ABSTRACT Experimental and thermodynamic studies on thermal plasma processing of zircon-carbon mixtures are reported in this paper. Plasma processing of zircon-carbon mixtures to convert the silicate mineral to zirconium dioxide with concurrent removal of silica was studied. Zircon sand was mixed with carbon powder and processed in a specially designed nontransferred arc plasma reactor operated using

ABSTRACT Hole making is an important phase in composite machining as structural applications of composites require assemblage. To do so, abrasive waterjet machining (AWM) is recommended by several fabricators and researchers. The quality of the holes produced in composites severely affects the durability of assembled structures. Hence, exploring this aspect is important. In this context, the current

ABSTRACT The purpose of the research is to examine the process variables of the Abrasive Waterjet Machining (AWJM) on Titanium Alloy (Ti–6Al–4V). The input variables considered are abrasive mesh size, abrasive flow rate and the number of passes on the depth of cut. Other performance variables considered are material removal rate, taper angle and top kerf width. The experimental investigation is conducted

ABSTRACT The present study investigates susceptibility of Inconel 617 to liquation cracking in laser-based welding techniques such as autogenous laser welding (ALW) and laser-MIG hybrid welding (LHW) with variation in heat input. Advanced characterization techniques such as high-speed Nano-Indentation testing and micro X-ray diffraction techniques were utilized to analyze microstructural variations

ABSTRACT Metal Matrix Composite (MMC) materials are having enhanced characteristics and considered as an alternate material for various engineering applications. Due to reinforcement added, the materials become harder which results in poor machining performance by conventional machining techniques. Wire Electrical Discharge Machining (WEDM) is an effective method for making complex shapes in harder

ABSTRACT Titania (TiO2) powder is the most extensively employed photocatalyst for the purification of water. Nonetheless, the usage of conventional powder catalysts in water treatment has the limitation of settling of the catalyst during the reaction and the additional step of separation of the powders from the liquid. To overcome this limitation and extend the application of TiO2 for practical applications

ABSTRACT Micromachining is the essential technology for production of miniaturized parts and components, which plays a lot of roles in today’s manufacturing technology with space limitations of products and economical aspects. In this investigation, response surface methodology with box-behnken design (BBD) is used to optimize the micro-turning parameters based on the relationships and interactions

ABSTRACT In recent years, increasing demand for biodegradable lubricants has been observed in precision machining owing to ISO 14000, which draws more attention toward the operator’s health and environmental issues. In this context, vegetable oils are adopted as eco-friendly lubricants in sustainable lubrication techniques such as Small Quantity Lubrication (SQL). The grinding performance and surface

ABSTRACT The dissimilar aluminum alloy of the T-lap joints between 7075 and 5083 was Friction Stir Welded (FSW). The attention was focused on the influence of probe length on the formation of a bonding interface between skin and stringer. The bonding interface of the joints was clarified by using skin and stringer tensile tests. Both the morphology and bonding strength of the interface were significantly

ABSTRACT Shaped-Tube Electrolytic Drilling (STED), being an electrochemical-based process, undergoes issues related to machining inaccuracies, e.g., stray cutting and non-uniform dissolution, and they still need attention. Along with other process-related factors, the instantaneous state of the inter-electrode gap (IEG) also affects the process behavior, as it can lead to electrolyte boiling and short-circuiting

ABSTRACT Progress in the manufacturing sector resulted in the need for products with enhanced mechanical properties, corrosion, and heat resistance. Thus, superalloy was produced with desired mechanical properties. Monel Alloy is one of those nickel-based superalloys, commonly used in industry for its high strength and resistance to corrosion. Monel is also acid- and saltwater resistant. Some properties

ABSTRACT The present study deals with a new technique for controlling the weld-induced distortion. This developed technique involves in-situ preheating of welding filler wire before it emerges from the contact tube. Welding filler wire preheating was carried out using an external constant current power source and a specially designed welding torch. Weld beads were deposited on 3.0 mm low carbon steel

