Faculty Publications

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    Evolutionary algorithm based structure search for hard ruthenium carbides
    (Institute of Physics, 2015) Harikrishnan, G.; Ajith, K.M.; Chandra, S.; Valsakumar, M.C.
    An exhaustive structure search employing evolutionary algorithm and density functional theory has been carried out for ruthenium carbides, for the three stoichiometries Ru1C1, Ru2C1 and Ru3C1, yielding five lowest energy structures. These include the structures from the two reported syntheses of ruthenium carbides. Their emergence in the present structure search in stoichiometries, unlike the previously reported ones, is plausible in the light of the high temperature required for their synthesis. The mechanical stability and ductile character of all these systems are established by their elastic constants, and the dynamical stability of three of them by the phonon data. Rhombohedral structure is found to be energetically the most stable one in Ru1C1 stoichiometry and hexagonal structure , the most stable in Ru3C1 stoichiometry. RuC-Zinc blende system is a semiconductor with a band gap of 0.618 eV while the other two stable systems are metallic. Employing a semi-empirical model based on the bond strength, the hardness of RuC-Zinc blende is found to be a significantly large value of ?37 GPa while a fairly large value of ?21GPa is obtained for the RuC-Rhombohedral system. The positive formation energies of these systems show that high temperature and possibly high pressure are necessary for their synthesis. © 2015 IOP Publishing Ltd.
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    Pressure-induced variation of structural, elastic, vibrational, electronic, thermodynamic properties and hardness of Ruthenium Carbides
    (Elsevier Ltd, 2016) Harikrishnan, H.; Ajith, K.M.; Natarajan, S.; Chandra, S.; Mundachali Cheruvalath, V.
    Three of the five structures obtained from the evolutionary algorithm based structure search of Ruthenium Carbide systems in the stoichiometries RuC, Ru2C and Ru3C are relaxed at different pressures in the range 0-200 GPa and the pressure-induced variation of their structural, elastic, dynamical, electronic and thermodynamic properties as well as hardness is investigated in detail. No structural transition is present for these systems in this pressure range. RuC-Zinc blende is mechanically and dynamically unstable close to 100 GPa. RuC-Rhombohedral and Ru3C-Hexagonal retain mechanical and dynamical stability up to 200 GPa. For all three systems the electronic bands and density of states spread out with pressure and the band gap increases with pressure for the semiconducting RuC-Zinc blende. From the computed IR spectrum of RuC-Zinc blende at 50 GPa it is noted that the IR frequency increases with pressure. Using a semi-empirical model for hardness it is estimated that hardness of all three systems consistently increases with pressure. The hardness of RuC-Zinc blende increases towards the superhard regime up to the limiting pressure of its mechanical stability while that of RuC-Rhombohedral becomes 30 GPa at the pressure of 150 GPa. © 2016 Elsevier Ltd. All rights reserved.
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    Effect of metalloid element on the microstructural and mechanical properties of AlCoCrCuFeNi high-entropy alloys
    (Taylor and Francis Ltd., 2024) Chandrakar, R.; Chandraker, S.; Kumar, A.; Jaiswal, A.
    The impact of the metalloid element silicon (Si) addition on the microstructural and mechanical properties of the AlCoCuCrFeNiSix high-entropy alloy system is examined in this paper. The alloys were synthesized using a vacuum arc melting route. X-ray diffraction was used to analyse the current high-entropy alloys’ phase formation to comprehend the alloying process’s behaviour. It is evident from the peak pattern of the X-ray diffraction that the inclusion of Si promotes the growth of body-centred cubic structures. The microhardness and wear resistance were increased by increasing the Si content from 0 to 0.9. Si presence enhances the hardness of the alloys and strengthens the grain boundary. Improved hardness and wear resistance results from the enhanced body-centred cubic-phase formation, which poses a barrier to the dislocation movement and prevents further deformation. Furthermore, the inclusion of Si improved corrosion resistance in potentiodynamic polarization measurements. Excellent compressive strength is possessed by all of the high-entropy alloys with Si addition. © 2024 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.
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    Effect of addition of Ce and accumulative roll bonding on structure-property of the Mg-Ce-Al hybrid composite and its prediction and comparison using artificial neural network (ANN) approach
    (Institute of Physics, 2024) Anne, G.; Bhat, N.; Vishwanatha, H.M.; Ramesh, S.; Maruthi Prashanth, B.H.; Sharma, P.; Aditya Kudva, S.; Jagadeesh, C.; Nanjappa, Y.
