Browsing by Author "Senthil Murugan, S."

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Analysis of UNS S31603 ferrous joint made by rotary friction welding
(Springer, 2024) Senthil Murugan, S.; Girisankar, S.; Devanathan, C.; Kattimani, S.
This study delves into the effects of employing low friction pressure and high axial penetration during the fabrication of friction-welded joints using UNS S31603 stainless steel. The experiments were conducted using a continuous-drive rotary friction welding machine. Crucially, the research showcases the feasibility of creating robust welds in the metal, surpassing the strength of the parent metal. The resulting weld interfaces were remarkably narrow and well-defined. The mechanical properties of the welded joints, including tensile strength, yield strength, microhardness, impact toughness, and bending/flexural strength, were meticulously evaluated following ASTM standards. The findings indicate that the welded joints exhibited impressive tensile strength, approximately 803 MPa, and withstood a peak load of 52.0 kN. Additionally, these joints demonstrated a maximum elongation of 15.3% and a yield strength of 714.0 MPa. When subjected to bending conditions, similar joints made of UNS S31603 withstood loads of up to 19.0 kN before experiencing crack propagation. Ductility was observed in the fracture mode within the weld region, characterized by the formation of cup and cone necking, highlighting the joints' ductile behaviour. Furthermore, the joint efficiency was calculated to be over 100%. Utilizing these specific parameters, this method resulted in a maximum axial shortening or material loss of approximately 14 mm. © Indian Academy of Sciences 2024.
Development of Metal Matrix Composites Through Liquid State Technique
(CRC Press, 2025) Senthil Murugan, S.; Kattimani, S.
The stir casting process (SC or SCP) is an established technique for achieving effective bonding and mixing between matrix materials and ceramic reinforcements. This method facilitates chemical interactions through vortex flow within the melt, ensuring uniform distribution of the reinforcements. While SCP has demonstrated notable success in producing aluminium and magnesium matrix composites, its potential for polymer composite development is still being explored, offering promising opportunities for innovation. This chapter examines the research advancements in SCP for various materials, its industrial challenges, and its evolving applications. Effective degassing is identified as a critical step in the production of high-quality metal matrix composites (MMCs). SCP-derived MMCs find extensive applications in the automotive and aerospace industries, underscoring their significance. The versatility of SCP extends to the fabrication of advanced materials such as hybrid metal composites, nanocomposites (NCs), functionally graded materials (FGMs), and ultra-fine graded composites (UFGs) when combined with other manufacturing methods. The performance and outcome of SCP are influenced by factors such as process temperature, reinforcement proportion, and key process parameters. Further research is essential to optimise these parameters, explore novel applications, and fully realise the potential of SCP in producing next-generation materials. © 2025 selection and editorial matter, Tharmaraj Ramakrishnan and PM Gopal; individual chapters, the contributors.
Effect of BTO piezoceramic on the mechanical and dielectric properties of 3D-printed PLA.BTO functional polymer composite
(Springer Nature, 2025) Senthil Murugan, S.; Kattimani, S.; Saminathan, R.
The development of polymer composite materials for additive manufacturing is critical for advancing industrial applications. This study enhances the functional performance of poly-lactic acid (PLA) by incorporating barium titanate (BTO/BaTiO?) particles. Uniform dispersion of BTO within the PLA matrix was achieved, and filaments were fabricated using fused deposition modelling (FDM) with a 60% infill rate, adhering to ASTM standards. The influence of BTO fillers on the mechanical and dielectric properties of PLA.BTO composites were analysed and compared to pure PLA. FESEM microstructural analysis confirmed distinct layering, defect-free deposition, and uniform BTO distribution. Mechanical testing revealed notable improvements, including increases in tensile strength (16.4%), flexural strength (17.1%), shore hardness (4.7%), impact strength (17.7%), and drop-weight energy absorption for a 5 mm plate (26%), attributed to enhanced interfacial bonding and reduced void formation. The dielectric properties exhibited significant enhancements, with a 12.9% increase in dielectric strength, a 15% higher dielectric constant, an 8% greater breakdown strength, and a 21.74% rise in electrical susceptibility. Furthermore, reductions in loss tangent (19.1%), AC conductivity (7.8%), and dielectric loss (6.8%) demonstrated the material’s ability to store and withstand electric fields efficiently. Ferroelectric analysis revealed improved remanence, coercivity, and polarization, underscoring the composite’s potential as a piezoelectric material. These findings highlight the suitability of PLA.BTO composites for energy storage devices, sensors, and biodegradable functional applications, offering a promising balance of mechanical durability and superior dielectric performance. © Qatar University and Springer Nature Switzerland AG 2025.
MULTI-RESPONSE OPTIMIZATION IN AA6063/SS304 BIMETALIC FRICTION WELDING USING TAGUCHI GREY RELATIONAL ANALYSIS
(Galati University Press, 2024) Senthil Murugan, S.; Vishnoi, M.; Kattimani, S.; Mamatha, T.G.
This study aimed to create a robust joint between dissimilar materials, specifically AA6063-T6 aluminium alloy and SS304 austenitic stainless steel (ASS), and optimize the parameters. The experiments were conducted by employing the rotary friction welding (RFW) process, with an experimental setup devised on a conventional lathe machine utilizing friction-generated heat and plastic deformation. The joint's performance was evaluated as per ASTM standards through hardness and Charpy impact tests, demonstrating favourable results and the results were used for further analysis. Higher hardness was observed at higher friction pressure with higher speed of rotation. It reached a maximum of 85 HRC. Conversely, the maximum impact energy was obtained at low speed with 32 J. According to microstructure of the dissimilar joint, very narrow welding interface (WI) was found, which is less than 20 microns in width. The Taguchi-Grey relational analysis (GRA)-L9 method with Minitab software was utilized for optimize the process parameters, providing insights into effective parameter selection and multi-response optimization for improved performance. The results indicated that the welding speed was the most influential parameter. Weld pressure also influenced the weld zone’s hardness. Through the results, it is confirmed that RFW is emerged as a promising method for creating dissimilar joints, surpassing the limitations of fusion welding techniques. © Galati University Press, 2024.