Advances in Materials and Manufacturing Technology
Select Proceedings of ICAMMT 2024 Volume I
- 2026
- Book
- Editors
- Ramesh Kumar Nayak
- J. Paulo Davim
- Rajiv Shekhar
- Geoffrey Mitchell
- Book Series
- Lecture Notes in Mechanical Engineering
- Publisher
- Springer Nature Singapore
About this book
This book comprises select proceedings of the 3rd International conference on Advances in Materials and Manufacturing Technology (ICAMMT-2024). Functional materials, smart materials, and intelligent materials stand as foundational elements in twenty-first-century technology, irrespective of their designation. The evolution of modern structural materials reflects an unprecedented trajectory of scientific and technological progress. The book discusses the latest materials, manufacturing processes, evaluation of materials properties for the application in automotive, aerospace, marine, locomotive, and energy sectors. The topics covered include advanced metal forming, bending, welding and casting techniques, recycling and re-manufacturing of materials and components, materials processing, characterization and applications, multi-physics coupling simulation, and optimization, alternate materials /material substitution, thermally-enhanced processes, and materials, composites and polymer manufacturing, the fabrication process of nanomaterial, powder metallurgy and ceramic forming, numerical modelling and simulation, advanced machining processes, functionally graded materials, non-destructive examination, optimization techniques, engineering materials, heat treatment, material testing, MEMS integration, energy materials, bio-materials, metamaterials, metallography, nanomaterial, SMART materials, application of AI and ML in advanced materials, automation, and superalloys. In addition, it discusses industrial applications and cover theoretical and analytical methods, numerical simulations and experimental techniques in the area of advanced materials and their applications. The recognition of benefits restricting from advanced materials and structures transcends various applications. Smart systems offer a streamlined approach to controlling material and system characteristics by autonomously adapting to environmental changes. Mechanistic comprehension across disciplines is paramount for developing materials with capabilities that surpass current standards. Our conference serves as a cross-disciplinary summit, transcending organizational and global barriers to integrate research and education in the vital field of advanced materials. We focus on major sectors including advanced processing, material characterization, modelling and simulation, properties, performance, and device fabrication, aiming to overlay the way for the next wave of scientific and technological advancements.
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Table of Contents
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Frontmatter
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Surface Texture Evaluation in Turning of Ti6Al4V Under Nano-Flood Cooling Environment
Amit S. Patil, Vivek K. Sunnapwar, Kiran S. Bhole, Sushil Ingale, Deepak Singh, Yogesh MoreThis chapter delves into the challenges and solutions associated with machining Ti6Al4V alloy, a material widely used in aerospace, biomedical, and automotive industries. The study focuses on optimizing cutting parameters such as speed, feed rate, and depth of cut, as well as evaluating the performance of different nanoparticle-enhanced coolants. Through a series of experiments conducted on a CNC turning machine, the research analyzes surface roughness, tool wear, and Z-axis load to determine the most effective machining conditions. The results highlight the superior performance of the C3 coolant, which contains Al2O3, CuO, and MWCNTs nanoparticles, in achieving lower surface roughness and reduced tool wear. The TOPSIS method is employed to rank the experimental trials, with Trial 4 emerging as the optimal parameter set. The conclusions underscore the importance of cutting parameters and coolant types in enhancing the machinability of Ti6Al4V, offering practical insights for professionals seeking to improve manufacturing efficiency and product quality.AI Generated
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AbstractThis research investigates the impact of nanofluid coolants on surface quality and tool wear during the turning of Ti6Al4V alloy. Machining Ti6Al4V, while desirable for its strength and corrosion resistance, is challenging due to its low thermal conductivity, high reactivity with tools, and propensity for work hardening, leading to accelerated tool wear, poor surface finishes, and reduced efficiency. This study explores the potential of nanofluids to mitigate these issues. Experimental results indicate that a hybrid nanofluid containing Al2O3 + CuO + MWCNTs nanoparticles exhibits superior performance compared to conventional coolants, yielding the best cylindrical and shoulder surface quality while minimizing flank and crater wear on the cutting tool. To determine the optimal turning parameters, the Technique for Order of Preference by Similarity to Ideal Solution method was employed. The analysis identified the following optimal parameters: a cutting speed of 60 m/min, a depth of cut of 0.8 mm, and a feed rate of 0.28 mm/rev. These findings highlight the potential of nanofluids to improve machining efficiency and surface integrity in the turning of Ti6Al4V alloy. -
A Detailed Work on the Method of Making Composites by Mixing PLA Polymer with Natural Bamboo Fiber
