Search Results

Additive manufacturing of aluminium alloy has paved way for the recent advancement in the automobile and aerospace industry due to its light weightlessness and good physical and mechanical features.Even though the additive process has an upper hand in terms of complexity and monotonous nature of the process its sustainability of it over traditional manufacturing is still a question when the whole cycle of the process is considered.This study mainly focuses on the quantitative life cycle analysis conducted on AlSi10Mg with cast AlSi10Mg as a baseline. Life cycle assessment measures environmental impacts, to determine where most impacts arise: machine and supporting hardware; aluminium powder material used, or electricity used to print

The utilization of Additive Manufacturing (AM) technology in the current manufacturing sector is growing day - by - day. This is made possible by the constant development of new materials and techniques to overcome the difficulties that are encountered while fabricating a part. In AM, parts are fabricated by laying successive layers on one another till the complete part is build. This gives AM an edge over conventional manufacturing. Even intricate or hollow parts can be fabricated with the same ease as fabricating a solid part. The key objective of this project is to evaluate and compare mechanical properties of Polyethylene Terephthalate - Glycol modified (PETG) and Carbon fiber reinforced Polyethylene Terephthalate - Glycol modified (CF - PETG), which are fabricated using Fused Deposition Modelling (FDM) process of AM. The ASTM standards D638 and D790 were followed for fabricating tensile test and Flexural test specimens respectively.

The developed model analysis is built in matrix runs to optimise the friction stir welding parameters of rotational speed, welding speed, shoulder diameter and tilt angle in this research. The aim of any design is to maximise the welded properties, either to surpass the base metal properties. The model that is created is the product of a number of regression methods that have been tested for adequacy. In this model we have taken three levels of varying parameters shoulder diameters, rotational speed, welding speed. Mathematical model is developed for the effect of three process parameter at three levels using response surface methodology (RSM).

This work inspects the metallurgical and tensile demeanor of pulsed current gas tungsten arc welded ERNiCrCoMo-1 filler wire on alloy 80A weldment. Defect free weldment was achieved in a four pass through PCGTA welding. The center of the weld microstructure is decorated with equiaxed dendritic structure and columnar dendritic structure. SEM analysis showed the existence of Mo, Fe and Ti secondary phase precipitation in the grain boundary region of the weld zone. Tensile testing was conducted to analysis the strength and ductility of weldment. The result showed that the tensile strength and ductility were lower than that of base metal (BM).

Fiber-reinforced polymer composites propose exceptional directional mechanical properties, and combining their advantages with the potential of 3D printing has resulted in many novel research fronts. Industries have started using 3D printed components which are rapidly replacing conventional material components in most of the industries. Carbon fiber reinforced Polylactic Acid (PLA) often finds its application in reasonably high loading conditions working at lesser speed like lightweight gears, spanners, nuts, and bolts. Wear reduction is an important factor that plays an important role in prolonging the component's life. Hence, it is crucial to optimize 3D printing parameters to get desired strength according to the application. The aim of this paper is to conduct the wear rate test on the Fused Deposition Modelled (FDM) printed carbon fiber reinforced PLA parts, to identify the optimum printing parameters which are crucial for wear reduction.

The fabrication or repairing of aircraft components made of Hastelloy X to be resolved using an arc welding technique. In this study, Hastelloy X was joint with ERNiCrCoMo-1 filler by pulsed current gas tungsten arc (PCGTA) welding. The high temperature tensile property of the weldment has been evaluated at three different temperatures such as 700 °C, 800 °C and 900 °C. The tensile properties such as yield strength (294, 259 and 205 MPa), ultimate tensile strength (475, 396 and 245 MPa) and percentage of elongation or ductility (17, 14 and 11 %) follows the similar trend with temperature at 700 °C, 800 °C and 900 °C respectively. It revealed the values of all the properties are decreased as the temperature increased. The lowest strength was evaluated for weldment at 900 °C. The high temperature tensile test also revealed that the fracture of weldments for all three conditions is found at the weld centre (WC).

The objective of the study is to investigate the effect of current pulsation frequency on the weld bead microstructure, segregation and hardness of Hastelloy C-2000 weldments. Bead on Plate (BoP) welds were made by using Pulsed Current Gas Tungsten Arc Welding method (PCGTAW) at eleven different frequencies. The weld bead width and depth of penetration was measured with the help of Dinolite macro analyzer. The microstructure of weldments are further examined through optical microscope and Scanning Electron Microscopy (SEM) to identify the type of grain, grain coarsening and extent of the Heat Affected Zone (HAZ). The grain structure turn into finer and equiaxed in all cases and there was an optimum frequency range over which the significant grain refinement was observed. Microsegregation of alloying elements were computed with the aid of Energy Dispersive X-ray Spectroscopy (EDS). Vickers Hardness Tester was used to measure the hardness of the weld samples at ambient conditions.

