This poster investigates the effects of metal surface coatings on the mechanical properties of parts fabricated by the Fully Dense Freeform Fabrication (FDFF) process. Researchers coated steel samples with nickel using electroplating and tested the tensile strength and coating thickness. Tensile strength tests showed results above 10,000 psi. Coating thickness measurements ranged from 395.08μm to 417.06μm with an average of 408.69μm. The electroplated coating improved mechanical bonding between layers and the process could potentially be expanded to create more complex multi-layered parts.
A Review of Severe Plastic DeformationIRJESJOURNAL
ABSTRACT: This article reviews about Ultrafine grained (UFG) materials processed by Severe Plastic
Deformation. From the period of 1950’s, the researchers made a fountain stone for this technique. Over the last
decades, this SPD technique experienced an enormous growth among the research field. There was a
development of different methods of SPD, production of various materials by SPD with improved and
interesting results based on our requirement. Moreover, different post processing techniques will also help to
enhance the property of the SPD processed material. This paper reviews the overall development of this
technique, various methods of SPD, discussed about the enhancement of the properties and finally concluded
with some specific challenges and issues faced by the modern researchers. It may be helpful to those who wants
specialise in bulk nanomaterials produced by SPD.
A Review of Severe Plastic DeformationIRJESJOURNAL
ABSTRACT: This article reviews about Ultrafine grained (UFG) materials processed by Severe Plastic
Deformation. From the period of 1950’s, the researchers made a fountain stone for this technique. Over the last
decades, this SPD technique experienced an enormous growth among the research field. There was a
development of different methods of SPD, production of various materials by SPD with improved and
interesting results based on our requirement. Moreover, different post processing techniques will also help to
enhance the property of the SPD processed material. This paper reviews the overall development of this
technique, various methods of SPD, discussed about the enhancement of the properties and finally concluded
with some specific challenges and issues faced by the modern researchers. It may be helpful to those who wants
specialise in bulk nanomaterials produced by SPD.
In materials science, Functionally Graded Material (FGM) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be designed for specific function and applications.
Improving Mechanical Properties of AL 7075 alloy by Equal Channel Angular Ext...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Mechanical and micro structural characterisation of Pure Al reinforced with S...BALA VENKATA SATYA PRAKASH
This paper deals extensively with the preparation of functionally grade material reinforced in layer wise manner with different reinforcements in order to serve the tough conditions in automobile industries
Experimental and Analytical Investigation of Drilling of Sandwich Composites:...IOSR Journals
A composite material is made out of a mixture or a combination of two or more distinctly differing
materials which are insoluble in each other and differ in form or chemical composition. The technological and
commercial interest in composite material lies in their superior properties of strength-to-weight, stiffness-toweight,
fatigue and thermal expansion compared to metals. Extensive use of composite in application such as
rockets, satellites, missiles, light combat aircraft, advanced light helicopter and trainer air craft has shown that
India is on par with the advanced countries in the development and use of composites in this area.
Drilling is probably the most important conventional mechanical process and it is the most widely used
machining operation. Prediction of cutting forces for any set of cutting parameters is essential in optimal design
and manufacturing of products. It has been predicted that most of the problem associated with hole making
operation, such as drilling, can be attributed to the force generated during cutting operation. Many
developments and experiments are going on drilling of Sandwich composite for damage free drilling along with
the quality of the hole and the effect of tool geometry and tool material.
This paper aims at the comprehensive analytical and experimental investigation work done on the
composites material. The conclusion of the paper discusses the development and outlines the trends for the
research in this field.
INFLUENCE MECHANISM OF THICKNESS AND VISCOSITY OF FLAT ENERGY DIRECTOR TO THE...adeij1
The research in this paper is an essential part of a bigger effort to develop ultrasonic welding using flat energy directors (FED) in thermoplastic composites. It mainly focused on assessing the effect of the changes in thickness and viscosity of FED on welding strength and welding strength stability. Furthermore, the welding and failure mechanisms were investigated by monitoring the real-time temperature evolution at the interface and analyzing the welding area (WA) and the macro and
microfracture surface. From the experimental results, the use of FED with thinner thickness (0.1-0.2 mm) and slightly higher viscosity greatly improved weld strength and weld strength stability. Due to the effect of glass fibers forming a mechanical interlocking effect between the adherend and FED, joints with 20% SGF/PP FED also had a surprisingly excellent weld quality. Welding area analysis indicated a significantly positive correlation between the lap shear strengthⅠand the welded area for the joints with FED. Based on real-time temperature curves, thinner FED had an improvement on the initial temperature
rate and the most temperature curves leveled off at the onset melting temperature (Tonset) of the FED after a time-lapse of about 0.4 s. Morphology analysis showed that the melting and flow of matrix at the interface started at the edges of the overlap; the melting area and morphology of the interfaces with 1% EG/PP FED and 20% SGF/PP are much bigger and coarse. And failure mechanisms of the joints with FED are a combination of adhesive failure, cohesive failure, and fiber-matrix debonding failure.