Roopesh Kumar, Rajesh Purohit, Vikky Kumhar, Abhijeet Ganguly, Santosh Sharma, Ashish KumarThis chapter delves into the innovative method of creating composites by mixing PLA polymer with natural bamboo fiber, focusing on the enhanced mechanical and thermal properties of the resulting materials. The study explores various manufacturing techniques, including compression molding, hand lay-up, and in situ polymerization, to produce short fiber, continuous fiber, and nanocomposites. It also examines the impact of chemical treatments, such as alkaline and silane treatments, on the strength and behavior of bamboo fiber. The research highlights the superior properties of bamboo fiber-reinforced PLA composites, including increased tensile strength, flexural strength, and thermal stability. The chapter concludes with a discussion on the environmental benefits and potential applications of these eco-friendly composites in industries such as automotive, packaging, and medical textiles.AI Generated
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AbstractIn the last few years, there has been a great reliance on naturally sourced elements for the development of biodegradable polymers. The weight of composite can be reduced with natural fiber and its cost can also be reduced. Composite fiber has less adverse effects on the environment. Polylactic acid (PLA) has been considered a suitable polymer to make composite materials. The properties of natural fibers used with PLA are said to be superior. PLA-reinforced composites are being widely used today. Affect the physical, mechanical, and thermal properties of PLA composite. PLA with bamboo fiber has been used in many researches. PLA and bamboo exhibit suitable properties when combined originally. This work described in details the work done with PLA on bamboo. -
Biogas Production from Paper Waste
Noura Said Abdallah Al Kiyumi, Khadersab AdamsabThis chapter delves into the promising potential of biogas production from paper waste, a solution that addresses both waste management and renewable energy needs. It examines various optimization strategies, including pretreatment methods, digester configurations, and microbial community manipulation, to enhance biogas yield. The text also explores the challenges associated with scaling up biogas production and integrating it into energy grids. Additionally, it highlights the benefits of co-digestion with other organic wastes, such as food waste and animal manure, and the impact of different factors like organic loading rate and pH on biogas production. The chapter concludes with insights into the economic impact and energy security benefits of biogas production, particularly in developing countries. Furthermore, it discusses the use of machine learning and metaheuristic approaches to predict biogas yield from various organic wastes.AI Generated
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AbstractPaper and its products have become a vital element of our daily life. Paper products, from newspapers and magazines to business documents and packaging materials, are used and discarded at an alarming rate. Unfortunately, our reliance on paper has a cost: an ever-increasing pile of paper waste is finds up in landfills, incinerators, and even our oceans. Biogas production from paper waste is an innovative and sustainable approach to waste management and renewable energy generation. In Oman and around the world, a vast amount of paper gets used and discarded by institutions, creating significant waste. Instead of polluting landfills and incinerators, this paper holds hidden potential. Its cellulose fibres, derived from wood and grasses, can be transformed into biogas. This study investigates the potential of paper waste as a source of biogas. It delves into the anaerobic digestion process, analysing how much methane is produced by paper waste alone and when combined with cow dung. The study also examines the impact of seasonal variations by testing the biodigester in summer and winter. Finally, it identifies challenges and suggests future research directions to improve the efficiency and optimize the parameters of this biogas production process. -
Manipulator Robot Development and Analysis of Motion Planning Libraries Through ROS2 and MoveIt2
Shivam Vishwakarma, Chandan Singh, Vijay Bhaskar Semwal, Deepak Kumar, M. TaufikThis chapter delves into the multifaceted world of manipulator robot development and the critical role of motion planning libraries in enhancing robotic performance. It begins with an introduction to the Robot Operating System (ROS2) and its significance in simplifying robotic software development, followed by an exploration of the MoveIt2 motion planning toolkit and its integration with various motion planning libraries. The text provides a detailed comparison of OMPL, CHOMP, and STOMP libraries, highlighting their unique features and applications. It also discusses the development of virtual models using CAD and URDF, and the implementation of control strategies for nonlinear systems. The chapter concludes with an analysis of the parallel motion planning interface in MoveIt2, demonstrating its effectiveness in solving complex motion planning problems and its potential to optimize robotic operations. This comprehensive overview offers valuable insights into the latest advancements in robotic motion planning and development, making it an essential read for professionals in the field.AI Generated
