Faculty Publications
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Item Mechanical and tribological behaviour of epoxy reinforced with nano-Al2O3 particles(Trans Tech Publications Ltd ttp@transtec.ch, 2014) Kurahatti, R.V.; Surendranathan, A.O.; Ramesh Kumar, A.V.; Auradi, V.; Wadageri, C.S.; Kori, S.A.In the present work systematic study has been conducted to investigate the matrix properties by introducing nanosize Al2O3 (particle size 100 nm, 0.5-10 wt %) fillers into an epoxy resin. High shear mixing process was employed to disperse the particles into the resin. The experimental results indicated that frictional coefficient and wear rate of epoxy can be reduced at rather low concentration of nano-Al2O3. The lowest specific wear rate 0.7 × 10-4 mm3/Nm is observed for the composites with 1 wt.% which is decreased by 65% as compared to unfilled epoxy. The reinforcement of Al2O3 particles leads to improved mechanical properties of the epoxy composites. The results have been supplemented with scanning electron micrographs to help understand the possible wear mechanisms. © (2014) Trans Tech Publications, Switzerland.Item Friction and dry sliding wear behaviour of Ni filled epoxy nanocomposite(2011) Kurahatti, R.V.; Suredranathan, A.O.; Kori, S.A.; Ramesh Kumar, A.V.; Mordina, B.; Mallapur, D.G.Nanosized metal particle filled polymer composites are finding numerous tribological applications in recent years. In the present work, the matrix properties were investigated by introducing nickel nanoparticles (60-100 nm, filler content of 0?5-10 wt-%) into epoxy resin. The influence of these particles on friction and dry sliding wear behaviour was measured using a pin on disc wear set-up. The experimental results indicated that the coefficient of friction and the specific wear rate of epoxy resin can be reduced with a rather low weight fraction of Ni particles. The lowest specific wear rate of 0?6461024 mm3 N21 m21 (compared to neat resin's value of 2?261024 mm3 N21 m21) was observed for composites with the filler content of 0?5 wt-%. The reinforcement of Ni particles leads to improved mechanical properties of the epoxy composites. The results have been supplemented with scanning electron micrographs to help understand the possible wear mechanisms. © 2011 W. S. Maney & Son Ltd.Item Role of nickel filler on friction and dry sliding wear behavior of bismaleimide nanocomposite(2011) Kurahatti, R.V.; Surendranathan, A.O.; Srivastava, S.; Singh, N.; Ramesh Kumar, A.V.; Kori, S.A.Nano-sized metal particles filled polymer composites are finding numerous tribological applications in recent years. In the present work, the matrix properties were investigated by introducing nickel (Ni) nanoparticles (60-100 nm, weight fractions of 0.5-10 %) into a bismaleimide (BMI) resin. The influence of these particles on the microhardness, friction and dry sliding wear behavior were measured using microhardness tester, pin-ondisc wear set up. The experimental results indicated that the coefficient of friction and the specific wear rate (SWR) of BMI resin can be reduced at rather low weight fraction of Ni particles. The lowest SWR of 9 ×10 -6 mm 3/Nm (i.e. 50% lower than the value of neat BMI) was observed for the nanocomposite with Ni weight fraction of 1%. The incorporation of Ni particles leads to an increased hardness of BMI and the wear performance of the composites shows good correlation with the hardness. The results have been supplemented with scanning electron micrographs to help understand the possible wear mechanisms. © 2011 CAFET-INNOVA TECHNICAL SOCIETY.Item Friction and wear study of graphite and bronze filled epoxy matrix composites(Elsevier Ltd, 2022) Patil, N.; Krishna, P.The composite material is made of different materials. It retains the advantages of the original material and reflects combined characteristics of all the constituents. Polymer matrix composites are popular in the recent industrial applications. Friction and wear governs the tribological aspects of polymer composites. This paper revel the experimental study of friction and wears behavior of epoxy composites filled with bronze and graphite fillers as per ASTM standards. Three compositions were studied and it was found that composition ‘A’ has lowest coefficient of friction (0.281) whereas composition ‘C’ has highest coefficient of friction (0.325). The composition ‘A’ has lowest wear rate of 0.5 μm/s and composition ‘C’ showed highest wear rate of 3.25 μm/s. Use of graphite and bronze along with epoxy exhibited formation of lubricating layer and enhanced friction and wear behavior of the composites. © 2021Item Synergistic effects of iron and hexagonal-Boron Nitride additions in copper-based composites for braking application(SAGE Publications Ltd, 2022) Cadambi, S.; K, K.; Lamture, N.; Kale, S.S.; Prabhu, T.This paper explores the addition of h-BN and iron to Cu-based brake pads on the performance benefits. It also investigates the effect of graded layering