Transverse Speed Research Articles

Structural and mechanical properties of friction stir welded Al2O3 and SiC reinforced Al 7075 alloys

Al 7075 of 4 mm thickness plates were welded by using ceramic particles of micron size. Different revolution speed, ranging from 1600 to 2000 RPM and transverse speed of 17 to 35 mm/min were applied. The sound weld is achieved at revolution speed of 1600 RPM and transverse speed of 17 mm/min. In this work, ceramic particles of Al2O3 and SiC were used to reduce the effect of the heat towards the base material during friction stir welding owing to their high friction coefficient and reasonable thermal conductivity and to enhance mechanical properties. Vickers microhardness test was performed on the plain, Al2O3, and SiC mixed Al 7075 welded samples. This test showed the welded joint by using Al2O3 and SiC have 10 to 12 % increase in hardness than that of the joint without using particles. Tensile strength of welded joints without ceramics particles showed improved results. Dispersion of ceramics particles was examined by metallurgical microscope. Scanning electron microscope (SEM) images and fracture analysis of the stir welded zone and base materials were observed. The structural-property relationship of plain, Al2O3, and SiC mixed Al 7075 welded samples was discussed systematically and found that improvement in hardness for Al2O3, and SiC mixed Al 7075 welded samples was due to the higher thermal conductivities of added ceramic particles and precipitation strengthening mechanism. While, reduction in tensile strength ascribed to the formation of intermetallic compounds.

Parametric Influences on Heat Affected Zone in Micro-channel Milling Process of Zirconia Ceramic

Zirconia, a bio-ceramic, is widely utilized in bioengineering, biomedical implants, dentistry, and the automotive industry due to high hardness, excellent wear resistance, etc. However, it is difficult to attain micro features on zirconia utilizing a laser machining system for the aforesaid properties. The paper deals with the study of the Heat Affected Zone (HAZ) formation during the micro-channel milling (V-shaped cross-sections) of zirconia utilizing a nanosecond fiber laser system. Experiments are accomplished to examine the consequence of control variables namely transverse feed, pulse frequency, laser power, scan number, and scan speed. The influence of each of the laser process variables on response parameter are studied in order to get the significant trends of laser parameters. With the increment of laser power, the number of pass and transverse feed, HAZ width dimensions tend to increase. The reverse phenomena are observed for pulse frequency and scan speed. The lower HAZ width which is achieved as 31.74 μm at a parametric setting of average power at 10 W, pulse frequency at 65 kHz, scanning speed at 11 mm/s, a number of pass at 1, transverse feed at 0.005 mm.

Effect of friction stir welding parameters on the residual stress distribution of Al-2024-T6 alloy

The objective of this study was to investigate the influences of the main parameters of friction stir welding (FSW) on the residual stresses remained in the FSW of Al 2024-T6. The main parameters were tool rotational speed and tool transverse speed. The effect of these parameters on the residual stresses was studied in both finite element simulation and hole drilling strain gauge measurement. The results showed a good agreement between the numerical results and the experimental outcomes. The change in transverse speed from 25 to 31.5 mm/min resulted in increase of longitudinal residual stresses in welding centerline in which the longitudinal residual stress was increased at the tool rotational speed of 1120 rpm and 1600 rpm about 12.5% and 2.67%, respectively. The results showed that at the low rotational speed, the strain rate had the most effect on the residual stresses whereas at the high rotational speed, some residual stress was released due to the generated heat in the weld zone.

Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates

PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

Effect of Friction Stir Process Parameters on Mechanical Properties of Al/Eggshell/SiC Composite Material

The rise in pollution is a serious matter of concern for all nations. Industries are mainly responsible for damaging the balance of the cycle of pollution. In this paper, the mechanical properties of Aluminum have been enhanced by reinforcing it with eggshell wastes and SiC as reinforcement particles. Ball-milling technique has been applied for up to 75 hours for making the densities of Aluminum, Eggshell and SiC equal. The prime focus of this work is to improve the hardness value of Aluminium-based final composite material. Friction Stir Process (FSP) technique has been used to develop the composite and the driving parameters of FSP like rotational speed, transverse speed etc. are optimized with the help of the Box-Behnken Design approach. The optimized value of rotation speed was 966.14 rpm as well as transverse speed was 23.18 mm/min. Hardness and tensile strength of composite developed at an optimum combination of parameters were found to be 72.2 BHN and 194.48 MPa respectively. Results showed that tensile strength and hardness were enhanced by about 44.05% and 64.09% respectively.

