Faculty Publications

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Author: search.filters.author.Jambagi, S.C.

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    Friction Stir Processing: An Emerging Surface Engineering Technique
    (Springer Science and Business Media B.V., 2020) Bajakke, P.A.; Jambagi, S.C.; Vinayak, V.R.; Deshpande, A.S.
    Surface modification technologies impart improved surface properties without affecting the bulk properties of the material. The properties could be mechanical, electrical or thermal properties. Until recent past, thermal spray techniques, namely, plasma spraying, high-velocity oxy-fuel coatings and many others widely used for these applications. Friction stir processing (FSP) is a relatively newer technique that uses friction (between two surfaces) as a heat source to form a surface composite on the base alloy. This solid-state process not only refines the given structure but also disperses the reinforcements well within matrix alloy to enhance the surface properties. FSP was earlier employed to low melting point alloys such as aluminum and magnesium-base alloys, but now, with the recent development in tool geometry and tool materials, it can even be effectively used for high melting point alloys like steel and titanium-based alloys. Several process parameters seem to affect temperature and dispersion of reinforcements at the surface. They include rotational speed and traverse speed of the tool, number of passes, cooling medium and the tool geometry. Among these, rotation speed and traversing speed of tool seem to greatly affect the temperature distribution in the plasticized zone formed at the surface. This temperature, in turn, affects the grain refinement and dispersion of reinforcement particles. The present chapter summarizes the effect of these parameters. This chapter also reviews the latest developments in the tool material and its design. Further, their role in augmenting the base alloy properties is also discussed. High hardness, high fracture toughness, chemical inertness and high-temperature strength are few desirable properties of a tool to be used for FSP. In the end, the applicability of FSP as a surface modification technique has been assessed. © 2020, Springer Nature Switzerland AG.
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    A brief review on fly ash and its use in surface engineering
    (American Institute of Physics Inc. subs@aip.org, 2018) Bhajantri, V.; Krishna, K.; Jambagi, S.C.
    Fly ash is a by-product obtained from coal power plants. Over the past two decades, handling this industrial waste has been a great challenge for many developing countries. However, this menace can be used in many industrial applications viz., civil, automobile and aerospace applications. In civil industry, the fly ash has been used in concreate to enhance the porosity that increases the curing time of the concrete. The fly ash has been gaining importance these days as a feedstock material for many thermal spray processes. In automobile sector, the fly ash has been used as a thermal barrier coating in IC engines, whereas in aerospace industry, which demands lighter and stronger materials, the fly ash has been used as a reinforcement material. Hence, so far, fly ash has been used as an either single or a composite feed stock material in thermal spray processes. The fly ash with other materials like alumina, titania and red mud have been deposited using thermal spray processes. These coatings have exhibited higher wear, corrosion and erosion resistance as compared to the uncoated specimens. In this paper, a brief review on fly ash and its use, especially its use as a feed stock in thermal spray coating, is presented. Therefore, the use of fly ash has opened a new frontier of research in thermal spray coating area where economically viable coatings can be produced using industrial waste like fly ash. © 2018 Author(s).
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    3D Printing & Mechanical Characteristion of Polylactic Acid and Bronze Filled Polylactic Acid Components
    (Institute of Physics Publishing helen.craven@iop.org, 2018) Aveen, K.P.; Vishwanath Bhajathari, F.; Jambagi, S.C.
    Rapid prototyping (RP) technologies have emerged as fabrication methods to obtain engineering components within a short span of time. Desktop 3D printing, also referred as Additive Manufacturing (AM) technology is a powerful method of rapid prototyping technique that can fabricate three-dimensional engineering components. Poly Lactic acid (PLA) is a green alternative to petrochemical commodity plastics, used in packaging, agricultural products, disposable materials, textiles, and automotive composites, 3-D printing technology enables fabrication of PLA and bronze filled PLA, which has less tensile and flexural modulus. In order for 3D printed parts to be useful for engineering applications, the mechanical properties of the material will play an important role in the functioning of the components. In the present study, commercial grade PLA & bronze filled PLA has been considered as material for preparation of samples using desktop 3D printer. The samples were tested for their mechanical characteristics like Tensile and flexural strength properties. The test Samples were fabricated using 3D printing with different layer height and with different layer build-up speed. Comparison between the PLA & bronze filled PLA based on the experimental results are discussed and found PLA has superior tensile and flexural property when compared to Bronze filled PLA. © Published under licence by IOP Publishing Ltd.
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    A Review on Surface Engineering Perspective of Metallic Implants for Orthopaedic Applications
    (Springer, 2021) Jambagi, S.C.; Vinayak, V.R.