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AbstractThis study presents two key research areas: manipulator robot development and motion planning analysis. This study aims to improve robot ability in various aspects like autonomy, efficiency, and safety. These are key areas for improvement with an objective to do complex operations, navigation in dynamic environments, and interaction with humans or machines. Developing a robot model involves designing, building, and programming to achieve ergonomics. Motion planning involves information about the motion of each joint of the robot to reach our target without colliding with the obstacle that comes in the path of the robot. It requires real-time calculation and understanding of non-linear environments for safe, efficient, and robust robot navigation. In addition, robotics also possesses abundant structured resources for learning and development. One primary concern in motion planning is managing libraries that guide robots in reaching specified targets without colliding with obstacles. This study presents a comprehensive analysis on the process of developing a manipulator robot and motion planning through MoveIt2, which would manage motion planning libraries. The motion planning is carried out using a parallel motion planning setup, which results in OMPL having a 66% higher chance of solving a given configuration of a 3DOF manipulator robot when compared to a STOMP motion planning library within a 1.5-s time constraint. -
Experimental Investigation Using R134a—Reduced Graphene Oxide—MO-Based Nanosuspension in Vapor Compression Refrigeration
Yogesh G. Joshi, Harish BhatkulkarThis chapter delves into the experimental investigation of vapor compression refrigeration systems using a novel rGO–MO-based nanolubricant. The study focuses on the synthesis and characterization of the nanolubricant, the experimental setup and procedure, and the results obtained from the investigation. Key findings include a notable increase in the coefficient of performance (COP) by approximately 9.72% and 14.58% with the addition of 0.02 wt% and 0.04 wt% rGO, respectively. Additionally, power consumption decreased by 20% and 28% for the same concentrations, and pull-down time was reduced by 10% and 14.44%. The study concludes that the incorporation of rGO nanoparticles significantly enhances the overall performance of vapor compression refrigeration systems, offering a promising approach for improving energy efficiency and reducing operational costs.AI Generated
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AbstractThe utilization of nanolubricants in the thermal system has shown significant efficiency and improvement in the last decade. In current research work, reduced graphene oxide (rGO)-based nanolubricant is utilized to enhance the efficiency of vapor compression refrigeration system. R134a is used as the refrigerant and mineral oil is utilized as base fluid in the experimentation. The two concentrations of rGO is synthesized, i.e., 0.02 wt% and 0.04 wt% using two-step method. The experimental results obtained from utilizing nanolubricant were further than the conventional refrigeration system in terms of coefficient of performance and power consumption. The experimentation result showed that the concentration of 0.04 wt% rGO is found to be the most effective, resulting in a 14.58% increment in the coefficient of performance, a 28% lessening in power consumption, and a 14.44% decrease in pull- down time. -
Enhancing Split Tensile Strength of Concrete by Using Hypo Sludge and Polypropylene Fiber
Rakesh Kumar, Jitendra Singh Yadav, Gurjeet SinghThis chapter delves into the innovative use of hypo sludge, a by-product of the paper industry, and polypropylene fibers to bolster the split tensile strength of concrete. The study meticulously examines the workability, compressive strength, and split tensile strength of concrete incorporating varying percentages of hypo sludge and polypropylene fibers. Key findings reveal that the inclusion of 10% hypo sludge and 0.5% polypropylene fibers yields the highest compressive strength and split tensile strength, making it an optimal choice for enhancing concrete durability. The research also highlights the cost-effectiveness and environmental benefits of using hypo sludge, reducing disposal costs for paper industry waste and minimizing the environmental impact of cement production. Additionally, the study explores the potential for future research to enhance the longevity, heat resistance, and water resistance of concrete, suggesting the use of a mix of synthetic and natural fibers along with steel fiber to further improve concrete strength.AI Generated
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AbstractThe growing issue of waste accumulation poses significant challenges to environmental sustainability. In the paper industry, the hypo plant produces considerable slurry as a form of waste, which contributes to environmental contamination when disposed of improperly. Additionally, cement manufacturing exacerbates global warming by emitting release of carbon dioxide into the atmosphere. To mitigate these environmental impacts, using industrial waste in concrete production can be beneficial. This study investigates the use of using hypo sludge as a partial substitute for cement in concrete mixtures. To enhance the concrete’s strength, polypropylene fiber (PPF), a synthetic polymer made from hydrocarbons, was included. A total of 450 specimens were cast by adjusting the ratios of hypo sludge and polypropylene fiber across multiple combinations, ranging from low to high proportions. The concrete’s workability was evaluated immediately after mixing, while compressive and split tensile strength (STS) tests were conducted after curing for 7, 14, and 28 days. The results reveal that increasing the proportions of hypo sludge and polypropylene fiber reduces workability, shifting it from moderate to low. However, the addition of both materials enhances the strength of the concrete up to a certain level, beyond which a significant decline in strength occurs. The ideal combination for attaining maximum strength and reducing brittleness is 10% hypo sludge and 0.5% polypropylene fiber. Furthermore, incorporating hypo sludge leads to an 18.35% saving in concrete costs. -