Steady-state thermal blooming effect of vortex beam propagation through the atmosphere

Based on the fast Fourier transform algorithm, the steady-state thermal blooming effect of a vortex beam propagation in the atmosphere is investigated using the multiple phase-screen simulation method. The variations of propagation distance, initial power, transverse wind speed, atmospheric absorption coefficient, initial radius and wavelength are demonstrated to illustrate the change in the thermal blooming effect. The results show that the thermal blooming effect can be enhanced by increasing the initial power, propagation distance and atmospheric absorption coefficient of a vortex beam propagation in the atmosphere without changing other parameters. In contrast, increasing the transverse wind speed, initial radius, and wavelength can reduce the thermal blooming effect. As a comparison method, based on the first order perturbations, the analytical expression of steady-state thermal blooming of a vortex beam propagation in the atmosphere is obtained. The variation law of the thermal blooming distortion and transversely centroid position with different parameters of vortex beam propagation in the atmosphere are analyzed in detail. Based on the comparison of two different methods, the results show that the simulation results obtained by the multi-phase screen method and the analytical results obtained by the first order perturbation method are basically the same in the near field propagation, but with the increase of the propagation distance, the results obtained by the two methods are significant differences.

Effect of Friction Stir Process Parameters on Mechanical Properties of Chrome Containing Leather Waste Reinforced Aluminium Based Composite

Nowadays, there is a lot of environmental pollution due to the wastes generated by the industries. In particular, the waste generated by leather industries produces more environmental pollution. Chrome containing leather waste (CCLW) also causes a lot of environmental pollution. In this study, an attempt has been made to use CCLW as reinforcement with aluminium. Collagen powder was extracted from CCLW. Extracted collagen powder was used to develop aluminium based composite after ball-milling with alumina particles. The parameters of the friction stir process (FSP) are optimized by the Box-Behnken Design. The optimum combination of FSP parameters was found to be the number of tool pass of 1, tool rotational speed of 965.20 rpm and transverse speed of 23.69 mm/min. Tensile strength and hardness were found to be 162.89 MPa and 53.24 BHN, respectively at an optimum combination of FSP parameters. Uniform distribution of reinforcement particles has been also observed for the composite developed at an optimum combination of FSP parameters. Results showed that tensile strength and hardness of composite were enhanced by about 20.65 % and 23.81 % respectively with respect to the base material.

Dry and underwater friction stir welding of aa6061 pipes - a comparative study

This work compared the parameters of friction stir welding (FSW) and under water friction welding (UWFSW) on the weld joint, such as tool rotation speed, transverse speed, and wall thickness, and compare the ultimate tensile strength (UTS) weld joint using the experimental work for FSW and UWFSW was performed using a new modified fixture to eliminate the post-process problems. Experiments were performed at three levels of three parameters: Wall thickness, tool rotational speed and travel speed using milling machine center by UWFSW and traditional FSW. The full factorial approach was introduced for statistical research. UTS i s measured as a reaction, meaning that the ultimate tensile strength achieved by welding the UWFS weld was greater than the conventional FSW weld. As a predictive research tool, regression analysis and variance analysis were used. From the study, it was observed that with minimal tool transverse speed, high tool rotation speed for UWFSW, maximum tensile strength is given, and that of traditional FSW.

