Browsing by Author "Hanumanthappa, H."

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A comparative study on a newly designed ball mill and the conventional ball mill performance with respect to the particle size distribution and recirculating load at the discharge end
(Elsevier Ltd, 2020) Hanumanthappa, H.; Vardhan, H.; Raj, G.R.; Kaza, M.; Sah, R.; Shanmugam, B.K.
The discharge end design of a ball mill plays an important role in discharging the desired particle sizes (?150 + 10 µm) and the percentage of recirculating load from the discharge end of the ball mill. In continuous wet ball mills, the composition of feed (hard ore or soft ore) to the mill varies continuously, leading to uncontrolled grinding in the mill. In view of this, a new design of the discharge mechanism has been implemented to remove the ground particles of desired particle size fraction with minimum recirculating load (+150 µm). The results from the discharge end with lifters (closed and open) show that the particle size fraction obtained from the discharge end has a maximum percentage of desired particle size fraction when the mill is operating at 60% critical speed. Discharge end without lifters has an uncontrolled particle size distribution in the discharge and the percentage of desired-size particles discharged was found to be very less. Also, the percentage of the recirculating load is minimum in the case of discharge end with lifter design compared with discharge end without a lifter. Hence, a new design of lifters in the discharge end leads to the discharge of the desired particle size fraction with minimum recirculating load. © 2019 Elsevier Ltd
ANN modeling and residual analysis on screening efficiency of coal in vibrating screen
(Taylor and Francis Ltd., 2022) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
In this paper, coal screening in vibrating screen was carried out with the size ranges of ?6 mm + 4 mm, ?4 mm + 2 mm, and ?2 mm + 0.5 mm. The vibrating screen was newly designed with flexibility in angle and frequency. The vibrating screen experimentation was carried out by varying screen mesh, angle, and screen frequency. During the screening, the angle was kept constant, and frequency was varied to obtain each size range’s screening efficiency. The experimental results of screening efficiency were evaluated for each size fraction range of coal. The maximum efficiency for screening coal with ?6 mm+4 mm, ?4 mm+2 mm, and ?2 mm+0.5 mm size range obtained was 87.60%, 80.93%, and 62.96%, respectively. Further, the prediction model was developed for each size range using a feed-backward artificial neural network (ANN) to consider the back-propagation error technique. For each screening condition, 10 ANN models were developed with the variation in 1–10 different neurons. ANN has provided mathematical models with a 99.9% regression coefficient for predicting each size range’s screening efficiency. Furthermore, the residuals of each optimal ANN model were analyzed using a normal probability plot and histogram. The ANN model’s accuracy was obtained from the residual analysis by evaluating four different model conditions, i.e., independence, homoscedasticity, normality, and mean error. © 2021 Taylor & Francis Group, LLC.
Application of fractional factorial design for evaluating the separation performance of the screening machine
(Taylor and Francis Ltd., 2022) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
Implementing the planned execution of experiments will optimize the resources and time of a newly developed process or equipment. In the present work, the screening machine is newly developed equipment designed for the separation of coal. The present work was carried out to evaluate the performance of separation efficiency of the screening machine using generalized and forward selection fractional factorial experimental design. Further, the present work will also determine the significance of each operational variable, such as moisture content, angle, and frequency, for increasing separation efficiency. A cube plot was developed from the experimental design, which shows the highest and lowest condition of separation efficiency for each level of the operational variables. Further, a Pareto chart was developed to evaluate the significant operational variable for the screening machine. The results of the generalized method and forward selection method of fractional design show that the moisture content was the most significant operational variable, followed by angle and frequency. The results also show that the screen blinding of a screening machine plays an important role in reducing the separation efficiency of a screening machine. © 2021 Taylor & Francis Group, LLC.
