Faculty Publications
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Item Influence of Process Variables on the Ultimate Tensile Strength of Friction Stir Welded AA6061 Matrix Composite(Springer Nature, 2021) Shettigar, A.; Prabhu B, S.R.; Herbert, M.A.; Rao, S.S.The present study is focused on the application of the friction stir welding process (FSW) to weld aluminium matrix composites (AMCs). Joints are formed by varying FSW process variables such as tool revolving speed (TRS), tool traverse speed (TTS) and the tool pin geometry (TPG). Influence of these parameters on the ultimate tensile strength (UTS) of the joints is investigated. Process variable optimization is done using Taguchi L18 orthogonal array design. Optimum process variables are determined and confirmed by confirmation tests based on the analysis of variance. © 2021, Springer Nature Singapore Pte Ltd.Item Correlational Study of Ultimate Tensile Stress and Hardness of Friction Stir-Welded Al–Ce–Si–Mg Aluminum Alloys(Springer Nature, 2024) D’Souza, A.D.; Herbert, M.A.; Rao, S.S.In this research article, an analysis of correlation between mechanical properties of aluminum alloy such as ultimate tensile stress and Vickers hardness is carried out. Research analysis shows that hardness and UTS have a direct relationship. Tool rotation speed also directly impacts hardness and UTS values by controlling the amount of heat generated and hence extent of plasticization and grain refinement in the region of the weld. According to the research results, the plane surfaces of the square profiled pin of the tool aid in introducing a pulsing effect, which contributes to improved strength of weld connection. When compared to other tool profiles, a higher dynamic-to-static ratio attained with the triangular profiled pin tool results in greater material sweeping. As a result, the highest UTS and hardness values were obtained for welding connections created with the triangular profile pin tool. The study shows that the various input process parameters pertaining to tool revolving velocity, welding velocity, and tool-pin profile have a similar relationship on both hardness and ultimate tensile strength of weldment connection obtained with friction stir weld process. Hence, a similar trend or correlation has been observed in the variation of hardness and UTS. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.Item Correlation of Tribological Properties with Microstructure and Mechanical Properties of Graphite Cast Irons Centrifugally Cast for Engine Liner(Springer India sanjiv.goswami@springer.co.in, 2014) Desai Gowda, H.S.; Mukunda, P.G.; Herbert, M.A.This is a study of the influence of centrifugal process on the graphite morphology, mechanical and wear properties on flake graphite iron (FGI), spheroidal graphite iron (SGI) and compacted graphite iron (CGI). Melts of hypereutectic and almost of identical composition with or without melt treatment were centrifugally cast. The microstructure, mechanical and wear properties of these specimens were studied. In the microstructure for FG iron it has been observed that the centrifugal process produces flake size range class 2–3 (range 160–320 ?m) and graphite of flake type A by about 67.9 % (field %) and combined flakes of type B, C, D and E will be of 32.1 % (field %). While SGI has been observed to have 96.1 % nodules and 330.0 nodules per square millimeter. Similarly CGI has been seen to produce 52.0 % nodules and 113 nodules per square millimeter. SGI possess the highest tensile strength, rupture strain and hardness of 604 N/mm2, 6.1 %, 233 BHN respectively. Whereas FGI possess the least tensile strength, rupture strain and hardness of 303 N/mm2, 0.65 %, 185 BHN respectively among the irons. CGI has a tensile strength, rupture strain and hardness of 369 N/mm2, 1.2 % and 200 BHN respectively which lies in between those of FGI and SGI. During the wear test similar materials for both disk and pin combination show higher co-efficient of friction and wear rate than those for dissimilar material combinations. SGI disk and FGI pin combination show least wear. This combination would be ideally suited for engine liner and piston rings. © 2014, Indian Institute of Metals.Item Effect of low temperature annealing on the properties of nano Ni-Ti alloys(Institute of Physics Publishing helen.craven@iop.org, 