Advances in Materials and Manufacturing Technology

Table of Contents

1. Frontmatter

2. A Research on Behaviour of Green Concrete with Waste By-products

   Premio Marak, Shobhana Singh, Chandra Prakash Gaur, Nitesh Kushwah, Priyanka Dhurvey

   Abstract

   The observation examines the properties and effectiveness of green concrete with ground granulated blast-furnace slag (GGBS), fly ash (FA), and rice husk ash (RHA). The studies examine the partial substitution of cement with those additives at proportions of 5, 10, 15, and 20% throughout periods of 7 and 28 days. Experimental study demonstrated that GGBS displayed the greatest strength amongst the materials at both time intervals, whereas RHA exhibited the least performance. FA offered moderate strength, appropriate for applications necessitating minimal strength. The maximum compressive strength was attained with a 20% GGBS substitution, while the minimum strength was observed with a 20% RHA substitution. GGBS, due to its rapid setting characteristics, demonstrated reduced workability, rendering it suitable for road building and repair endeavours. GGBS is advised for high-strength concrete, FA is suitable for intermediate strength applications, and RHA, while diminishing strength, can be utilized in low-strength applications owing to its favourable workability. The results underscore the feasibility of GGBS and FA as effective substitutes for cement in diverse applications, while RHA's utilization is confined to low-strength contexts.

3. Analysis of Tall Structures Compared with Lateral Loads Using Software STAAD PRO, SAP 2000, and ETABS

   Ankit Verma, Sarvesh Vyas, Nitesh Kushwah, Priyanka Dhurvey, Chandra Prakash Gaur

   Abstract

   Vulnerable regions in a structure are the first to experience the failure during an earthquake, typically because of discontinuities in mass, geometry, and stiffness. Such irregularities in structure plays a significant role in the development of modern urban infrastructure. Vertical irregularities are often the causes of structural collapse during seismic occurrence, making it crucial to understand their impact on a building’s seismic performance. The main goal of this study is to determine the most suitable and reliable systems for analysing structural results. Prior to the analysis, the designer must select between ETABS, SAP2000, or STAAD Pro. As preferred tool. To assess the effectiveness of these software tools, a comparative study is conducted on buildings with irregular geometries across different heights: GROUND + 5 STOREYS, GROUND + 10 STOREYS, GROUND + 15 STOREYS, and GROUND + 20 STOREYS.

4. An Empirical Investigation on Manufacturing of Sustainable Interlocking Paver Blocks Using Stone Dust by Partially Substituting Fine Aggregates

   Ravi Mohare, Sarvesh Vyas, Nitesh Kushwah, Priyanka Dhurvey, Chandra Prakash Gaur

   Abstract

   The building sector consistently pursues sustainable and economical substitutes for traditional materials. This study investigates the feasibility of utilizing stone dust as a partial substitute for fine aggregates in the production of interlocking paver blocks. The main aim is to assess the fresh and mechanical characteristics of paver blocks by altering the ratios of stone dust. The research concentrates on mix designs in which stone dust substitutes 0–40% of fine aggregates by weight in the formulation of M30 grade concrete. Paver blocks with a thickness of 60 mm are reengineered and evaluated based on workability, compressive strength, and flexural strength assessments. Findings demonstrate that the inclusion of stone dust improves both compressive and flexural strength to a specific substitution threshold. Consequently, identifying the ideal stone dust content is crucial for attaining a balance between workability and strength in concrete applications.

5. An Empirical Investigation into Green Concrete Utilizing Eco Sand and Sugarcane Bagasse Ash as Partial Replacement of Sand and Cement

   Deepak Prakash, Sarvesh Vyas, Chandra Prakash Gour, Nitesh Kushwah, Priyanka Dhurvey