    Light alloys play a crucial role in realizing the national strategy for energy conservation and emission reduction, as well as promoting the upgrading of manufacturing industries. Mg/Al composite laminates combine the corrosion resistance and ductility of aluminium alloy with the lightweight characteristics of magnesium alloy. The addition of Ce (rare earth elements) can improve the mechanical properties of magnesium via grain refinement and improve the ductility of the hybrid composites. In the present work, an investigation on addition of Ce into the Mg/Al matrix through Accumulative Roll Bonding (ARB) has been presented. The Mg/Ce/Al hybrid composite consists of Mg-4%Zn alloy and Al 1100 alloy with 0.2% Ce particles added between the dissimilar layers. The changes occurred in the evaluation of microstructure, corrosion and mechanical properties of the Mg/Ce/Al hybrid composite as a result of deformation process and also the addition of Ce have been explicated. The ARB parameters: temperature, rolling speed, percentage reduction, and aging time, have been studied. An increase of about 2.36 times in strength and hardness of the hybrid composite, has been reported. Further, the structure-property relations in the Mg/Ce/Al hybrid composites were aslo predict and compare using machine learning models: Decision Tree and Multi-Layer Perceptron (MLP) models. © 2024 The Author(s). Published by IOP Publishing Ltd.
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    Effect of surface remelting on the characteristics of IN718 components fabricated using laser powder directed energy deposition
    (Institute of Physics, 2024) Thanumoorthy, R.S.; Jadhav, S.V.; Oyyaravelu, R.; Bontha, S.; Balan, A.A.S.
    Laser Powder Directed Energy Deposition (LP-DED) fabricated components exhibit poor surface finish, necessitating additional post-processing steps prior to their practical application. Enhancing the surface quality of additively manufactured IN718 specimens through conventional post-processing methods is particularly challenging, given the material’s poor machinability and the complexity of the fabricated components. The current study is centered on comprehending the impact of Laser Surface Remelting (LSR) on the surface properties of Laser Powder Directed Energy Deposited (LP-DED) IN718 material. To gain insights into how remelting influences surface characteristics, remelting was carried out using various sets of parameters. The remelted zone exhibited a refined grain structure, leading to increased hardness. Moreover, significant reductions in surface roughness and residual stress were observed in the remelted samples. Regression analysis indicated that laser power played a pivotal role, with positive impact on surface finish and depth of influence but a negative impact on residual stress and hardness. Therefore, considering all the comparison metrics, remelting using laser power of 150 W and a scan speed of 1140 mm min−1 were found to yield optimal surface conditions. © 2024 IOP Publishing Ltd. All rights, including for text and data mining, AI training, and similar technologies, are reserved.
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    Combined effect of multidirectional forging and heat treatment on erosion and corrosion behaviour of the Mg-Zn-Mn alloys
    (Korean Society of Mechanical Engineers, 2024) Anne, G.; Hegde, A.; Kudva, S.A.; Sharma, P.; Kumar, P.; Matapati, M.; Ramesh, S.; Sharma, S.S.
    Multidirectional forging (MDF) was successfully applied to the Mg-4Zn-1Mn alloy for five passes at 300 °C. The grain size of 5 pass MDF processed samples reached 18 ± 3 µm from 256 ± 6 µm, and ?-Mg, MgZn2 and MnZn13 peaks were observed. Further MDF processed samples were solution treated (ST) at 300 °C for 2 h and quenched in SAE 20W40 oil and followed by artificial ageing (A) at 170 °C for four different timings including 1.5 h, 2 h, 2.5 h and 3.5 h respectively. The peak hardness of 219 Hv (5 pass MDF + H sample) was found in 2h artificial ageing which is 3.1 times higher compared to counterpart homogenised samples. Improvement of mechanical properties was attributed to smaller grain size and precipitation strengthening as well as distribution of the secondary phases. The combined effect of MDF and heat treatment was analysed using solid particle erosion tests at 30° and 90° impact angles using alumina. It was observed that higher impact angle (90°) had more erosion rate in all conditions and 5 pass MDF + H samples exhibited better erosion (0.0001 mg/g) due to higher hardness. On the other hand, polarisation and electrochemical impedance spectroscopy measurements were used to assess the alloys’ corrosion behaviour. The 3 pass MDF + H sample was found to have a corrosion rate of 0.0235 mm/y, which is two times lower than the counterpart 3 pass MDF processed samples and sixteen times lower than the homogenised sample (0.3838 mm/y). This was primarily due to the secondary phases’ better distribution and smaller grain size. © The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2024.
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    The influence of laser direct energy deposition processing parameters on Al7075 alloy and Zr-modified Al7075 alloy
    (Springer Science and Business Media Deutschland GmbH, 2024) Balla, S.K.; Mallaiah, M.; Nagamuthu, S.; Gurugubelli, R.C.; Aranas, C.; Bontha, S.
    The Laser Directed Energy Deposition (LDED) technique in metal additive manufacturing (MAM) offers intricate geometries while maintaining material properties akin to cast and wrought components. However, challenges persist in fabricating high-strength aluminum alloys like 2xxx, 6xxx, and 7xxx series due to hot cracking during rapid solidification in LDED. This study addresses Al7075 hot cracking issue by introducing 1 wt% Zr. To evaluate this novel approach, the influence of process parameters on track geometry, porosity, microstructure, hardness, and tensile properties of both Al7075 and modified Al7075 (with 1 wt% Zr) was examined using an L27 orthogonal array of experiments. Findings indicate that increased laser power widens bead width and wetting angle. Conversely, higher scan speeds reduce bead height but marginally increase width, impacting wetting angle. Notably, the addition of Zr decreased porosity from 0.07 to 0.032%, indicating enhanced material quality. Microstructural analysis reveals Zr’s role in preventing solidification cracking by enhancing molten metal fluidity during solidification, transitioning the microstructure from columnar to equiaxed fine grain due to Al3Zr precipitates, and promoting grain refinement. This addition of Zr also improved hardness and tensile strength by 11% and 10%, respectively, attributed to Al3Zr precipitates’ role in grain refinement and precipitation strengthening within Al7075. In summary, incorporating 1 wt% Zr into Al7075 via LDED demonstrates promising improvements in microstructure, reducing porosity, enhancing mechanical properties, and mitigating solidification cracking, thereby offering potential enhancements in the fabrication of high-strength aluminum alloys. © The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2024.