Artificial neural network modeling for predicting the screening efficiency of coal with varying moisture content in the vibrating screen
(Routledge, 2021) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
In India, coal is one of the prime sources of energy used in the power generation and metallurgy sector. The processing of coal below 3 mm is not successfully carried out in India. The quality of coal below 3 mm can be improved by decreasing the coal’s particle size, which reduces the ash percentage of coal. Screening is one of the significant beneficiation techniques used to reduce the size fraction of coal. The difficult to process coal of size ?3 + 1 mm was selected in the present work. In this work, an attempt has been made to screen the coal of size ?2 + 1 mm from ?3 + 1 mm using a 2 mm screen mesh in the vibrating screen generated at different moisture content, angle, and frequency of the deck. The performance of the vibrating screen was evaluated using screening efficiency. Furthermore, prediction using a feed backward artificial neural network (ANN) model was developed on the experimental results for ten different neuron conditions. From the results, it was clear that the prediction results obtained from the ANN model were in good correlation with the experimental results. © 2021 Taylor & Francis Group, LLC.
A comparative study on a newly designed ball mill and the conventional ball mill performance with respect to the particle size distribution and recirculating load at the discharge end
(2020) Hanumanthappa, H.; Vardhan, H.; Mandela, G.R.; Kaza, M.; Sah, R.; Shanmugam, B.K.
The discharge end design of a ball mill plays an important role in discharging the desired particle sizes (?150 + 10 m) and the percentage of recirculating load from the discharge end of the ball mill. In continuous wet ball mills, the composition of feed (hard ore or soft ore) to the mill varies continuously, leading to uncontrolled grinding in the mill. In view of this, a new design of the discharge mechanism has been implemented to remove the ground particles of desired particle size fraction with minimum recirculating load (+150 m). The results from the discharge end with lifters (closed and open) show that the particle size fraction obtained from the discharge end has a maximum percentage of desired particle size fraction when the mill is operating at 60% critical speed. Discharge end without lifters has an uncontrolled particle size distribution in the discharge and the percentage of desired-size particles discharged was found to be very less. Also, the percentage of the recirculating load is minimum in the case of discharge end with lifter design compared with discharge end without a lifter. Hence, a new design of lifters in the discharge end leads to the discharge of the desired particle size fraction with minimum recirculating load. 2019 Elsevier Ltd
Comparison of the Experimental and Modelling Results of Mechanical Characteristics of LM6 and LM9 Alloy for Tractor Application
(Springer, 2023) Shetteppanavar, C.C.; Shinde, R.B.; Hanumanthappa, H.; Mohanraj, G.T.; Shanmugam, B.K.S.; Srivatsav, S.K.Y.; Kavitha Kumar, A.R.B.K.
In India, the development of composite and alloys material has provided the required characteristics material. In this study, an attempt has been made to compare the performance of LM6 and LM9 alloy for an automobile application. These alloys are studied based on the tensile strength and fatigue test required for the pullet used in tractor application. The tensile test results showed that the LM9 alloy specimen has higher strength than the LM6 alloy specimen. Furthermore, results showed that the fatigue strength of the LM9 alloy specimen was found to be higher than the LM6 alloy specimen. Further, the tensile and fatigue materials behaviour of LM6 and LM9 specimens were compared through ANSYS modelling. From the experimental and modelling results, it was clear that the modelling results are in close agreement with the tensile and fatigue experimental results. The mechanical characteristics such as tensile and fatigue strength of the LM9 specimen were found to be much better than the LM6 specimen. The microstructural analysis also showed higher silicon particles providing higher strength for LM9 specimens than LM6 specimens. The pulley material made out of LM9 alloy will avoid the shear failure occurrence of the pulley. © 2022, The Institution of Engineers (India).
Comparison of the prediction performance of separating coal in separation equipment using machine learning based cubic regression modelling and cascade neural network modelling
(Taylor and Francis Ltd., 2023) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
The availability of low-grade coal with a high amount of ash has urged the improvisation of separation equipment with minimal or no water utilization. The present work addresses the study on the separation equipment performance with different moisture coal. The experimental results were obtained in terms of separation efficiency. After obtaining the experimental results, the mathematical modeling results were obtained using different techniques. The cubic regression and cascade neural network models were considered to study the mathematical correlation with experimental results. The R-squared value of each mathematical modeling technique was correlated with the model fitting to check the model’s validity. The results clearly showed that the cubic model fitting for the experimental condition had provided an excellent R-squared value varying from 92% to 99%. The cascade model fitting for the experimental condition has provided a higher R-squared value, i.e., more than 99%. Results show that for all experimental conditions, the cascade model fitting of the neural network technique provides the significant mathematical modeling technique suitable for predicting the separation equipment’s performance compared to the cubic model of the regression technique. © 2022 Taylor & Francis Group, LLC.