Microwave-Assisted Compression Molding of Eco-friendly Composites: An Experimental and Computational Study
Ravi Vijaykumar Sevak, Ankit Gupta, Ramesh Gupta BurelaThis chapter explores the innovative use of microwave-assisted compression molding (MACM) to create eco-friendly composites, focusing on high-density polyethylene (HDPE) reinforced with ramie fibers. The study investigates the mechanical properties of these composites, including tensile, flexural, impact, and hardness tests, and compares them to plain HDPE. The results demonstrate significant improvements in strength, flexibility, and durability, attributed to the enhanced interfacial bonding between the HDPE matrix and ramie fibers. The research also employs the Mori-Tanaka homogenization model to predict the elastic properties of the composites, validating its accuracy through experimental data. Additionally, the study optimizes the process parameters for MACM, highlighting its energy efficiency and reduced fabrication time. The findings suggest that MACM is a promising method for producing high-performance, sustainable composites, with potential applications in various industries.AI Generated
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AbstractThe current investigation focuses on developing composites by combining biodegradable and environmentally sustainable natural fibers with a thermoplastic matrix that can be recycled. Microwave-assisted compression molding (MACM) was used to create natural fiber composites of high-density polyethylene (HDPE) with a 15 wt% Ramie fiber content. The HDPE specimens were manufactured without any other modifications to observe the impact of reinforcing ramie fibers. The mechanical properties of the composite were assessed by tensile, flexural, impact, and hardness tests. Fractured surfaces were analyzed using scanning electron microscopy to identify the causes of failure. The HDPE/Ramie composites had an ultimate tensile strength (UTS) of 23.8 ± 0.3 MPa, which exceeded the UTS of pure HDPE (18.9 ± 0.4 MPa). HDPE/Ramie had a flexural strength of 20.3 ± 0.4 MPa, whereas plain HDPE had the lowest strength at 16.6 ± 0.7 MPa. The impact strength exhibited a comparable pattern, with the HDPE/ramie composite displaying the highest value at 35.2 KJ/m2, while plain HDPE followed at 23.7 KJ/m2. The hardness testing indicated that the HDPE/Ramie composite had a hardness that was 16.29% greater than plain HDPE. A computational study was conducted to create a model for accurately predicting the orthotropic properties of HDPE/Ramie composites. There is a notable consensus between computational and experimental studies. The new composite can be considered appropriate for various low-intensity uses, including roofing, automotive interior panels, and mobile covers. It has the potential to provide advantages in terms of decreasing carbon emissions. -
Study on the Optimized Design Model of Glass Fiber Plastic Based on Chaotic Ant Colony Algorithm
Rong Guo, Mingjian GongThis chapter delves into the optimization of glass fiber plastic design using the chaotic ant colony algorithm, a heuristic optimization method that combines ant colony behavior with chaos theory. The text outlines the algorithm's principles, including pheromone propagation, volatility, and the incorporation of chaos theory to enhance search diversity. It details the optimization model's implementation steps, from data collection and preprocessing to initialization, optimization, solution updating, and convergence judgment. The chapter also presents experimental settings and results, demonstrating the algorithm's effectiveness in improving the tensile strength and overall performance of glass fiber plastics. Additionally, it discusses future research directions, such as algorithm optimization, multi-scale coupling, and intelligent manufacturing integration. The text concludes with the potential of the chaotic ant colony algorithm in enhancing the design and performance of glass fiber plastics, offering a reliable method for engineering applications.AI Generated
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AbstractThis study proposes a design model based on chaotic ant colony algorithm for the optimal design of glass fiber plastics. First, the wide application of glass fiber plastics in the engineering field and the importance of optimized design are introduced. Then, the principle of the chaotic ant colony algorithm and its application to optimization problems are described in detail. Then, an optimized design model of glass fiber plastic based on chaotic ant colony algorithm is proposed, and described in detail. Finally, the effectiveness and superiority are verified through numerical experiments, and the results show that the model can effectively optimize the design of glass fiber plastics, improve its performance index, and provide a reliable design method for engineering practice. -
Fuzzy Clustering Method-Based Hybrid Metaheuristic Models of Chloride Diffusivity in Mortar Containing Nano-titanium Dioxide
