Advances in Engineering Materials

Table of Contents

1. Mechanical, Chemical and Thermal Recycling of Bio-Composites: A Review

   Partha Pratim Das, Vijay Chaudhary

   Abstract

   In a wide variety of uses, such as the automobile, aerospace and renewable energy industries, composite materials are used. But due to their inherent nature of heterogeneity, they were not properly recycled, especially for the polymer composites based on thermosets. The current and future legislation on waste management and the environment mandates that all engineering materials from end-of-life (EOL) items such as cars, wind turbines and aircraft be adequately recovered and recycled. Ultimately, recycling can lead to a saving of money and electricity. Various technologies have been developed, mainly based on fiber reinforcement and yet to be commercialized: mechanical recycling, chemical and thermal treatment. It is anticipated that new separation and recycling technologies for composite materials recycling will be available through collaborative efforts from design, manufacturing and end-of-life management, and that more easily recyclable composite materials will be produced in the future. A thorough analysis of the different methods of reuse of bio-composites is addressed in this paper.

2. Testing of Material for Disc Brake Rotor

   Manish Kumar Chauhan, Animesh Garg, Aditya Syal, Manmeet Singh

   Abstract

   The vehicle disc is part of a rear-wheel drive or suspension steering wheel while travelling at a specific speed. All considered brake rotor material is a solid metal that consumes a ton of fuel due to its high display power. The objective of this paper is to make an alternate material for disc brake rotors. Two systems for building materials were introduced, for example, cost per unit area and modern location system. Material requirements were analysed and the selected processes were combined between solid steel, aluminium amalgam, titanium mixing, dissolved creams and composites. The mechanical properties including compressive quality, adequate kicks, square coating, thermal mobility and gravity at approximately cost were used as key parameters in the material validation stages. The appraisal combined with the aluminium iron cross-component composite as the most suitable for the brake disc system.

3. Advancement in Different Materials Used for Aircraft Structure Processed Through Equal Channel Angular Pressing

   Krishna Mohan Agarwal, R. K. Tyagi, Arshit Kapoor

   Abstract

   Equal channel angular pressing (ECAP) is a forming technique where a metal is exposed to a severe plastic strain with no considerable change in the cross-sectional area of the workpiece. The main principle of the process is to produce the refinements in grains which leads to improvement in mechanical properties of the material used in various aircraft and automotive applications. There has been an tremendous development in materials used in aircraft applications since beginning. In the present study, the advancement in different materials such as aluminum alloys of 7000 series (Al–Zn–Mg–Cu) and 2000 series (Al–Cu–Mg) used for aircraft structure has been studied. The study also includes and suggests the latest technique of ECAP for improving the mechanical properties of materials used for aircraft structures.

4. Modelling and Simulation of Wind Turbine Blade Hub for Its Life Enhancement Using Epoxy Fibre Glass as Material

   Aseem Acharya, Prem Narayan Vishwakarma, Ajay Sharma

   Abstract

   The hub will experience a number of loadings and other effects; a variety of designs have been conceived to best handle these conditions. The ultimate goal is to conduct finite element analysis on typical hub designs with the purpose of predicting the fatigue life of the hub, for various numbers of cycles and able to increase the fatigue life of the hub while reducing the cost of manufacture by using the composite material. Lift and drag forces along with the angle of attack are the important parameters in a wind turbine system. These parameters decide the efficiency of the wind turbine. The hub encounters various types of effects and various loading conditions. A variety of designs have been recommended to face these conditions. Finite element analysis has been conducted in this paper with aim of forecasting the fatigue life for number of cycles so that the fatigue life is improved along with reduction in manufacturing cost.

5. Review on Thermal Spray Coating Methods and Property of Different Types of Metal-Based Coatings

   Gaurav Gupta, R. K. Tyagi, S. K. Rajput, Rahul Maan, Siddhant Jacob, Shiva Verma

   Abstract

   To enhance performance of industrial tools and components, deposition of thin film or coating presents a good option. Coating is done on the surface of the objects such as machine parts, tools, and on other similar components. For protecting components from erosion, wear, and corrosion, this method presents a cost-effective method. Thermal spray is one of the coating methods. Thermal spraying is a well-known technique in industries for improving the surface properties of the components. Thermal spraying can be used to apply coating of different materials such as metals, ceramic blends, alloys, and carbides many more on variety of components. Thermal spray provides benefits like repairing engineering component, improves performance, and extended life of the components. Many materials can be deposited through thermal spray coating such as Zn, Al, Ni, WC, Fe, Cr, and even the combination of materials. These coatings have considerable effect on performance without affecting environment.

