Diffusion bonding of AA7075/AZ80 joint has been synthesized, studied and demonstrated to optimize the lap shear, Ram tensile and hardness properties. Response surface methodology (RSM) is applied to develop mathematical relationships between the control parameters of two factors and three-level responses. Optimization experiments were carried out to check the models’ adequacy. The results show a high degree of coincidence between the optimized and actual values, implying that the proposed models can accurately forecast lap shear, Ram tensile, and hardness properties force within the process parameter constraints of the diffusion bonding process. Scanned electron microscopic Scanning Electron Microscope (SEM) images, optical images, and radiography film photography investigations also revealed the excellent fracture resistance of the AA7075/AZ80 alloy, making it a suitable material for deployment in engineering applications.

Of late, due to the launch of improved machine tool designs and extremely hard cutting tools, “Hard Turning” (HT) or “Hard Finish Turning” (HFT) has turned out to be an innovative, cost-effective, and smart alternative to the traditional grinding and subsequent superfinishing processes. As a result, HT clenches the potential to produce excellent part quality in very little time along with negligible additional costs, which is considered to be a boon for the manufacturing industries. Hence, an attempt was made to review the development, key insights, and research progress in the HT process. So, a huge pool of HT studies has been reviewed to achieve a better understanding of the evolution and key insights namely process, workpiece materials, cutting inserts, machine tools, and machining parameters. Additionally, the effectiveness of HT using CBN (Cubic Boron Nitride) insert under different machining conditions is briefed. The review highlights the growing potential of HT in modern manufacturing and outlines the challenges and future research direction.

The search for alternative fuels compatible with internal combustion engines has escalated as a result of worldwide pollution and the exhaustion of fossil resources. Alcoholic fuels, such as methanol, ethanol, butanol, and fusel alcohols, are being considered as viable alternatives to gasoline and gaseous fuels. This review analyzes the effects of alcoholic fuels on the performance, combustion, and emissions of spark-ignition (SI) engines. It specifically focuses on several fuel supply modes, including blending, dual mode, and dedicated (100

Lightweight and high-strength materials are the significant demand for energy storage applications in recent years. Composite materials have the potential to attain physical, chemical, mechanical, and tribological qualities in the present environment. In this study, graphene (Gr) and biosilica (Bs) nanoparticle extracts from waste coconut shell and rye grass are utilized as reinforcement materials to add to the aluminum silicon (Al-Si) alloy matrix materials. Selective laser melting (SLM) is a rapidly manufacturing technology used to create Al/Gr/Bs hybrid composites. The specimens are made up of four distinct combinations of base matrix alloy (100 wt

This study aims to develop hybrid polymer laminate (HPL) structure utilizing the 3D printing fused filament fabrication (FFF) method and analyze the printing process. The HPL plates were fabricated using PETG and nylon 66 thermoplastic polymers at varying infill densities, printing speeds, and layer thicknesses. The experimental setup followed a fixed matrix based on the L9 orthogonal array (OA). Each HPL consisted of a bottom layer printed with nylon 66, with PETG layers sandwiched on top. Subsequently, the samples underwent testing using a UTM m/c to assess their tensile and flexural strength, as well as printing efficiency. Warping was observed on the printed samples, with a maximum tensile strength of 27 MPa and flexural strength of 14.5 MPa recorded. Notably, different strength values were observed when altering printing parameters. While the printing process was successful, the resulting HPL exhibited slightly lower strength compared to PETG or nylon 66 filaments. The study achieved a maximum printing efficiency of 90

This study investigates the impact of Acacia catechu (AC) gum filler at various volume percentages (5

Of late, hard turning is widely accepted as an innovative and cost-effective machining solution for the hard-to-cut materials in a single machining set-up using Dry machining and other cooling medium such as liquid and solid lubricants. The hard turning provides better part quality than grinding, but hard turning surfaces are affected by the distressed surface pattern termed as white layer (WL). This WL is detrimental to the part produced by decreasing the fatigue life. Also, the surface integrity is deteriorated due to dynamic phase transformations. So, an attempt was made with super hardened AISI D4 steel turned with cubic boron nitride insert under Dry Machining, also gas mixture cooling. Noticeably, the results revealed that the dry machining didn’t eliminate WL and produced more roughness. But WL elimination and better surface finish were accomplished under Gas mixture cooling.

