that the effect of arc current (AC) on bead width was more than on depth of penetration. Hence, the proposed models predict the responses adequately within the limits of welding parameters being used. Index Terms: Hybrid Welding, Ansys Parametric Design language (APDL), FEA, AISI 304 Austenitic stainless Steel, and Central composite rotatable design
Comparative study of tensile properties of forged hybrid alloys of aa6061 si...eSAT Journals
Abstract Hybrid materials are important engineering materials due to their outstanding mechanical properties. AA6061 and silicon carbide (SiC) particles and Graphite (Gr) particles were synthesized used stir casting method, which can be used in aircraft and automobile industries to improve the strength and reduce the weight of the components. The major physical parameters like composition ratio, total particle content in%, particle size combination are playing an important role in deciding the mechanical properties. Hot forging involving the shaping of metal to improve strength. Tensile tests were conducted on standard specimens machined from the hot forged sections. The tension test is the most common test for determining the mechanical behavior of materials. The results show that, the reinforcement of the metal matrix with SiC and graphite particulates up to a volume fraction of 10% Keywords: AA-Aluminium alloys, SiC-silicon carbide, Gr-Graphite, AMC-Aluminium matrix composite
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.
A Review: Welding Of Dissimilar Metal Alloys by Laser Beam Welding & Friction...IJERA Editor
Welding of dissimilar metals has attracted attention of the researchers worldwide, owing to its many advantages and challenges. There is no denial in the fact that dissimilar welded joints offer more flexibility in the design and production of the commercial and industrial components. Many welding techniques have been analyzed to join dissimilar metal combinations. The objective of this paper is to review two such techniques – Laser welding and Friction stir welding. Laser beam welding, a high power density and low energy-input process, employs a laser beam to produce welds of dissimilar materials. Friction stir welding, a solid-state joining process, is also successfully used in dissimilar welding applications like aerospace and ship building industries. This paper summarizes the trends and advances of these two welding processes in the field of dissimilar welding. Future aspects of the study are also discussed.
Study of brass wire and cryogenic treated brass wire on titanium alloy using ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
Abstract
Soil stabilization has proven to be one of the oldest techniques to improve the soil properties. Literature review conducted revealed
that uses of natural inorganic stabilizers are found to be one of the best options for soil stabilization. In this regard an attempt has
been made to evaluate the influence of RBI-81 stabilizer on properties of black cotton soil through laboratory investigations. Black
cotton soil with varying percentages of RBI-81 viz., 0, 0.5, 1, 1.5, 2, and 2.5 percent were studied for moisture density relationships
and strength behaviour of soils. Also the effect of curing period was evaluated as literature review clearly emphasized the strength
gain of soils stabilized with RBI-81 over a period of time. The results obtained shows that the unconfined compressive strength of
specimens treated with RBI-81 increased approximately by 250% for a curing period of 28 days as compared to virgin soil. Further
the CBR value improved approximately by 400%. The studies indicated an increasing trend for soil strength behaviour with
increasing percentage of RBI-81 suggesting its potential applications in soil stabilization.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
Abstract
Increase in traffic along with heavier magnitude of wheel loads cause rapid deterioration in pavements. There is a need to improve
density, strength of soil subgrade and other pavement layers. In this study an attempt is made to improve the properties of locally
available loamy soil using twin approaches viz., i) increasing the compaction of soil and ii) treating the soil with chemical stabilizer.
Laboratory studies are carried out on both untreated and treated soil samples compacted by different compaction efforts. Studies
show that increase in compaction effort results in increase in density of soil. However in soil treated with chemical stabilizer, rate of
increase in density is not significant. The soil treated with chemical stabilizer exhibits improvement in both strength and performance
properties.
Keywords: compaction, density, subgradestabilization, resilient modulus
Geographical information system (gis) for water resources managementeSAT Journals
Abstract
Water resources projects are inherited with overlapping and at times conflicting objectives. These projects are often of varied sizes
ranging from major projects with command areas of millions of hectares to very small projects implemented at the local level. Thus,
in all these projects there is seldom proper coordination which is essential for ensuring collective sustainability.
Integrated watershed development and management is the accepted answer but in turn requires a comprehensive framework that can
enable planning process involving all the stakeholders at different levels and scales is compulsory. Such a unified hydrological
framework is essential to evaluate the cause and effect of all the proposed actions within the drainage basins.