This research is an attempt to investigate the possibility of enhancing wear and corrosion behaviour of aluminium alloy and composites for high-temperature applications. The 319 alloys with minor additions of Ni, Ti and Fe elements using the liquid metallurgy technique, Al-Si-Cu-Mg matrix alloy (Al alloy) was obtained and it was used as a base alloy and it is reinforced with Silicon carbide (SiC), Magnesium oxide (MgO) under the following composites, namely Al alloy/3wt % MgO (AA-SRM), Al alloy/ 3wt % SiC (AA-SRS) and Al alloy/3wt %SiC-3wt % MgO (AAHRSM) using a stir casting route. The wear test was investigated under the following factors, namely constant sliding velocity 3.21 m/s, sliding distance up to 10000 m under different loadings (4.9, 9.8, 14.7, 19.62, and 24.5 N) using wear test by a pin on the disc test rig. The wear rate was calculated using the tested samples under different loadings, sliding distance, and weight concentration conditions.

This study examines the influence of cryogenic treatment on the microstructure and on the physical properties of the rapid prototype SLS material. The wear properties of the rapid prototype SLS material both before and after cryogenic treatment are studied in three phases. Phase I deals with the sample preparation through the SLS technique; Phase II involves the preliminary tests like roughness test, hardness test, SEM and wear test. Phase III is the cryogenic treatment of the sample in the setup designed. The cryogenic coolant used is Nitrogen, having a boiling point of 77 K, and the whole treatment process takes about 2 to 3 days. Phase IV deals with the testing of the cryogenically treated samples in which similar tests to that in Phase I are carried out. These results are tabulated and graphs are plotted. Furthermore, the percentage change in the hardness and wear properties of the samples are found.

The current research work scrutinized the influence of plasma arc in the metallurgical and mechanical behavior of Nimonic 80A weldment. Defect free weld bead of 6 mm thickness was achieved in a single pass through plasma arc welding. The microstructure of weldment is decorated with cellular dendritic structure at the center and at the weld interface region columnar dendritic structure was observed. Metallurgical analysis showed the Cr and Ti secondary precipitates in the interdendritic region of the WZ. The existence of M23C6 and Cr2Ti were observed through the X-ray diffraction analysis. Both tensile test and microhardness test were conducted to study the mechanical properties of weldment. The result concluded that both the strength and ductility inferior than base metal and the hardness of the weld bead is similar to that of BMl.

The current work investigates the hot corrosion demeanour of Hastelloy X weldment produced with autogenous mode through key-hole plasma arc welding (K-PAW). The hot corrosion test has been performed for weldment in molten salt-1 (MS-1) (75 % Na2SO4 + 25 % V2O5) and molten salt-2 (MS-2) (75 % Na2SO4 + 20 % V2O5 + 5 % NaCl) circumstance for 25 hrs (25 cycles) at 900 °C. The MS-1 substrate of both base metal and weldment provided the lowest weight gain than the MS-2 substrate. The NaCl in the MS-2 causes severe hot corrosion on the substrate, whereas the absence of NaCl in MS-1 reduces the hot corrosion effects. The highest parabolic constant is observed for K-PAW weldment in MS-2 condition. The tendency of hot corrosion rate follows the order of, Base Metal MS-1 < K-PAW MS-1 < Base Metal MS-2 < K-PAW MS-2. The occurrence of protective phases like chromium oxides (Cr2O3), spinel oxides (NiCr2O4 and NiFe2O4) Nickel oxide (NiO) on the substrate resist the further oxidation.

Duplex stainless steel (DSS) 2205 grade is welded with austenitic filler wires (ERNiCrMo-3 and ERNiCrMo-4) using gas tungsten arc welding (GTAW) process to operate at marine environments. Microstructure using optical (OM) and scanning electron microscopes (SEM) with energy dispersive spectroscope (EDS) are utilized to examine the metallurgical characterization of DSS 2205 weldments. Microhardness, impact, and tensile tests are employed to obtain the mechanical properties of weldments. Secondary precipitates such as Mo23C6 and Cr23C6 are formed in the ERNiCrMo-3 weldment which reduced the mechanical properties. In this study, ERNiCrMo-4 filler wire is provided enhanced mechanical properties for welding DSS 2205.

Collection of various data from sensed data or raw availability of data from transcript or interdependency of data from various sources is a tedious task in a real time scenario like an Indian context is considered. Planning to find a solution to collect the data from various vehicular devices about the information related to the pollution becomes a cumbersome job. The need of the data, under what time duration data has to be transmitted, how they are interconnected and whether data needs to be stored or how they are processed is a major question that arise when dealing with collecting data and internetworking with various vehicular devices. A study of two different types of approaches for internetworking between the devices is discussed. One related to real time setup of mobile application and other with the dynamic cluster approach when the nodes are moving in a region was considered.