   Abstract

   The building sector is progressively utilizing sustainable materials to mitigate its environmental impact. This study examines the feasibility of utilizing the sugarcane bagasse ash (SCBA) and Eco Sand as the partial substitutes for cement and sand in the making of sustainable concrete. Eco Sand, an industrial by-product, and SCBA, sourced from agricultural waste, were integrated into concrete compositions in diverse quantities. Specifically, by weight ten percentage of cement is replaced with SCBA, while conventional fine aggregates at 0, 5, 10, 15, and 20% were replaced with Eco Sand. The research designed for M35 grade concrete and assessed for fresh and hardened properties which mainly influence the critical strength criteria, such as workability, flexural strength, split tensile strength and compressive strength. The results show that substituting 15% of Eco Sand and 10% of SCBA yielded excellent compressive and flexural strength, showcasing the efficacy of these replaced materials in sustainable concrete manufacturing and reducing the conventional natural materials. The utilization of these waste by-product alternatives resulted in reduced production costs, facilitating the advancement of green construction materials and endorsing sustainable business practices.

6. Analysis of Seismic Performance of Tall Structures with Floating Columns and Shear Panels in Seismic Zone IV Using STAAD Pro V8i Software

   Rahul Nagar, Sarvesh Vyas, Priyanka Dhurvey, Chandra Prakash Gour, Nitesh Kushwah

   Abstract

   This study examines the seismic performance of high-rise building structure in Seismic Zone IV using STAAD Pro V8i, comparing structures with and without floating columns. The analyzed building has 11 stories, a height of 33.8 m, and a floor plan of 18.92 m × 19.78 m. It consists of 50 columns, 12 of which are floating, supported by beams on the second level instead of extending to the foundation. Shear walls are used to support these columns and transfer loads to the underlying structure. Both structures share identical height, configuration, and loading parameters. This study evaluates key factors, including beam moment, shear force, nodal deflection, concrete volume, and steel usage. Results show a minor difference in concrete consumption (654.6 CUM for floating columns vs. 666.4 CUM without). However, integrating floating columns with shear walls significantly reduces maximum displacement and inter-story drift, enhancing the structure’s seismic performance. These findings highlight the potential benefits of floating columns when combined with shear walls in high-rise building design.

7. Optimization of Machining Parameters of Al6061 Nanocomposites Reinforced with MWCNTs on CNC Machines

   Madhusudan Baghel, C. M. Krishna, Anurag Namdev, Surendra Kumar Patel, Siddharth Yadav

   Abstract

   Tool wear rate (TWR) and material removal rate (MRR) are two most important factors for improving productivity while machining any component using CNC milling machine in CIM (computer integrated manufacturing) environment. This investigation for multi-walled CNT (MWCNT) composite with Al6061 aims at optimization of the process parameters for minimization of TWR and maximization of MRR for improving productivity. In this study, aluminum alloy 6061 was reinforced with 0.5 wt. % MWCNTs using bottom pouring stir casting under specified conditions. Effect of process parameters, viz. (i) cutting speed (2500, 3500, and 4500 rpm), (ii) feed rate (150, 200, and 250 mm/min), and (iii) depth of cut (0.2, 0.3, and 0.4 mm) was studied on TWR and MRR. Process parameters were optimized using Taguchi design of experimentation using L₉ array and nonlinear regression method. For a selected CNC machine in a CIM environment, it is observed that cutting speed affects TWR and MRR significantly compared to other parameters (depth of cut and feed rate). Experiments with optimum process parameters were performed for validation of results.

8. Deep Learning Algorithms for Intelligent Diagnosis of Rotating Machinery Bearing Faults

   Khadersab Adamsab, Vinayak V.Kulkarni

   Abstract

   The focus of industry experts and academicians on developing new deep learning (DL) algorithms is intensifying. DL algorithms show greater performance and accuracy based on conditions like input data, hyperparameters, data size, and parameters. This paper presents the developmental changes that have taken place in the DL method and algorithms and use in the direction of intelligent diagnosis for rotating machinery faults. The transformations of DL algorithms’ architecture variables to perform intelligent fault diagnosis are compared. Further characterization of DL methods and algorithms for various types of rotating machinery faults like rolling element bearing misalignment imbalance and looseness is compared.