The present paper describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) which is
intended to meet the specific information needs of the various line departments of a typical State connected with water related aspects.
The HIS consist of a hydrologic information database coupled with tools for collating primary and secondary data and tools for
analyzing and visualizing the data and information. The HIS also incorporates hydrological model base for indirect assessment of
various entities of water balance in space and time. The framework would be maintained and updated to reflect fully the most
accurate ground truth data and the infrastructure requirements for planning and management.
Keywords: Hydrological Information System (HIS); WebGIS; Data Model; Web Mapping Services
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
Abstract
This paper presents an outlook on experimental behavior and a comparison with predicted formula on the behaviour of circular
concentrically loaded self-consolidating fibre reinforced concrete filled steel tube columns (HSSCFRC). Forty-five specimens were
tested. The main parameters varied in the tests are: (1) percentage of fiber (2) tube diameter or width to wall thickness ratio (D/t
from 15 to 25) (3) L/d ratio from 2.97 to 7.04 the results from these predictions were compared with the experimental data. The
experimental results) were also validated in this study.
Keywords: Self-compacting concrete; Concrete-filled steel tube; axial load behavior; Ultimate capacity.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
Intake towers are typically tall, hollow, reinforced concrete structures and form entrance to reservoir outlet works. A parametric
study on dynamic behavior of circular cylindrical towers can be carried out to study the effect of depth of submergence, wall thickness
and slenderness ratio, and also effect on tower considering dynamic analysis for time history function of different soil condition and
by Goyal and Chopra accounting interaction effects of added hydrodynamic mass of surrounding and inside water in intake tower of
dam
Key words: Hydrodynamic mass, Depth of submergence, Reservoir, Time history analysis,
Evaluation of operational efficiency of urban road network using travel time ...eSAT Journals
Abstract
Efficiency of the road network system is analyzed by travel time reliability measures. The study overlooks on an important measure of
travel time reliability and prioritizing Tiruchirappalli road network. Traffic volume and travel time were collected using license plate
matching method. Travel time measures were estimated from average travel time and 95th travel time. Effect of non-motorized vehicle
on efficiency of road system was evaluated. Relation between buffer time index and traffic volume was created. Travel time model has
been developed and travel time measure was validated. Then service quality of road sections in network were graded based on
travel time reliability measures.
Keywords: Buffer Time Index (BTI); Average Travel Time (ATT); Travel Time Reliability (TTR); Buffer Time (BT).
Estimation of surface runoff in nallur amanikere watershed using scs cn methodeSAT Journals
Abstract
The development of watershed aims at productive utilization of all the available natural resources in the entire area extending from
ridge line to stream outlet. The per capita availability of land for cultivation has been decreasing over the years. Therefore, water and
the related land resources must be developed, utilized and managed in an integrated and comprehensive manner. Remote sensing and
GIS techniques are being increasingly used for planning, management and development of natural resources. The study area, Nallur
Amanikere watershed geographically lies between 110 38’ and 110 52’ N latitude and 760 30’ and 760 50’ E longitude with an area of
415.68 Sq. km. The thematic layers such as land use/land cover and soil maps were derived from remotely sensed data and overlayed
through ArcGIS software to assign the curve number on polygon wise. The daily rainfall data of six rain gauge stations in and around
the watershed (2001-2011) was used to estimate the daily runoff from the watershed using Soil Conservation Service - Curve Number
(SCS-CN) method. The runoff estimated from the SCS-CN model was then used to know the variation of runoff potential with different
land use/land cover and with different soil conditions.
Keywords: Watershed, Nallur watershed, Surface runoff, Rainfall-Runoff, SCS-CN, Remote Sensing, GIS.
Estimation of morphometric parameters and runoff using rs & gis techniqueseSAT Journals
Abstract
Land and water are the two vital natural resources, the optimal management of these resources with minimum adverse environmental
impact are essential not only for sustainable development but also for human survival. Satellite remote sensing with geographic
information system has a pragmatic approach to map and generate spatial input layers of predicting response behavior and yield of
watershed. Hence, in the present study an attempt has been made to understand the hydrological process of the catchment at the
watershed level by drawing the inferences from moprhometric analysis and runoff. The study area chosen for the present study is
Yagachi catchment situated in Chickamaglur and Hassan district lies geographically at a longitude 75⁰52’08.77”E and
13⁰10’50.77”N latitude. It covers an area of 559.493 Sq.km. Morphometric analysis is carried out to estimate morphometric
parameters at Micro-watershed to understand the hydrological response of the catchment at the Micro-watershed level. Daily runoff
is estimated using USDA SCS curve number model for a period of 10 years from 2001 to 2010. The rainfall runoff relationship of the
study shows there is a positive correlation.