ABSTRACT In this study, face milling operation was carried out on an Inconel 625 superalloy. About 27 experiments (L27) were conducted using Design of Experiments (DOE), which comprised three levels of cutting speed (V c ) and feed rate (f z) with a constant cutting depth (ap ). The study included three coolant environmental conditions such as no coolant (dry), normal coolant (wet) and cryogenic CO2

ABSTRACT RMD™ welding has been developed for a variety of steels to regulate the rate of metal transfer effectively during the short-circuiting mode of the GMAW process. To achieve the desired weld quality, distinct process variables must be tuned precisely, which leads to an encouraging field of research known as parametric optimization. In this context, the gas flow rate (GFR), current (A), and voltage

ABSTRACT Fine finishing of the inner surfaces of the cylindrical blind holed (CBH) components has a rising demand in the manufacturing industries to reduce their frictional characteristics and improve functional efficiency. So, an attempt has been made in the present work to develop a new magnetorheological finishing (MRF) process with a grinding wheel type single magnetic tool for fine finishing the

ABSTRACT The microchannels are one of the most prominent components used in Lab on a chip device for mixing applications. For effective mixing, microchannels with obstacles are commonly used. Design and fabrication of a microchannel with obstacles (micro features) is a crucial one. By considering this motivation, a study on optimization of control parameters for fabrication of different microfeatures

ABSTRACT Stainless steel is a widely used material in various industries such as aerospace, chemical processing and transportation. Tungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW) process is extensively used for joining thin sections of stainless steel. However, it is not useful in joining thick sections in a single pass. Activated TIG (A-TIG) significantly increases weld penetration up

ABSTRACT NiTi thin sheets were ultrasonic spot welded with a Cu interlayer, where different welding vibration amplitudes were applied to study the influence on the surface and interface microstructural characteristics, phase transformation behavior and mechanical response of the joints, which aimed to enhance the joint performance by proper optimization of the process parameters. An excellent bonding

ABSTRACT Drilling of high-strength carbon/epoxy composites has been a critical procedure in the industry due to the need to create holes for mechanical assemblies. However, the inherent anisotropy and heterogeneity of the fibrous composites complicate the material removal process and induce tremendous challenges for the manufacturing sectors. The present paper addresses the machining issues of T700

ABSTRACT In the Electrochemical discharge machining (ECDM) process, the geometry and quality of the desired feature mainly depend on the thickness and structure of the gas film over the tool electrode, respectively. In order to machine various arbitrary-shaped profiles, control over the gas film shape is necessary for the ECDM process. The present research work deals with controlling the gas film shape

ABSTRACT The study of densification on the porous surface of cross-section bilayer Iron powder compact was covered in this work. Both manipulated layers consisted of similar mechanical properties of powder with a mass of 10 grams applied and compacted under three different force magnitudes in a lubricated die condition. Three samples of bilayer were prepared according to the different load applied

ABSTRACT Weaving amplitude and welding energy were varied in order to investigate the effects of the weaving technique in metallurgical aspects and mechanical properties of welds produced via SAW process. This investigation and subsequent discussion were based on metallographies and Vickers microhardness tests, both performed on the cross section of the weld beads. The application of the weaving technique

ABSTRACT Parameters appearing in deterministic optimization (DO) models are kept constant during optimization, though uncertainty in these parameters is an inherent and unavoidable. Investigations about the effect of these uncertain parameters (UP) on the final outcomes are, therefore, necessary. Chance-Constrained Programming (CCP) can handle such situations by introducing the probability of constraint

ABSTRACT Discharge channel motion characteristics are one of the focuses of electrical discharge machining (EDM) mechanism research. Based on single pulse discharge experiments, discharge channel motion laws of wire-cut EDM (WEDM) under different electrical parameters were researched. Results show that discharge channel motion speeds are highest at the beginning of the discharge, then drop sharply

ABSTRACT Micro endmilling is emerged as a potential micromachining technique in many industries like biomedical, aerospace, optics, electronics and marine, etc. due to the huge demand for micro components with precision. However, relatively higher tool wear and poor surface characteristics are limiting its applicability in many areas. Therefore, the need has been raised to improve the machining characteristics