by synthesizing three and four-layer brake pads by powder compaction and sintering route. The top one or two layers are made of Cu-based composite containing Fe, h-BN, and W, while the middle layer is pure Cu and, bottom steel plate. Two different compositions were explored for the composites by varying Fe content. From the two composite compositions, brake pads with single-layer composite or two-layer composite were synthesized. Characterization of brake pad specimens was carried out using density measurements, optical microscopy, scanning electron microscopy, energy dispersive spectroscopy. The brake pads were subjected to simulated braking tests at braking energy/cycle of 60, 96, and 136 K Joules. Wear rate, coefficient of friction, stopping distance, stopping time, and hardness were measured and compared among other brake pads. The brake pad containing single-layer Fe rich Cu composite showed the best performance in the simulated braking tests. EDS analysis of wear debris shows the formation of iron (boride, nitride, oxide) complex which is indicative of a surface with superior dry lubricating properties. This surface is a result of synergetic interaction between h-BN and Fe particles. The iron particles which are scattered in the Cu matrix composite act as low friction regions on the brake pad surface that interrupt the high friction regions on the Cu matrix, thus reducing the local and bulk temperature rise. The two-layer composite brake-pad showed performance intermediate to the two single-layer brake pads. No advantage due to higher thermal conductivities in Fe deficient composite was observed as the two composite layers, showed similar Fe contents in their matrix phases. © IMechE 2021.Item Optimization of Wear Properties of B4C Nanoparticle-Reinforced Al7075 Nanocomposites Using Taguchi Approach(Springer, 2023) Kumar, G.A.; Satheesh, J.; Murthy, K.V.S.; Mallikarjuna, H.M.; Puneeth, N.; Koppad, P.G.In the present work, Al7075 nanocomposites with varying B4C contents were produced using powder metallurgy technique. The developed nanocomposites were subjected to microstructure, grain size and wear behaviour analysis. Dry sliding wear test of nanocomposites was conducted as per ASTM G99 standard using pin on disc test ring using Taguchi L9 approach with varying B4C nanoparticles (2.5, 5 and 10%), load (10, 20 and 30 N), speed (200, 250 and 300 rpm) and sintering temperature (500, 550 and 600 °C). Scanning electron microscopy (SEM) analysis showed uniform dispersion and good bonding between B4C nanoparticles and Al7075 matrix. Grain size analysis conducted according to ASTM E112-96 showed that irrespective of sintering temperature the average grain diameter of nanocomposites decreased as the B4C nanoparticle content increased. According to response table for S/N ratio, the most influential parameter on wear volume was B4C nanoparticles content. Worn surface analysis showed delamination and abrasion as dominant mechanisms for nanocomposites with lower B4C nanoparticle content and abrasion for nanocomposites with higher B4C nanoparticle content. © 2022, The Institution of Engineers (India).Item Effect of thermal expansion on the high temperature wear resistance of Ni-20%Cr detonation spray coating on IN718 substrate(Elsevier B.V., 2023) Purushotham, N.; Parthasarathi, N.L.; Babu, P.S.; Govindarajan, G.; Rajasekaran, B.The temperature-dependent materials properties on the dry sliding wear resistance of the detonation sprayed Ni-20%Cr coating have been studied. In-situ high-temperature X-ray diffraction (HT-XRD) was used to investigate high-temperature properties such as stress relieving, recrystallization, and thermal expansion. The dry sliding wear test was performed by using a ball-on-disc tribometer by sliding velocities (0.1 m/s), varying loads (6 N and 10 N), and temperatures (25 °C and 850 °C) against alumina (Al2O3) ball. The phase evolution, thermal expansion, crystallite size, and lattice strain were determined by the Williamson-Hall method. Field emission scanning electron microscopy and a non-contact optical profilometer was used to characterize the wear scar and calculate the wear rate. The wear test results demonstrated that the as-deposited coatings coefficient of friction (CoF) and wear rate (ω) continuously decreased as the temperature increased. The primary wear mechanism changed from abrasive and surface fatigue to adhesive and oxidative wear. The impact of stress relieving, recrystallization, and forming a composite tribolayer (Cr2O3, NiO) at elevated temperatures reduced the friction and enhanced the wear resistance. The effect of stress relieving, recrystallization, thermal expansion, and oxidation on the wear resistance of the coating has been discussed with a suitable mechanism. © 2023 Elsevier B.V.Item Effects of Addition of Graphite on the Tribological Behaviour of Al7075-SiC Hybrid Composites Using Design of Experiments(Springer Science and Business Media Deutschland GmbH, 