Comparison of the predictive model performance of Taguchi’s L27 and Box Behnken design optimization method for separating coal in vibrating screen
(Taylor and Francis Ltd., 2023) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
The present research work evaluates the influential process parameters such as moisture content, angle, and frequency for separating coal in the vibrating screen. The design of the experiment for three factors with three levels was obtained using Taguchi’s and Response surface methodology’s (RSM) method. Taguchi’s L27 and RSM Box–Behnken design (BBD) method was used to conduct the separation experiment on a vibrating screen. The main effect plot of Taguchi’s L27 and BBD method was used to evaluate the optimized condition for obtaining the highest separation efficiency of the vibrating screen. The optimized condition obtained was lower moisture content (4%), lower angle (1 degree in upward slope), and medium frequency (9 Hz). The interaction plot of Taguchi’s L27 and BBD method was used to evaluate the interaction between the process parameters. From the interaction plot and ANOVA results, it was clear that the moisture content is the most significant parameter compared with the angle and frequency parameter for separating coal in a vibrating screen. From the prediction results, it was also clear the regression coefficient of Taguchi’s L27 was higher when compared with the RSM BBD method. This shows that Taguchi’s L27 is the most suitable optimization method compared with RSM. © 2022 Taylor & Francis Group, LLC.
Design and fabrication of optimized magnetic roller for permanent roll magnetic separator (PRMS): Finite element method magnetics (FEMM) approach
(Elsevier B.V., 2021) Mohanraj, G.T.; Rahman, M.R.; Joladarashi, S.; Hanumanthappa, H.; Shanmugam, B.K.; Vardhan, H.; Rabbani, S.A.
In the present work, an attempt has been made to develop a PRMS in a cost effective and environmental friendly way through FEMM analysis of magnetic roller (active part of PRMS). The FEMM analysis indicates that, the optimized magnetic roller having magnet-to-steel disk thickness ratio of 5 mm: 2.5 mm was proved to be gainful in beneficiating paramagnetic minerals due to the best magnetic field value from the roller surface that is, 0.89 to 2.59 T. Prediction analysis was performed on FEMM data using artificial neural network (ANN) modelling technique. Further, the design calculations of lab scale PRMS in terms of power requirements and belt tensions were addressed. The fabricated PRMS was tested on paramagnetic mineral (hematite ore) assayed 51.24% of Fe, 10.20% of SiO2, and 2.98% of Al2O3 for different roller speeds and the belt thickness. The result showed that, at 0.5 mm belt thickness with 180 rpm roller speed the fabricated lab scale PRMS works well in terms of improvement in the Fe content up to 59.5% at the concentrate along with the Fe recovery of 71.41%. The obtained results suggest that, the FEMM analysis is more suitable to optimize the effective magnetic roller for the PRMS. © 2021 The Society of Powder Technology Japan
Effect of Wollastonite Filler on the Experimental and Microstructural Analysis of Epoxy Composite Reinforced with E-glass Fibre
(Springer, 2022) Lokesh, K.S.; Pinto, T.; Shrinivasa Mayya, D.; Shanmugam, B.K.; Panduranga, B.P.; Hanumanthappa, H.; Mohanraj, G.T.
In the present study, the polymer composite was produced with epoxy, E-glass and wollastonite as the matrix, reinforcement and filler material, respectively. The present study investigates the effect of the filler material on the mechanical performance of developed composite specimens. The reinforcement material selected was woven and chopped-type fibre material. The filler material composition in the woven and chopped-type specimens was individually varied with 0%, 1%, 3%, 5% and 7%. The specimen was subject to mechanical testing, viz., tensile and flexural strength tests. Further, the wear rate of the normal specimen was tested to 5, 10 and 15 min. Additionally, the specimen was subjected to SEM (scanning electron microscope) analysis after attaining fracture for each study. The results showed that the specimen with 1% filler material had better tensile strength. It was also found that the flexural strength was good and was increasing with the filler material. The wear rate was reduced with the increase in filler material composition in the specimen. The results show that the woven fabric specimen shows better mechanical performance than the chopped specimen. © 2022, The Institution of Engineers (India).