Mechanical Properties Of Fibre Reinforced Concrete Subjected To Elevated Temp...IJARIDEA Journal
The impact of high temperature on the break property of solidified cements which are strengthened with steel and polypropylene filaments have been explored inside the extent of this review. Test comes about demonstrates that higher temperature brings about lessening quality in both the filaments however with a variety in the most extreme temperature. Steel fiber strengthened cement and polypropylene fiber fortified cement is a cementitious material fortified with a given substance of discrete strands. The better mechanical property makes these filaments critical in building development and has expanded use fundamentally in view of its vitality assimilation limit. The vitality required to haul out the strands from the broke cement is more than the vitality required to split the solid grid. Hence, the vitality ingestion limit is the primary material property profited by fiber fortifications. Be that as it may, this vitality retention property holds great just up to a specific temperature. This consider was examined the present work keeping in mind the end goal to evaluate the ideal temperature up to which the quality of the solid filaments would be most extreme.
Keywords— Compressive Strength, High Temperature, Steel Fibre, Polypropylene Fibre.
Study on Vibration Analysis of Hybrid Laminated CompositesPremier Publishers
This paper represents the review on vibration analysis of hybrid composites. As we know that vibration and composite materials are two main growing research topics now-a-days. Almost all the structural components subjected to dynamic loading in their working life and vibration affects working life of the structure so it is very important in designing a component to reduce the structural vibration and its amplitude. Composite material applications are wide in the aerospace, civil, marine, and automotive industries due to their high specific stiffness and strength, excellent fatigue resistance, long durability and many other superior properties compared to ordinary composites. Carbon fiber reinforced polymers have high strength and light weight properties. But CFRP suffer from high frequency vibrations at low operating conditions. In this paper studying the hybridization of high stiffened CFRP with basalt fiber to reduce vibrations under cantilever boundary condition.
Deformation behavior of consecutive workpieces and Stable -Unstable Flow in Materials Processed in equal channel angular pressing and grain refinement.
In materials science, Functionally Graded Material (FGM) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be designed for specific function and applications.
Improving Mechanical Properties of AL 7075 alloy by Equal Channel Angular Ext...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Mechanical and micro structural characterisation of Pure Al reinforced with S...BALA VENKATA SATYA PRAKASH
This paper deals extensively with the preparation of functionally grade material reinforced in layer wise manner with different reinforcements in order to serve the tough conditions in automobile industries
Experimental and Analytical Investigation of Drilling of Sandwich Composites:...IOSR Journals
A composite material is made out of a mixture or a combination of two or more distinctly differing
materials which are insoluble in each other and differ in form or chemical composition. The technological and
commercial interest in composite material lies in their superior properties of strength-to-weight, stiffness-toweight,
fatigue and thermal expansion compared to metals. Extensive use of composite in application such as
rockets, satellites, missiles, light combat aircraft, advanced light helicopter and trainer air craft has shown that
India is on par with the advanced countries in the development and use of composites in this area.
Drilling is probably the most important conventional mechanical process and it is the most widely used
machining operation. Prediction of cutting forces for any set of cutting parameters is essential in optimal design
and manufacturing of products. It has been predicted that most of the problem associated with hole making
operation, such as drilling, can be attributed to the force generated during cutting operation. Many
developments and experiments are going on drilling of Sandwich composite for damage free drilling along with
the quality of the hole and the effect of tool geometry and tool material.
This paper aims at the comprehensive analytical and experimental investigation work done on the
composites material. The conclusion of the paper discusses the development and outlines the trends for the
research in this field.