The purpose of this research is to develop novel framework based on advanced tools, including machine learning and the Internet of Things and self-attention mechanisms. Traditional and advanced tools were used in the data-driven predictive maintenance mechanism and served as a basis for comparing the tools. At the power plant, thirty-four datasets were collected to monitor three industrial motors continuously. The tools’ predictive ability was analysed using conceptualized features from the sensory data , and the management strategy remained dependent on the network. The study results show that each tool performs at high-performing levels because each exceeded 75% of the performance metric. The study results indicated that the proposed framework gave a consistent high-performance metric, 86.4%, in all the ten experimental scenarios used . The rate determination was attributed to the choice of the long short-term memory architecture, the self-attention mechanisms, and the optimization techniques. The choice of using mean squared logarithmic error also contributed to the outcomes because these tools yield high-performance scores. In addition to these, the test of the forecasting models chosen also influenced this performance. This study’s findings show that this framework is reliable in predicting pending failure equipment and developing relevant management strategies in industrial motors failure. It was found that the use of advanced tools in the development of the framework was a crucial aspect. Scaled tools and optimization techniques are of crucial importance in predictive management in equipment failure as they assist the frameworks in identifying ideal features from the sensory data. It should also be noted that the choice of a loss-function model is also important in the predictability of framework..

Aluminum metal matrix composites (AMCs) have been employed in automobile manufacturing to reduce weight. Also this research concentrates on the tribological performances on the processed AMCs by the stir casting liquefying method. The aluminum alloy Al2024 was employed to nanoparticles of aluminum oxide for the preparation of AMCs with constant processing condition of stirring speed to produce the homogeneous dispersion. The processed composites were further investigated to identify the wear characteristics. Therefore, the dry sliding condition was achieved on the processed composites. The input parameters of dry sliding conditions are sliding distance, functional load, and sliding velocity, and the output characteristics are wear rate and coefficient of friction (COF). Those input parameters are framed by the Taguchi L9 array and parameters were further employed to optimize with grey relational analysis. From the L9 parameters, the better wear rate and COF were accumulated in the following parameter: 2,100 mm of sliding distance, 25 N of functional load, and 2.5 m/s of sliding velocity, respectively. Then the wear rates and COF values are subjected to produce the predicted responses with supporting of artificial neural network. Most of the predicted values are much higher than the actual wear response vales. The wear resistance of all the samples composed better performances with dispersion of nanoaluminum oxide particles on the Al2024 alloy.

In the recent days, super alloys especially nickel based materials are used more than 50% of aerospace gas turbine components such as turbine disc, blades etc., It becomes very hard to shape these materials with the use of traditional machining processes due to its improved strength at higher temperature. To overcome the issues faced during conventional machining, the various advanced machining techniques are tried for machining these super alloys. In the present study, Inconel 738 was cut by wire electrical discharge machining using 0.25 mm diameter copper wire. Demineralized water was used as dielectric fluid between tool and workpiece electrode. During the process, voltage, wire feed rate, time of pulse on and pulse off were adjusted at four different values and totally sixteen slots were cut to analyze the machining characteristics. The machined surfaces were tested for its surface finish, rate of material removal and kerf width. The ANOVA was performed using Minitab software to find out the optimized variables and percentage contribution of each parameter in providing the influencing results. Wire feed rate was the most influencing parameter to have the lowest kerf width. As far as Material removal rate, the four parameters were had the significant impact in increasing the MRR. Voltage is the important process parameter to reduce the surface roughness.