ABSTRACT Cryogenic treatment is a thermal treatment process in which the parts are usually cooled to temperatures below −70 C (< 203 K) to induce metallurgical changes in materials. The treatment has shown a significant performance improvement in most of the ferrous materials and it’s alloy, by transforming retained austenite to martensite and precipitating secondary carbides. However, the effect of

ABSTRACT In this work, a hybrid pattern material is introduced for investment casting process to enhance the properties/characteristics of the pattern. The hybrid pattern material is prepared by mixing coconut oil into conventional wax pattern material’s ingredients and named as coconut oil-based hybrid (COBH) pattern material. A comprehensive experimentation was performed to examine the influence

ABSTRACT In this study, the microwave hybrid heating process has been exploited to produce optimized joints of SS304/SS316. Three input parameters: materials of the specimens to be joined (X), grain-size of filler powder (Y), and processing time (Z) have been investigated to see their effects on two major joint properties: micro-hardness (P) and micro-tensile strength (Q). Welded joints of specimens

ABSTRACT The shaping of the electrically insulating ceramic component in post sintered state has always been a difficulty in developing ceramic applications. Wire electrical discharge machining is an ascertained option to produce near net shape products in conductive materials. When it comes to insulating ceramics, sustaining the threshold electrical conductivity comes into the picture. This paper

ABSTRACT Machining of novel light weight 7075 aluminum alloy reinforced with thin-walled hollow ceramic bubbles present a significant challenge to the manufacturing industry. The presence of hollow bubble phase causes poor surface finish and high machining cost. In this paper, an effort has been made to elucidate the mechanics of machining new grade AA7075 syntactic foams through an analytical force

ABSTRACT Nowadays, finite element analysis is the best suitable approach to reduce the need for several experiments. This paper is based on the FE modeling and model validation via the experimental value of turning operation in 2D on heat-treated Titanium alloy (Ti-10-2-3 is also named as Ti-10 V-2Fe-3Al). Turning operation is treated as an orthogonal cutting process and this operation is simulated

ABSTRACT The use of nickel aluminum bronze (NAB) is found in components that include landing gear bearings, cast valve bodies, and perforated orifice for pharmaceutical industries. Machining of the NAB alloy in the micro-domain is a great challenge because of its unique mechanical and chemical properties. This work investigates the suitability of electrode materials for anodic dissolution of the NAB

(2020). Correction. Materials and Manufacturing Processes: Vol. 35, No. 16, pp. i-i.

ABSTRACT Die-Sink Electric Discharge Machining (DS-EDM) is a preferred advanced method, used to produce the complex geometry, cavities, die, and mold facing difficult in cutting the materials. In the current research work, machining of AISI420 stainless steel with copper electrode has been performed. Gap voltage (V), Pulse current (A), and Pulse on time (T) are considered as machine control variables

ABSTRACT A novel double-wire gas tungsten arc additive manufacturing (DE-GTA-AM) approach in which a former wire is fed into the arc and a latter wire is melted by the molten pool is developed to regulate the microstructure features and tensile performances of austenitic stainless steel. Attempting to achieve this aim, thin walls were fabricated via regulating the latter wire feed speed (LWFS). The

ABSTRACT Continuous carbon-fiber-reinforced acrylonitrile butadiene styrene (ABS) has been manufactured by a method based on fused deposition modeling (FDM). Before 3D printing, the carbon fibers pass through an ABS-acetone bath to prepare solution impregnated fibers (prepregs). Continuous fiber-reinforced thermoplastic composites (CFRTCs) were printed by feeding carbon fiber prepregs and ABS filament

ABSTRACT Electrochemical micromachining (EMM) process is a contactless versatile electroforming process, used to fabricate highly precise micro-features and complex contours with the desired surface finish. In this research work, a fabricated-tapered hollow tool (THT) close to Ø0.3 mm is fabricated adopting reverse potential drop off approach and compared against the standard cylindrical hollow tool