9. Effect of Water Absorption on the Inter-Laminar Shear Strength of Glass Fiber-Reinforced Epoxy Composites Under Static Loading

   Gaurav Bajpai, Anurag Namdev, Vivek Mishra, Harshvardhan Rajpurohit, Rajesh Purohit

   Abstract

   Glass–epoxy composite materials are subjected to various environmental conditions for prolonged periods during their usage in engineering and structural applications. Environmental conditions play a crucial role in their degradation. Glass–epoxy composites were produced by using the hand lay-up method. The specimens were exposed to moisture using a custom-made boiling water degradation setup up to 192 h. To assess the inter-laminar shear strength (ILSS) of the specimens, the quasi-static tests were conducted for 12, 24, 48, 96, and 192 h following the water immersion. This study examines how water absorption affects glass fiber epoxy composites under quasi-static stress scenarios.

10. An Experimental Investigation on Pool Boiling Heat Transfer with Cationic Surfactant Solution on Copper Substrate

    Abhishek Sinha Mahapatra, Satya Prakash Kar, Abhilas Swain, R. K. Sarangi, P. C. Sekhar

    Abstract

    The present article explains the pool boiling of Cetyltrimethyl Ammonium Bromide (CTAB) with Acetone as base fluid. The boiling is carried out on a copper substrate at different values of heat flux to determine the critical micelle concentration (CMC) of the surfactant. The CMC value is found to be 400 ppm beyond which no heat transfer improvement is observed. The heat transfer coefficient and the super heat temperature are determined at different concentration of the surfactant and different heat flux values. As a result, the heat transfer coefficient is calculated as 19.251 kW/m² °C at a heat flux of 65.45 kW /m² with 400 ppm solution. With pure Acetone, this value is 10.557 kW/m² °C. This shows an improvement in heat transfer of 82.352%.

11. Optimization of Carbon Nanotubes (CNTs) in Concrete for High-Performance Rigid Pavements

    Jitendra Singh Yadav, Kamal Singh, Chandra Prakash, Danish Raza, Md. Afsar Hussain

    Abstract

    The use of nanoparticles into cement concrete has garnered increased interest due to its potential to significantly improve the mechanical properties of rigid cement concrete pavements. This study examines the incorporation of carbon nanotubes (CNTs) into concrete mixtures and its impact on key performance metrics such as flexural, tensile, and compressive strength. Concrete specimens were created, cured, and assessed with different concentrations of CNT (0, 0.025, 0.050, 0.075, and 0.1%). Tensile strength consistently improved with the incorporation of CNTs; at 0.01% CNTs, it exhibited a significant increase of 26.80%. The 0.050% CNT dosage resulted in the most substantial enhancement in compressive strength, over twice that of the control mix. The 0.075% CNT dosage exhibited the most significant enhancement in flexural strength, surpassing the usual control mix by 23.11%. The findings indicate that CNTs can substantially enhance the mechanical properties of concrete, thereby being an excellent option for high-performance cement concrete rigid pavements. This study demonstrates that the incorporation of carbon nanotubes into concrete enhances its load-bearing capability, so offering an effective approach for constructing robust and sustainable infrastructure.

12. Influence of Micron-Sized SiC Reinforcement on Microstructural and Mechanical Properties of AZ91 Magnesium Alloy

    Rahul Sharma, Jayashree Baral

    Abstract

    AZ91 alloy of magnesium is mostly used commercially among all magnesium alloys because it provides optimal combination of strength and ductility. In this work, AZ91 magnesium alloy was synthesized using under inert atmosphere of argon in stir casting furnace. Then AZ91-8%SiC composite was prepared with addition of 8 wt.% micron-sized SiC particles under an inert gas atmosphere, magnesium melting furnace. The microstructural properties of the magnesium alloy and its composite were examined by X-ray diffraction, optical microscopy, and scanning electron microscopy. Microstructural examination of the composites revealed a highly uniform dispersion of the reinforcing particles, along with substantial grain refinement. The β-phase Mg₁₇Al₁₂ precipitated in the AZ91 alloy matrix in the form of lamellar and massive structure. However, after addition of SiC particles, fully massive β-phase Mg₁₇Al₁₂ precipitation was formed which gives hardening to the material. Also, the incorporation of SiC particles resulted in increase in % elongation and hardness of the AZ91 composite material 73.33% as compared to the AZ91 magnesium alloy. But ultimate tensile strength and yield strength values was higher for the AZ91 magnesium alloy. These findings show that the AZ91-8%SiC composite may be acceptable for applications where enhanced hardness and ductility are preferred over tensile strength.