Prashant Tiwari, Yogesh Iyer Murthy, Abhishek VermaThis chapter delves into the experimental and analytical investigation of chloride diffusivity in mortar containing varying levels of nano-titanium dioxide (NT). The study focuses on developing hybrid fuzzy clustering method (FCM) models optimized through genetic algorithms (GA), particle swarm optimization (PSO), and pattern search (PS) to predict chloride diffusivity accurately. Key topics include the experimental setup for measuring chloride ion diffusion, the development and comparison of hybrid FCM models, and the performance evaluation of these models using metrics such as R², VAF, RMSE, and a-10. The results indicate that increasing NT percentages significantly reduce chloride ion diffusivity, with 3% NT achieving up to a 90% reduction compared to the control mix. The FCM-PSO model emerged as the most effective, demonstrating exceptional accuracy and efficiency with the highest R² and VAF values. This research highlights the potential of AI-based models in predicting chloride diffusivity and optimizing mortar compositions for enhanced durability and corrosion resistance.AI Generated
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AbstractThis research investigates the incorporation of nano-titanium dioxide (NT) into mortar to enhance its resistance to chloride ion penetration and extend the service life of marine structures. Mortars were prepared with varying NT content (0–3% by weight of cement), and the effective chloride diffusivity (Deff) and migration coefficient (Dmig) were experimentally determined. Fuzzy C-Means (FCM) clustering combined with hybrid algorithms was conducted to model and predict these parameters. Results demonstrated that 3% NT reduced chloride ion diffusivity by up to 90% compared to the control, with significant decreases in Deff and Dmig, and improved service life by up to 35%. FCM effectively clustered data with a silhouette score of 0.87. Particle Swarm Optimization-based FCM models achieved the highest accuracy with an R2 of 0.9887 and VAF of 99.63%. The study highlights the potential of data-driven models to replace extensive laboratory experimentation, offering significant reductions in time and cost with high scalability and adaptability for future research on chloride resistance in marine concrete structures. -
Topographical and Magnetic Investigations of Pulse-Electrodeposited Co/Cu Multilayer Structure
Dhirendra Kumar Gupta, Madhulika Sharma, Neeraaj Agrawal, Anchit Modi, Varsharani MehtoThis chapter delves into the topographical and magnetic investigations of pulse-electrodeposited Co/Cu multilayer structures, highlighting their remarkable properties and potential applications. The study employs various advanced techniques, including X-ray photoelectron spectroscopy (XPS), glancing angle X-ray diffraction (GAXRD), X-ray reflectivity (XRR), and magnetic force microscopy (MFM), to analyze the composition modulation, domain structure, and magnetic behavior of these multilayers. Key findings include the confirmation of multilayer formation through GAXRD and XRR, the observation of sub-micron size magnetic domains via MFM, and the measurement of magnetic hysteresis loops. The results demonstrate the successful deposition of multilayers with controlled mono/bilayer periods and low interface roughness, as well as the antiferromagnetic coupling of adjacent Co layers. These insights underscore the potential of pulse electrodeposition in creating advanced materials for sensor technology, mass storage systems, and spin-based electronic devices.AI Generated
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AbstractComposition modulation of copper/cobalt (Cu) multilayer (two-dimensional nanostructure) has been deposited by using wet chemical method (electroplating technique). Low-angle X-ray diffraction (LAXRD) and depth profiling X-ray photoelectron spectroscopy (XPS) techniques used to investigate multilayer structure. The optimization of the pulse frequency utilized in pulse electrodeposition has been empirically demonstrated to facilitate the development of a copper/cobalt multilayer phase. The formation of a coherent multilayer, showcasing antiphase oscillations within the Cu/Co compositional profile, has been substantiated. Anti-ferromagnetic coupling among the layers of the multilayer film have been confirmed by magnetic force microscopy (MFM) and magnetization measurement studies. -
Two Phase Pressure Drop in Non-uniform Heat Flux Microchannels: Homogeneous Flow Model
A. Swain, R. K. Sarangi, S. P. Kar, P. C. SekharThis chapter delves into the pressure drop characteristics of microchannels under non-uniform heat flux, utilizing a homogeneous flow model. The study examines the influence of various parameters such as inlet temperature, outlet pressure, and mass flow rate on pressure drop and phase transformation. Different heat flux arrangements, including hot spots at various locations, are analyzed using water and ethanol as working fluids. The research highlights the significance of hot spot positioning, revealing that downstream hot spots lead to lower pressure drops. Additionally, the study compares the pressure drop behaviors of water and ethanol, noting that ethanol generally results in higher pressure drops due to its lower density and higher flow velocity. The numerical model is validated against experimental data, demonstrating its accuracy in predicting pressure drop trends. The findings underscore the importance of optimizing design parameters for better performance in microchannel heat sinks, particularly in applications requiring high heat transfer rates and minimal pressure drops.AI Generated
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AbstractTwo phase pressure drop in microchannels for non-uniform heat flux condition is analyzed in this paper. Homogeneous flow model has been assumed with constant heat flux boundary condition with fixed inlet temperature and outlet pressure. Water and ethanol are taken as working fluids. Modeling scheme is used to do the parametric investigations for total pressure drop. The model has been compared with the experimental results from literature. The results show that the working fluid properties and heat flux distribution play a significant role for overall pressure drop. -
