1. Journal Articles
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Item Tribological behaviour of natural fibre 3D braided woven fabric reinforced PLA composites(2020) Kanakannavar S.; Pitchaimani J.; Ramesh M.R.This study aims to investigate the potential of natural fibre 3D braided woven fabric (NFBF) reinforced PLA (poly lactic acid) composites for tribological applications. Composites with different fibre contents are prepared using film stacking process and hot press methods. Friction co-efficient and wear rate of the composites are analysed using pin-on-disc tribometer under dry contact sliding condition and various operating conditions (velocity and load) for a fixed sliding distance of 3000 m. The morphology of the worn surfaces is studied using scanning electron microscope (SEM). The reinforcement of fibre with the PLA reduced the polymer film generation and improved the surface roughness significantly. Wear rate of the composites are decreased drastically compared to pure PLA. Composite with 35 wt.% of NFBF reinforcement showed better wear characteristics. © IMechE 2020.Item Solid Particle Erosion Behavior of Partially Oxidized Al with NiCr Composite Coating at Elevated Temperature(2021) Subba Rao M.; Ramesh M.R.; Ravikiran K.The composite coating was developed and investigated the solid particle erosion performance at elevated temperature by varying impact angles. Al2O3 erodent of grit size 50 µm was used in air-jet erosion tester to investigate the resistance to erosion at RT, 200, 400, 600, and 800 °C by varying 30, 45, 60, 75, and 90° impact angles. The composite coating was deposited on MDN321 steel by plasma spray process with feedstock of “30 weight percent of partially oxidized Al powder and 70 wt.% of NiCr alloy powder.” The composite coating was characterized by bond strength, porosity, micro-hardness, and density. Volumetric erosion loss concerning temperature and impact angle was studied using SEM, EDAX, and XRD analysis. Non-contact three-dimensional optical profilometer was used to quantify the volumetric erosion loss. MDN321 steel showed better erosion resistance than composite coating at all the temperatures. Due to the formation of stable oxides at 800 °C the erosion resistance of the coating was improved. © 2021, ASM International.Item Hot corrosion behavior of plasma-sprayed NiCrAlY/TiO2 and NiCrAlY/Cr2O3/YSZ cermets coatings on alloy steel(2021) Reddy M.; Prasad C.D.; Patil P.; Ramesh M.R.; Rao N.The objective of the Present research work is to evaluate the hot corrosion resistance of plasma-sprayed 70% NiCrAlY+ 30% TiO2 and 70% NiCrAlY+ 25% Cr2O3+5% YSZ coatings on MDN 420 alloy. Hot corrosion tests are carried out under molten salt environment of Na2SO4+60 % V2O5 salt mixture at 700°C for 50 cycles. Each cycle consisting of 1 hour heating in a silicon carbide tubular furnace followed by 20 min of cooling. The thermogravimetric technique was used to determine the kinetics of corrosion. The scanning electron microscopy (SEM), energy dispersive analysis (EDAX), electron probe microanalyser (EPMA) and X-ray diffracton (XRD) techniques were used to evaluate the characterization of coatings with regard to coating bondstrength, thickness, microhardness and porosity. The parabolic rate constants of coated steels are lower when compared to the uncoated substrate. The NiCrAlY+ Cr2O3+YSZ coating is found to be more protective when compared to NiCrAlY+ TiO2 coating. The oxides of Al2O3, NiCr2O4, and Cr2O3 are formed on the outermost layer of the coatings which gives the resistance the coatings to high-temperature corrosion. © 2020Item High-temperature wear and frictional behavior of partially oxidized Al with NiCr composite coating(2019) Medabalimi S.R.; Ramesh M.R.; Kadoli R.The influence of composite coating in improving wear and frictional behavior from room temperature to 600 °C was investigated. Partially oxidized Al powder was prepared with a flame spray process by spraying pure Al powder into distilled water. The composite powder is the mixture of 30 weight percent of partially oxidized Al and 70 weight percent of NiCr alloy powder. The composite powder was subsequently coated on MDN321 steel by air plasma spray process. The composite coatings are characterized with respect to adhesion strength, porosity, micro-hardness, and density. Wear and frictional behavior of coatings are evaluated under disc speed of 1 and 2 m s-1, loads of 10, 20 and 30 