Manufacturing Technology Today

Balasubramanian, V.

• Corrosion and Metallurgical Characteristics of AZ31B Magnesium Alloy Under NaCl Environment

Abstract Views :207  |  PDF Views:0

Authors

D. Thirumalaikumarasamy ¹, K. Shanmugam ¹, V. Balasubramanian ¹, S. Sree Sabari ¹

Affiliations
1 Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Chidambaram, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 15, No 11 (2016), Pagination: 9-28

Abstract

An investigation was carried out to quantify and characterize the corrosion behaviour of AZ31B magnesium alloy. The specimens were underwent immersion, salt spray, pitting and galvanic corrosion tests in order to quantify and characterize the corrosion rates of the AZ31B specimens with the influence of different pH values, chloride ion concentration and the corrosion time. An attempt was also made to develop an empirical relationship to predict the corrosion rate of AZ31B magnesium alloy. Three factors, five level, central composite rotatable design matrix was used to minimize the number of experimental conditions. Response surface methodology was used to develop the relationship. The developed relationship can be effectively used to predict the corrosion rate of AZ31B magnesium alloy at 95% confidence level. The results show that the corrosion rate was higher in salt spray corrosion tests than the immersion, pitting and galvanic corrosion tests.

Keywords

AZ31B Magnesium Alloy, Response Surface Methodology, Corrosion Rate.

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References

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• Zhou, WQ; Shan, DY; Han, EH; Ke, W: Initial corrosion behavior of AZ91 magnesium alloy in simulating acid rain under wet-dry cyclic condition, ‘Transactions of Nonferrous Metals Society of China’, vol. 18, no. 2, 2008, 334-338.
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• Rong-chang Zeng; Jin Zhang; Wei-jiu Huang; Dietzel, W; Kainer, KU; Blawert, C; Wei Ke: Review of studies on corrosion of magnesium alloys, ‘Transactions of Nonferrous Metals Society of China’, vol. 16, no. 2, 2006, 763-771.
• Feng Liu; Ying-Wei Song; Da-Yong Shan; En-Hou Han: Corrosion behavior of AZ31 magnesium alloy in simulated acid rain solution ‘Transactions of Nonferrous Metals Society of China’, vol. 20, 2010, 638-642.
• Lei Wang; Tadashi Shinohara; Bo-Ping Zhang: Influence of chloride, sulfate and bicarbonate anions on the corrosion behavior of AZ31 magnesium alloy, ‘Journal of Alloys and Compounds’, vol. 496, no.1, 2010, 500-507.
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• Influence of Welding Speed on Tensile and Impact Properties of Friction Stir Welded High Strength Low Alloy Steel Joints

Abstract Views :194  |  PDF Views:1

Authors

S. Ragu Nathan ¹, S. Malarvizhi ¹, V. Balasubramanian ¹, A. G. Rao ²

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Dept., of Manufacturing Engg, Annamalai University, Annamalainagar, Tamilnadu, IN
2 Marine Metallurgy Dept., Naval Materials Research Laboratory (NMRL), Ambernath, Mumbai, Maharastra, IN

Source

Manufacturing Technology Today, Vol 15, No 6 (2016), Pagination: 15-24

Abstract

Friction Stir Welding (FSW) of high strength low alloy (HSLA) steel has drawn attention of researchers worldwide owing to its many benefits in construction of warships. In order to improve the weld quality and tool life, it is important to optimize the welding speed with the objective of producing defect free friction stir welded HSLA steel joints with excellent combination of strength and toughness. Hence, in this investigation an attempt has been made to understand the influence of welding speed on tensile and impact toughness properties of friction stir welded high strength low alloy (HSLA) steel joints. Five different welding speeds (20, 25, 30, 35 and 40 mm/min respectively) and constant tool rotational speed (600 rpm) are used to fabricate the HSLA steel joints. Due to the formation of lath upper bainite and acicular ferrite microstructure in the stir zone under optimum heat input condition could be the reason for superior mechanical properties of the joint fabricated using welding speed of 30 mm/min compared to other joints.