Keywords: morphometric analysis, runoff, remote sensing and GIS, SCS - method
-
Effect of variation of plastic hinge length on the results of non linear anal...eSAT Journals
Abstract The nonlinear Static procedure also well known as pushover analysis is method where in monotonically increasing loads are applied to the structure till the structure is unable to resist any further load. It is a popular tool for seismic performance evaluation of existing and new structures. In literature lot of research has been carried out on conventional pushover analysis and after knowing deficiency efforts have been made to improve it. But actual test results to verify the analytically obtained pushover results are rarely available. It has been found that some amount of variation is always expected to exist in seismic demand prediction of pushover analysis. Initial study is carried out by considering user defined hinge properties and default hinge length. Attempt is being made to assess the variation of pushover analysis results by considering user defined hinge properties and various hinge length formulations available in literature and results compared with experimentally obtained results based on test carried out on a G+2 storied RCC framed structure. For the present study two geometric models viz bare frame and rigid frame model is considered and it is found that the results of pushover analysis are very sensitive to geometric model and hinge length adopted. Keywords: Pushover analysis, Base shear, Displacement, hinge length, moment curvature analysis
Effect of use of recycled materials on indirect tensile strength of asphalt c...eSAT Journals
Abstract
Depletion of natural resources and aggregate quarries for the road construction is a serious problem to procure materials. Hence
recycling or reuse of material is beneficial. On emphasizing development in sustainable construction in the present era, recycling of
asphalt pavements is one of the effective and proven rehabilitation processes. For the laboratory investigations reclaimed asphalt
pavement (RAP) from NH-4 and crumb rubber modified binder (CRMB-55) was used. Foundry waste was used as a replacement to
conventional filler. Laboratory tests were conducted on asphalt concrete mixes with 30, 40, 50, and 60 percent replacement with RAP.
These test results were compared with conventional mixes and asphalt concrete mixes with complete binder extracted RAP
aggregates. Mix design was carried out by Marshall Method. The Marshall Tests indicated highest stability values for asphalt
concrete (AC) mixes with 60% RAP. The optimum binder content (OBC) decreased with increased in RAP in AC mixes. The Indirect
Tensile Strength (ITS) for AC mixes with RAP also was found to be higher when compared to conventional AC mixes at 300C.
Keywords: Reclaimed asphalt pavement, Foundry waste, Recycling, Marshall Stability, Indirect tensile strength.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
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.
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.
Preliminary study of on cladding process on gray cast iron substrate
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 5
PRELIMINARY STUDY OF ON CLADDING PROCESS ON GRAY CAST
IRON SUBSTRATE
Hussein, N. I. S1
, Kamarul S. R.2
, Ayof, M. N3
1, 3
Senior Lecturer, Department of Manufacturing Process, Faculty of Manufacturing Engineering, Universiti Teknikal
Malaysia Melaka, Malacca, Malaysia,
2
Student, Department of Manufacturing Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia
Melaka, Malacca, Malaysia,
izan@utem.edu.my, kamarul.shaufi@student.utem.edu.my, nizam@utem.edu.my
Abstract
Cladding, also called as hardfacing or surfacing, is a deposition process with a purpose of improving the properties of the substrate
accomplished either using laser beam or arc as the heat source for the process. Filler material used in the process is deposited layer-
by-layer until covering required thickness before being machined to achieve the final dimension. Gas metal arc welding is seen as the
best method for accomplishing the cladding operation as the alternative for laser cladding in term of operation cost. The process
parameters of gas metal arc welding are discussed on in the aspect of the cladding process. Grey cast iron with its inherent brittleness
characteristic is difficult to be weld cladded because the thermal cycle of the cladding process can cause the material to crack. It is
understood that the coarse graphite flake structure that gives the lack of ductility characteristic to the material and cause the material
to crack when suffer the stress occur during the temperature drop of the process. Nickel based filler material is seen as the best choice
to be used for the deposition process because of its ability to precipitate carbon in its free form of graphite and prevent the migration
of carbon from cast iron substrate thus avoiding the formation of hard carbide phase. The addition of tungsten carbide in the matrix
of nickel base alloy gives the filler material good hardness and wear resistant properties. This paper serves as the preliminary study
to get an insight into the understanding of cladding process on cast iron as the substrate before performing the experiment of the
cladding operation.