N and 3000 m sliding distance. The test results indicated that at room temperature, frictional heat generated due to applied load produce three-body abrasion at the interface caused to increase the wear and friction in the coating. The oxide film formed at high temperature due to plastic deformation avoids surface degradation at the interface and reduce the wear and friction. The worn surfaces at 600 °C consist phases of α-Al2O3, NiO, and Cr3O. These phases are contributing to improving the wear resistance of the coating more than 4-times compared to uncoated steels under varying load and sliding velocities. The coefficient of friction reduced with increase in temperature due to generated oxides act as lubricants at the interface. © 2019 IOP Publishing Ltd.Item Dynamic study of composite material shaft in high-speed rotor-bearing systems(2019) Gonsalves T.H.; Mohan Kumar G.C.; Ramesh M.R.In this work the composite material shaft in high-speed rotor-bearing systems is analysed to achieve better rotor dynamics along with the effect of internal damping of the composite shaft. The pioneering studies on rotating composite shaft and internal damping are revisited to evaluate its effects on rotor dynamics of high-speed rotor-bearing systems. Two practical rotor-bearing systems are selected to study their suitability for composite shaft application where the composite material is used in the cold section while the existing steel alloy is retained in the hot section as well as at the ends. The rotor dynamic analysis shows significant improvements in rotor dynamics of one of the rotor-bearing systems where the first lateral mode changes to desirable rigid mode from flexure mode shape of existing metallic shaft rotor-bearing system. The frequency values of second and third modes also increase above the operating speed indicating a clear advantage in rotor dynamics. Copyright © 2019 Inderscience Enterprises Ltd.Item Developing partially oxidized NiCr coatings using the combined flame spray and plasma spray process for improved wear behaviour at high temperature(2021) Medabalimi S.R.; Ramesh M.R.; Kadoli R.The powders of NiCrBSiFe and NiCr are partially oxidized using a flame spray process and are deposited on MDN321 steel substrate using a plasma spray process. The effect of partial oxidization on microstructure, microhardness, density, bond strength, and porosity of the coatings is analyzed. The friction and wear behaviour of the coatings was assessed using a pin-on-disc tribometer by varying loads (10, 20 and 30 N), sliding velocities (1, 2 m/s) and temperatures (RT, 200, 400 and 600 °C). Worn surfaces of NiCrBSiFe and NiCr coatings consist of oxide phases of SiO2, NiO, Cr2O3 and NiCr2O4 at elevated temperatures. These phases contributed to reducing the wear rate by five folds in coated steels compared to uncoated steels at 600 °C. The wear rate in coating decreases with an increase in temperature. The coefficient of friction was reduced gradually with the temperature in coatings and substrate. The wear rate coefficient of NiCr coating was 1.7 times higher than the NiCrBSiFe coating. © 2021 Elsevier B.V.Item Characterisation and performance evaluation of TiSiN &tiAlSiN coatings by RF magnetron sputtering deposition during end milling of maraging steel(2019) Varghese V.; Ramesh M.R.; Chakradhar D.; Shaik H.Monolayer nanostructured thin films of TiSiN & TiAlSiN were deposited on WC-Co milling inserts using RF magnetron sputtering for metal cutting. The alloy targets of TiSi (80/20 at%) & TiAlSi (34/56/10 at%) were used for the deposition in an Ar + N atmosphere. The deposition time and parameters are optimized to develop a uniform and homogenous coating. The mechanical and metallurgical properties are characterized to analyze the wear resistance of the coating. The machinability studies on MDN 250 maraging steel is carried out using TiSiN and TiAlSiN coated WC-Co inserts under dry and wet environment. The machining responses such as surface roughness, cutting force, tool wear and tool life are analyzed by varying spindle speed. The results showed that TiAlSiN coating had a higher wear resistance and machining performance compared to the TiSiN coating owing to the high hardness and plasticity index of the coating. © 2020 IOP Publishing Ltd.Item Characterization and Sliding Wear Behavior of Iron-Based Metallic Coating Deposited by HVOF Process on Low-Carbon Steel Substrate(2020) Prasad