ABSTRACT Polymer matrix composites (PMCs) are the most used in aerospace fields due to their special mechanical properties coupled with reduced weight. Metallic structures can be manufactured on the surface of PMCs producing hybrid constructions with intriguing characteristics. The cold spray technology (CS) seems to be the best solution for the manufacturing of metallic coatings on polymer-based substrates

ABSTRACT The present article demonstrates the procedure for fabrication of aluminum alloy 2014 based metal matrix composites having particulates of silicon carbide as reinforcement. Using the stir casting route, three different compositions of aluminum alloy metal matrix composites were fabricated. Microstructure of as-cast composites revealed a homogeneous distribution of silicon carbide particles

ABSTRACT The current focus on low-cost and high strength materials for advanced engineering applications attracted the research on the development of metal matrix syntactic foams. It is due to its highly tailorable properties. They are lightweight, higher ductility, quasi-static and dynamic compressive strength, better damping and energy absorption behavior and plateau strength. Different hollow particles

ABSTRACT Roller burnishing process is a post-machining surface finishing technique that has an advantage over other finishing processes, such as shot blasting or abrasive-tooling processes, because of its simplicity and excellent results (both improved surface finish and improving the mechanical properties of the material). Roller burnishing allows you to eliminate the part grinding step. Nickel super

ABSTRACT In this research, the effect of ultrasonic vibrations in the turning process on geometric tolerances has been investigated. This has always been one of the most important challenges in the production of high-quality and precision parts. One of the important applications of the turning process is making parts with high dimensional accuracy. In this study, by applying ultrasonic vibrations to

ABSTRACT The structures adopted in the aeronautic field should have three main characteristics: they must be strong, stiff, and light. These targets can be obtained by choosing high performance and low weight materials, as composite or titanium alloy, but also the wise design of the structure itself is important for enhancing the mechanical performances. The isogrid structures, that are composed of

ABSTRACT Ultraviolet (UVUV) nanosecond laser cutting of polyvinyl chloride (PVC) films was evaluated by experimental design and laser ablation principle. Factors such as laser power, cutting speed, and repetition numbers of laser cutting will influence the quality of cutting seam. Narrower width of cutting seam (55.1 ±4.6 μm) and smaller area of heat-affected zone (HAZ) (25.5 ±2.4 μm) were obtained

ABSTRACT Incremental Tube Forming (ITF) is a comparatively new forming process in which the ends of a tube are expanded into the desired shape using a hemispherical tool. ITF process finds its applications in various sectors like automotive, aerospace, and heavy industries for interconnection of the piping system, structural elements, etc. It is crucial to analyze the tube’s deformation behavior for

ABSTRACT The present article introduces chemical etching for the fabrication of a patterned tool to manufacture micro-sized products. Further, a feasibility study is conducted to produce intricate features using the fabricated patterned tool. High depth with the desired width of geometric feature is required on the patterned tool for this study. Three etching process parameters, concentration, time

ABSTRACT Inconel 718 superalloys are known materials with high applicability to components that demand exceptional chemical and mechanical properties at higher working temperatures combined with excellent surface finish requirements. However, due to the lack of in-depth knowledge regarding its machining process, the material is considered a difficult-to-machine material. Therefore, to improve the machining

ABSTRACT Different manufacturing techniques unveil their importance to gain advancement in the mechanical, physical, and anti-corrosion properties of Mg-based biomaterial (BM). The present work elucidates the comparative study of mechanical and degradation properties of recently developed novel Mg-based BM viz. Mg3Zn1Ca15Nb fabricated using different manufacturing techniques. The different manufacturing

ABSTRACT Barium Zirconate Titanate–Barium Calcium Titanate (BZT–BCT) is an environmentally friendly piezoelectric-ferroelectric ceramic that is a promising alternative to lead zirconate titanate (PZT), whose toxicity is well known. Producing thin films by sol–gel deposition with properties comparable to their bulk counterparts is quite a difficult task, because of the substrate constraints which typically