CFD Simulation for Performance Evaluation of Thermosyphone
P. K. Jha, R. K. Sarangi, S. P. Kar, A. Swain, P. C. SekharThis chapter delves into the heat transfer capabilities of thermosyphons, focusing on the impact of fill ratios, heat transfer coefficients, and working fluids. Through CFD simulations, the study validates a 2-D model against experimental data, testing various heat inputs and coefficients for water and ethanol. The results highlight the significant reduction in thermal resistance and improved performance with higher fill ratios, particularly for water. The chapter also explores the effects of different heat transfer coefficients on thermal resistance and temperature distribution, providing a detailed analysis of the thermosyphon's efficiency. The study concludes that water outperforms ethanol in terms of thermal resistance and overall performance, offering valuable insights for optimizing thermosyphon design and application.AI Generated
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AbstractThis paper presents a two-dimensional CFD model designed to simulate two-phase flow, evaporation, condensation, and heat transfer within a thermosyphon. The simulation utilized the mixture model in ANSYS FLUENT 19.2. Water and ethanol were chosen as working fluids to evaluate thermosyphon performance. The evaporator section was subjected to a constant heat flux with inputs of 200, 400, and 600 W, while the condenser section had three different heat transfer coefficients: 200, 500, and 1000 W/m2 K. Due to ethanol’s lower latent heat compared to water, simulations were performed with heat inputs of 100 and 200 W. Additionally, three fill ratios of 25, 50, and 75% were examined. The study numerically assessed the overall effective thermal resistance and temperature distribution along the length of the thermosyphon. It has been observed that, fill ratio, heat flux, and condenser side heat transfer coefficient significantly affect the overall thermal resistance of the thermosyphon. -
Erosion Wear Behavior of ZTM-Filled Giant-Cane Fiber Composite: Experimental and Optimization Approach
Pruthwiraj Sahu, Asit Behera, Sudhansu Sekhar Patro, Amlana Panda, Ashok K. SahooThis chapter delves into the erosion wear behavior of giant-cane fiber epoxy composites reinforced with zirconia-toughened mullite (ZTM) filler. The study focuses on the impact of process parameters such as impact velocity, impingement angle, and filler percentage on erosion rates. Through experimental testing and optimization using Response Surface Methodology (RSM), the research identifies the optimal conditions for minimizing erosion. Key findings include the significant influence of impact velocity and impingement angle on erosion rates, while the filler percentage shows a less pronounced effect. The chapter also explores the mechanical properties of the composites, such as tensile strength, hardness, and impact strength, and their relationship with erosion resistance. The conclusion highlights the potential of giant-cane fiber composites filled with ZTM for applications requiring high wear resistance and sustainability.AI Generated
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AbstractNatural fiber composite materials are widely used in various structural fields, interior design, and sports equipment in the present scenario because of their high specific strength, stiffness and biodegradability properties. Various applications in these emerging fields induce the manufacturers to examine its tribological performance. This work deals with the development and erosion wear characteristics of giant-cane (Arundinaria gigantea) fiber-reinforced filled nanozirconia toughened mullite (ZTM) epoxy composite. The three-layered composite laminate is fabricated by hand lay-up technique using woven cellulosic giant-cane fiber mat, epoxy resin and ZTM nano-filler. Three different types of specimen are fabricated by varying weight percentages of ZTM filler as 0, 5 and 10. Angle-ply [+ 45°/− 45°/ + 45°] configured specimens are fabricated and tested to study the erosion wear behavior of composite specimens. The test is carried out by taking the parameters such as impact velocity, impingement angle and filler content by adopting Research Surface Methodology (RSM). The erosion wear test revealed that the impact velocity, impingement angle and contents of filler influence the wear characteristics of giant-cane fiber composite. Further, the impact velocity and impingement angle play significant role in determining the erosion rate. The impact velocity of 40 m/s, impingement angle at 45° and filler percentage of 10% bears the minimum erosion rate which is predicted to be 109.26 mg/k. -
Thermal Efficiency and Performance Assessment of a Solar-Driven Binary Vapour Cycle with Ammonia Water and CO2
Ayoushi Shrivastava, Mayank Maheshwari, Amrit Anand DosarThis chapter delves into the thermal efficiency and performance assessment of solar-driven binary vapour cycles, focusing on ammonia-water and CO2 mixtures. The study explores two main configurations: the External Source Heating-Based Binary Vapour Power Cycle (ExSBVP) and the Solar Source Heating-Based Binary Vapour Power Cycle (SSBVP). Each configuration is further analyzed with and without reheating mechanisms to optimize power output and energy recovery. The research highlights significant efficiency gains, particularly when reheating is applied in the ExSRBVP configuration. Key findings include the impact of varying turbine pressures and temperatures on cycle efficiency, with notable improvements observed at higher pressures and temperatures. The study also emphasizes the potential of integrating renewable energy sources, such as solar energy, to enhance the sustainability and performance of power generation systems. The detailed analysis and comparative data tables provide a comprehensive understanding of the thermodynamic behavior and potential improvements in cycle efficiency under different operating conditions. This chapter offers valuable insights into the optimization of binary vapour power cycles, making it a crucial read for professionals seeking to advance sustainable energy solutions.AI Generated