    Orthopaedic metallic implant design is expected to meet two critical challenges—biocompatibility and mechanical strength. According to a survey conducted in 2017, the global market of implants will grow by ~46% by 2025. Researchers have been trying to alleviate the problems of these implants, namely, biocompatibility, microbial invasion, bio-inertness, corrosion, and wear. Surface modification techniques that operate at low temperature and diffusion-based processes are preferred to circumvent the problems. These methods include thermochemical (carburizing, nitriding, etc.), electrochemical processes (electrochemical deposition, chrome plating, etc.), and ion implantation. This review presents the significance of these methods while meeting various challenges, such as wear, biocompatibility, and corrosion. The implants reviewed are stainless steel, Co-Cr alloys, titanium alloys, and magnesium alloys. Finally, the friction-stir process, another low-temperature process, has been reviewed for Mg and its alloys. © 2021, The Minerals, Metals & Materials Society.
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    Bioactive surface modifications through thermally sprayed hydroxyapatite composite coatings: a review of selective reinforcements
    (Royal Society of Chemistry, 2022) Jagadeeshanayaka, N.; Awasthi, S.; Jambagi, S.C.; Srivastava, C.
    Hydroxyapatite (HA) has been an excellent replacement for the natural bone in orthopedic applications owing to its close resemblance to the bone properties; however, it is brittle and has low strength. Surface modification techniques have been able to allay such mineral issues by depositing on substrate. These methods, being economical, impart mechanical strength without compromising biocompatibility. In this review article, the discussion is confined to plasma spray (high temperature) and other low temperature surface modification techniques: high-velocity oxy-fuel (HVOF) and cold spray. The processing temperature seems to significantly affect the performance of implants deposited with HA. Monolithic HA may not add enough strength to the bioimplants. Hence, this review discusses selective reinforcements to HA and their roles in enhancing the properties. Herein, a variety of selective reinforcements are discussed, such as carbon allotropes: graphene, carbon nanotubes, and nano diamond; metallic materials: Ag, Sr, Mg, and Ti; ceramic materials: Al2O3, SiO2, ZrO2, and TiO2; multi-materials: Al2O3-CNT/HA, Al2O3-TiO2/HA and others; and functionally graded composites: HA, 20 and 50 wt% Ti-6Al-4V/HA layered coating. Most of these reinforcements could not trade-off between biocompatibility and strength. The detailed in vitro and in vivo studies are still lacking. The literature on the relative effectiveness of these reinforcements is scanty, while the interface between HA coating and reinforcements is seldom explored. This review presents the suitability of thermal spray techniques based on the microstructure, mechanical, and biological properties. Therefore, it is envisaged that the present review can intrigue future researchers to understand the scope of surface coatings in achieving the better performance of implants at clinical trials. © 2022 The Royal Society of Chemistry.
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    Scratch adhesion strength of plasma sprayed carbon nanotube reinforced ceramic coatings
    (Elsevier Ltd, 2017) Jambagi, S.C.
    This report investigates the effect of both mechanical and thermal properties of Carbon nanotube (CNT) on scratch adhesion strength of ceramic coatings. Micro sized alumina and titania with 1 wt% CNT powders were prepared by three routes: dry/wet milling (with alcohol) and heterocoagulation. First, degree of CNT dispersion in the coatings was analysed. Heterocoagulated coatings displayed homogeneous dispersion of CNT. Next, the effect of homogeneous dispersion on phase transformation was studied. Higher thermal conductivity of CNT and its degree of dispersion seemed to affect the melting of powders and thus the phase transformations in the coatings. A higher fraction of stable phase was detected in the coatings. In addition, CNT/ceramic interface was analysed for the reaction layer. A stable phase layer was found covering the entire CNT surface, protecting it from thermal degradation. Finally, the scratch adhesion strength was quantified for both CNT reinforced and unreinforced coatings. The scratch resistance of heterocoagulated coatings improved by ?36–176%. Improvement in strength was attributed to: a) a higher stable phase fraction in the coatings, b) Strong wettability at CNT/ceramic interface, c) improvement in elastic moduli of the coatings has also led to the improvement in the work of adhesion of the coatings, and d) a toughening mechanism, CNT bridging. © 2017 Elsevier B.V.
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    Investigating Mechanical and Corrosion Behavior of Plain and Reinforced AA1050 Sheets Fabricated by Friction Stir Processing
    (Springer, 2020) Vinayak, V.R.; Bajakke, P.A.; Jambagi, S.C.; Chavana, C.; Deshpande, A.S.