Keywords: Cladding, Hardfacing, Cast Iron, Nickel Based Alloy
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1. INTRODUCTION
Surface treatment technology is employed to functional parts
with the purpose to ensure that they possess certain properties
and characteristics like wear and corrosion resistant and high
hardness. Some example of surface treatment processes are
mechanical plating, case hardening, thermal spraying, vapor
deposition, and cladding technique. The weld cladding
technique, either for the purpose of manufacturing or repairing
components, is commonly used in wide range of industries [1].
In manufacturing industry, the term cladding may refer to roll
cladding, explosive cladding, sheet cladding, or braze cladding
[2], but throughout this paper the term cladding is strictly
focused to weld cladding.
1.1 Cladding
Cladding, also called as Hardfacing or surfacing, is a type of
deposition process where a filler material is deposited onto the
substrate layer-by-layer with the objective to improve the
properties of the substrate. The cladding process can be
accomplished by using either laser beam or arc as the heat
source for melting the filler material during depositing onto
the surface of the substrate. Laser cladding technique is the
cladding process that utilizes laser beam as the heat source and
the filler material is deposited by powder injection [3].
Weld cladding technique is the cladding process that utilizes
arc as the heat source which is accomplished using welding
equipment. Weld cladding process is similar to arc welding
process but the difference is that weld cladding not aiming for
joining separate parts. Weld cladding can be realized through
any one of these arc welding techniques; gas metal arc
welding (GMAW), flux cored arc welding (FCAW), shielded
metal arc welding (SMAW), gas tungsten arc welding
(GTAW), plasma arc welding (PAW), and electroslag welding
(ESW) [2].
1.2 Background of Development
Weld cladding techniques were initially developed for the use
of navy defense components by Strachan & Henshaw, Bristol;
a major defence and nuclear engineering company [2]. The
developed cladding techniques were to be used on components
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 6
where the equipment needs to work in seawater with minimum
maintenance and be exposed to very high pressure and shock
loading. The revolution of cladding process is comparable to
rapid prototyping and rapid manufacturing using layered
processes [4]. Nowadays, the cladding techniques are being
utilized in a wide range of industries such as food processing,
fertilizer, chemical, petrochemical, automotive, and, nuclear
and power plant [1, 2, 5, 6].
1.3 Principle of the Process
In cladding techniques, the filler material is deposited onto the
substrate in multiple of layers until essential thickness is
achieved before being machined to achieve the required
dimension. Figure 1 shows an arrangement of bead and
interpasses of weld clad onto cast iron substrate based on the
work of Buchanan et al. [1] in their study on microstructure
and wear resistant behaviour cladding on grey cast iron. The
filler material is deposited until three layers and then, the clad
machined to get the total thickness of 6 mm.
Fig-1: Arrangement of bead and interpasses of weld onto cast
iron substrate [1].
There is also another situation where the clad is deposited just
to cover a small portion of a surface like in repair welding. In
the case where crack happened on cast steels, a certain amount
of material from the cast steels is removed in shape of V-
groove around the crack before the weld-repair is performed
[5]. Figure 2 shows the cladding layers arrangement of the
repair welding using the principle of buttering technique based
on the work of Branza et al. [5] in their study on weld-repair
on heat-resistant cast steels.
Figure 2 is showing the principle of buttering technique which
passes 1-12 are buttering passes with a soft and ductile filler
material and passes 13-26 are filling passes with a heat-
resistant filler metal. The idea of using soft ductile filler
material for the buttering passes is to sustain strain and stress
which generated by the welding process and therefore prevent
crack from occurring.
1.4 Application in Industries
The weld cladding technique is regularly applied in various
types of industries, either for the purpose of maintenance or
manufacturing new component [1]. According to Buchanan et
al. [1], the cladding technique is used to reduce wear of grey
cast iron mill rollers in the sugarcane industry. Reducing the
wear of the rollers helps in the use of greater extraction loads
and better movement of the crushed cane through the rollers.
Fig-2: Cladding layers arrangement of weld-repair on heat-
resistant cast steels [5].
Cladding is also used for repair welding on heat-resistant cast
steels which are widely used for the manufacturing of
component parts for the petrochemical industry [5]. Whereas
Chatterjee and Pal [6], stated that cladding is used on top
bearing plate of coal crushing unit in power plant industry in
India.