ABSTRACT Ni204 cladding layers were prepared on the surface of 45# steel alloys via laser cladding under different overlap modes. The effects of overlap modes on microstructure evolution, microhardness, wear resistance, compressive and tensile strength were investigated. The intensity of the diffraction peaks is related to the cladding strategy. The remelting mode introduced by “double vertical cross”

ABSTRACT In this paper, the parameters of microtextured tools were studied in the threading of aluminum 7075-T6 alloy. The primary focus of this work is to optimize the parameters of microtextured tools using the RSM method to produce high-accuracy threaded parts. Microtextures were generated through laser micromachining on the rake surface of carbide inserts. Geometric parameters considered were diameter

ABSTRACT This study examined experimentally and statistically the machinability of AISI 430 stainless steel on a lathe using two type different coated tool inserts, three various cutting speeds (80, 140, 200 m/min) and three various feed rates (0.75, 1.5, 2.25 mm/rev). Experimental studies were carried out using a coolant and cutting depth of 1.5 mm was used constant under all experiment conditions

ABSTRACT High precision and close tolerance is an essential requirement of current manufacturing industries dealing in micro-fabrication. The quality of surface obtained after machining process exhibits the utility of product. The various material and alloys are developed continuously to fulfill the need of application in critical conditions. The versatile characteristics of material also required

ABSTRACT Since the invention of Magneto-rheological abrasive honing (MRAH), it is realized as one of the innovative ultra-precise surface finishing techniques employed for finishing of external intricate surfaces. In this technique, required level of finishing is achieved by assigning simultaneous rotation and reciprocating motion to the workpiece and magneto-rheological fluid, respectively. To recognize

ABSTRACT It is an undisputable fact that surface texture has a profound influence on the functional behavior of products. A method is proposed for manufacturing an anti-icing surface on silicone rubber composite material. Using a multi-function laser engraving machine, cylindrical micro-textures with different size and depth parameters are processed on the umbrella skirt surface of composite insulator

ABSTRACT In recent years, significant attempts have been made to harness the exceptional thermal, electrical and mechanical properties of wonder material “Graphene” by employing it as reinforcement in aluminum matrix composites. Graphene reinforced aluminum matrix composites offer excellent strength, stiffness, hardness, wear and thermal properties. The developed composites find wide applications in

ABSTRACT Conventional Austempered Ductile Irons (ADI) are lacking in adequate wear resistance. Introduction of hard alloy carbide phase in the microstructure by strong carbide formers imparts wear resistance. Deep cryogenic treatment subsequent to austempering is another way to improve the wear resistance without a major reduction in toughness. The present study encompasses the microstructural evolution

ABSTRACT Fabrication of a copper Metal Matrix Surface Composite (MMSC) via Friction Stir Processing (FSP) is discussed in this research, wherein Titanium Dioxide (TiO2) and Alumina hybrid particles (Al2O3) were dispersed onto copper surface. TiO2 and Al2O3 blended in equal proportion were compacted onto the grooves for friction stir processing at varying volume fractions i.e. 5, 10 and 15 volume percentages

ABSTRACT This document explains the machining of EN31 steel using an Abrasive Water Jet Machine. The work is aimed at investigating the role of Pressure, Abrasive Mass Flow Rate, Traverse Speed, and Standoff Distance on; Machining Time, Surface Roughness, and Hardness, followed by the optimization of these responses. Taguchi approach and Analysis of Variance are practiced to investigate the effecting

ABSTRACT High-aspect-ratio cylindrical tungsten microtools were fabricated through the electrochemical micro-machining (µECM) process. The effects of eight different electrolytes in combination with the different major machining parameters were investigated and reported in this article. KOH(aq) electrolyte was found to be the most suitable electrolyte for the fabrication of tungsten microelectrodes

ABSTRACT Inconel 625 is a nickel-based super alloy especially used in aeronautical industries, due to its high mechanical strength, exceptional weldability and good corrosion resistance properties. However, machinability of Inconel 625 is quite challenging because of high-level heat generation in the cutting zone. In this work, to improve sustainable machining of Inconel 625; cryogenic CO2 and LN2