2019) Mukunda, S.; Mahesh, M.; Narendranath, S.; Herbert, M.A.Binary 1:1 Ni-Ti alloy has been the work horse for many industrial and of late biomedical applications amongst all shape memory alloys. Apart from being employed for endovascular applications like stents and filters, they are also used as orthodontic braces and in endodontic tools. Ni-Ti drills and files are used in a few procedures with sterilization between uses. However, the effect of these sterilizing heat-treatments on the properties of the tools is not clearly investigated. In addition to this, satisfactory metallurgical explanations for the wear resistance of these alloys in absent in the literature. Therefore, this paper attempts to define the transformational temperatures for the Ni-Ti as-received and low temperature heat-treated conditions have been investigated using Differential Scanning Calorimetry (DSC). Attempts are made to justify their suitability for endodontic applications by evaluating their mechanical strength parameters using the Tensile and Wear tests. It was found that the samples showed did not show much variations in strength when subjected to tensile tests whereas the same was not observed for DSC tests. Ambient temperature x-ray diffraction studies indicate the presence of Austenitic and Martensitic phases in all the samples. DSC results are strongly affected by presence of internal stresses but stress-induced-martensitic forms in all the samples with equal facility. © 2019 IOP Publishing Ltd.Item Evaluation of Microstructure, Hardness and Mechanical Properties of Friction Stir Welded Al–Ce–Si–Mg Aluminium Alloy(Korean Institute of Metals and Materials, 2020) D’Souza, A.D.; Rao, S.S.; Herbert, M.A.Abstract: A vast majority of the research on friction stir welding(FSW) is mainly focused on welding of aluminium alloys. The research studies in this paper are based on one such alloy known as Al–Ce–Si–Mg aluminium alloy, of which, the microstructure and other mechanical properties of the friction stir welded joints are yet to be studied. The plates of Al–Ce–Si–Mg aluminium alloy were friction stir welded using a non consumable, rotating tool with triangular profile pin and circular shoulder, with different combinations of tool rotation speeds and weld speeds. The microstructure, hardness and mechanical properties of the weld were analyzed. The microstructure of the weld zones revealed that, the average grain size at the bottom of the Nugget Zone (NZ) is 5 ± 0.12 ?m and gradually increases to 15 ± 0.23 ?m at the top of the NZ. In the TMAZ the grain size is 20 ± 0.14 ?m and is bigger compared to the NZ. In the HAZ, the grain size is around 37 ± 0.21 ?m and is bigger than that in the TMAZ. The maximum Vickers hardness value at the NZ center is 231.9 ± 2 Hv, and uniformly reduces to 100 ± 2.4 Hv in the TMAZ and 65 ± 1.3 Hv in the HAZ and then increases to 98 ± 1 Hv in the base material (BM). The maximum ultimate tensile strength (UTS) of FSW joint was found to be around 102.55 ± 3 MPa with elongation at fracture of 2.5%. The BM UTS was 154 ± 4.5 MPa. For a tool rotation speed of 800RPM and a weld speed of 20 mm/min a maximum joint efficiency of 67%. was obtained. Hence these were chosen as the optimum process parameters to join the alloy Al–Ce–Si–Mg by FSW. Graphic Abstract: [Figure not available: see fulltext.] © 2019, The Korean Institute of Metals and Materials.Item Optimization of FSW process parameters for maximum UTS of AA6061/rutile composites using Taguchi technique(Sharif University of Technology, 2022) Prabhu B, S.R.; Shettigar, A.; Herbert, M.A.; Rao, S.S.In the friction stir welding process, preferred joint property is vastly reliant on the selection of optimal welding conditions. The present study aims to use the Taguchi technique to find the optimal process conditions for achieving superior Ultimate Tensile Strength (UTS) in friction stir welded Aluminum Matrix Composite (AMC) joints. AMCs reinforced with rutile particles which have a potential application in the aerospace, automotive, and marine industries are used in the present work. Taguchi parametric design technique was used to identify the effect of rotational speed, tool traverse speed, and tool geometry on joint strength. Taguchi approach confined the optimum level of process variables and these variables were optimized. The investigation showed that the parameters within the selected