6. Influence of Process Parameters on Weld Width of Tungsten Inert Gas Welded Joints for Low Carbon Steel AISI 1010 Plates

   Ashish Pal, R. P. Singh

   Abstract

   The present work deals with the investigation of effect of input welding process parameters on weld width in tungsten inert gas welding process. The important input welding process parameters considered are as welding voltage, welding current, speed of welding, and the feed rate. The plates having dimensions of 75 mm × 50 mm × 5 mm from the material of low carbon steel AISI 1010 are used to obtain the weld. A total of 16 pairs of these plates are required to be welded to have 16 different welds using tungsten inert gas welding process. Welding voltage, welding current, rate of feed, and speed of welding are considered as input welding process parameters, and the weld width is selected as output parameter. Three input welding parameters are kept at constant at a time by varying the fourth parameter to investigate the effect of fourth parameter. In this way, the effect of all input welding parameters on weld width are obtained. And recorded in table number 1 and shown in Figs. 1, 2, 3 and 4. Generally, the weld width increases with increase of current, feed rate, and welding voltage but decreases with welding speed in the present work.

7. Effect of Welding Speed on the Dimensions of Bead in Tungsten Inert Gas Welding Process

   Ajit Singh, Rudra Pratap Singh

   Abstract

   Generally, the joining of parts in our industrial life is very important. The industries use joints to increase the length or surfaced area for their requirements and these requirements can be fulfilled generally by joints. Welding is one of the best methods of making joints in which the tungsten inert gas welding is an important method in the welding process. In welding, the beads are formed which are consisted of depth of penetration, weld width and reinforcement height. These dimensions of the beads are the deciding factors of mechanical properties of the weld. In this work, the several experiments were performed with tungsten inert gas welding machine to critically study the effect of welding speed on the dimensions of the bead. All the other input variables except the welding speed were fixed, as the feed rate at 2.12 mm/s, voltage at 9.0 V, welding current at 100 A for whole the experimentation period. Only the values of welding speed were varied and the effect of this variation on depth of penetration, weld width and reinforcement height was investigated. Total six pairs of mild steel plates of dimensions 75 mm × 50 mm × 5 mm were welded for six variations of welding speed. The results were tabulated and were expressed in three different diagrams in which one was for depth of penetration, one was for reinforcement height and one was for weld width. This study explains the sensitivity analysis of the effect of the welding speed on the three dimensions of the weld bead.

8. Fabrication of Hybrid Material (Al-SiC-Fly Ash) for Industrial Application

   Rohan Raj, Kartik Bhardwaj, Sanchit Sharma, Naveen Kumar, Priyank Srivastava

   Abstract

   With the development, reinforced Metal matrix composites (MMC) is becoming a significant area of research, and it is rapidly growing in various engineering fields because it exhibits exceptional mechanical properties. Keeping this in view, the present study is aimed to focus on formation of hybrid material and discover the numerous possibilities of reinforcing aluminium 7075 with low priced and readily available silicon carbide (SiC) and fly ash (FA) for the development of hybrid material. The reinforcements were added into the aluminium matrix alloy with different weight proportions with the help of stir casting apparatus. The planning of experiments was done through Taguchi’s technique, and experiments were conducted on this plan. This technique is employed to analyse the contribution of most influential parameters on aluminium matrix composites (AMC) during stir casting process. L9 orthogonal array is selected for this analysis. The influential parameters associated for achieving the uniform distribution, wettability and porosity in AMC are presented and discussed.

9. Current Scenario in Optimization of Machining Parameters While Electric Discharge Machining for Biocompatible Ti-Alloy: A Review

   Subodh Kumar, Vikas Sharma

   Abstract

   This paper represents the current trends for optimization of process parameters while EDM of biocompatible titanium alloy parameters in terms of peak ampere, pulse on time and pulse off time, etc., on the mechanical properties of titanium alloy (Ti-6Al-4V). Titanium alloy is a hard material which possesses poor ability to get machined by working on traditional machining methods, while using electrical discharge machining (EDM) is very easy to machining titanium alloy. The machining efficiency as well as accuracy is to be improved by using integrated EDM machining mechanism. During the experiments, parameters like discharge peak current and pulse duration had to be varied to find out the effect on the material removal rate (MRR), electrode wear rate (EWR) and relative electrode wear ratio (REWR). In this work, several current research papers on titanium alloy were studied for analysis and investigation. The researchers have given their own views on the performance of the electrical discharge machining process, the materials selected for their study, the effect of machining parameters, etc., in their researches. In this audit paper, it was additionally attempted to consider distinctive research papers containing the exploration and examination made on input yield parameters while working with electrical discharge machining.