ABSTRACT Tool–chip interface friction significantly affects the machining characteristics like cutting forces, machining temperature, tool wear, and surface finish. Structuring the tool rake face using micro-textures is a recent method adopted to reduce tool–chip interface friction. The effect of varying the depth of these rake face micro-textures on the machinability of AISI4340 is studied. Textures

ABSTRACT The demand for high temperature-resistant superalloys such as Inconel 718 is increasing rapidly, as they possess superior mechanical, chemical, and physical properties. Hence, these materials are highly adaptable for aerospace, nuclear, and marine applications. Nonetheless, during machining of such alloys, high temperatures develop at the interface region. It accelerates the tool wear and

ABSTRACT Owing to the exceptional mechanical properties of Ti-6Al-4V, it is widely utilized in numerous critical mechanical parts for the uncompromised factor of safety. However, performing machining operations on this alloy in close tolerance is a challenging task. Moreover, establishing a process for its efficient finishing has become the interest of researchers. In this research study, the magnetic

ABSTRACT Due to the continuous demand for miniature products, demand for microtool increases. Various conventional and non-conventional methods have been employed for the fabrication of microtool. In this paper, electrochemical micromachining (EMM) is used for the fabrication of microtool as it offers good accuracy, no heat generation, contactless process, no tool wear and good surface finish. The

ABSTRACT To explore machining parameters for tool wear rate, surface roughness, and material removal rate, Zircaloy-2 was machined with EDM using Cu, CuW and graphite tool. Taguchi L18 Design was used to perform experiments with five independent process parameters (tool material, on-time, off-time, polarity, and current). Response parameters were evaluated and optimized using gray relation analysis

ABSTRACT This paper aims to examine the influence of nanoclay as secondary reinforcement in carbon epoxy (CFRP) composite on the abrasive water jet machining (AWJM) response for the process parameters, namely, jet pressure (96 and 304 MPa), traverse rate (50, 100, and 150 mm/min), and nanoclay (0.00, 1.25, and 2.50 wt%). The most dominating parameters for AWJM response such as average surface roughness

ABSTRACT Ever-growing needs in pipeline welding relating to quality, frequent usage of advanced, heat-sensitive, and corrosion-resistant materials alongside high production costs encourage the evaluation of a welding process thoroughly. The only way to overcome those problems is the adaptation of technically evolved welding methods that combine the goodness of cutting-edge power supply sources and

ABSTRACT Machinability of cryogenic carbon-dioxide (CO2) coolant was compared with conventional wet coolant during end milling SKT4 die steel with TiAlN-coated cutting tools in this study. The cutting temperature values were reduced by about 3% to 51% by using CO2 compared to wet cooling. During end milling, CO2 cooling decreased by around 54% feed, 45% normal, and 32% thrust forces compared to wet

ABSTRACT Emerging trends toward miniaturization and growing demands have led to fabricate the nanofeatures size product for electronics, robotics, aeronautics, biomedical, automobile, and Bio-MEMS sectors. This article investigates an approach to downsize the resolution limits of EDM to nanometric scale, bridging the gap between micro and nanoscale machining considering the thermal impact of electrical

ABSTRACT A customized Al-Cu-Mg-Si alloy is successfully processed by selective laser melting. AlSi10Mg powder, used as a master alloy, has been mixed with pure Cu powder through a fluidized bed and the obtained powder mix was used as feedstock material for the printing process. To investigate the feasibility of the process and to discuss the effect of the process parameters, a two-step experimental

ABSTRACT Shape memory alloy (SMA), also called memory metal, is a smart material that exhibits unique shape memory effect and superelasticity properties. NiTi alloys attract researchers because of their myriad applications in areas such as aerospace, medicine, and robotics. In the present NiTi SMA fabrication, the Cu and Zr elements were added to increase the martensitic transformation temperatures

ABSTRACT This study presents an investigation on the effectiveness, automation characteristics, and mechanics of joints between different material types namely glass fiber reinforced plastics (GFRPs) and SS304 stainless steel using an industrial Nd: YAG continuous-wave laser welder and a 2-axis custom design jig. The custom design jig includes computer-controlled (CNC) step motors, which provide high