Estimation of Grinding Time for Desired Particle Size Distribution and for Hematite Liberation Based on Ore Retention Time in the Mill
(2020) Hanumanthappa, H.; Vardhan, H.; Mandela, G.R.; Kaza, M.; Sah, R.; Shanmugam, B.K.
Iron ores obtained from different sources differ in their chemical and physical properties. These variations make the process of grinding a difficult task. The work carried out in this context focuses on three different samples of iron ore, viz., high silica high alumina, low silica high alumina, and low silica low alumina. The grinding process for all the three iron ores is carried out individually in Bond s ball mill and the total retention time taken by each iron ore sample is calculated. The present investigation focuses on utilizing the calculated retention time of the iron ore as a standard grinding reference time to the laboratory ball mill for optimizing the grinding time of each ore. The desired P80 (150 ?m) with an acceptable range of hematite liberation (> 75%) was obtained in the laboratory ball mill after reducing 6 min from the total retention time taken in the Bond ball mill. 2020, Society for Mining, Metallurgy & Exploration Inc.
Estimation of Grinding Time for Desired Particle Size Distribution and for Hematite Liberation Based on Ore Retention Time in the Mill
(Springer, 2020) Hanumanthappa, H.; Vardhan, H.; Raj, G.R.; Kaza, M.; Sah, R.; Shanmugam, B.K.
Iron ores obtained from different sources differ in their chemical and physical properties. These variations make the process of grinding a difficult task. The work carried out in this context focuses on three different samples of iron ore, viz., high silica high alumina, low silica high alumina, and low silica low alumina. The grinding process for all the three iron ores is carried out individually in Bond’s ball mill and the total retention time taken by each iron ore sample is calculated. The present investigation focuses on utilizing the calculated retention time of the iron ore as a standard grinding reference time to the laboratory ball mill for optimizing the grinding time of each ore. The desired P80 (150 ?m) with an acceptable range of hematite liberation (> 75%) was obtained in the laboratory ball mill after reducing 6 min from the total retention time taken in the Bond ball mill. © 2020, Society for Mining, Metallurgy & Exploration Inc.
Evaluation of a new vibrating screen for dry screening fine coal with different moisture contents
(Routledge, 2022) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
A new vibrating screen was developed with a circular mode of vibration for dry screening of moist coal of size fraction ?3 + 1 mm. Screen mesh of 2 mm aperture size will be used to separate the finer coal particles of size fraction ?2 + 1 mm. The new vibrating screen has the flexibility in changing the operational parameters such as the angle of the screen in upward or downward sloping direction and frequency of vibration of the screen deck. The circular mode of vibration provided to the screen deck will incorporate the inertial force on the particle in the screen deck, reducing screen clogging. The present study involves the analysis of the screening performance of the new vibrating screen with the coal feed of varying moisture content of 4%, 6% and 8%. The maximum screening efficiencies obtained for screening the coal feed with the moisture contents of 4%, 6% and 8% were 85.96%, 77.84%, and 68.27%, respectively. The higher screening performance of new vibrating screen was obtained due to good exposure time, particle mixing, particle segregation and particle stratification of coal on the screen deck. The results of the new vibrating screen will be a breakthrough in dry screening technology and accelerate the pilot-scale development. © 2019 Taylor & Francis Group, LLC.
Evaluation of the Parametric Effects of Separation of Coal in Vibration Separator Using Plackett–Burman Design of Experiments
(Springer, 2023) Shanmugam, B.K.S.; Vardhan, H.; Govinda Raj, M.; Kaza, M.; Sah, R.; Hanumanthappa, H.
Plackett–Burman’s design of experiment (DOE) technique provides a mathematical interrelationship between the output parameter and influential input parameters. The vibration separator performance was evaluated by considering three input variables: moisture, inclination, and frequency. Plackett–Burman DOE consists of a minimum number of 12 experimental trials for obtaining the most influential input parameter of the vibration separator. The output parameter of the vibration separator obtained for each experimental trial was separation efficiency. So, the present work provides the most influential input parameter, which highly controls the separation efficiency of the vibration separator for the separation of coal. The model was validated using the residual analysis. Further, the revalidation of the Plackett–Burman DOE mathematical model for the separation of coal was carried out by comparing the closeness of the experimental cube plot and predicted cube plot. Furthermore, the Pareto chart, normal plot, and ANOVA table were utilized to determine the significant input parameter for obtaining higher efficiency of vibration separator. The main effect plot, interactive plots, and optimization results provide the most optimized input parameter for obtaining higher efficiency of coal separation. So, the present work will provide the most influential parameters using Plackett–Burman DOE for separation of coal in the vibration separator. © 2022, The Indian Institute of Metals - IIM.