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AbstractOne of the primary strategies towards the enhancement of energy efficiency through the incorporation of renewable energy is solar-assisted binary vapour power cycles optimization. The focus of this study will be two configurations: an External Source-Based Binary Vapour Power Cycle and an improved ExSRBVP configuration, containing a reheating mechanism. Thermodynamic models were created by the authors for various parameters analysis—turbine pressure, temperature, and absorber pressure on first law efficiency. The results show that the ExSRBVP cycle has better performance, and higher pressures and temperatures in the topping cycle lead to a higher efficiency. This happens especially at absorber pressures of 5–15 bar. The improvement in efficiency is due to the increase in enthalpy and energy recovered by the bottoming cycle, thus compensating for the mass flow rates that have decreased. Data table and figure show that while the ExSBVP setup has an enormous efficiency if optimized, the ExSRBVP setup does improve energy significantly due to reheating. This, in turn, opens an opportunity for integration of solar power with some advanced techniques in thermodynamics to have efficiency in generating power without jeopardizing its sustainability. Integration with further renewable resources for enhanced robustness and longer-term sustainability is what research should explore in the future. The current work will therefore contribute towards the development of renewable energy technology in advancing eco-friendly and efficient power generation systems that are environmentally and economically beneficial. -
Estimation of Angular Distortion Using Mathematical Modeling in MIG-Welded Stainless Steel 304L Plates
Noorakshi Dahiya, Rohit Jayaswal, Shiwangi Goel, Pradeep KhannaThis chapter delves into the critical factors influencing angular distortion in MIG-welded stainless steel 304L plates, focusing on input parameters such as wire feed rate, welding speed, voltage, nozzle-to-plate distance, and torch angle. Through a meticulous Design of Experiments (DOE) approach and Central Composite Rotatable Design (CCRD), a mathematical model was developed to predict and minimize angular distortion. The study highlights the significant impact of voltage on angular distortion and the nuanced effects of other parameters. Key findings include the identification of optimal welding conditions to achieve minimal distortion, validated with an 8% error rate. The research provides practical insights for enhancing welding precision and reducing post-weld corrections, making it an essential read for professionals seeking to optimize their welding processes.AI Generated
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AbstractMIG welding is a widely employed joining process across the industry for its many advantages. Similar to other fusion welding processes, the rapid thermal cycles experienced by the base metal results in the generation of thermal stresses, consequently leading to the angular distortion of the weldment in case of thin plates. The post weld rectifications of this distortion can be costly or at times not practically feasible. Therefore, predicting and minimizing angular distortion is essential. The current study seeks to examine the impact of input parameters like welding speed, distance between nozzle and plate, feed rate of wire, voltage and torch angle on the angular distortion, which is the response parameter. A series of trials were performed based on a design matrix; mathematical modeling was done to devise a mathematical formula relating the input parameters with the response parameters. The accuracy of the developed model was assessed through ANOVA, i.e., analysis of variance. Response surface methodology (RSM) was used to visualize the results. Finally, the input parameters were calibrated for minimal angular distortion in present setup. This experimental work is expected to give an insight how stainless steel 304L behaves under different combination of input parameters with regards to angular distortion. -
Effect of Pulsating DC and Pure DC Power Supply on Tapered End of Cathode Tool After Micro-machining of Alumina Ceramic in ECDM Process
Layatitdev Das, Siba Sankar Mahapatra, Jayadev RanaThis chapter delves into the effects of pulsating DC and pure DC power supplies on tool wear and surface finish during the micro-machining of alumina ceramics using Electrochemical Discharge Machining (ECDM). The study compares the performance of stainless steel and copper electrodes under different power supply modes, highlighting the advantages of pulsating DC in reducing tool wear and improving surface finish. The experimental setup and methodology are thoroughly described, including the use of a dual-mode ECDM setup with detailed dimensional specifications of the electrode tools. The results reveal that pulsating DC power supply leads to less erosion and distortion of the tool surface compared to pure DC, due to the controlled heat flux and cooling effects provided by the periodic pulses. The study also discusses the significance of tool material properties, such as thermal and electrical conductivity, on dimensional accuracy. The conclusion emphasizes the suitability of pulsating DC for applications requiring better control over spark discharge, improved tool life, and higher surface finish, while pure DC is more suited for processes prioritizing higher material removal rates. The chapter provides valuable insights into optimizing ECDM processes for micro-machining of hard, non-conductive materials.AI Generated