Welding is necessary in industries like light and heavy-duty manufacturing, construction, automotive, aerospace, maintenance, repair works, etc. Friction stir welding (FSW) is a recently created welding technique that is employed with a non-consumable pin in all of the above-mentioned production areas. The cross-sectional size and shapes of the pin are also showing a great impact on the properties of the joints. This review article begins with the history of welding methods and it covers the topics of welding evolution, principle, joining of similar and dissimilar materials using FSW, applications and defects, as well as the various process factors in managing the qualities of the welded joint. The necessity of FSW is inevitable as it shows a good response of the mechanical properties with solid state temperature. It is a versatile welding process that has the capacity to join numerous materials, beginning with aluminium alloys and moving on to magnesium alloys, steel, composites, polymers, and dissimilar metals combinations.

The key focus of the automobile and aerospace sector on composites materials is increasing since its mechanical properties and applications. The new field of attention for researchers and scientist as conventional machining of metal matrix composite (MMCs) which is complex and difficult. To overcome this difficult and complexity the Electric discharge machining (EDM) is on the unconventional machining process widely applied for machining of MMCs. This research work investigates different the process various parameters of EDM and the microstructure study of machined component. The components are manufactured with hybrid metal matrix composite. The performance measurements indicators are Material Removal Rate (MRR), Tool Wear Rate (TWR) are calculated by L9-orthogonal array 4 factors 3 level. The process parameters such as Pulse interval time (Toff), Pulse on (Ton ) and Pulse withdrawal time (Tf), specimen type were considered at three levels. Experiments were conducted based on L9 orthogonal array. The influence of process parameters over measurement performance like MRR and TWR were discussed along with the microstructure image of the work piece materials. Results showed that type of specimen was influencing parameter for the output response considered.

Ceramic matrix composites (CMCs) have grown in popularity as a material for a range of high as well as protection components, increasing the need to better understand the impacts of multiple machining methods. It is primarily composed of ceramic fibers embedded in the matrix. Ceramic materials, especially carbon fibers and carbon were used to create the matrix and fibers. These ceramics include a huge variety of non-metallic inorganic materials that are regularly utilized under high temperatures. The aircraft industry became revolutionized by this unique combination of materials, which made parts better resistant under extreme conditions as well as lighter than the earlier technology. The development, properties, and production of ceramic matrix composites, as well as space applications, are discussed in this article. Ceramic materials have an interesting set of properties, including great strength and stiffness under extremely high temperatures, chemical inertness, low density, etc. In CMC, ceramics are used in the matrix as well as reinforcement. The matrix material keeps things running smoothly while the reinforcement delivers unique special properties. Ceramic matrix composites are developed for applications that required high thermal and mechanical characteristics, which include nuclear power plants, aircraft, chemical plants, space structures, and transportation services. Even though advanced aircraft relies on high-performance propulsion systems, improving the total impulses over the total mass ratio for rocket engines becomes essential for improving their performance that demands reduced engine structural weight as well as higher component heat resistance. The evolution of new ultra-high-temperature composites having high-temperature resistance as well as low density that a substitute super alloy and refractory metal material has become so essential and laid the foundation for high-performance engine design. The benefits of continuous fiber- reinforced CMC with high-temperature engine designs have long been recognized as a better measure of a country’s ability to design and produce spacecraft, modern aircraft, and weapons. Ceramic matrix composites materials are used in various aircraft type engines, aircraft brake disks, high-temperature gas turbines components, slide bearing components, hot gas duct, flame holders and components for burners are made by using oxide CMCs.