Influence of nano fly ash on wear behavior of friction stir weld joints of Al6063/nano fly ash composites

The manufacturing industries attracted aluminium metal matrix composites (AMCs) to utilize in the modern spectrum of applications. Inexpensive particulate reinforced composites are exhibiting superior qualities at reduced costs. Fly ash is an industrial waste that can be adopted as reinforcement, particularly for aluminium matrix materials. Friction stir welding (FSW) is best suitable to weld aluminum-based materials. In this work, the Al6063/nano fly ash composites with 0, 1, 2, and 3% wt. of nano fly ash were fabricated through ultrasonic-assisted stir casting. Consequently, FSW joints were obtained for the fabricated composites by considering rotational tool speed and transverse tool speed as welding parameters. Wear analysis carried on weld beads of composites through the pin on disc equipment. The nano fly ash addition in the composites results in increased wear resistance in the FSW joints. Higher wear resistance was achieved with increased reinforcement inclusion. Increased tool feed rate also enhances the wear resistance of FSW joints. It can be concluded that the nano fly ash particles are the most influential in improving the mechanical properties of the AMC weld beads, and FSW is the better option to weld aluminum composites.

An experimental study of the wetted surfaces of two- stepped planing hulls

In the present paper, hydrodynamic behavior and bottom wetted surfaces of two-stepped planing hull are investigated by conducting towing tank tests. To this accomplishment, hydrodynamic resistance, reattachment length, trim angle, and bottom wetted surfaces are determined under different geometric variables of the two transverse steps and planing hull speeds. Qualitative investigation is also conducted on the forebody and aftbody wetted surfaces. Based on the obtained experimental data, lower hydrodynamic resistance is achieved by decreasing the aft step height at Fr∇ < 2.12, while, greater aft step height is resulted to lower total resistance under Fr∇ > 2.12. Reattachment length after the aft step is increased by an enhancement in aft step height and the longitudinal position of the aft step from transom. Moreover, aftbody wetted area after the aft step and total wetted areas are decreased by increasing the aft step height and decreasing the position of the aft step from transom. Also, an algorithm is suggested to calculate the forebody and aftbody wetted areas of two-stepped planing hulls.

Stability of Lines with Zero Receding Contact Angle Produced by Inkjet Printing at Small Drop Volume.

We present an experimental study of the maximum and minimum bounding drop spacing for a parallel-sided liquid line produced by inkjet printing with drop volumes of 1.5 and 8.5 pL, on substrates with advancing contact angles of 46 and 54°, and zero receding contact angle. The results are used to validate models of the limiting bounds for the formation of stable parallel-sided lines as a function of drop spacing and transverse printing speed. The model for the maximum drop spacing bound (minimum line width) shows a good agreement with our results, but, when used to predict the stable line width, there is an influence of printing speed not captured by the model. This is probably because of a coupling between printed drop volume and ejection velocity outside the scope of the model. The minimum drop spacing bound (maximum stable line width) is limited by a bulging instability, and our results agree with the existing model, except for printing with the largest drop volumes at low temperature. It is shown that under these conditions, there is a different mechanism for bulging that occurs after printing over a period of minutes, if the liquid bead is present on the surface for a significant period of time before drying. Our results suggest that this mechanism is possibly triggered by imperfections on the substrate.

Influences of pinprofile and transverse speed on microstructure, mechanical properties, and wear behavior of nanocomposite AA6082/WC and fabricated via friction stir processing

ABSTRACT Friction stir processing (FSP) was successfully employed to produce AA6082/WC composite material. This research uses nano-sized WC particles of 50 nm average diameter as a reinforcement material. In order to identify the best condition for producing AA6082/WC composite material, two-pin profiles and four feed rates at 1200-rpm tool rotational velocity were used. The microstructure of the AA6082/WC obtained composites was investigated using a light optical microscope (LOM), Scanning Electron Microscope (SEM), and Transmission Electron Microscope (TEM). Results showed a homogenous distribution and excellent interfacial bonding between WC nanoparticles and the base matrix.The mechanical tests result showed significant improvement in obtained composite mechanical properties using different pin profiles and transverse speed. The composite processed by a cylindrical left pin tool had the highest ultimate tensile strength (UTS) strength, yield strength (YS), and microhardness compared to the hexagonal pin tool. The well-distributed nano-WC particles within the matrix improved the wear resistance by preventing the peeling of the A6082 grains during the sliding wear test.