2. GAS METAL ARC WELDING (GMAW)
Gas metal arc welding is one of the arc welding techniques
widely utilized for the cladding process. GMAW offers a
relative economical and low cost but high power density and
allows good process control rate of rapid processing [7]. By
providing proper manipulation system, GMAW has high
potential in being operated for robust and rapid layered
deposition processes.
2.1 GMAW Based Deposition Process
GMAW technique uses consumable electrode which is in the
form of wire feedstock and according to Clark et al. [7], the
use of consumable electrode offers a standard consumable
form provides consistent feed angles during the additive
manufacturing process which is a significant advantage. Also,
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 7
the deposition process using wire feedstock, if compared to
the powder-based techniques, has further advantage in the
aspect of material utilization.
Schneebeli et al. [8] was the first to propose wire-based metal
deposition. In gas metal arc (GMA) shape metal deposition
system, the consumable electrode wire is melted by the
generated arc and the droplets of molten metal are deposited
onto a substrate in a sequential of layers until specific width
are covered. This shaped metal deposition process has
potential application in building a structure (rapid
manufacturing) and repairing worn out parts. Zhang et al. [9]
has established GMAW-based rapid prototyping system
performing layered deposition process and able to fabricating
numerous complex parts. However, the case of rapid
prototyping is difference from weld cladding as its purpose is
not for improving the properties of the substrate.
2.2 Process Parameters in GMAW
In weld cladding through the method of GMAW, the role
process parameters is a bit difference from the welding for
joining purpose as in cladding, the depth of penetration of the
process need to be as minimum as possible to get minimum
dilution [12]. The required optimum parameters to be achieved
are not for the quality of joining parts but for the quality of the
clad.
Karadeniz et al. [10] mentioned that the parameters of GMAW
can be divided into several groups. The first group is the first
order adjustable parameters which are the welding current, arc
voltage and welding speed. The second group is the second
order adjustable parameters consist of the torch angle, free
wire length, nozzle distance, welding direction, welding
position, and the flow rate of shielding gas. These two groups
are the parameters defined before the welding process and can
be changed during the process. Furthermore, the wire
electrode diameter and its chemical composition, and the type
of shielding gas are the parameters defined before starting the
welding process and cannot be changed during the welding
process.
The arc and the welding bath are affected by the process
parameters and when all the parameters are in conformity, the
perfect arc can be achieved [10, 11]. Karadeniz et al. [10] also
stated that enough penetration, high heating rate and right
welding profile are the aspects of welding joint quality.
However, in this paper, the discussion of using GMAW is for
cladding purpose and not for joining two separated parts.
There are differences in terms of quality between the bead of
weld-cladding and weld-joining.
When cladding is performed, the preferred geometry of the
bead is the one which has minimum penetration depth,
maximum bead width, reinforcement, and minimum dilution
percentage [12]. Figure 3 shows the weld bead geometry as
defined by Palani et al. [12].
Fig-3: Weld bead geometry [12].
2.3 Current
Increase in welding current leads to increasing depth of
penetration and bead width [13]. In their research on the effect
of process parameters on penetration in GMAW using DIN
EN 10120 steel as the substrate, Karadeniz et al. [10] found
that the welding current affects penetration depth about 2.5
times greater than arc voltage and travel speed. Getting the
optimum value of welding current is important because as far
as cladding is concerned, minimum depth of penetration needs
to be achieved but at the same time, maximum bead width is
also achieved.
2.4 Arc Voltage
Arc voltage does not give significant effect on penetration
depth as welding current does but still, arc voltage gives
significant effect on the bead width [10, 13]. Also, Shahi and
Pandey [14] mentioned that increased arc voltage increases the
arc cone, therefore the arc is spread over a larger area of the
substrate which leads to less welding penetration; less
penetration depth means less dilution of the filler material.
However, excessive arc voltage can cause spatter, porosity,
and also undercut. Any increment of arc voltage or welding
arc will make the heat input of the welding process rises.
2.5 Travel Speed
Travel speed gives significant effect on the filler material
deposition rate and thermal transmitted to the substrate.