value range will seriously affect the output. The predicted value of the output response was 155.48 MPa, which was validated by further experiments using the optimum process variables. Analysis Of Variance (ANOVA) results indicated that the UTS of the composite joint is mainly affected by the tool traverse speed followed by rotational speed, and tool geometry. The microstructural study unveiled that grain size is dependent on process variables and finer grains offer better joint properties. © 2022 Sharif University of Technology. All rights reserved.Item Optimization of process parameters for friction stir processing (FSP) of AA8090/boron carbide surface composites(Springer Science and Business Media Deutschland GmbH, 2024) Adiga, K.; Herbert, M.A.; Rao, S.S.; Shettigar, A.K.Friction Stir Processing (FSP) is an innovative and promising technique for microstructure refinement, material property enhancement, and surface composite production. The current study describes the fabrication of AA8090/boron carbide surface composites (SCs) by FSP. Experimental studies were conducted by varying the FSP parameters, specifically the rotational speed (800–1400 rpm), traverse speed (25–75 mm/min), and groove width (1–1.8 mm). Ultimate Tensile Strength (UTS), Surface Roughness (SR), and Percentage Elongation (El) were used as response measures. Experiments were planned based on the central composite design (CCD) of Response Surface Methodology (RSM) and a mathematical relationship between the input parameters and UTS, SR and El, and were obtained by RSM. The model adequacy was tested using analysis of variance (ANOVA). The models enabled the examination of individual and interaction effects of input parameters on the UTS, SR, and El of the produced SCs. AA8090/boron carbide SC strength was optimal of 366 MPa at 800 rpm, 75 mm/min, and 1.8 mm and optimal 21.13% elongation at 1400 rpm, 25 mm/min, and 1 mm. A smoother surface with 0.82-μm roughness was optimal at 1400 rpm, 25 mm/min, and 1.2 mm. The present study uses the FSP method to synthesize near-net-shaped SCs without further machining by systematically selecting process parameters. The study shows that the increase in rotational speed during AA8090/boron carbide SC fabrication produces composites with a good surface finish, lower UTS, and good ductility. However, the increase in the other two parameters, namely, traverse speed and groove width, produces low ductile composites with rougher surfaces and higher strengths. Graphical abstract: (Figure presented.) © International Institute of Welding 2024.Item Control factor optimization for friction stir processing of AA8090/SiC surface composites(Elsevier B.V., 2024) Adiga, K.; Herbert, M.A.; Rao, S.S.; Shettigar, A.K.Friction Stir Processing is a state-of-the-art technology for microstructure refinement, material property enhancement, and surface composites fabrication. This investigation concentrates on AA8090/SiC surface composites produced via friction stir processing. Experiments were conducted by varying the following friction stir processing parameters: Tool rotational speed (800–1400 rpm), Tool traverse speed (25–75 mm/min), and Groove width (1.0–1.8 mm). Response measures encompassed Ultimate Tensile Strength and surface roughness. Central Composite Design of Response Surface Methodology designed the experiments and mathematical relationships established between input parameters and ultimate tensile strength and surface roughness. Analysis of variance was used to test the model's adequacy. The models examined individual and interaction effects of input factors on ultimate tensile strength and surface roughness of surface composites. A combinations of input parameters was identified that yields the maximum ultimate tensile strength and minimum surface roughness. The current work employs the friction stir processing approach to synthesis near-net-shaped surface composites without additional machining by systematically optimizing process parameters. Results indicate that increasing tool rotational speed produces well-finished AA8090/SiC surface composites with decreased strength. In contrast, increased tool traverse speed and groove width generate surface composites with rougher surfaces and higher strength. Surface and contour plots further explored the influence of parameter interactions on responses. © 2024 The Authors