Process parameters optimization in machining of duplex 2205 stainless steel alloy using AWJM technique

The AWJM process is highly used for the machining of very difficult to cut tough materials. In this study a novel attempt was made to find the influence of various process parameters of AWJM process over the machining of duplex 2205 stainless steel alloy. The process parameters considered in this study are transverse speed, abrasive flow rate and stand- off distance. The work is mainly concentrated to obtain reduced angle of kerf taper and minimum surface roughness. The taguchi L9 orthogonal array matrix was used to optimize the responses recorded after the machining. ANOVA table is used to verify the influence of each parameter on the machining of duplex 2205 alloy. The results showed that the stand –off distance is the major influencing parameter which is followed by transverse speed and abrasive flow rate.

Influence of process parameters on laser beam machining of leather for oil hydraulic system application

Laser Beam Machining (LBM) is an unconventional process where the laser beam is directed to the work piece where the thermal energy is utilized to remove the material. Laser Beam Machining (LBM) is best suited for machining tough to cut material like leather as it provides several advantages like high precision, and no tool wear as there is no contact between work piece and nozzle. Leather seals are used in oil hydraulic systems. The laser beam machining was carried out for leather with different levels of process parameters like Power (P), Transverse Speed (Sp), Standoff Distance (SOD) and Gas Pressure (G.Pr) and its effect on various response parameters such as MRR, Conicity, Overcut and Circularity are studied. From the results obtained, out of two trials conducted on leather the second trial has high MRR, better overcut and circularity because of the fact that second trial has lesser SOD so the intensity is more and beam divergence is less compared to trial one. The most influential parameter for leather is transverse speed because the heat transfer on the workpiece gets changed with respect to time available for the heat to spread.

Optimization of process variable in abrasive water jet Machining (AWJM) of Ti-6Al-4V alloy using Taguchi methodology

Ti-6Al-4V alloy is still considered challenging to machine with conventional technology due to low thermal conductivity. To overcome this difficulty due to the material, Abrasive Water Jet Machine is used for the machining needs. The study of the machining process variable (pressure, abrasive throughput, stopping distance and transverse speed) on the response variable (machining time, surface roughness and HRC strength of the finished surface) is considered. L25 (54) orthogonal matrix, conceived in Minitab 18 is taken to carry out experimental work and the same is statistically analyzed with Taguchi Technique. The pressure appeared to be the most influential input variable for processing duration and surface roughness. The hardness is influenced as much as possible by the abrasive flow caused by the incorporation of particles into the material.

A re-investigation of mechanical properties of aluminium-based surface composites prepared by friction stir processing

The properties of the alloys and metal matrix composites processed by friction stir processing are significantly affected by some fundamental parameters like; type of reinforcement, weight or volume % of reinforcement, number of passes, rotational speed, etc. The current study was done to explore the effect of these parameters on the mechanical properties of aluminium-based materials processed by friction stir processing. It was observed during the literature survey that the strength and hardness increased by 30%–40% after processing Al-based materials up to 3–4 friction stir processing passes. The wear rate decreased by 25%–30% after processing the Al-based materials up to 3–4 friction stir processing passes. The wear rate gets reduced on increasing the value of rotational speed (about 60%–70% reduction in wear rate after processing the aluminium based materials at a rotational speed 1300 rpm–1500 rpm). As the grain size increases on increasing the tool rotational speed, strength and hardness decreases. On increasing the transverse speed, there is a reduction in the grain size. Hence, the strength and hardness increase with an increase in the transverse speed.

Investigation on surface modified Al7075 with niobium by friction stir processing

In this present work Aluminum alloy 7075 is used as a base metal and niobium is used as an additive material to enhance the surface microstructure and mechanical properties like tensile strength, hardness and wear by using friction stir processing method. For optimizing the process parameters Taguchi L9 orthogonal array has been used. The process parameters for the present work are rotational speed, transverse speed and groove width. The experimental results indicate that rotational speed of 900 rpm, transverse speed of 20 mm/min and groove width of 1.2 mm gives maximum tensile strength of 344.79 MPa, hardness value of 283 and wear of 1.290 mm3. The microstructure and mechanical properties such as tensile strength, hardness and wear has been enhanced by addition of niobium in the Al7075 metal. The optimum process parameter from signal-to-noise ratio is used to identify the maximum tensile strength, hardness and wear behaviour. The optimized values are rotational speed of 700 rpm, transverse speed of 40 mm/ min and groove width of 0.6 mm are obtained from signal-to-noise ratio.