Decreasing the travel speed will decrease the thermal
transmission to the substrate but increase the filler material
deposition rate. However, according to Shahi and Pandey [14],
travel speed gives less effect on dilution compared to arc
voltage because changing in travel speed will change the
geometry of the bead proportionally. Minimum dilution is a
target in cladding, therefore lower travel speed is more prefer
because by doing so, less penetration is achieved and so, less
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 8
dilution. Higher travel speed is also not preferable because
undercutting might occur if travel speed is too high.
3. CAST IRON
Cast iron can be defined as an alloy which the main element is
iron and the major alloying elements are carbon and silicon.
Other alloying elements that would be in the composition of
various types of cast iron in the industry today are nickel,
copper, chromium, vanadium, molybdenum, boron and more
others. It is commonly considered that cast iron is a difficult
material to be welded because of the inherent brittleness of the
material and the effect of weld thermal cycle on its
metallurgical structure [15]. There are five major types of cast
iron in the industry today; gray, ductile, white, malleable, and
compacted graphite cast iron. The one which is used as the
substrate for this research is gray cast iron.
3.1. Gray Cast Iron
Gray cast iron, or easily called as gray iron, is the most
common form of cast iron. This type of cast iron has moderate
strength, excellent damping and machinability, but poor
ductility. It contains 2 to 4% C, 1 to 3% Si, and up to 1% Mn,
and has a tensile strength up to 275 MPa [16]. It is also
reported that gray iron has low hardness value; 25 – 35 HRC
(~ 260 – 340 HV) [17]. The typical microstructure of gray iron
is a matrix of α-ferrite or pearlite matrix with graphite flakes
spread all over the matrix. Figure 4 shows the optical
micrograph of gray cast iron.
3.2 The Cladding of Gray Cast Iron
Cladding is a deposition process in which involves producing
heat to melting the filler material onto the substrate. The
problem lies when gray iron as the substrate is that the
material suffers thermal cycle produced by the process. The
lack of ductility due to the coarse graphite flakes structure in
gray iron makes the material often fails to withstand stresses
caused by temperature drop [15]. The inherent brittleness
characteristic makes gray iron vulnerable to cracking upon
cooling of the process.
Pouranvari [15], in his study on the weldability of gray cast
iron using nickel based filler material concluded that the
cracking problem can be solved by using nickel based filler
material and proper post-weld heat treatment. Using the nickel
based filler material alone without post-weld heat treatment
just can only solve the problem in fusion zone (FZ) but not in
heat affected zone (HAZ) as the thermal cycle of the process
allows martensite formation in HAZ that leads to the cracking
problem.
Fig-4: Optical micrograph of gray cast iron with 500x
magnification: the dark graphite flakes are embedded in α-
ferrite matrix [18].
However, even though crack defect always seen as problem
and need to be avoided, that depends on the function of the
substrate in its real operation. Chatterjee and Pal [6], in their
research on wear behavior of cladding on gray iron substrate,
where gray iron is used as the material for top bearing plate in
coal crushing unit of thermal power plant, mentioned that
cracking does not always significantly decrease the service
wear life of the component, but occasionally acts as a benefit
in decreasing residual stress level.
4. FILLER MATERIAL
Filler material for cladding purpose is chosen based on the
required final properties of the clad like wear resistance or
corrosion resistance for example. Some of the filler materials
used for cladding cast iron are copper based alloy, stainless
steel, and nickel based alloy [19].
4.1 Types of Filler Materials for Cladding Cast Iron
Copper based alloy is used for the purpose of corrosion
resistance or building up surfaces of wear. Copper based alloy
is also reported can give superior thermal fatigue resistance in
laser cladding on gray cast iron [20].
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 9
Fig-5: Martensite formation in the heat affected zone of gray
iron substrate [15].
Stainless steel filler material is used for increasing the
corrosion and oxidation resistance properties. However, when
using stainless steel as the filler material in cladding cast iron,
the migration of carbon from the substrate into the stainless
steel deposit usually cause cracking problem. The absorption
of carbon into stainless steel causes the formation of
chromium carbide which leads to the cracking problem. This
problem is solved by using nickel based alloy for the buffer
layer in the clad. Nickel based alloy helps in reducing the
carbon migration from the substrate into the stainless steel
layer because of the low diffusivity of carbon in nickel based
alloy. The disadvantage of using nickel based alloy as the
buffer layer is its high cost [6].
Nickel based alloy have the characteristic of outstanding wear
and corrosion resistance properties at elevated temperature,
either on their own or with the combination of other
reinforcement particles [21]. Another advantage in using
nickel based alloy as the filler material is the ability
precipitates the carbon from the cast iron substrate in the form
of graphite, thus preventing the formation of carbide [15].