2024) Gudipalli, K.R.V.; Chapke, Y.; Hareesha, H.; Doddamani, S.Despite the widespread use of Al7075-SiC composites in various engineering applications, their tribological performance remains a subject of interest due to challenges related to friction and wear. This study addresses the need for improved lubrication in such composites by investigating the potential of Al7075-SiC/Graphite hybrid materials. The incorporation of graphite particles, up to 9% by weight, aims to enhance the self-lubricating properties of these composites. Stir casting is employed to fabricate specimens with varying graphite content (3–9% by weight), followed by comprehensive tribological assessments under dry sliding conditions. Factors including sliding distance, load, and graphite composition are systematically evaluated using Taguchi’s optimization techniques, including design of experiments, ANOVA, and regression analyses. Results reveal that the addition of 9% graphite content notably reduces both the coefficient of friction and wear rate. According to the data, sliding distance significantly impacts wear behaviour, followed by the applied load. In contrast, the composition has a 77% impact on the coefficient of friction than load, while the sliding distance has a relatively small impact. As a result, the Al7075-SiC/Graphite composite material demonstrated its suitability as a self-lubricating substance. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.Item Improving Surface Finish of Laser Additively Manufactured Curvilinear Surfaces Via Electropolishing and Electroless Coating(American Society of Mechanical Engineers (ASME), 2025) Praharaj, A.K.; Kambikath, N.V.; Suvin, P.S.; Bontha, S.Laser-directed energy deposition (LDED) is a very useful additive manufacturing technique for repairing and manufacturing complex-shaped parts compared to traditional manufacturing techniques. However, the inadequate surface quality of the LDED fabricated components limits their direct utilization in different sectors. In addition, improving the surface finish of the curvilinear surfaces (useful for cooling channels and fuel nozzles) is also challenging. Hence, the current study focuses on surface modification of LDED fabricated SS 316L hollow cylindrical samples by combining electropolishing and electroless coating. We have performed electropolishing (two different currents, 8 A and 15 A) on the as-deposited (AD) sample with and without the application of the grinding process. The electropolishing reduced the roughness of the AD sample from 3.2 ?m to 0.85 ?m and 0.74 ?m for 8 A and 15 A, respectively. The reduction in roughness was more at a higher current value due to the rapid anodic dissolution of the surface peaks. A further reduction in roughness was observed when grinding was performed before electropolishing. However, grinding resulted in higher material removal from the deposited surfaces and reduction in roughness was also minimal. Hence, only the electropolishing sample was selected for the next step, in which Ni-P electroless coating was performed on the surface to form a protective layer. After electroless coating, the coefficient of friction and wear-rate were reduced by 9.5% and 25.6% compared to the AD sample. Delamination and severe plastic deformation were the major wear mechanisms for the AD sample, whereas abrasion was dominant for the coated sample. The current work proposes a combined surface modification approach of electropolishing and electroless coating for the LDED processed components with curvilinear surfaces. © © 2024 by ASME.Item Mechanical and chemical post-treatments for enhancement in tribological performance of laser powder directed energy deposited Inconel 625(Elsevier B.V., 2025) Praharaj, A.K.; Byregowda, T.; Bontha, S.; Suvin, P.S.Laser powder-directed energy deposition (LP-DED) technique has shown tremendous potential to fabricate high-performance superalloy parts for real engineering applications. However, certain disadvantages like poor surface quality and incompetent mechanical and wear properties limit its practical usage. Hence, the current work investigates the effect of different post-processing techniques, including laser shock peening (single shot) (LSP1), laser shock peening (three shots) (LSP2), shot peening (high pressure) (SP1), shot peening (low pressure) (SP2), glass bead blasting (GB), sand blasting (SB), and electroless coating (EC) on the surface quality, hardness, and wear resistance of Inconel 625 (IN625) samples fabricated by LP-DED technique. EC sample resulted in the least surface roughness value (0.09 µm), whereas LSP2 sample exhibited the highest increase of 32.4 % in hardness compared to the as-polished (AP) sample. This can be attributed to grain refinement and the plastic deformation in the samples. Further, the wear test confirmed that LSP2 sample resulted in the lowest coefficient of friction (0.6) and wear rate (0.58 × 10-4 mm3/N.m) among the post-processed samples. © 2025 Elsevier B.V.