Keywords

Friction Stir Welding, Welding Speed, HSLA Steel, Tensile Properties.

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• Developing Empirical Relationship to Predict the Strength of Friction STIR Lap Welded Joints of AA2014-T6 Aluminum Alloy

Abstract Views :165  |  PDF Views:1

Authors

C. Rajendran ¹, K. Srinivasan ¹, V. Balasubramanian ¹, H. Balaji ², P. Selvaraj ²

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Dept of Manufacturing Engineering, Annamalai University, Annamalainagar, IN
2 Aeronautical Development Agency (ADA), Bangalore, IN

Source

Manufacturing Technology Today, Vol 15, No 3 (2016), Pagination: 12-23

Abstract

AA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking, alloy segregation, partially melted zone, and porosity. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to develop empirical relationship to predict strength of friction stir lap welded (FSLW) joints of AA2014 aluminum alloy using statistical tools such as design of experiments (DoE), analysis of variance (ANOVA). The developed empirical relationship can be effectively used to predict the strength of friction stir welded lap joints of AA2014 -T6 aluminum alloy at the 95% confidence level.

Keywords

Friction STIR Welding, Aluminum Alloy, Design of Experiment, Lap Joint, Tensile Strength.

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• Performance of Plasma Transferred ARC Hard Faced Friction Stir Welding Tools for Joining AA7075-T₆ Aluminium Alloy

Abstract Views :197  |  PDF Views:1

Authors

A. Baskaran ¹, K. Shanmugam ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 15, No 5 (2016), Pagination: 17-26

Abstract

In the present work an attempt was made to develop low cost high temperature wear resistance hard facing tools. The hard facing was applied on mild steel rod using chromium carbide powder and tungsten carbide powder by plasma transferred arc (PTA) hard facing technique. A comparative study was done to study the performance of hard facing tools with conventional tools. In this work, friction stir welding of AA7075-T6 plate of 6 mm thickness was investigated with an aim to understand the performance of tool materials on weld microstructure and tensile properties. The results showed that sound joints can be achieved with a joint efficiency of 83% while using PTA hard faced tools with careful selection of optimized process parameters.

Keywords

Plasma Transferred Arc Hard Facing, Friction Stir Welding, Aluminum Alloy, Tensile Properties.

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• Microstructural Characterization and Immersion Corrosion Behavior of Atmospheric Plasma Sprayed Alumina Coatings on AZ31B Magnesium Alloy in Nacl Solution

Abstract Views :186  |  PDF Views:2

Authors

D. Thirumalaikumarasamy ¹, K. Shanmugam ¹, V. Balasubramanian ¹

Affiliations
1 Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Chidambaram, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 15, No 2 (2016), Pagination: 10-23

Abstract

Plasma sprayed ceramic coatings are successfully used in many industrial applications, where high wear and corrosion resistance with thermal insulation are required. The corrosion degradation of a uncoated and atmospheric plasma sprayed alumina (APS) coatings on AZ31B magnesium alloy was investigated using immersion corrosion test in NaCl solutions of different chloride ion concentrations viz., 0.01 M, 0.2 M, 0.6M and 1M. The corroded surface was characterized by an optical microscope and X-ray diffraction. The results showed that the corrosion deterioration of uncoated and coated samples were significantly influenced by chloride ion concentration. The uncoated magnesium and alumina coatings was found to offer a superior corrosion resistance in lower chloride ion concentration NaCl solutions (0.01M and 0.2MNaCl). On the other hand the coatings and Mg alloy substrate were found to be highly susceptible to localized damage, and could not provide an effective corrosion protection in solutions containing higher chloride concentrations (0.6M and 1 M). It was found that the corrosion resistance of the ceramic coatings and base metal gets deteriorated with the increase in the chloride concentrations.

Keywords

Atmospheric Plasma Spraying, Magnesium Alloy, Chloride Ion Concentration, Corrosion, NaCl.