INFLUENCE MECHANISM OF THICKNESS AND VISCOSITY OF FLAT ENERGY DIRECTOR TO THE...adeij1
The research in this paper is an essential part of a bigger effort to develop ultrasonic welding using flat energy directors (FED) in thermoplastic composites. It mainly focused on assessing the effect of the changes in thickness and viscosity of FED on welding strength and welding strength stability. Furthermore, the welding and failure mechanisms were investigated by monitoring the real-time temperature evolution at the interface and analyzing the welding area (WA) and the macro and
microfracture surface. From the experimental results, the use of FED with thinner thickness (0.1-0.2 mm) and slightly higher viscosity greatly improved weld strength and weld strength stability. Due to the effect of glass fibers forming a mechanical interlocking effect between the adherend and FED, joints with 20% SGF/PP FED also had a surprisingly excellent weld quality. Welding area analysis indicated a significantly positive correlation between the lap shear strengthⅠand the welded area for the joints with FED. Based on real-time temperature curves, thinner FED had an improvement on the initial temperature
rate and the most temperature curves leveled off at the onset melting temperature (Tonset) of the FED after a time-lapse of about 0.4 s. Morphology analysis showed that the melting and flow of matrix at the interface started at the edges of the overlap; the melting area and morphology of the interfaces with 1% EG/PP FED and 20% SGF/PP are much bigger and coarse. And failure mechanisms of the joints with FED are a combination of adhesive failure, cohesive failure, and fiber-matrix debonding failure.
Mechanical Properties Of Fibre Reinforced Concrete Subjected To Elevated Temp...IJARIDEA Journal
The impact of high temperature on the break property of solidified cements which are strengthened with steel and polypropylene filaments have been explored inside the extent of this review. Test comes about demonstrates that higher temperature brings about lessening quality in both the filaments however with a variety in the most extreme temperature. Steel fiber strengthened cement and polypropylene fiber fortified cement is a cementitious material fortified with a given substance of discrete strands. The better mechanical property makes these filaments critical in building development and has expanded use fundamentally in view of its vitality assimilation limit. The vitality required to haul out the strands from the broke cement is more than the vitality required to split the solid grid. Hence, the vitality ingestion limit is the primary material property profited by fiber fortifications. Be that as it may, this vitality retention property holds great just up to a specific temperature. This consider was examined the present work keeping in mind the end goal to evaluate the ideal temperature up to which the quality of the solid filaments would be most extreme.
Keywords— Compressive Strength, High Temperature, Steel Fibre, Polypropylene Fibre.
Study on Vibration Analysis of Hybrid Laminated CompositesPremier Publishers
This paper represents the review on vibration analysis of hybrid composites. As we know that vibration and composite materials are two main growing research topics now-a-days. Almost all the structural components subjected to dynamic loading in their working life and vibration affects working life of the structure so it is very important in designing a component to reduce the structural vibration and its amplitude. Composite material applications are wide in the aerospace, civil, marine, and automotive industries due to their high specific stiffness and strength, excellent fatigue resistance, long durability and many other superior properties compared to ordinary composites. Carbon fiber reinforced polymers have high strength and light weight properties. But CFRP suffer from high frequency vibrations at low operating conditions. In this paper studying the hybridization of high stiffened CFRP with basalt fiber to reduce vibrations under cantilever boundary condition.
Deformation behavior of consecutive workpieces and Stable -Unstable Flow in Materials Processed in equal channel angular pressing and grain refinement.
Beach volleyball Olympian turned business strategist, speaker, mentor, deal negotiator. Increase productivity through effective communication and teamwork. Conflict resolution, group facilitator.
Analyzing Adhesion of Epoxy/Steel Interlayer in Scratch TestIJERA Editor
The aim of this paper is to investigate use of an experimental technique to determine which parameters effects
on the interfacial durability performance of adhesive on the metallic adherends as zinc plated mild steel (S235)
by using Taguchi method. The experimental layout has been used four scratch force parameters using the L16
(41x23) orthogonal array. The statistical methods of signal to noise ratio (SNR) and the analysis of variance
(ANOVA) were applied to examine effects of surface treatment, adhesive type, blade angle and thickness on
scratch force and scratch energy. Besides, the surface analysis was carried out the morphological modifications
as well as to perform elemental analyses of the pre-treated surfaces. Results of this study indicate that the
thickness and surface treatment are main parameters influencing scratch force (by 52.4% and 19.9%) and
scratch energy (by 44.0 % and 25.6%), respectively.