13. Surface Modification of Aluminum 6068 Using Friction Stir Processing for Enhancing the Mechanical and Tribological Properties

    Hemesh Sharma, Sandeep Gupta, Anand Shukla

    Abstract

    The friction stir processing (FSP) technique enables the creation of multifunctional features in aluminum alloys, which are one of the preferred materials with steadily rising demands in the industrial sectors. A substantial amount of attention has been paid to surface modification methods in the area of materials science in order to improve the mechanical and tribological characteristics of a variety of materials. In this research paper, we investigate the surface modification of Aluminum 6068 by reinforcing silicon carbide (SiC) particles using the FSP technique. The modified surface is characterized using various analytical techniques, including scanning electron microscopy (SEM) and tensile testing. The results demonstrate that the incorporation of SiC particles through FSP significantly improves the microhardness, wear resistance, and strength properties of the aluminum alloy. This research work aims to experimentally analyze the microstructural and mechanical properties of a workpiece during 1 pass top friction stir processing (SPTFSP) and 3 pass top stir processing (TPTFSP) containing groves and holes (random and sequentially oriented) on the upper surface of Aluminum Alloy 6068 using SiC to fill these holes and grooves. This research investigation is performed on a super-classical traditional turret milling machine. This paper also shows that the presence of silicon (0.2–0.3%) can provide high ultimate tensile strength. In this paper, a number of experiments are carried out to obtain optimum mechanical properties and a better microstructure under different rotational speeds and tool travel speeds.

14. ANN-Based Models for Strength Prediction of Concrete Incorporating Processed Recycled Aggregate

    Ashutosh Shishodiya, Velaga Sarath Babu, Yogesh Iyer Murthy

    Abstract

    This investigation attempts to use two commonly used algorithms, namely, LMA and SCG optimization techniques to predict the compressive and flexural strength of concrete incorporating processed (PRA) and treated recycled aggregate (TRA). The input parameters used were: TRA, PRA, Slump, and age of concrete. The two approaches were tested on a neural network model using error measurements and convergence characteristics. The LM algorithm had the best validation performance with an MSE of 0.07145 at epoch 58, whereas the SCG algorithm had 2.4266 at epoch 905. The LM model has a higher convergence rate, with a final gradient of 1.47 × 10⁻⁶ compared to 6.2953 for SCG. R-values near 0.999 for training, validation, and test sets revealed good predictive accuracy for both models. LM algorithm error histograms showed a narrower error distribution centered on zero, suggesting more accurate predictions. Despite six validation failures, both models stabilized and generalized across datasets. The LM algorithm predicted concrete strength more accurately and efficiently, producing lower error in fewer epochs. These results imply that LM is better for this application than SCG, offering accurate results with faster convergence.

15. Steamjet Technology in Green Energy Solutions: Harnessing Steam Power for Clean Energy Production

    Bhuvneshwar Tekam, Pramod Kumar Shakya, Kapil Raje, Ankur saxena

    Abstract

    Undoubtedly, steamjet technology is the most recent advancement in clean energy production, and it is expected to bring considerably better efficiency to renewable energy systems like solar-thermal, geothermal, and biomass energy. In this respect, these steamjet systems utilize high speed jets of the steam to drive turbines in order to transform the thermal energy into mechanical work more effectively than that conventionally experienced in steam turbines. This reduces energy losses and lowers the productions of greenhouse gases, and hence the steamjet technology can be considered to be more environment-friendly compared to fossil fuel-based power generation. This paper discusses at length the theoretical bases and working principles of a steamjet system while paying attention specifically to how steamjet operation contributes to renewable energy generation. This paper, therefore, critically evaluates the environmental and economic implications of embracing steamjet technology, revealing potential application in future carbon footprint reductions, water conservation, and overall improvement of energy efficiencies in green energy infrastructures. Other than exploring current applications for steamjet technology, this paper further deals with technological challenges and impediments that must be successfully overcome before full potential can be unlocked. Key issues concern durable material, efficiency of energy conversion, and scalability of the steamjet. All these are discussed at length with an intent to identify future research and development. The paper concludes with hints at future directions and novelties that would make steamjets a more efficient and versatile device: advances in design, thermodynamics, materials science, and automation. With these new developments finding their ways into existing infrastructures of renewable energy, steamjet technology may become an essential pillar to this global shift toward a sustainable future.