C.D.; Jerri A.; Ramesh M.R.The main aim of this work is to improve the sliding wear resistance of boiler steel material. The iron-based or Metco 41C metallic feedstock was deposited over the ASTM-SA213-T11 steel substrate using high-velocity oxy-fuel spraying process. The resultant deposits were subsequently characterized for microstructure, density, hardness, porosity and surface roughness. These characterizations were carried out with the help of XRD, SEM and Vickers’s microhardness tester. The sliding wear performance of the substrate and coatings were investigated by varying normal loads of 10 N and 20 N at temperatures of 200 °C, 300 °C as well as room conditions by employing pin-on-disk tribometer. The friction coefficient, volume of wear loss and wear rate were being found out. The wear results were compared among the substrate and coating. The formation of additional carbide phases such as Fe2C and SiC in Metco 41C coating led to higher hardness results in better wear resistance compared with the substrate. © 2020, Springer Nature Switzerland AG.Item Tribological performance of wire arc additive manufactured 347 austenitic stainless steel under unlubricated conditions at elevated temperatures(2020) Duraisamy R.; Kumar S.M.; Kannan A.R.; Shanmugam N.S.; Sankaranarayanasamy K.; Ramesh M.R.Wire Arc Additive Manufacturing (WAAM) is an effective metal additive manufacturing process. In this research, 347 Austenitic Stainless Steel (ASS) walls were manufactured with ER347 consumable material. The microstructure of the WAAM processed 347 plate is entirely heterogeneous with changing grain morphology along the building direction and this is attributed to the complex cyclic thermal history during WAAM process. The microstructure is composed of columnar, cellular and equiaxed structures at various regions. The hardness decreased gradually from bottom to top along the building direction. The volume fraction of ferrite ranged from 0.5% to 4.2% at various regions and the presence of niobium carbide (NbC) was confirmed. The aim of the current work is to provide an outline of the WAAM processed 347 steel under dry sliding conditions at elevated temperatures. The elevated temperature wear mechanism has mild oxidative wear characteristic due to the formation of tribo-oxides on the wearing and sliding surfaces. However, the average coefficient of friction (COF) is lower for the WAAM processed 347 compared to 347 substrate. In all cases after initial running-in, the wear debris from the wearing and sliding surface forms mechanically mixed composite layer of tribo-oxides (Fe2O3, Fe3O4 and Al2O3). The worn surface at 200 °C presents different wear behavior compared to the samples at 400 °C and 600 °C. The wear at 200 °C is a typical adhesive wear, while the wear at 400−600 °C is mild oxidative wear. The increase in the percentage of Fe3O4 helps to heal the wear surface by forming a mechanically mixed composite layer. The characteristics of mild oxidative wear were elucidated. © 2020 The Society of Manufacturing EngineersItem Microstructural and Tribological Resistance of Flame-Sprayed CoMoCrSi/WC-CrC-Ni and CoMoCrSi/WC-12Co Composite Coatings Remelted by Microwave Energy(2020) Prasad C.D.; Joladarashi S.; Ramesh M.R.; Srinath M.S.The hard facing composite coatings such as CoMoCrSi/30%WC-CrC-Ni and CoMoCrSi/30%WC-12Co are coated on grade-2 titanium substrate through Flame spray technique. Prior to deposition of coatings CoMoCrSi feedstock were processed using high energy ball milling to obtain intermetallic laves phases. The sprayed coatings are subjected to post-heat treatment through microwave energy to homogenize coating structure which reduces surface defects and to achieve metallurgical bonding. The as-sprayed and microwave treated coatings are examined for metallography analysis by using XRD, SEM–EDS and mechanical properties are estimated by using microhardness, universal tensile equipment. The high-temperature sliding wear tests are performed against alumina counterpart under dry conditions. The sliding wear test is conducted with normal loads of 10 N and 20 N at a sliding velocity of 1.5 m/s with a constant sliding distance of 3000 m. Microwave treated coatings obtained homogeneous structure and metallurgical bonding with improved hardness. Fused coatings revealed better wear resistance due to formation of oxides and fatigue spalling mechanism. © 2020, Springer Nature Switzerland AG.