Among the mechanical parts which used nickel based alloy in
their manufacturing are piston rings, rollers in steel making,
roller tables, wearing plates and pump shafts in box packing
areas [22].
4.2 Tungsten Carbide Reinforced NiCrBSi Alloy
Many research in cladding using this alloy for the deposition
are done using laser cladding and plasma transferred arc
(PTA) technique in which the alloy is supplied in the shape of
powder [23, 24, 25, 26, 27]. The addition of tungsten carbide
particles in the material significantly increases the wear
resistance and the overall hardness of the alloy. Figure 6
shows the alloy with most percentage of tungsten carbide
addition has highest wear resistance compare to the ones with
less and no tungsten carbide addition whereas Figure 7 shows
the comparison in terms of hardness.
Fig-6: Wear rates of the NiCrBSi and NiCrBSi/WC–Ni
coatings [27].
However, there is not many literature reviews on tungsten
carbide reinforced NiCrBSi alloy consumables deposited
using GMAW technique. According to Mendez et al. [28],
tungsten carbide (WC) reinforced nickel based alloy
consumables usually available with NiBSi or NiCrBSi matrix
alloy with the matrix microstructure is usually contained of
soft primary nickel dendrites with relatively low hardness of
about 350HV whereas the inter-dendritic regions consist of
hard carbides, borides, and silicides with hardness of about
500 to 800 HV. Figure 8 shows the backscattered SEM
micrograph of the alloy microstructure obtained using GMAW
and hot-wire GMAW.
The tungsten carbide (WC and W2C phases) reinforced
NiCrBSi filler alloy was also reported to have even higher
hardness; the NiCrBSi matrix having the hardness of 560 to
620 HV and the carbides having the hardness of 2340 HV
[29]. In this research, the tungsten carbide reinforced in
NiCrBSi matrix alloy consumable will be used for cladding
using GMAW technique.
CONCLUSIONS
Gray cast iron is difficult to welded mainly because the natural
characteristic of cast iron which is inherently brittle and has
tendency to cracking when subjected to the temperature drop
cause by the arc welding process. The weld cladding by using
gas metal arc welding technique and method would be
accomplished effectively without cracking by choosing nickel
based alloy as the filler material.
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 10
Fig-7: Micro hardness profiles of the NiCrBSi and
NiCrBSi/WC–Ni coatings [27].
Fig-8: Backscattered SEM micrographs of typical Ni-WC
alloys microstructure obtained using GMAW and hot-wire
GMAW [28].
The nickel based alloy material can prevent the migration of
carbon from the cast iron substrate into the fusion zone thus
preventing the carbide phase to form in the fusion zone.
Moreover, nickel can precipitate the carbon in the form of
graphite therefore the martensite formation can be prevented.
The reinforcement of tungsten carbide into the nickel based
alloy matrix provides high wear resistant and hardness
properties. The tungsten carbide reinforced alloy filler
material is available in the form of powder to be used in laser
cladding and also in the form of wire to be used with gas metal
arc welding equipment. While laser cladding technique is the
more popular choice to perform the cladding process, gas
metal arc is more economic yet flexible in its operation. Future
work should focus more detail on the technique of the
cladding operation using GMAW equipment in optimizing the
process parameters to find the right combination of the
parameters with optimum values to maximize the required
properties of the clad beside performing the cladding
operation experiment.
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BIOGRAPHIES
Dr. Nur Izan Syahriah bt. Hussein is a
senior lecturer and the head of Department
of Manufacturing Process in Faculty of
Manufacturing Engineering in Universiti
Teknikal Malaysia Melaka (UTeM),
Malacca, Malaysia. She is specializing in
welding and near net shape manufacturing
processes.
Mohd Kamarul Shaufi Bin Rasidi is
currently pursuing his post graduate study
at the Faculty of Manufacturing
Engineering, Universiti teknikal Malaysia
Melaka (UTeM), Malacca, Malaysia. He
is currently focusing in GMAW based
cladding process.
Mohamad Nizam b. Ayof is a senior
lecturer in the Department of
Manufacturing Process in Faculty of
Manufacturing Engineering in
Universiti Teknikal Malaysia Melaka
(UTeM), Malacca, Malaysia. His
research areas are physics and laser cutting.