Tungsten carbide is one of the cutting tools which has good wear resistant, abrasion resistant and better toughness during normal machining. To improve its tool life and also the surface finish of the machined component, various types of coatings such as TiAlN, TiN + AlCrN, TiN + TiAlN by physical vapour deposition (PVD) technique and boronising operation were being employed on WC substrate cutting tools. XRD analysis was carried out to check the peaks and phases of the boronised tools. SEM analysis was performed to check the microstructure images and the coating thickness. Hardness test was conducted to check the micro-vickershardness for the coated and boronised samples. Corrosion test was carried out to check the corrosion rate of the coated inserts. Machining studies were carried using EN19 workpiece material with different tools under study. Surface roughness of the workpiece was measured on the workpiece for the different coated tools. The better suitable coated tool was selected for machining EN19 alloy steels. (C) 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials, Manufacturing and Mechanical Engineering for Sustainable Developments-2020.

Surface metal matrix composites are considered as new group of newer engineered materials in which the surface of the bulk materials is modified by reinforcing the hard ceramic fine particles. Because of the enhanced properties of the materials, these groups of materials found variety of applications in different fields like biomedical, aerospace, power sectors and automobile industries. Even though different processes are there to prepare these surface composites, Friction stir processing is gaining attractiveness in producing surface composites due to its processing in solid state. In the present experimental work, Silicon carbide particles are dispersed in the surface of the Al 6063 base materials and studied the microstructure of the processed specimens. Totally four experiments were conducted using two different pin profiles such as cylinder and square. Spindle speed and tool traverse speed is changed in two different levels and specimens were prepared using vertical milling machine. The processed specimens were examined for its microstructure and results revealed that square pin tool has performed better in terms of forming the better surface and stirring the reinforcement particles in matrix aluminum specimen.

This paper discusses about predicting the machining parameters of Sink EDM drilling of Hybrid Metal Matrix Composite of Aluminum (LM6) strengthened with Boron Carbide (B4C) and Multi Wall Carbon Nano Tube (MWCNT), manufactured using stir casting technique. Three different specimens were prepared with different % wt Composition. The output process parameters like Metal Removal Rate (MRR), rate of tool wear, and surface finish of the dilled specimens were predicted by Artificial Neural Network (ANN) technique. To develop the model the input process parameters like pulse interval time (Toff), pulse duration time (Ton), current (I), voltage (V), MWCNT weight percentage and distance between electrode and work piece (G) were considered. From the experimental results it was found that after training the model, the developed Artificial Neural Network model was found to be very effective in predicting the output parameters with 98 % accurate with the experimental results better in terms of forming the better surface and stirring the reinforcement particles in matrix aluminum specimen.

The ever increasing service necessities in industries like automobile and aerospace demands the engineers to use the aluminium based composites which are reinforced by either single or mixture of ceramic particles. When hybrid reinforcements are used, the resulting composites are having superior mechanical properties. In the present experimental work, the Al 5083 was reinforced by Titanium oxide and aluminium oxide to the depth of 2mm and processed by solid state friction stir processing technique. To prepare the surface composites, three non-consumable rotating tools were used with different tool pin profile such as square, straight cylinder and taper cylinder. The other parameters like tool rotational speed, tool traverse speed, number of passes were maintained uniform. Totally three workpieces were processed in order to inspect the ultimate tensile strength, yield strength and micro hardness. The test results shown that the square tool pin has delivered the highest strength and hardness than the other tool pin profile. The micro hardness test results showed that the hardness of the reinforced zone is higher than unreinforced region.

The demand for advanced materials with low density and high strength is always present in areas like aerospace, automotive, and military applications. Aluminum based hybrid composites are the new generation group of materials that have the prospective to satisfy the above need. In the present work, an attempt was made to develop AA 5083 reinforced with silicon carbide and titanium oxide surface composites. Number of passes, revolving speed, and welding speed were the process parameters considered and varied in three levels. Ultimate tensile strength was measured and modeling equation was developed by response surface methodology and suitability of the equation was checked by ANOVA. The model was best to predict the ultimate tensile strength of the processed workpiece and it was observed that number of passes was the dominating parameter followed by revolving speed. The ultimate tensile strength of the processed workpiece was 237Mpa with an increase of nearly 50%.