Conference Papers

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    Process parameter optimization for ultimate tensile strength of friction stir welded joint of Al-10Mg-8Ce-3.5Si aluminium alloy plates using Taguchi technique
    (Elsevier Ltd, 2022) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.
    The Friction stir welding (FSW) process has become a popular method of joining metals, due to its clean and efficient nature of producing welds. The input process parameters: the tool rotation speed, tool feed and tool pin shape are the deciding parameters for an optimum output quality characteristic, the Ultimate tensile stress (UTS) of the weld joint. Here in this research, the Taguchi full factorial design technique is discussed for maximizing the UTS of the weld joint formed in Al-10Mg-8Ce-3.5Si aluminium alloy plates. The ANOVA of means and Signal to Noise ratios for UTS was used to assess the influence of each of the input process parameters on output UTS. The main effect plots of the ANOVA results demonstrated that, the tool rotation speed at level 2 or 1000 rpm, the tool feed at level 3 or 20 mm/min and tool pin shape at level 1 or triangular cross section, gave the optimum results for output UTS. The ANOVA for UTS also showed the percentage contribution of input process parameters; the shape of tool pin as 60.06%, the tool feed as 15.42% and shape of tool pin as 2.41%. The UTS value predicted by the Taguchi analysis was at 108.47 MPa which was in good agreement with the experimentally obtained value of 106.84 MPa. A nonlinear regression equation was developed by correlating the input process parameters, which could be used to predict the optimum UTS results. © 2022 Elsevier Ltd. All rights reserved.
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    Influence of Process Parameters on Microstructural Properties of L-DED Produced Ti64 Alloy
    (Springer Science and Business Media Deutschland GmbH, 2025) Suresh, S.; Kuriachen, B.; Kumar, V.; Bontha, S.; Gurugubelli, R.C.
    Additive manufacturing (AM) techniques have revolutionized the manufacturing of complex and customized parts across various applications. However, they are known for producing titanium parts with high anisotropy and low ductility, due to high cooling gradient in the build direction and the presence of martensite phase in microstructure respectively. These are inherent problems which limit their application in critical engineering fields. Laser—Direct Energy Deposition (L-DED) produced parts also have the same disadvantages. Thus, the primary objective of this paper is to identify the optimal combination of process parameters for L-DED that can mitigate these inherent limitations. Keeping the parameters such as powder size, orientation angle and hatch angle as constant, the laser power and scan speed are varied to fabricate 9 different sets of samples using L-DED. The research methodology includes an analysis of the microstructure, focusing on grain width, phase distribution, lath characteristics and presence of defects, if any. Microscopy and XRD techniques were used to observe the microstructure. Additionally, hardness studies were performed to evaluate the changes in material hardness. It was noticed that laser power significantly influences β width and α’ length while scan speed has a lesser dominant effect on both of them. The findings will contribute to the development of process-structure-property relations for L-DED-produced Ti64 and further, optimized manufacturing strategies for producing titanium parts with reduced anisotropy and increased ductility. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.