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• Effect of Tool Velocity Ratio on Microstructural Characteristics of Friction Stir Processed Aluminium Based Metal Matrix Composite

Abstract Views :186  |  PDF Views:3

Authors

P. Vijayavel ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 15, No 4 (2016), Pagination: 11-19

Abstract

Stir casted aluminium (Al) based metal matrix composites (MMCs) have inferior properties due to uneven distribution of reinforcement particles. Friction stir processing (FSP) is used to overcome the uneven distribution of SiC particles in the Al matrix. The FSPed microstructure is significantly influenced by the process parameters used for processing. In FSP, the effect of tool velocity ratio (Tool rotation velocity/Tool travel velocity) on material flow, material mixing, material consolidation is predominant than other parameters. Hence a perfect combination of tool rotation speed and tool traverse speed is required to produce the surface modification. In this investigation the tool rotation speed is varied from 800 rpm to 1200 rpm while the tool rotation speed is maintained constant at 40 mm/min. The FSPed zones produced for different toolvelocity ratiowere subjected to micro structural characterization using optical microscope and SEM. From this investigation it is found that tool velocity ratio of 2.62 exhibited defect free stir zone with higher hardness compared to other ratios. The reasons for the above effects are discussed in detail in this paper.

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• Predicting Corrosion Rate of Weld Nugget (Stir Zone) of Friction Stir Welded Dissimilar Joints of Aluminium - Magnesium Alloys

Abstract Views :195  |  PDF Views:1

Authors

R. Kamal Jayaraj ¹, S. Malarvizhi ¹, V. Balasubramanian ²

Affiliations
1 Dept of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN
2 Centre for Materials Joining and Research (CEMAJOR), Dept of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 15, No 4 (2016), Pagination: 20-28

Abstract

Joining of dissimilar alloys such as Aluminium (Al) and Magnesium (Mg) by fusion welding processes was very difficult due to formation of Al12Mg17 intermetallic compounds in fusion zone. However, friction stir welding (FSW) is expected to join dissimilar alloys with adequate joint strength because it is a solid-state process. But the Al/Mg FSW dissimilar joints are more prone to corrosion attack due to intercalated microstructure present in weld nugget (stir zone). The limitation of low corrosion resistance restricts practical applications of these types of joints. In this investigation, an attempt has been made to develop an empirical relationship to predict the corrosion rate of nugget region of friction stir welded dissimilar joints of AA6061 Al - AZ31B Mg alloys. Three important immersion corrosion test parameters, namely, chloride ion concentration, pH value and immersion time are chosen as input parameters. Three factors, five level, central composite rotatable design matrix is used to minimize the number of experimental conditions. Response surface methodology is used to develop an empirical relationship. The developed relationship can be effectively used to predict the corrosion rate of friction stir welded dissimilar joints of AA6061 Al - AZ31B Mg alloys at 95 % confidence level. The methodology adopted to develop the relationship is presented in this paper.

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• Comparison between Riveted Joints and Friction STIR Welded Joints of AA2014 Aluminum Alloy

Abstract Views :176  |  PDF Views:1

Authors

C. Rajendran ¹, K. Srinivasan ¹, V. Balasubramanian ¹, H. Balaji ², P. Selvaraj ²

Affiliations
1 Center for Materials Joining and Research, Dept of Manufacturing Engg, Annamalai University, Annamalainagar, Tamil Nadu, IN
2 Aeronautical Development Agency, Bangalore, IN

Source

Manufacturing Technology Today, Vol 14, No 12 (2015), Pagination: 3-8

Abstract

AA2014 aluminum alloy has been widely used in aircraft and automotive industries as structural members. Conventionally, these structures were fabricated using rivets, as it is difficult to join this alloy by fusion welding processes. Friction Stir Welding (FSW) can be successfully applied to replace the riveted construction of aluminum alloy (AA2014) in aircraft structures. Hence, an attempt has been made to evaluate and compare the load carrying capabilities of FSW joints and riveted joints of AA2014 aluminum alloy. FSW joints were fabricated using optimized process parameters, and riveted joints were fabricated using standard shop floor practice in butt and lap configurations. FSW joints exhibited 75% higher tensile and shear fracture load compared to the riveted joints.

