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2 Cast Aluminium Metal Matrix Nanocomposites Fabricated by Friction Stir Processing
Published in Satyajit Chakrabarti, Ayan Kumar Panja, Amartya Mukherjee, Arun Kr. Bar, Intelligent Electrical Systems: A Step towards Smarter Earth, 2021
S. Laxmanaraju, Lingaraju Dumpala, R. Pavankumar
Manufacturing industries such as aircraft, automobile, marine impose the need for optimizing product designs using lightweight materials such as alloys of aluminium, magnesium, titanium. Because of increasing lightweight requirements especially these alloys are quite propitious for various applications owing to their reduced weight concentration, enhanced strength-to-weight ratio, and higher corrosive resistance. However, strength of these alloys is not adequate for some structural purposes thereby necessitating requirement of reinforcement. After reinforcement, these metal matrix composites (MMCs) are found to exhibit improved mechanical, metallurgical, and tribological characteristics (Puviyarasan and Senthil Kumar, 2016). The effect of tool pin and shoulder profiles on particle distribution and microstructure of 6063 aluminium alloy reinforced with SiC particles was investigated. There are eight tool pin profiles used: a tapered cylindrical pin, plain cylindrical pin, triangle pin, square pin, clockwise scroll and anti-clockwise scroll with cylindrical pin, clockwise scroll with square pin, and anti-clockwise scroll with square pin. Anti-clockwise scroll with square pin and cylindrical pin will give high reinforced zone area compared to clockwise. Hence, anti-clockwise scrolled shoulder with cylindrical pin tool geometry was found best among the other tool pin with uniform distribution of particles. There are no defects that can be found in this process (Gangil, Maheshwari, and Siddiquee, 2018). The fabrication of aluminide-reinforced nanocomposites such as Al-Al2Cu, Al-Al3Ti, and Al-Al3Fe2 by this method has recently been shown. In situ formation of Al3Ti particles during FSP of Al-Ti and Al-TiO2 systems are very attractive because the nanocomposites demonstrate high specific strength and modulus at ambient and elevated temperatures (Zhang, Xiao, Wang, and Ma, 2011; 2012; Cavaliere, 2005). An investigation to fabricate a composite by FSP of AA6061/TiB2 aluminum alloy was carried out. It was observed that tensile strength and hardness were augmented with increase of rotational speed. The analysis of variance (ANOVA) results indicate that rotational speed was found to be the most influential process parameter. The optimal speed for ultimate tensile strength (UTS) and microhardness is 1400 rpm (Venkateswarlu, Davidson, and Sammaiah, 2014). The effects of the process parameters such as tilt angle, rotation speed, and traverse speed on the mechanical properties such as tensile strength, microhardness, and impact energy of the AZ31B Mg alloy were analysed. Experiments have been carried out with Taguchi L9 orthogonal Array that consists of nine combinations of rotational speeds, traverse speed, and tilt angle. Traverse speed has the strongest influence on the impact energy (Abraham, Isaac, Selvam, and Akinlabi, 2019). Experiments are conducted on the three-level process parameters – welding speed, tool speed, and tilt angle – as per Taguchi’s L9 orthogonal array. The mechanical properties of the weld specimens studied are % elongation and Vickers hardness (Prasad, Durga, and Namala, 2018).
Experimental and Numerical Investigation on Flow Boiling in a Small Semi-circular Channel of Plate Once-Through Steam Generator
Published in Heat Transfer Engineering, 2021
Xiaofei Yuan, Lixin Yang, Zemin Shang
The test section is represented in Figure 2(a). The horizontal experimental piece is 880 mm long, 70 mm wide, and 64 mm high. The diameter of semi-circular channel is 3 mm. The effective heating length is 700 mm and hydraulic diameter Dh of semi-circular channel is 1.83 mm. Twenty-eight holes of heat rods are processed in the 6063 aluminum alloy foundation to provide uniform heat flux. The density specific heat and thermal conductivity of 6063 aluminum alloy are 2690 kg/m3, 900 J/(kg·K), and 201 W/(m·K), respectively. Two slots with a width of 5 mm and a depth of 39 mm are processed near the inlet and outlet so as to prevent axial heat transfer loss. A total of 28 thermocouples are arranged with 4 thermocouples every 100 mm to measure the wall temperature of 7 points along the path. In order to reduce heat loss, the glass fiber cotton of low conductivity covered with the outer surface of the test section.
Corrosion behavior of aluminum alloy in sulfur-associated petrochemical equipment H2S environment
Published in Chemical Engineering Communications, 2023
Xingyan Cao, Yawei Lu, Zhirong Wang, Haoyue Wei, Longtao Fan, Rongrong Yang, Wenjie Guo
Figure 4 shows the macro-corrosion morphologies of the three types of aluminum alloy samples in the gas-phase environment of the H2S saturated solution. As shown in Figure 4, the corrosion product on the sample surface was white, with a trace amount of a yellow-gray material. The corrosion products were primarily aluminum oxides, such as Al(OH)3. This indicates that the three types of aluminum alloy samples underwent significant corrosion. The 6061 aluminum alloy sample exhibited more severe corrosion, and the amount of the white-yellow-gray material was more significant. Compared with the 3A21 and 6061 samples, the 6063 aluminum alloy sample presented a higher corrosion resistance.
Investigation and optimization of machining through hole by abrasive water jet machining in AA6063/Bagasseash/TiN hybrid composites
Published in Materials and Manufacturing Processes, 2021
K Ravi Kumar, Nisha Soms, S. Selvakumar, V.S. Sreebalaji
Literature study reveals that Abrasive Water Jet Machining is a nontraditional machining process in which material is removed by the erosion of high-velocity water jet containing abrasive particles. Traverse velocity, particle density, mass flow rate, standoff distance, water jet pressure, impingement angle are the major parameters influencing AWJ machining. The influence of process parameters on AWJM of aluminum composites was studied by researchers. Few studies were carried to study the influence of parameters on aluminum hybrid composites. Furthermore, there is no literature available to study the influence of AWJM parameters on hybrid aluminum AA6063 composites. Hence an attempt was made to study the influence of parameters on the AWJM behavior of AA6063/TiN/Bagasse ash composites. AA 6063 aluminum alloy commonly referred to as architectural alloy contains Mg and Si as the major alloying elements and has good mechanical and heat treatable properties. AA6063 alloy normally used in intricate extrusions finds applications in automotive and building industries due to its excellent formability, good corrosion resistance, and relatively low cost is used in this study. Sugarcane bagasse ash, a multi-process by-product obtained from sugarcane carrying elements like SiO2, Al2O3 is used as reinforcement in addition to Titanium Nitride (TiN) particles. Composites were fabricated using the low-cost stir casting technique. This study focuses on the influence of AWJM parameters on the surface roughness and material removal rate of Al/TiN/Bagasse ash hybrid composites. Analysis of variance and response surface methodology was employed to develop mathematical models and to analyze the influence of parameters. Desirability based approach was employed to evaluate the optimum abrasive water jet machining parameters and the mechanisms were analyzed by Scanning Electron Microscopy (SEM).