ABSTRACT The chilled cast iron tappet comprises three gradient microstructures, including chill, mottle, and gray iron. In this work, the effect of Tellurium (Te) on the chilled iron tappet’s microstructure and properties is studied. The addition of Te to gray cast alloy enhances its mechanical and thermal properties, which can be used in new designing of materials for heavy automotive applications

ABSTRACT In this work, a uniquely designed imidazolium-based dicationic ionic liquid (IL) was synthesized as a greener template and applied for the synthesis of ZSM-5 zeolite as a heterogeneous catalyst for the dehydration of fructose to 5-hydroxymethylfurfural (HMF). Characterization results confirmed that due to the presence of dicationic IL as template, effective interactions and structural alterations

ABSTRACT Machining superalloys through conventional methods is extremely difficult due to their inherent mechanical properties such as improved toughness, lower thermal conductivity, and strength-to-weight ratio. The paper deals with machining studies on Inconel 718, a nickel-based superalloy, through the plasma arc cutting (PAC) process. Response surface methodology -based Box–Behnken Design) approach

ABSTRACT Metal FDM process is a valid alternative to costly, energy consuming and less accessible metal Additive Manufacturing technologies. Metal parts were fabricated by means of a low-cost FDM machine with a filament composed of 316 L stainless steel particles and polymeric binder mixture, followed by debinding and sintering treatments. The objective of the study is to investigate the possible influence

ABSTRACT Most of the studies on cutting mechanisms and surface integrity in turning are investigated with a straight tool path (longitudinal/end face turning) while few contributions have been done in curved surface turning. This work explores the evolutions of cutting force, chip morphology and surface integrity when turning a curved surface, using fillet surface machining of AISI 304 stainless steel

ABSTRACT Micromachining of alumina has gained a lot of interest due to unique combinations of electrical resistivity and good thermal conductivity, thus being a potential substrate for microsystems packaging in high-power electronics. Creating multiple through-holes simultaneously in alumina is difficult due to its hard and brittle nature. In this article, the formation of multiple through-holes in

ABSTRACT Abrasive water jet (AWJ), which is a non-traditional machining method, is more widely used today. Various materials such as metals, ceramics, polymers, and composites can be easily machined with AWJ. In this study, cutting of St37 steel plates in stacked form with AWJ was investigated. The experiments were carried out according to the general full factorial design. Experimental parameters

ABSTRACT CFRP plates are important advanced material used in the aerospace field, high-quality and high-efficiency drilling is the main application processing demand of CFRP. In this paper, a 532 nm nanosecond fiber laser with adjustable pulse duration is used and the scanning path was planned as Z-direction up-bottom incremental cutting, and X-Y direction concentric circle cutting scanning mode to

ABSTRACT Surface quality is an important output measure in all the machining processes. In this research, cotton and viscose fabrics were used as a reinforcement, graphene was used as a filler (1.5, 3, 4.5 weight percentage (wt. %)) for the development of hybrid composite using compression molding process with hand layup techniques. The machinability of the prepared hybrid composite was studied using

ABSTRACT Inconel 690TT has an excellent high-temperature corrosion resistance and has been widely applied in steam generators of pressurized water reactor (PWR) nuclear power plants. In this paper, Inconel 690TT was investigated in the rolling reduction (RR) of the ultrasonic surface rolling process of 0, 0.2, 0.4 and 0.6 mm, respectively. It was found that the specimens with RR of 0 mm were basically

ABSTRACT In this work, two typical surface characteristics, i.e., mean surface roughness and angle of the kerf during laser processing of 3D-printed Polylactic Acid (PLA) plates with 4.00 mm in thickness, are investigated. A carbon dioxide laser was utilized to separate 27 work pieces of rectangular shape. The governing laser parameters, speed of cutting and laser power, were varied according to full

ABSTRACT In advanced machining processes on hard metals, fabrication of textured insert is still a challenge. To improve the machinability of a textured cutting insert the most effective factors are the area covered, design pattern, and orientation of micro-texture. For the coated cutting inserts, the fabrication of micro-grooves must not remove the coating from the surface. Due to the generation of