Today manufacturing industries have become more competitive and to survive, industries should be capable of accommodating the sudden market change. The conventional manufacturing systems like Dedicated Manufacturing Lines (DMLs) can produce high volume of product but difficult to cater to varying product types. On the other hand, Flexible Manufacturing System (FMS) is capable of handling product variety but not suited for mass production, The Reconfigurable Manufacturing System (RMS) gives the advantage of both the system, as it has the capability to adjust to both high volume requirement and product variety, and it able to upgrade to new process technology with minimal effort. In this work the reconfiguration is carried out in machine and system level. At machine level, a new inspection machine is proposed which can be used for multiple products with minimal adjustments and a special drilling and bore tool is suggested to reduce the cycle time and ramp up time when product changes.

Considerable weight of an automobile is constituted by the engine and there is scope for improvement in fuel efficiency and emission control through optimization of weight in the engine. In this work, AlSi10Mg alloy produced by the direct metal laser sintering (DMLS) is suggested for engine application which is a lightweight aluminum alloy. Mechanical properties like tensile strength, compressive strength, and hardness of both cast and DMLS manufactured alloy are compared followed by analysis of SEM images of tensile test fractured surfaces. Reciprocating wear test is carried out for one lakh cycles at 125°C temperature with SAE 40 grade oil as lubricant. Co-efficient of friction (COF), wear rate of the cast and DMLS manufactured samples are compared. Wear patterns are analyzed using SEM images of the wear tracks.

Experimental investigations were carried out on the machinable wax filament using the fused deposition modelling (FDM) rapid prototyping process. The printer used for conducting the experiments was Flash Forge guider 2. The filament material used for this study was machinable wax filament of 1.75 mm diameter. Experimental trials were carried out as per Taguchi L9 orthogonal array to determine the optimum process parameter combination. The dimensional analysis of test samples were carried out in terms of change in volume of samples which is result of combine effect of deviations in all the dimensions of test sample. Four factors each at three levels was used to obtain the optimum printing parameters for better dimensional accuracy and proper printing. The four important printing parameters were taken as factor and set to analyse the significant factor affecting on printing. The complexity in printing of wax filament is taken in to consideration during the experimental study.

The transportation of hot metal from blast furnaces to melting shops is carried out by molten steel transfer vehicle such as Torpedo ladle car in the steel plants. In need to design Torpedo ladle car within size limitation, capacity requirement and withstanding the impact, static, thermal shock and abrasion conditions, structural analysis is essential for validation. In this paper, stress and model analysis for upper and lower bolsters of Torpedo Ladle Car is carried out. The components are modelled in CAD and analysed using finite element method using software with the required boundary conditions. The results of structural analysis of bolster components are presented and discussed. The results shows that the deflection at the centre of upper and lower bolster was due to bending and applied load. The modal analysis predicted the natural frequencies by using block lanczos method.

Digital data extraction is the most important and advance informative system that are embedded in the modern world functioning machinery to acquire the most precise feedback about the real-time operational situation of the machine to the control centre of operation. This data that is acquired from the machinery can be used to increase the efficiency, operational timing, production-cost and the overall human effort that is required for the operation. This paper focuses on the development on the advanced telemetry system that is capable to acquire real-time data of the modern vehicle wirelessly during its motion. A mobile automotive telemetry system for installation on-board a vehicle, includes: diagnostic structure for monitoring operational functions of the vehicle and generating operational information; memory for storing the generated operational information; and a server, in communication with the diagnostic structure and the memory.

The aim of this paper is to demonstrate the methodology to simulate the induced stresses/strains due to thermo-mechanical loading of automobile brake drum.. The brake drum undergoes mechanical load due to applied brake pressure and thermal load due to friction generated between brake pad and brake drum while brake is applied. This coupled thermo-mechanical loading affects the life of the brake drum as the stiffness of the brake drum is reduced. The conventional method of simulating this problem is done using Lagrangian discretization in which the load is applied and inertia effect due to angular velocity is applied to a drum at static condition. In contrast, in this paper Eulerian discretization is adopted for finite element analysis, in which drum brake model is discretized as spatially dependent that facilitates actual rotation of brake drum with simultaneous application of brake load resulting more precise simulation.

In the current work the metallurgical and tensile properties of the weld joints of alloy C-2000 were investigated. Welding technique employed in this study is Tungsten Inert Gas Welding (TIG) and Pulsed Current Tungsten Inert Gas (PC-TIG) welding with autogenous mode and Ni-Cr-Mo rich ERNiCrMo-10 filler wire. The results show that PC-TIG weldment obtained the refined microstructure compared to the TIG weldment. Energy dispersive spectroscopy (EDS) showed the extent of Cr segregation was observed in all the weldments. PC-TIG welding shows reduced segregation compared to the corresponding TIG. X-ray diffraction (XRD) corroborated the existence of Ni3Cr2 phases in the weld fusion zone. Tensile test results show the PC-TIG weldment obtained marginally higher tensile properties comparing over the corresponding TIG weldment. The strength of the weldments is inferior in all cases in comparison to base metal.