10. Enhancement of Adhesive Wear Resistance of AISI 409 M Steel by Deposition of WC-10Co-4Cr Powder Using GTAW Process

    Amit Kumar, Guru Prakash, N. K. Batra

    Abstract

    AISI 409 M stainless steel is widely used for manufacturing automobile exhaust systems, automotive mufflers, fuel filters, farm equipment, and shipping containers. The shipping containers and farm equipment during transportation and handling experience wear which reduces their life cycle. To improve the life of AISI 409 M stainless steel, WC-10Co-4Cr powder is cladded on the surface of AISI 409 M steel by gas tungsten arc welding (GTAW) process. Extensive characterization by X-ray diffraction (XRD) and SEM imaging of the cladded AISI 409 M was carried out. The hardness of the cladded AISI 409 M steel specimen and AISI 409 M steel was found to be 42 HRC and 6 HRC, respectively. The wear study of cladded AISI 409 M and AISI 409 M steel specimen was done on pin-on-disk equipment. It was found that the cumulative weight loss of the cladded AISI 409 M steel is 69.73% less than by AISI 409 M steel. The structure property relation shows that wear is proportional to hardness of the cladded AISI 409 M steel.

11. Fabrication of Jackfruit Stems Fiber Composites

    G. Srinivasa Rao, Saurav Saha, Ashiq Mohammed, Rakesh Kumar Phanden, Eswara Krishna Mussada, Gadudasu Babu Rao, Praveen Kumar Bannaravuri, Umesh Kumar Vates, Bhupendra Prakash Sharma, Vijay Chaudhary, Gaurav Gupta

    Abstract

    The following work has been done to fabricate new composites created by reinforcing newly identified jackfruit stem fibers into an unsaturated polymer resin matrix. The fibers have been extracted by mechanical and chemical processes, and hand layup technique has been used to fabricate the composites. First, the identification of the specimen is done and jackfruit stem fibers are decided to be checked for feasibility of extraction for this study. When it is found that the fibers can be extracted successfully from the jackfruit stem, then both retting process and chemical treatment is used to successfully extract the fibers. After extraction of the fibers, the density of the extracted fibers is to be calculated. After that, the fibers of proper length are used to create composite matrix of polymer resin using a calculated amount of volume fraction of fibers. The composites are then post cured after fabrication and prepared for further studies.

12. Analysis of the Composite Sample Under Low Velocity Multi-impact Test: FEA Investigation

    Punita Kumari, Ashraf Alam, Saahil

    Abstract

    The effect of the stacking sequence under multi-impact was investigated in this paper. Finite element (FE) model was prepared for the multi-impact composite sample while taking Hashin failure criteria into account. Force, impact time and absorbed energy of the sample were computed for each impact. The stacking sequence comparison was carried out that depends upon peak force, maximum impact time, absorbed energy and damage region. From the results, it is evident that each impact degrades the material properties and brings it close toward the fatal condition. From FE analysis, it was observed that the backside of the samples gained more damage in comparison with the front side, which could be attributed solely to compression and tension. Analysis of the result discerns that there exists the correlation between absorbed energy and the damage region. The FE model showcased here demonstrates the potential to investigate the damage that occurred to the composite material that was under multiple impacts.

13. Microstructure and Porosity Behavior of Spray Formed Al Alloy Processed by Cold Rolling

    Rashmi Mittal, Prabh Simranjit Singh, Rajeev Sehrawat, Deepak Kr Tyagi, Milan Kr Bera, Anil Sharma

    Abstract

    An efficient spray forming technique was utilized to cast Pb-added Al-Si alloys. It was then rolled to a different percentages (0–80%) using rolling machine and microstructural characteristics as well as porosity behavior of casting alloy were systematically studied. It is noteworthy that the distribution of Pb was nearly uniform all through the aluminum phase and it was mainly at the grain boundary. Also, the grains of aluminum were found to be elongated along the rolling direction after 80% rolling. Porosity was minimum at peripheral region of the deposit and it decreased as rolling percentage is increased.

14. Two-Body Abrasive Wear Behavior of Woven Carbon/Glass/Aramid Polytherimide Reinforced Hybrid Composites

    N. K. Batra, Iti Dikshit, Dilpreet Singh Sidana

    Abstract

    The increased use of composites in industrial applications, recommended knowing their behavior of the developed composites under various working conditions. Wear is an important parameter and its experimental behavior must be known. Polyetherimide (PEI) is a thermoplastic polymer with very good mechanical properties, and its reinforced composite shows a significant tribo-potential. In the present study, wear behavior of woven carbon/glass/aramid fabrics reinforced composite and their hybrid materials are experimentally investigated. Two-body abrasive wear behavior of reinforced composites has been studied out by pin-on-disk apparatus. Abrasive wear rate was calculated at room temperature with grit size 35 µm of silicon carbide paper as a counter face. The abrasive wear studies were carried out at different loads (10, 20, 30 N) at a constant sliding velocity (v = 2 m/s) of steel disk. The wear in the experiment determined by wear loss and specific wear rate as a function of load. The wear loss increases with increasing load. Eventually, with increase in the load, specific wear rate decreases. However, carbon/PEI composite and its hybrid show less wear as compared to glass/PEI and aramid/PEI composite. In addition, photographs of the unworn and worn surface of the specimen have been examined under scanning electron microscope (SEM) to give an insight into the wear mechanisms.