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AbstractThe micro-machining of electrically inert, chemically inert, hard to machine materials like glass and ceramic, can be done efficiently by a hybrid non-conventional micro-machining technique, i.e., electro-chemical discharge machining (ECDM). All the experiments, in this present work, have been conducted by an indigenously designed and developed ECDM set up. The power circuit unit is designed in such a manner that it can operates on two different power supply mode, i.e., pulse DC power supply and pure DC power supply. The current research work examined the influence of pulsating DC and pure DC power supply on the erosion of tapered tool end made of stainless steel and cupper during micro-machining of ceramics. The authors have demonstrated the optical images of the machined tool tip end and the images of sparking in both mode of power supply unit during machining. The simulated and isotherm images of surface temperature for both types of power supply have also been carried out in COMSOL multi-physics 5.6. Apart from the factors like tool–work piece gap, and tool surface texture, concentration of electrolyte during micro-machining, the factors like nature of pulse wave supply, electrical and thermal conductivity of tool also have significant role in tool wear during machining. The experimental results and the simulated images reveal that the pulse DC power supply generates periodic direct current, resulting smooth and controlled heat flux generation, whereas the pure DC supply continuous direct current, leading to generation of uninterrupted heat flux. Due to this uninterrupted heat flux, more heat supply to the work-piece, hence the temperature of the tool surface increases and more material removed from the tool surface. -
Energy Recovery Through Pump as Turbine (PAT): Innovations and Applications in Hydropower Systems
Pramod Kumar Shakya, Bhuvneshwar Tekam, Kapil Raje, Ankur SaxenaThis chapter delves into the innovative Pump-as-Turbine (PAT) technology, which repurposes standard pumps to function as turbines, offering a cost-effective and efficient solution for energy recovery in micro and pico-hydropower systems. The text begins by outlining the environmental and economic challenges faced by traditional hydropower production, setting the stage for the introduction of PAT technology. It then explores the theoretical framework of pumps and turbines, highlighting their distinct roles in fluid mechanics and energy systems. The chapter also discusses the design considerations for PAT systems, including the selection of appropriate pump types and the optimization of hydraulic parameters. Practical applications of PAT technology are examined, emphasizing its adaptability, low cost, and environmental benefits. The text concludes by addressing the challenges and future trends in PAT technology, underscoring its potential to contribute to sustainable energy goals and reduce carbon emissions.AI Generated
This summary of the content was generated with the help of AI.
AbstractPump-as-Turbine (PAT) technology has shown itself to be quite promising within energy recovery as well as small-scale hydropower generation particularly in micro and pico-hydro systems. This work examines multiple uses of PAT technology focusing on its extensiveness from water distribution networks to renewable energy hybrid systems. This converts hydraulic energy into mechanical energy by using conventional pumps in reverse operation. It thus serves as an affordable and portable solution for off-grid and remote locations. The integration of PATs into water networks would mean a lot of energy recovery potential, reduce their reliance on fossil fuels, and reduce further the related emissions. This paper explores in detail the current trends in computational modeling and optimization techniques that back artificial neural networks (ANNs) and computational fluid dynamics (CFD), which have maximized PAT systems performance and efficiency across different conditions of operation. PAT technology, though having increased efficiency with artificial neural networks and other methods of computation, has posed a challenge in the technology with respect to efficiency during pulsating flow conditions and other risks such as cavitation, which have their impact on the long-term durability. System integration with existing infrastructures must be carefully designed and optimized for reliable performance. Future innovation in PAT technology will come from smart control systems, advanced materials, and modular designs to bring the technology to more renewable projects around the globe. Policy support, standardized components, and investment in research and development are key pathways to scaling PAT systems, which will further the global transition toward sustainable energy solutions.
- Title
- Advances in Materials and Manufacturing Technology
- Editors
-
Ramesh Kumar Nayak
J. Paulo Davim
Rajiv Shekhar
Geoffrey Mitchell
- Copyright Year
- 2026
- Publisher
- Springer Nature Singapore
- Electronic ISBN
- 978-981-9687-73-2
- Print ISBN
- 978-981-9687-72-5
- DOI
- https://doi.org/10.1007/978-981-96-8773-2
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