Keywords

Aluminum Alloys, Friction Stir Welding, Riveting, Butt and Lap Joint.

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• Hot Tensile Properties of Autogenous Pulsed Current Gas Tungsten Arc Welded Super 304HCu Austenitic Stainless Steel Joints

Abstract Views :193  |  PDF Views:0

Authors

M. Vinoth Kumar ¹, V. Balasubramanian ², A. Gourav Rao ³

Affiliations
1 Dept. of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN
2 Center for Materials Joining and Research (CEMAJOR), Dept. of Manufacturing Engg., Annamalai University, Annamalai Nagar, Tamil Nadu, IN
3 Naval Material Research Laboratory (NMRL), Ambernath, Mumbai, IN

Source

Manufacturing Technology Today, Vol 14, No 9 (2015), Pagination: 11-17

Abstract

The super 304HCu austenitic stainless steel tubes containing 2.3 to 3 (% wt) of Cu is mainly used in superheaters and reheater of ultra super critical boilers. The addition of Cu to super 304HCu has caused improvement in its corrosion and creep resistance. Austenitic stainless steels welded by constant current gas tungsten arc welding (GTAW) produce coarse columnar grains, increase alloy segregation and may result in low mechanical properties of the weld joint. Hence, autogenous pulsed current GTAW (PC-GTAW) was used to weld super 304HCu tubes of 57.1 mm outer diameter and 3.5 mm thick to control the solidification structure by altering the prevailing thermal gradients in the weld pool. The microstructure, hot tensile properties (550 °C, 600 °C and 650 °C), and fracture surface of the autogenous PC-GTAW welded joint was evaluated. Current pulsing in PC-GTAW joint cannot eliminate segregation in weld metal and exhibited lower tensile strength than the parent metal at all test temperature.

Keywords

Super 304HCu Stainless Steel, Autogenous Pulsed Current Gas Tungsten Arc Welding, Hot Tensile Properties, Microstructure.

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• Friction STIR Welding of Copper Alloys by Pta Hardfaced Tungsten Carbide Tools

Abstract Views :159  |  PDF Views:1

Authors

A. Baskaran ¹, K. Shanmugam ¹, V. Balasubramanian ¹

Affiliations
1 Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 14, No 11 (2015), Pagination: 3-11

Abstract

In the present work an attempt was made to develop high temperature wear resistant hardfacing tools for friction stir welding (FSW) of commercial grade copper alloy. Hardfacing was applied on mild steel rod using Tungsten carbide forming powder by plasma transferred arc hardfacing (PTA) process. Commercially available tool materials like high carbon steel (HCS), high speed steel (HSS) and super high speed steel (SHSS) were also used to friction stir weld copper alloy for comparison purpose. From this investigation, it is found that the PTA hardfaced tool yielded defect free joints without tool wear compared to other joints. The optimum level of heat generation, formation of finer grains and higher hardness of stir zone are main reasons for the superior tensile properties of the joints fabricated by PTA hardfaced tungsten carbide tools.

Keywords

Friction Stir Welding, Copper Alloy, Plasma Transferred Arc Hard Facing, Tensile Properties, Microstructure.

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• Developing Empirical Relationship to Predict the Strength of Friction Stir Spot Welded Dissimilar Joints of Aluminum and Magnesium Alloys

Abstract Views :141  |  PDF Views:0

Authors

S. Manickam ¹, C. Rajendran ¹, V. Balasubramanian ¹

Affiliations
1 Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Tamilnadu, IN

Source

Manufacturing Technology Today, Vol 14, No 11 (2015), Pagination: 12-20

Abstract

Friction Stir Spot Welding (FSSW) is a variant of Friction Stir Welding (FSW) process, in which a non-consumable rotating tool is plunged into a material under high forging force to create a bond. It is employed to join dissimilar materials like aluminum and magnesium as it is a solid state welding processes, and helps to avoid defects found in fusion welding processes. In this investigation, an attempt is made to join Aluminum Alloy (AA6061) with Magnesium Alloy (AZ31B) by FSSW process. An empirical relationship was developed to predict the Tensile Shear Fracture Load (TSFL) incorporating the four most important FSSW parameters, i.e., tool rotational speed, plunge rate, dwell time and tool diameter ratio, using Response Surface Methodology (RSM). The maximum TSFL obtained was 3.61 kN, with the tool rotation speed of 1000 rpm, plunge rate of 16 mm/ min, dwell time of 5 sec and tool diameter ratio of 2.5.