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    Achieving ultra-fine grains in Ti-6Al-4V alloy welds through pre-weld friction stir processing
    (Elsevier B.V., 2024) Rao, R.N.; Rao, S.S.; Vijayan, V.
    Titanium Ti-6Al-4V alloy, recognized for its exceptional strength, is extensively employed in the aerospace, biomedical, and automotive industries. Friction Stir Processing (FSP) has been found to enhance the overall performance, while friction stir welding (FSW) is recognized as the most effective technique for joining the Ti-6Al-4V alloy. This study focusses on the implementation of friction stir welding on a Ti-6Al-4V alloy that had previously undergone friction stir processing. The objective was to analyse the microstructure and mechanical characteristics. The examination using Electron Backscatter Diffraction revealed notable alterations in the microstructure, such as variations in grain size, misorientation angle, and grain boundaries. The proportion of high angle grain boundaries (HAGBs) on the advancing side and stir zone of the friction stir treated Ti-6Al-4V were 59 % and 66 %, respectively. Signifying grain refinement, grains measuring sizes between 0.83 ?m and 1.05 ?m were achieved as result of processing. Subsequent, friction stir welding resulted in about 50 % further decrease in grain size compared to base metal, with HAGBs comprising 71 % and 52 % at the advancing side and stir zone, respectively. As a result the Vickers micro hardness values increased to 397 ± 13Hv upon friction stir processing to 444 ±7Hv upon subsequent friction stir welding respectively. © 2024 The Authors
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    Investigation on Tribological Behavior of Al7075-TiC/Graphene Nano-composite Using Taguchi Method
    (Springer Science and Business Media Deutschland GmbH, 2024) Lingaraju, S.V.; Hatti, G.; Jadhav, M.R.; Dhuttargaon, M.S.; Doddamani, S.
    This study addresses the limited understanding of how nano-materials affect the mechanical properties and wear behavior of AMMNCs, focusing on challenges in achieving uniform nano-material distribution and optimizing processing parameters. This study explores the fabrication and tribological performance of Al7075 hybrid metal matrix nano-composites reinforced with TiC and Graphene using ultrasonic stir casting. By varying TiC content (0.5 to 2.5 wt%) and maintaining 0.25-wt% Graphene, the composites were tested under dry sliding conditions. Results indicate that the hybrid nano-composite with 1.5 wt% TiC and 0.25 wt% Graphene exhibits optimal wear resistance and frictional behavior, attributed to improved hardness and reduced surface damage. This results from harder particles intermingling with the softer alloy, which shows increased hardness with reduced delamination, cracks, and fractures of inside surfaces during wear. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.
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    Microstructural evolution and cyclic oxidation behavior of HVOF-sprayed NiCrSi and NiCrC coatings on T11 steel
    (Elsevier Inc., 2024) Medabalimi, S.; Hebbale, A.M.; Singh, R.; Desai, V.; Ramesh, M.R.
    This study analyzes NiCrSi and NiCrC coatings developed on low alloy ferritic stainless steel (grade T11) through the HVOF spraying technique. The coatings were characterized by their phase constitution, microstructure, cyclic oxidation behavior, and hardness. X-ray diffraction (XRD) analysis confirmed the presence of the NiCr solid solution matrix as the primary phase in both coatings. Moreover, the microstructure of the NiCrSi coating included the hard intermetallic compounds like Cr?Si and Ni?Si and the NiCrC coating contained the hard phases like Cr?C? and Ni?C which improved the hardness and the wear resistance of the coatings. Microhardness measurements revealed that the coatings had an average hardness of 300 ± 50 HV, significantly greater than the substrate hardness of 225 ± 25 HV. Cyclic oxidation tests were carried out at 700 °C revealed that both the coatings showed a lower weight gain than the uncoated substrate, suggesting enhanced oxidation resistance. This was because the protective oxide layers like Cr?O? and SiO? in the NiCrSi coating and Cr?O? and NiO in the NiCrC coating were formed. X-ray analysis establish ed. the presence of these oxides, which inhibited oxygen penetration through the coatings and provided additional protection against oxidation. Therefore, the study revealed that both NiCrSi and NiCrC coatings have good mechanical and oxidation resistance properties, which make them suitable for high-temperature applications where there is a need for improved durability, wear resistance, and protection against oxidation. © 2024