Evaluation of the Wear Behaviour of Thermally Aged E Glass Reinforced Epoxy Composite Filled with Wollastonite Using Taguchi L27 Technique
(Springer, 2022) Lokesh, K.S.; Pinto, T.; Mayya, D.S.; Shanmugam, B.K.; Panduranga, B.P.; Hanumanthappa, H.; Mohanraj, G.T.
In the present study, the E glass reinforced epoxy composite filled with wollastonite was developed. Taguchi’s L27 technique was selected for developing and analysing the effects of control factors on the wear behaviour of composites. The control factors considered for the present study was filler (%), time (minute) and temperature (°Celsius). The wear experiments were carried out using pin on disc arrangements for different experimental conditions. After the wear test, the microstructural analysis was carried out on the specimens using scanning electron microscope (SEM) analysis. The regression coefficient of 98.8% and probability plot shows that the model was accurate and valid. From the optimization results, it was clear that the 7% filler percentage (high level), 5 min sliding time (low level) and 50 °C temperature (high level) will yield high wear resistance and lower material loss due to the wear of the composites. Further, a confirmation test with the optimized condition was conducted and validated using the SEM image. The results also showed that the Taguchi technique effectively studies the effects of the control factors for obtaining the maximum wear resistance of the composites. © 2022, The Institution of Engineers (India).
Experimental analysis of vibratory screener efficiency based on density variation for screening coal and iron ore
(Taylor and Francis Ltd., 2024) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Hanumanthappa, H.; Reddy Byrareddy, R.; Sah, R.
In the coal and mineral beneficiation industries, screening is one of the crucial physical separation methods carried out to separate the undersized fine particles from the oversize coarse particles. The vibratory screener is a relatively advanced screening technology applied for coal and iron ore beneficiation. This paper deals with the experimental investigation for assessing the efficiency of screening coal and iron ore in the vibratory screener. Furthermore, a comparative study between the test performance of screening coal and iron ore was carried out depending on moisture and density variation. Test results show that the vibratory screener can provide a high recovery of fines and increased efficiency for screening iron ore than coal material. The maximum efficiency of iron ore was attained at a higher angular position, such as 3 and 5 degrees in an upward slope, whereas the maximum efficiency of coal was attained at 1 degree in an upward slope. © 2023 Taylor & Francis Group, LLC.
Experimental and Statistical Evaluation of the Mechanical Performance of (Jute and Cocopeat) Plant and (Silk) Animal-based Hybrid Fibers Reinforced with Epoxy Polymers
(Taylor and Francis Ltd., 2022) Lokesh, L.K.; Shanmugam, B.K.; Paavan Kumar, T.; Hanumanthappa, H.; Thimmegowda, M.; Mayya, S.D.; Yashaswini Srivatsav, S.K.; Kavitha Kumar, A.B.
In India, research on the development of new composite materials is extensively increased. In the present study, composites are developed with the renewable materials of plant and animal-based natural fibers. The present study will lead to the experimental and statistical investigation of the composite produced with a combination of plant-based natural fibers, i.e., jute and coco peat powder with the animal-based natural fibers, i.e., silk. In the present study, jute and silk were utilized as reinforcement material, cocopeat powder as a filler material (5%), and epoxy resin as matrix material (35%). The composites were prepared with the varying composition of reinforcement material, and also the filler and matrix material were kept constant. Furthermore, mechanical properties such as tensile, flexural, and impact tests were performed on the developed composites. Further, a comparative study was drawn on the mechanical test results of tensile and flexural strength of the composite using power and polynomial regression model. The regression coefficient (R2) was used to study the correlation between the experimental and predicted values. The results showed that the polynomial regression is the best suitable mathematical model than the power regression model for predicting the composites’ tensile and flexural test performance. © 2022 Taylor & Francis.