Effect of tool material on mechanical properties of friction stir welded dissimilar aluminium joints

Frictional stir welding (FSW) is a solid-state welding process. FSW has many advantages over giving high quality welds; it is environmentally friendly and maintained with low operating cost etc. It is used to join high strength aluminium and its alloys, which are difficult to weld using conventional fusion welding and use a tool that cannot be used to join without two facing work pieces without melting of the work piece material. The mix of material flow conditions specifically affects the quality of the weld, so tool material and geometry are very important. High quality welding comes from using the right tool design with efficient processing parameters. The development of cost-effective and durable tools that lead to structurally sound welds is still awaited. Improper selection of welding parameters can cause defects in the welding joints. This FSW technique requires specific parameters to produce a defect-free joint. The parameters involved in FSW joint are tool design, tool rotation speed, tool material, axial force, transverse speeds, tilt angle and plunge depth. This paper mainly depends on how the change in tool material affects the mechanical properties of the welded joint by maintaining constant spindle speed and feed rate. Aluminium alloys are selected 6061-T6 and 6082-T6. Tool materials selected are H13, D2 and SS316 grade. Mechanical properties are evaluated by Tensile Test, Hardness Test and Charpy Impact Test through Destructive Testing. Results conclude that if the application requires toughness and hardness as major property then D2 tool material can be used for producing FSW joint and if the application requires tensile strength as major property then H13 tool material can be used for producing FSW joint.

Models for predicting the performance of fertilizer metering in seed cum fertilizer drill

ABSTRACT This study aimed to establish mathematical models that predict the performance of helical fertilizer metering according to the longitudinal and transverse inclinations, angular speed, and helical pitch. Laboratory tests were carried out with helical meterings with lateral and longitudinal discharge through overflow and with two helicoids, working at an angular speed of 16 and 46 rpm at the following longitudinal inclination angles: -20, -15, -10, -5, 0, +5, +10, +15, and +20° and on the transverse axis: -15, -10, -5, 0, +5, +10, and +15°. It was found that the variation of the transverse inclination has little effect on the dosage. When using fertilizer metering with a helicoid, the higher the longitudinal inclination, the greater the dosage in a linear manner, while the meterings with two helicoids provided less oscillation of the dosages according to the inclinations.

A review on friction stir welding: A sustainable way of manufacturing

Abstract Friction stir welding (FSW) process has gained popularity due to its energy efficiency in joining similar or dissimilar materials as compared to traditional way of joining materials and as it involves no use of shielding gas and little harmful emissions due to which it is regarded as ‘green technology’. It’s a solid-state joining process in which plastic deformation takes place to join the similar or dissimilar materials rather than melting. Due to this its applications can be found in the field of industries ranging from aerospace to ship building and rail to electronics. FSW plays a key role in joining many ‘non-weldable’ aluminium alloys such as from 2xxx series alloys (Al-Cu) and 7xxx series alloys (Al-Zn) which is not possible with conventional process leads to softening of weld plates which leads to decrease in the mechanical properties. Hence, the study of various interlayers such as zinc, copper, brass, nickel, tin etc. has become a hot topic for researchers. The joining of dissimilar material is often difficult due to difference in physical properties and composition and hence use of interlayer in FSW helps in effective joining. Insertion of interlayer between the interface of plates to be joined not only enhances the tensile strength of the weld joint but also restricts the excessive formation of hard and brittle intermetallic compounds (IMCs) and leads to controlled formation of fine and uniformly distribution of IMCs and reduces the residual stresses and further increases the joint efficiency. This work contains the review of some important research papers on FSW of similar alloys (Al-Al), dissimilar alloys (Al-Mg), and effects of interlayer on similar alloys (Al/Cu/Al) and dissimilar alloys (Al/Zn/Mg). This paper also throws light on effects of process parameters such as (tool rotation, tool transverse speed, tool materials) on joining of materials by FSW has been discussed along with the suggestions of the researchers.