Keywords

Frictions Stir Spot Welding, Magnesium Alloy, Aluminum Alloy, Dissimilar Joint, Response Surface Methodology, Tensile Shear Fracture Load.

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• Effect of Tool Pin Profiles on Joint Characteristics of Under Water Friction STIR Welded AA2519-T87 Aluminium Alloy

Abstract Views :160  |  PDF Views:0

Authors

S. Sree Sabari ¹, V. Balasubramanian ², S. Malarvizhi ²

Affiliations
1 Dept of Manufacturing Engg, Annamalai University, Annamalai Nagar, Tamil Nadu, IN
2 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 14, No 11 (2015), Pagination: 21-28

Abstract

AA2519-T87 is an age hardenable aluminium alloy used in the fabrication of light combat vehicles in the military application. Fusion welding of this aluminium alloy results in solidification related problems like porosity, hot cracking, etc. In order to overcome such problems, friction stir welding (FSW) process is used to join this material. The thermal cycle experienced by the thermo mechanical affected zone (TMAZ) and heat affected zone (HAZ) is causing grain coarsening and precipitates dissolution and resulting in poor joint properties. To get rid of this problem, under water friction stir welding (UWFSW) process can be adopted. However, the material flow during friction stirring will be entirely different in FSW and UWFSW. Hence an investigation is undertaken to study the effect of tool pin profiles on stir zone characteristics and the resultant tensile properties of the joints fabricated by UWFSW. Four different pin profiles, namely, straight cylindrical (STC), taper cylindrical (TAC), straight threaded cylindrical (STC), and taper threaded cylindrical (TTC) were used to fabricate the joints. From this investigation, it is found that the joint made by taper threaded pin profiled tool exhibited higher tensile properties and this may be attributed to the grain boundary strengthening and narrowing of lower hardness distribution region (LHDR).

Keywords

Underwater Friction Stir Welding, Pin Profiles, Microstructure, Tensile Properties, Microhardness.

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• Development of Empirical Relationships to Predict Strength of P/M Sintered Pure Copper and Pure Nickel Diffusion Bonded Bimetallic Joints

Abstract Views :152  |  PDF Views:1

Authors

A. Murugan ¹, T. Senthilvelan ¹, V. Balasubramanian ²

Affiliations
1 Dept. of Mechanical Engineering, Pondicherry Engineering College, Puducherry, IN
2 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 14, No 2 (2015), Pagination: 11-19

Abstract

In the present study, pure copper (Cu) and pure nickel (Ni) plates prepared by powder metallurgy (P/M) method were bonded by diffusion bonding technique. From the literature, it was identified that the predominant diffusion bonding process parameters such as bonding temperature, holding time and bonding pressure influence the shear and bonding strength of diffusion bonded joints. In this investigation an attempt was made to develop empirical relationships to predict the shear strength and bonding strength of diffusion bonded bimetallic joints of pure Cu/Ni incorporating the above parameters using statistical tools such as design of experiments, analysis of variance and regression analysis. The developed empirical relationships can be used to predict the strength of Cu/Ni bimetallic joints at 95% confidence level.

Keywords

Powder Metallurgy, Diffusion Bonding, Design of Experiments, Analysis of Variance and Regression Analysis.