Experimentation and Prediction Analysis on the Mechanical Performance of Fish Scale and Coconut Shell Powder-Based Composites
(Taylor and Francis Ltd., 2022) Lokesh, L.; Shanmugam, B.K.; Mayya D, S.; B.p, P.; Naveen Kumar, N.; Hanumanthappa, H.
In India, the utilization of natural fibers for developing new composites with desirable properties has been increasing from the last decade. Bio-waste such as fish scale and coconut shell (CS) powder was utilized to develop natural fiber-based composites in the present work. Three composite specimens, i.e., 30 wt% fish scale (FS), 30 wt% CS powder (CS), and 5 wt% fish scale (FS)+ 5 wt% CS powder specimen, were developed. The tensile, flexural, and impact strength testing was carried out on each specimen. A comparative study was drawn between the test results of the specimen. The experimental results showed that the CS powder-based composites yield improved mechanical properties compared to the fish scale-based composites. Furthermore, a quadratic and cubic mathematical model was developed on the experimental results of tensile and flexural testing for each specimen. The regression results show that the cubic regression model yields better prediction results than the quadratic regression model for all the composite specimens. The experimental results showed that the largely available fish scale and CS powder could be used to produce biowaste-based value-added material that provides a sustainable and eco-friendly approach. © 2021 Taylor & Francis.
Experimentation and statistical prediction of screening performance of coal with different moisture content in the vibrating screen
(Routledge, 2022) Shanmugam, B.K.; Vardhan, H.; Raj, M.G.; Kaza, M.; Sah, R.; Hanumanthappa, H.
Screening of coal is one of the processes carried out to produce clean coal suitable for the blast furnace. In this work, the screening of moist coal was carried out for different angles of the screen and frequencies. A 2 mm screen perforation was used to separate undersize coal of size +1 mm-2 mm from the +1 mm-3 mm coal samples. For each experimental condition, the screening efficiency was calculated. Maximum screening efficiency of 85.96%, 75.64%, and 63.46% was obtained at 4%, 6%, and 8% moisture content, respectively. As the moisture content of coal increases, the efficiency minimizes due to high screen clogging. After determining the screening efficiency, prediction was carried out using regression modeling. In this work, linear and second-order polynomial regression modeling was utilized to develop a prediction model for the experimental values. From the results, it was clear that the polynomial regression model has high regression coefficient (R2) percentage and low P-value in comparison with the linear regression model. After prediction, validation was carried out on the best fit model. The value of Variance Account For (VAF), Root Mean Square Error (RMSE), and Mean Absolute Percentage Error (MAPE) was in the acceptable range, which shows that the developed model was most effective. © 2020 Taylor & Francis Group, LLC.
High-Temperature Tribological Studies on Hot-Forged Al6061–TiB2 In Situ Composites
(Springer Science and Business Media Deutschland GmbH, 2022) Venkategowda, C.; Hanumanthappa, H.; Prasad, C.D.; Shanmugam, B.K.; Sreenivasa, T.N.; Kumar, M.S.R.
The present investigation deals with the tribological behavior of high-temperature hot-forged Al6061–TiB2 in situ composites. Three samples of Al6061–TiB2 in situ composites were prepared with the variation in the in situ TiB2 particles. An in situ technique forms TiB2 particles by facilitating a reaction between Al–3%B and Al–10%Ti parent metals in the Al6061 melt at 800 °C. Further, approximately 5 wt% and 10 wt% TiB2 particles were created in the Al6061 composite using suitable quantities of parent alloys. At 500 °C, the Al6061 and its in situ composites were subjected to hot forging, and about 50% reduction is employed. The scanning electron microscope (SEM) and optical microscopy analysis were conducted to check the TiB2 particle dispersion and worn surfaces in the in situ composites. The TiB2 particle dispersion is found to be fairly uniform throughout the Al6061 matrix with minimal clustering. The results indicate that the friction coefficient increases initially when the temperature increases and then declines due to the oxides in the debris released from the top surfaces of the samples. The results show that the increase in the TiB2 content in the Al6061–TiB2 composites increases the composite wear rate. © 2022, The Author(s), under exclusive licence to Springer Nature Switzerland AG.