ABSTRACT Glass comprising of SiO2-B2O3-Na2O-CaO-K2O is melted at 1523 K in the microwave (MW) and conventional heating. Evaporation loss was studied with varying melting time (30 min to 3 h). Assessment of B2O3, a more volatile component in the studied composition, is carried out by adopting wet chemical method like volumetric titrimetry. The rate of evaporation loss (of B2O3) is found ~ 20% less in

ABSTRACT Inclusion of multi-walled carbon nanotubes (MWCNTs) as an inter-layer sandwiched between the mating sides of AISI 1008 steel joints in resistance spot-welding and its impact on microstructure/mechanical behavior of the subsequent lap joint is discussed here. A thin layer of MWCNTs approximately 50 μm is incorporated as a coating at one of the mating surfaces of the lap joint. It was found

ABSTRACT Efficacy and outcome of all magnetorheological finishing (MRF) processes depend on rheological properties of the magnetorheological (MR) fluid which consists of carbonyl iron particles (CIPs), abrasives and carrier fluid. Thus it is important to understand particle distribution in MR fluid which affects the rheological properties of the fluid under the influence of the applied magnetic field

ABSTRACT It is known that there are some grinding issues for difficult-to-machine materials, such as adhesion of the grinding wheel, grinding burns, and poor surface quality. In this work, a novel abrasive tool which was based on the principle of liquid body armor was developed with flexible composite to improve the grinding performance. During grinding, particles in the abrasive tool will produce

ABSTRACT A Mo-doping LiFe1-xMoxPO4/C cathode material was synthesized via carbothermal reduction route, and the effect of the content of Mo on the structure and electrochemical performance of LiFePO4/C was studied. XRD results revealed doping of Mo did not change the olivine structure of LiFePO4/C, but also formed the Li+ vacancies, which contribute to increase the diffusion rate of Li+. The experimental

ABSTRACT In this paper, a two-directional automated machine with a controller for flat gas metal arc welding is developed for welding along any complex shape. Consistent and uniform weld bead deposition can be done with this setup. Bond graph was used to model the mechanical system along with electrical/electronic control unit. The system responses (voltage, current, torque) can be obtained from this

ABSTRACT Surface roughness, microhardness, and wettability are the surface characteristics which significantly influence the implant performance. Laser surface modification with raster scan is a well-known technique for processing the material surfaces. This technique has potential to modify multiple surface characteristics together. However, multiple process parameters are involved and each parameter

ABSTRACT This article discussed the impact of various nanofluids on the machinability aspects during hard turning of AISI 4340 alloy steel. The experiment was performed using minimum quantity lubrication (MQL) technique. The effect of various fluid properties like thermal conductivity, viscosity, surface tension and contact angle were analyzed for all nanofluids. Various samples of nanofluids were

ABSTRACT Machining of high strength and shock-absorbent Metal Fiber Laminate (MFL) becomes inevitable to attain the geometric shape and size, as to validate the functionality in various impact protection environments. A class of titanium metal laminate alternatively interleaved with high strength basalt and shock absorbing flax fibers have been machined with an abrasive water jet method. Machining

ABSTRACT The nickel-base superalloys have significant usage in aviation, aerospace and other modern industries owing to its valuable engineering properties, which include good corrosion, creep resistance, high strength and elevated temperature resistance. However, its machinability faces extreme difficulty due to inherent characteristics. In this study, one such attempt has been made to enhance the

ABSTRACT Functionally graded material (FGM) are a composite material which consists of filler material and matrix. FGM properties vary along the composition gradient. Common FGMs employs one type of filler material with specific properties. The application of two types of filler materials makes an opportunity to achieve the advantages of two types of filler materials, simultaneously. This study focuses

ABSTRACT In the present research, an attempt was made to determine the suitable coated tool for drilling AA5052 nano hybrid sandwich sheet using Response Surface Methodology (RSM) and Taguchi method. The work aims at minimizing thrust force and torque on a friction drilling tool for drilling holes. Plasma Nitriding, Liquid Nitriding, and PVD Titanium Nitride (TiN) coating are applied on H13 steel tool