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• Statistical Analysis and Optimization of Atmospheric Plasma Spraying Parameters to Attain Maximum Corrosion Resistance in Alumina Coatings on AZ31B Magnesium Alloy

Abstract Views :149  |  PDF Views:1

Authors

D. Thirumalaikumarasamy ¹, K. Shanmugam ¹, V. Balasubramanian ¹

Affiliations
1 Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Chidambaram, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 14, No 6 (2015), Pagination: 10-26

Abstract

In this study, an attempt has been made to establish an empirical relationship is developed to predict corrosion rate of the atmospheric plasma sprayed alumina coatings on AZ31B magnesium alloy by incorporating process parameters such as power, stand-off distance and powder feedrate. Statistical tools such as design of experiments, analysis of variance, and regression analysis are used to develop the relationships. The developed empirical relationship can be effectively used to predict the corrosion rate of plasma sprayed alumina coated AZ31B magnesium alloy at the 95% confidence level. Sensitivity analysis was carried out and compared with the relative impact of three process parameters on corrosion rate to verify the measurement errors on the values of the uncertainty in estimated parameters. The results indicate that the input power has the greatest influence on corrosion rate, followed by stand-off distance and powder feedrate.

Keywords

Atmospheric Plasma Spraying, Corrosion Rate, Response Surface Methodology Alumina Coating.

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• Comparative Study of the Corrosion Behavior of AZ31B Magnesium Alloy under Immersion and Salt Fog Environments

Abstract Views :176  |  PDF Views:0

Authors

D. Thirumalaikumarasamy ¹, K. Shanmugam ¹, V. Balasubramanian ¹

Affiliations
1 Dept of Manufacturing Engineering, Annamalai University, Annamalainagar, Chidambaram, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 13, No 8 (2014), Pagination: 12-29

Abstract

The comparative evaluation of corrosion behavior of AZ31B magnesium alloy was investigated by conducting immersion and salt spray tests in NaCl solution. The specimens were exposed to immersion and salt spray environments in order to characterize their corrosion rates. In addition, an attempt was made to develop an empirical relationship to predict the corrosion rate of the AZ31B magnesium alloy in immersion tests and salt spray corrosion tests using response surface methodology. The corrosion morphology observation was carried out by scanning electron microscopy. General corrosion was more prevalent on the immersion surface. However, the pits on the salt spray surface showed larger surface areas, larger volumes, and covered more area on the micrographs as compared to the pits on the immersion surfaces, due to the pit debris that trapped chloride ions within the pits. Finally, it concludes that the AZ31B magnesium alloys are suitable for immersion conditions than salt spray environments.

Keywords

Magnesium Alloys, Immersion Tests, Salt Spray Tests, Corrosion Rate, Response Surface Methodology.

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• Developing Empirical Relationship to Predict Hardness of the Laser Hardfaced Ni-Based Alloy Surfaces

Abstract Views :188  |  PDF Views:1

Authors

S. Gnanasekaran ¹, G. Padmanaban ¹, V. Balasubramanian ¹, Hemant Kumar ², Shaju K. Albert ²

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar, Tamil Nadu, IN
2 Material Technology Division, Indira Gandhi Center for Atomic Research (IGCAR), Kalpakam, IN

Source

Manufacturing Technology Today, Vol 16, No 1 (2017), Pagination: 9-17

Abstract

Nuclear reactor components generally undergo wear damage due to severe operating conditions. The operating temperature of nuclear components generally falls in the range of 573-873 K. Among the reactor components, feed water regulator valves, used to throttle coolant flow, experiences higher wear rate. To enhance the wear resistance, nickel (Ni) and cobalt (Co) based alloys are hardfaced into austenitic stainless steels (ASS) through laser hardfacing technique. Laser hardfacing technique is an established surfacing process to deposit Ni base alloys with minimum dilution. Though lot of research works have been carried out so for to characterize laser hardfaced Ni base alloy surfaces, there is no direct correlation between laser parameters and hardness of the hardfaced surfaces. Hence in this investigation, an attempt has been made to develop empirical relationship to predict hardness of laser hardfaced Ni base alloy surface incorporating laser parameters using statistical tools such as design of experiments (DoE), analysis of variance (ANOVA). The developed empirical relationship can be effectively used to trail the hardness of laser hardfaced nickel alloy surfaces by altering laser parameters.

Keywords

Austenitic Stainless Steel, Laser Hardfacing, Design of Experiment, Hardness.