15. Enhancement of Grain Structure and Mechanical Properties of Scrap Material AA6063 Through ECAP

    Krishna Mohan Agarwal, Arshit Kapoor, Bhuwan Gupta, Priyanka Singh

    Abstract

    The objective of current study is to improve the hardness and tensile strength of Aluminium Alloy 6063 which is used in construction and infrastructure. Practical implementation of our research will be to increase the life span of the material. A cast-iron die is fabricated with a channel carved in it using CNC cutting machine. A hub is put on the die and aluminium alloy material in the form of 20 mm (diameter) rod is passed in the die using a hydraulic press. There will be grain refinement in the structure of the aluminium rod, due to severe plastic deformation, this technique of passing the rod is equal channel angular pressing (ECAP). The few parameters which will be focused are thermodynamics while plastic deformation, homogenizing of aluminium, severe plastic deformation (SPD), melting properties and grain structure The experimental results show that there is the maximum smooth flow when the material is passed in the channel with angle 90°.

16. Machine Learning Approach to Predict Compressive Strength of Green Sustainable Concrete

    Priyanka Singh, Aman Namdeo, Chakshu Garg, Krishna Mohan Agarwal

    Abstract

    Sustainable construction contributed to the usage of recycled and waste materials to substitute conventional concrete. This research focuses on prediction of compressive strength of cement concrete substituted by large amounts of waste materials and products with strong mechanical properties and sustainability. It also emphasizes on using analytical model for the prediction of compression strength of the green concrete, so that there is a reduction in the cost of construction, conserve energy, and it will lead to a reduction of CO₂ production from cement industries within reliable limits. In this paper, machine learning approach has been used to predict the compressive strength of green and sustainable concrete. Machine learning empowers machines to learn from their experiences and data provided. The system analyses the datasets and finds different patterns formed in the given data. Then, based on its learnings the machine can make certain predictions. In civil engineering application, a special computing technique called the artificial neural network (ANN) is in huge demand. ANN is a soft computing technique that learns from previous situations and adapts without constraints to a new environment. In this work, a neural network model for prediction of compressive strength of concrete has been illustrated. Different sets of data based upon several concrete design mixes were taken and were fed to the model. The model is then trained for prediction, which are being influenced by several input attributes and were jotted down a linear regression analysis.

17. Biodegradable Metal Matrix Composites for Orthopedic Implant Applications: A Review

    Kundan Kumar, Ashish Das, Shashi Bhushan Prasad

    Abstract

    Biodegradable implant metals such as iron (Fe), magnesium (Mg), and Zinc (Zn) and its alloys have attracted extensive interest in biomedical application. Low mechanical strength of Zn, significant slower degradation of Fe, and rapid degradation Mg impede their orthopedic implant application. Further research is going on the development of biodegradable metal matrix composite owing to best suited for biomedical applications. This paper delivers a review of biodegradable metal matrix composites based on corrosion resistance, biocompatibility, and mechanical properties as favorable implant materials for orthopedic applications.

18. A Taguchi Approach to Optimize Electrochemical Discharge Machining of E-glass Fibre Reinforced Polymer Composite

    Gaurav Saini

    Abstract

    E-glass fibre reinforced polymer composite becomes very popular in advance manufacturing industries due to their attractive mechanical properties. E-glass fibre is an electrically non-conductive material which is very intricate to machine by conventional machining processes and facing many problems. In this research work, the experiments were done according to Taguchi L27 orthogonal array with S/N ratio analysis. DC supply voltage, electrolyte concentration, pulse-on-time, pulse-off-time and inter-electrode gap were used as machining parameters, and their effect were observed as a response characteristic such as tool wear rate (TWR). The experimental results were concluded with the help of analysis of variance (ANOVA) which indicated that voltage was the most dominant factor for tool wear rate followed by pulse-off-time. Further establish the optimal machining parameter combination while machine micro-hole in e-glass fibre reinforced polymer composite using electrochemical discharge machining (ECDM) process and the surface texture of the used tool electrode was analysed by scanning electron microscope (SEM).