    The present investigations help in improving the bendability and corrosion resistance of AA1050 rolled sheets by selective friction stirring. The processing of AA1050 with a tapered square pin at a tool rotation speed of 1200 rpm yielded the highest strain of 0.345 at ultimate tensile strength compared with 0.054 in as-received material. The identified processing conditions produced an ultimate tensile strength of 89.23 MPa with a toughness of 34.451 × 106 J/m3 and a lower corrosion rate with Icorr of 0.324 × 10?6 A/cm2. Further, processing with a simple tapered circular pin resulted in maximum ultimate tensile strength of 102 MPa with a toughness of 33.990 × 106 J/m3. However, it came at the expense of least resistance to corrosion with Icorr of 4.813 × 10?6 A/cm2. Consequently, the addition of zinc oxide during friction stirring showed a remarkable improvement in corrosion resistance with Icorr of 0.094 × 10?6 A/cm2. Future studies are planned on these lines. © 2020, The Minerals, Metals & Materials Society.
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    Corrosion behavior of novel AA1050/ZnO surface composite: A potential material for ship hull
    (Elsevier B.V., 2020) Bajakke, P.A.; Vinayak, V.R.; Jambagi, S.C.; Deshpande, A.S.
    Friction stir processing is one of the effective surface treatments which was employed to process the AA1050 sheets in bare and reinforced condition. The primary objective of the investigation was to expand the applications of AA1050 as a ship hull element in shipbuilding with the least corrosion rate to withstand the harsh marine environment. The base material processed with a rotational speed of 1200 rpm resulted in the highest corrosion rate of 0.173622 mpy. The formation of Al-Fe intermetallic phases was responsible for pitting corrosion. Further, processing by embedding zinc oxide with a rotational speed of 1000 rpm exhibited ~6.68 times improvement in corrosion resistance compared to as-received material. The corrosion rate was found to be 0.003390 mpy. The Al2O3 passive film hinders the initiation and propagation of pits. This study coins a novel composite material and future investigations are emphasized on the same lines. © 2020 Elsevier B.V.
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    Influence of carbon nanotube reinforcement on the heat transfer coefficient, microstructure, and mechanical properties of a die cast Al-7Si-0.35Mg alloy
    (Elsevier Ltd, 2021) Usef, A.P.; Bhajantri, V.; Kannoth, V.; Jambagi, S.C.
    Al-7Si-0.35Mg or A356 alloy is most widely used in aircraft and automobile industries owing to its high strength to weight ratio. This alloy has been reinforced with a 1 wt% carbon nanotube (CNT) to improve its properties in this investigation. First, A356/1 wt% CNT powders were ball milled in the presence of ethanol and subsequently consolidated using gravity die casting. Ball milling was effective in achieving homogeneous dispersion of CNT. The microstructural study revealed the segregation of the Al4C3 phase at the grain boundary. This mechanism is known as grain boundary precipitation. Also, the grain size has decreased by ~44%. Next, the casting-die interfacial heat transfer coefficient (IHTC) has been evaluated using Beck's inverse heat transfer algorithm. With the reinforcement, the IHTC has increased by ~2.5%, which indicates the rise in heat transfer rate during solidification. Then, the experimental and theoretical tensile properties of A356 were correlated using simulation software. The experimental results showed the synergistic effect of grain size, Al4C3, and IHTC improving yield strength by ~19.8%, ultimate tensile strength by ~14.13%, elongation by 7%, and hardness ~22%. Therefore, a meagre 1 wt% CNT has improved the heat transfer rate of the melt as indicated by IHTC values. This effect was further corroborated by evaluating the thermal conductivity of the sample. The thermal conductivity has improved by 10% that resulted in finer grain size of the sample. Therefore, such reinforced alloys are expected to display higher strength demanded in various industrial applications. © 2021
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    Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications
    (American Chemical Society, 2022) Chavana, N.; Bhajantri F, V.; Jambagi, S.C.
    Fly ash (FA), a multicompound mineral, is an industrial waste produced during coal burning in thermal power stations. It has been regarded as the most environmentally hazardous material. Furthermore, handling FA has been a significant challenge for many developing countries. Therefore, researchers have been exhorted to enhance its usage to counter its handling issues. FA is enriched with mullite, silica, and alumina. Having such mineralogy, FA can be envisaged as a promising candidate for combating erosion and corrosion in marine environments. With this motivation, the research aims to deposit as-received FA using the plasma-spraying technique onto a marine-grade steel substrate without additives and assess the performance of such coatings for erosion and corrosion properties. The coating has exhibited more than 100% improvement in microhardness. The erosion resistance was improved by ∼11% compared to that of the uncoated sample, which is attributed to the hardness to elastic modulus ratio (H/E) and its unique mineralogy. The minor improvement in erosion resistance was attributed to the coating's poor fracture toughness. The erosion study shows that slurry concentration and rotational speeds were the most influential parameters. The scar depth was significantly shallower for FA-coated samples. The corrosion resistance has improved only by ∼13.49%, owing to the porous nature of the coating. Therefore, such coatings with appropriate improvements in their properties are expected to assuage both environmental and industrial challenges. © 2022 The Authors. Published by American Chemical Society.