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References

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• Predicting Porosity and Microhardness of the High Velocity Oxy-Fuel (HVOF) Sprayed Iron Based Amorphous Metallic Coatings

Abstract Views :217  |  PDF Views:4

Authors

S. Vignesh ¹, K. Shanmugam ¹, V. Balasubramanian ¹, K. Sridhar ²

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN
2 Protective Technologies Department, Naval Materials Research Laboratory (NMRL), Ambernath, Thane (Dist), Maharashtra, IN

Source

Manufacturing Technology Today, Vol 16, No 1 (2017), Pagination: 18-28

Abstract

Fluid handling equipment such as propellers, impellers, pumps posses the inherent risk of flow-dependent erosion-corrosion problems. Though there are many coating materials available to combat erosion-corrosion damage in the above components, iron based amorphous coatings exhibits high erosion-corrosion resistance. High velocity oxy-fuel (HVOF) spray process is extensively used to deposit erosion-corrosion resistance amorphous coatings. In this investigation, iron based amorphous metallic coating was deposited on 316 stainless steel using HVOF spray process by varying the parameters such as oxygen flow rate, fuel flow rate, powder feed rate, carrier gas flow rate, and spray distance. Empirical relationships were established to predict the porosity and micro hardness of iron based amorphous coating. Microstructure observations of the coating were done by optical microscope. From the results, it is found that, fuel flow rate and spray distance appeared to be the most significant parameters affecting the mechanical properties of the iron based amorphous coating.

Keywords

High Velocity Oxy Fuel Spray, Iron Based Amorphous Metallic Coating, Micro-Hardness, Porosity.

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References

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• Determination of Minimum Corrosion Conditions for the Stir Zone of Friction Stir Welded AZ31B Magnesium Alloy

Abstract Views :193  |  PDF Views:1

Authors

R. Kamal Jayaraj ¹, S. Malarvizhi ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 16, No 4 (2017), Pagination: 12-21

Abstract

Joining of magnesium alloys is increased because of its superior properties like light weight and high specific strength. Compared to fusion welding process, friction stir welding (FSW) is widely adaptable to join magnesium and its alloy. In the FSW joint, grains are very fine in stir zone (SZ) compared to the other zones. This leads to severe corrosion attack at the stir zone. The chloride ion concentration, pH value and immersion time are reported to be the more influencing parameters on corrosion attack. The present work aims to identify the minimum corrosion conditions in the SZ of friction stir welded AZ31B magnesium alloys by statistical tools such as design of experiments (DoE), analysis of variance and response surface methodology (RSM). From the results, it is found that the chloride ion concentration has a greater influence on corrosion rate than the other two parameters.

Keywords

Friction Stir Welding, AZ31B Magnesium Alloy, Response Surface Methodology, Corrosion Rate.

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References

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• Developing Empirical Relationship to Predict the Diameter of Multiwall Carbon Nano Tubes (MWCNTs) Synthesized by Chemical Vapor Deposition (CVD) Process

Abstract Views :223  |  PDF Views:2

Authors

V. Sivamaran ¹, V. Balasubramanian ¹, M. Gopalakrishnan ², V. Viswabaskaran ³, A. Gourav Rao ⁴

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Chidambaram, Tamil Nadu, IN
2 Department of Chemistry, Annamalai University, Chidambaram, Tamil Nadu, IN
3 VB Ceramic Research Centre (VBCRC), Chennai, IN
4 NMRL, Mumbai, IN

Source

Manufacturing Technology Today, Vol 16, No 6 (2017), Pagination: 3-11

Abstract

The thermal chemical vapor deposition (CVD) route was used to synthesize multi walled carbon nano tubes (MWCNTs) and metal NiO powders was used as catalyst and it supported on crystalline alumina nano particles. Acetylene was used as the carbon source gas and Argon was used as the carrier gas. An empirical relationship was developed to predict the diameter of MWNTs incorporating important CVD process parameters. Three factors, five levels central composite design was used to minimize number of experimental conditions. The CVD parameters such as reaction temperature, gas flow rate and process time were chosen as the important parameters. The diameter of MWNTs was measured using field emission scanning electron microcopy (FESEM). Analysis of variance (ANOVA) method was used to identify significant main and interaction factors. Final empirical relationship was developed using these significant factors. The developed empirical relationship can be effectively used to predict the diameter of MWNTs synthesized through CVD process at 95% confidence level.