ABSTRACT Drawing dies have been playing a momentous role in the cold-forming industry for centuries, and nowadays the drawn products such as wires and tubes are adopted for a wide spectrum of applications. With the increased demand of productivity and quality of drawn products, which give higher requirements on the mechanical and tribological performance of the working surface of drawing dies, a variety

ABSTRACT Al-matrix composites specifically Al6061-7.5%SiC which holds promising mechanical properties, is a potential candidate in aeronautical industry. Though the reinforcement of SiC in Al-substrate has appreciably enhanced the mechanical characteristics, but it complicates its machining as the composite bears excellent hardness and strength. Moreover, its intended applications require the formation

ABSTRACT A noncontact machining process such as electrical discharge machining (EDM) is generally employed for machining electrically conductive materials irrespective of its hardness. However, the process becomes unstable and slow when deep features are to be machined. Furthermore, the standard dielectric-based EDM process is unable to meet the requirements of today’s fast moving manufacturing industry

ABSTRACT Generation of micron-scale structures on a substrate is an emerging area in the manufacturing sector owing to its application in different fields such as micro-lenses, micro-needles, micro-reactors, micro-pumps, etc. Specifically, a patterned polymer is a much-desired product having applications in optics, hydrophobicity, micro-fluidic chip, etc. Such structures can be fabricated through photolithography

ABSTRACT Given the non-biodegradable nature of plastic, its recycling and upcycling are critical to ensure effective waste management and resource conservation, with a cradle-to-cradle approach. Herewith, we report a low-effort and nature-friendly upcycling route for plastic waste to manufacture large quantities of graphene nanosheets (GNs) via a two-stage pyrolysis process. To analyze the utility

ABSTRACT The carbon nanofibers (Cnfs) dispersed SiC-Cnfs composite powder has been produced by spray freeze-granulation technique. SiC-based hybrid composite tubes (BN-Cf/SiC-Cnfs) were fabricated by systematically laying of boron nitride-coated continuous carbon fiber (BN-Cf) in the SiC-Cnfs composite matrix. High-density hybrid composite tubes were processed by cold isostatically pressing (CIP) of

ABSTRACT The alternative dielectrics like vegetable oils, emulsions, and different organic solutions have captured the emerging research attentions, and few pieces of literature also discussed about their potentiality to replace conventional kerosene. However, observations of the existing literatures are limited up to the assessment of the primary responses like material removal rate (MRR), surface

ABSTRACT The deposition of steel powders on glass fiber reinforced polymer (GFRP) with the Cold Spray technique is investigated. Metallization of composite materials is still challenging when high-strength and dense powders, such as steel, are used due to excessive erosion of the polymer or disruption of the fibers during the deposition. To overcome these issues, low-pressure cold spray equipment has

ABSTRACT Electrolytic codeposition is a promising alternative low-cost process for fabricating MCrAlY coatings. In this process, CrAlY particles are codeposited with the (Ni,Co) to form an (Ni,Co)-CrAlY composite coating, which is subsequently heat treated at elevated temperatures to be transformed to the MCrAlY coating containing phases of β-NiAl, γ-(Ni,Co), etc. A permeable rotating barrel was utilized

ABSTRACT In this work, various reciprocating cycle times of 80, 160, 240, and 320 sec in the diamond wire sawing (DWS) process were adjusted to improve the slicing ability in solar industry. During the same slicing time, the long reciprocating cycle time had less velocity inverse points in comparison with the short reciprocating cycle time. Consequently, the total friction force of the slicing wires

ABSTRACT This work has described about the generation of complex shaped pattern using reverse electro discharge machining process. Powder metallurgical green compact tool has been used to generate a predefined pattern by depositing its constituent materials. A predefined star shaped pattern has been generated on the aluminum 6061 work surface. The pattern has been created by adjusting the process factors