ABSTRACT An investigation on joining of carbon fiber-reinforced thermoplastics to an aluminum alloy 6061 has been demonstrated using ultrasonic plastic welding process. A separate energy director, as required for focusing heat generation at interface during ultrasonic plastic welding, is replaced by high-performance thermoplastic coating on aluminum via a fluidized bed to make the process convenient

ABSTRACT This analysis presents the outcome of Cutting Environment (CE) through wet and Minimum Quality Lubrication (MQL) over the formation of friction during the slot milling process of Nimonic 263 alloy. Because the establishment of Frictional Stress (FS) over the rake face entirely depends on the method of cutting environments (dry, wet and MQL) and the dispense of the smallest mineral components

ABSTRACT This article reviews environmentally friendly and/or cost-effective processes. Topics covered are minimum-quantity-lubrication (MQL), cryogenic-cooling and near-dry-machining; polishing slurries; recycled metals; processing wood materials; microfluidic paper devices; life-cycle-assessment; electrical-discharge-machining; friction-stir-processing; and green and/or cost-effective processes.

ABSTRACT In barrel finishing, the grinding fluid as a liquid processing medium has an important effect on aluminum alloy parts finishing. Therefore, the wettability of grinding fluid by contact angle and quantum chemical calculation was analyzed. Based on different grinding fluid, the experiments on barrel finishing were achieved. And, the effect of barrel finishing on plastic deformation and residual

ABSTRACT A crack-free Inconel 718 – Stainless steel 316 L bimetallic structure has been fabricated using the laser powder bed fusion (LPBF) process. Firstly, an optimum process parameter set resulting in defect-free bonding of both materials has been predicted by carrying out a parametric study. Thereafter, microstructural and mechanical characterization such as optical microscopy, X-ray diffraction

ABSTRACT Robotic Automated Fiber Placement (R-AFP) technology was developed to manufacture composite laminates by placing carbon fiber thermoset towpregs, obtained by impregnating 12 K high-strength grade carbon fibers in an epoxy resin system. In order to avoid placement induced defects, a thermographic scanning technique was implemented for on-line quality monitoring of the R-AFP process. The thermal

ABSTRACT The powder mixed electrical discharge machining, also called PMEDM, is gaining much attention, because it is demonstrated as a good solution for enhancing productivity and surface integrity. In this research, the influence of main process parameters, including peak current, pulse on time, and powder concentration in the PMEDM with tungsten carbide powder on the machinability of SKD61 steel

ABSTRACT The heat curing process using an electric oven has been generally applied for curing geopolymer material as it accelerates strength development. However, a microwave curing process is an alternative approach to obtain a shorter heat curing process. This paper focuses on the strength development and required curing duration of a cellular lightweight geopolymer mortar using a microwave-assisted

ABSTRACT Fabrication of the 316 L steel with moderate surface roughness (SR) and thin recast layer (RLT) is very difficult using both the conventional and non-traditional machining processes. Due to the stochastic behavior of electro-discharge machining (EDM) process, the machining performances significantly rely on the system variables. This research work aims to investigate the influences of EDM

ABSTRACT In this paper, we propose the tilted milling method for the fabrication of the precise microlens array (MLA) by eliminating the influence of tool error. In the conventional milling process, the surface morphology problem especially hump formation is often provoked by tool error on the center area of the machined surface. The hump formation initiated by tool error is very difficult to remove

ABSTRACT 7Cr13Mo steel is widely used in many industries given its good properties. However, it has poor wear resistance and difficult-to-cut characteristics. In this study, ultrasonic-assisted and powder-mixed electrical discharge machining (US-PMEDM) was applied to investigate the machining characteristics of 7Cr13Mo steel. The parameters including peak current and pulse duration were varied to explore

ABSTRACT The laser-powder bed fusion (L-PBF), also known as selective laser melting (SLM), is widely processed to a narrow powder size of 15 (D10) to 45 (D90) µm. However, expanding the particle size distribution (PSD) that can be processed by L-PBF can have important technical and economic benefits. Using 420 stainless steel as a case study, the current investigation successfully shows that finer