Cold rolling of high entropy alloy and investigation of mechanical proeprties...virajsolankure
Cold rolling was done on the cantor alloy to better understand and investigate the characteristics of HEAs, and a breakthrough reduction ratio of 99% was reached. from 3 mm to 0.044 mm. The original sample is created utilising the PAAM operation. The cold rolling operation is done in four phases, with the initial sample rolled from 3mm to 0.36mm. The second sage moved from 0.36mm to 0.2mm. 3rd = 0.2 to 0.12mm; in the first step, 0.12mm was treated at 750C before being reduced to 0.044mm using the sandwich process. The UTM findings are linked to the ppt.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
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Study on laser hardening parameters of ASTM Grade 3 pure titanium on an angle...Premier Publishers
This research paper includes the laser transformation hardening of commercially pure titanium sheet of 1.6mm thickness is investigated using CW Nd:YAG laser. Commercially pure titanium has prevalent application in various fields of industries including the medical, nuclear, thermal, marine, defense, automobile aerospace and pharmaceutical industries. A FFD with RSM is employed to establish, optimize and to investigate the relationships of three laser transformation hardening process parameters: laser power, scanning speed, and focused position on laser hardened bead profile parameters such as angle of entry of hardened bead profile and power density. RSM is used to develop pseudo-closed-form models from the computational parametric studies. Adequacies of developed models were analyzed by ANOVA. Effects of laser process parameters on an angle of entry of hardened bead profile and power density were also carried out using RSM. The laser power and scanning speed consecutively have a positive and significant effect on angle of entry of hardened bead profile and power density respectively as compared to the focal point position among all laser hardening process parameters. The optimum laser hardening conditions are identified sequentially to minimize an angle of entry of hardened profile, power density. The validation results demonstrate that the developed models are accurate with low percentages of error.
This research was conducted by using the electrochemical anodizing technique in oxalate solution. This research focused on the effects of coating parameters on the fabrication of hard nano-CuO coating with hydrophobic properties, studying the effect of coating grain size on the coating characteristics and heat transfer performance.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
In this investigation, experimental work and computational work are combined to obtain
improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means
of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel
alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time
(Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this
project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The
surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer
is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are
fed to the Minitab software and optimum input parameters for the desired output parameters are
identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of
effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is
performed in order to remove the recast layer and again the surface roughness is measured by using
stylus type roughness tester. Finally from the obtained results it was found that there was significant
improvement in the Surface roughness of the nickel alloy material. In addition using regression
analysis this work is stimulated by computational method and the results are obtained.
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.
Fluid Dynamic Simulation and Experimental Study of Honeycomb Seal Structures ...ijmech
Electrochemical discharge machining (ECDM) is a composite technology that combines electric discharge machining (EDM) with electrochemical machining (ECM). In this study, ECDM was used for the processing of honeycomb seal structures, and fluid dynamic simulation and experimental study were conducted. A vortex effect was observed, hindering the electrolyte flow. Compared to other fluid supply methods, a bilateral fluid supply can reduce vorticity and velocity, weakening the vortex effect. According to the result and the current signals after discrete wavelet transformation (DWT), the higher voltage and flow rate can increase total energy and exacerbate the vortex effect respectively, and strengthen the EDM and ECM effect, resulting in more processing depth, over corrosion depth, and molten product height. However, the higher electrolyte concentration can reduce the EDM effect, and enhance the ECM effect, which leads to more over corrosion depth, less processing depth and molten product height. The research results proved that ECDM has a good effect on processing honeycomb seal structures.
Analysis and Weight Optimization of Split Dish Reactor Using Thermo-Structura...IJERA Editor
A vertical split dish reactor with leg supports is modeled using ansys workbench. Thereafter, external loads, such as self –weight, internal pressure and temperature are applied to the model. Pressure and temperature has been continuously a concern which may lead to structural failure if the resulting stresses are severe and excessive. It is a significant study which requires in-depth investigation to understand the structural characteristics. This paper presents and focuses on some Finite Element (FE) analysis of a split dish reactor will be carried out and maximum stresses in the structure will be determined.