16. Scientometric Analysis of Waste Material Utilization in Concrete for Sustainable Construction

    Sourabh Jain, Indra Pratap Shukla, Mohit Sahu

    Abstract

    The growing need for high-performance, green concrete has caused an increase in the use of recycled materials in sustainable construction. This research is about optimizing the mechanical properties of recycled aggregate concrete (RAC) by incorporating fly ash and ground granulated blast furnace slag (GGBS) as partial cement replacements. Different concrete mixtures were made utilizing recycled aggregates by partially replacing cement with fly ash and GGBS. The mixtures were tested for compressive strength, split tensile strength, and flexural strength, and the results of these tests were compared to those of a control mix. The study confirms pozzolanic activity of fly ash and GGBS and their filler effect contribute to strength and durability improvements, influencing mechanical properties. The findings suggest replacing cement with fly ash, GGBS, and recycled aggregates enhances concrete performance, thus fortifying sustainable construction by reducing reliance on natural resources as well as carbon emission. This research establishes a platform for designating RAC for structural application while promoting green building methodologies, proving recycled materials effectively satisfy requirements of modern-day green engineering while improving concrete quality and sustainability.

17. Optimization of TIG Welding Parameters for Enhancing Mechanical Characteristics of AISI 316 Austenitic Stainless Steel

    Mukhtar Sama, Amit Sata, Dhruv Patel, Anjali N. Dave, Minal Shukla, Divya Mobarsa

    Abstract

    Mechanical properties of weld joints are weld penetration dependent. Penetration in TIG welding process is always difficult. Stainless steels are always used in high valued products such as aerospace, defence, and nuclear. There are different type of stainless steel like austenitic stainless steel, ferritic stainless steel, duplex stainless steel, and precipitation stainless steel. This research considers the significant welding parameters of AISI 316 by TIG welding. The experiments are designed based on Taguchi methodology. Parameters such as electrode diameter, arc gap, welding speed, welding current, and gas flow rate are taken into consideration in the experiments to observe how they influence hardness, elongation, and tensile strength under various conditions. The results showed good agreement with the results calculated using the Taguchi optimization method. The results shows that optimum current 175 A, gas flow rate is 20 litter per min, electrode size is 1.4 mm, and arc gap of 1.5 mm to optimize the mechanical properties. The yield strength of the material can be improved by using higher current and electrode diameter. The work identifies the important parameter to improve the weld quality of varying thickness by using Taguchi method. The outcomes contribute to the advancement of precision welding processes, enhancing mechanical performance and structural integrity in stainless steel applications.

18. Multi-criteria Decision-Making (MCDM) of EDM Process Parameters of AISI-D2 Steel with Morphological Study

    Satyabrata Barik, Basanta Kumar Nanda, Swayam Bikash Mishra, Santosh Kumar Nayak, Mantra Prasad Satpathy, Sourav Kumar Mohanty

    Abstract

    Electric discharge machining (EDM) is the controlled attrition method of electrically conducting materials. This non-traditional machining technique employs the repeating and interrupted electric spark inside a dielectric medium among the cathode—tool and anode—work piece that removes material from the work-piece. This experimental work is focused on the electric discharge machining of AISI-D2 steel using copper electrode. Experiments are conducted according to the response surface methodology (RSM) of the design of experiment (DoE) to explore the effects of machining features on material removal rate (MRR) and surface morphology concerning surface bumpiness (R_a). The responses, namely MRR and Ra of this die-sinking EDM work are obtained by changeable current (I_p), voltage (V_g), and pulse-on-time (T_on) with the suitable values. Surface roughness values are quantified by of a surface tester and finally the machined surface morphology is examined with scanning electron microscope (SEM).