Study on Influence of heat treatment on Tribological properties of mild steeldbpublications
A study was made on the effect of heat treatment upon the mild steel. Total six samples were prepared for each test (hardness test, tensile test, microstructure test and wear test) from those two was tested as received and rest four were subjected to different heat treatment that are annealing and normalizing (heated on a temperature of 850 degree Celsius). The hardness of all sample was measured by Rockwell hardness testing machine. Wear measurement was done on pin-on disc wear machine. Tensometer was used to find out the ultimate stress and strain of the sample. The result of tensile test showed that the strength is decreased by heat treating and the surface hardness is also decreased by heat treatment. Microstructure of the mild steel specimens shows the grain boundary of the particles and the content of % of carbon present. It justifies the experimental results of tensile test and hardness test. Surface Hardness is the measure of resistance that any material applies. As the specimen gets soft on treating the hardness also gets decreased. Tensile strength of any specimen is specified as how much stress the material can withstand before breaking. As the metal gets soft after heat treatment the load required for breaking goes on decreasing. Wear test is carried out to see the variation in wear measurement and coefficient of friction as the mesh size of paper are varied. More soft the surface of material is more wear is seen and vice-versa.
Study on Influence of heat treatment on Tribological properties of mild steel
TSUGRC2015-FDFF-Final2
1. Presenter name, Associates and Collaborators
Department of XXXXXXXXXXXXXXXX, College of XXXXXXXXXXXXXXXXXX, University of Illinois at Urbana-Champaign
Template for a 48”x36” poster
Bahram Asiabanpour, Abbas Fahami, Aron Zamora, Maedeh Dabbaghianamiri
Ingram School of Engineering & Material Science, Engineering, and Commercialization,, Texas State University
An Investigation on the Effects of the Metal Surface Coating Factors on the Mechanical
Properties of Parts Fabricated by Fully Dense Freeform Fabrication Process
Introduction
Fully Dense Freeform Fabrication(FDFF) process is a freeform fabrication
process based on thin line cutting processes, variable thickness layering, and bulk
layer attachment. Combination of these capabilities enables the production of
complex parts of metals and various other materials. Building highly dense
metallic parts using Additive Manufacturing concept. The FDFF process uses an
integrated layer aligning, compression, and heat based bonding method that can
accurately align, position, bond layers together leading to fully dense metallic
parts in a short time and cost effective way.
FDFF Process Using Metal Surface Coating
The objective of this research is to investigate a method of bulk bonding of
stacked layers using external coating generating by the Electroplating Processes.
Electroplating Process is where a coating of metal is added to a conductor using
electricity through a reduction reaction. Metal ions in a solutions are reduced onto
the electrode to form a layer. Combining this two processes of FDFF and
Electrodepositing can increase the mechanical properties of a metal surface and
then create a layered complex geometrical metal part. This research investigates,
the mechanical (tensile strength) and physical (coating thickness) properties on
the fabricated bonded samples.
Methods and Processes
Steel samples were cut in the size of 4”X1” according to the STM 2294-6
standard. Nickel was used as the coating material and the following chemical were
used as the solution composition. Under adjusted solution composition, voltage,
current, process time, and temperature, successful bonding were produced
between two rectangle samples overlapping 0.5 inch.
Characterizations and Results
Mechanical property: Tensile strength test of the samples were conducted
based on ASTM Standard 2294-6 using Using Tinius Olsen Electro
Mechanical Tester, 600kn capacity.
The results for two runs were both above 10,000 psi. Below graph illustrate
the Stress – Strain Curve.
Coating composition and thickness:
Energy Dispersive X-ray Analysis (EDXA) method was used to measure
the composition and thickness of the electroplated nickel coating on the
substrates. As shown in below image, the percentage of Ni in the selected
area was at 88.88 weight %.
Also, coating thickness results ranged from 417.06µm to 395.08µm and an
average thickness of Ni coating of 408.69µm
Conclusion and Future Works
Bonding two metals by Electroplating process was
successfully achieved.
Layered electroplated parts tensile strength had good layer
attachment.
The process is highly experimental and any variation in the
impacting factors such as materials’ compositions, process
voltage, current, temperature, time, and sample surface
preparation make significantly different results.
The process can be expanded to many layers samples and
none flat layers.
The process can be extended to other materials and coating
processes.
Geometrical changes due to the coating can be predicted and
compensated in the CAD and metal cutting stage.
Acknowledgments
Authors would like to thank Ingram School of Engineering,
Material Science, Engineering, and Commercialization
(MSEC), Engineering Technology department, MicroPower
Inc., Dr. Casey Smith, and Reenergize-MSEIP grant for the
funding, lab space, materials, technical advice, and equipment
support and access. The content of this article are solely the
responsibility of the authors and do not necessarily reflect the
views of the sponsors and supporting individuals and
institutions.
ASTM Standard
2294-6