Keywords

Carbo Nano Tube, Chemical Vapor Deposition, Design of Experiments, Analysis of Variance.

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References

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• Notch Tensile Properties of Various Regions of Dissimilar Joints of Austenitic and Ferritic Steels

Abstract Views :190  |  PDF Views:5

Authors

K. Karthick ¹, S. Malarvizhi ¹, V. Balasubramanian ¹, S. A. Krishnan ², Shaju K. Albert ²

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar, IN
2 Materials Mechanics Section, Materials Technology Division,Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, IN

Source

Manufacturing Technology Today, Vol 16, No 6 (2017), Pagination: 12-22

Abstract

In sodium cooled fast breeder reactor at Kalpakkam, the steam generators are constructed using modified 9Cr-1Mo (also called as Grade 91 or P91) ferritic steel because of its high temperature strength and resistance to stress corrosion cracking. The interconnecting sodium piping between reactor and steam generator is made up of AISI 316LN because of its high creep strength and corrosion resistance. Nickel based fillers (Inconel 82/182) are commonly used to weld the 316LN piping with steam generator. For a better structural integrity assessment of this dissimilar joint, the tensile properties of each region need to be evaluated. Evaluating the tensile properties of various regions by smooth tensile specimens is quite complex and time consuming. In the present investigation, the notch tensile properties of various regions were evaluated by placing a notch at the desired locations of the dissimilar metal weld joint (DMWJ). The dissimilar joint between P91 and 316LN is fabricated by manual metal arc welding (MMAW) process using Inconel 182 electrodes. Notch tensile properties of each region were evaluated by placing a notch at different locations (viz. weld metal, buttering, HAZ of P91 and HAZ of 316LN). Microhardness variation across the DMWJ was recorded. Microstructural features of various regions were characterized by optical and scanning electron microscope. From this investigation, it is found that the notch placed in the HAZ of P91 exhibited highest notch tensile strength than other regions. A non-uniform hardness distribution is observed across the DMWJ and the maximum hardness is recorded at the interface between P91 HAZ to Inconel 182 buttering. The hardness is minimum at the outer edge of HAZ of P91 side. Evolution of carbon enriched hard zone at the interface between P91 and Inconel 182 buttering could be the reason for highest notch tensile strength.

Keywords

Dissimilar Metal Weld Joint, Notch Tensile Test, Microhardness, Microstructure.

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References

• Kumar, P; Pai, A: An overview of welding aspects and challenges during manufacture of Intermediate Heat Exchangers for 500MWe Prototype Fast Breeder Reactor, 'Procedia Eng.', vol. 86, 2014, 173-183.
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• Response Surface Methodology Approach for Predicting Grain Size and Tensile Strength of Friction Stir Welded AA 1100 Aluminium Alloy Joints

Abstract Views :159  |  PDF Views:0

Authors

S. Rajakumar ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Dept. of Manufacturing Engg., Annamalai University, Annamalai Nagar, Tamilnadu, IN

Source

Manufacturing Technology Today, Vol 10, No 6 (2011), Pagination: 20-25

Abstract

This paper reports empirical relationship to predict grain size and tensile strength of friction stir welded (FSW) AA 1100 aluminium alloy joints. Six factors, five level, central composite rotatable design matrix is used to predict the experimental conditions. The empirical relationships are developed by response surface methodology (RSM) incorporating tool and process parameters.

Keywords

Welding, ANOVA, Aluminium, Microstructure.

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• Understanding the Role of FSW Process Parameters on Strength Properties of Ferritic Stainless Steel Joints

Abstract Views :149  |  PDF Views:0

Authors

A. K. Lakshminarayanan ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Dept. of Manufacturing Engg., Annamalai University, Annamalai Nagar, IN

Source

Manufacturing Technology Today, Vol 10, No 2 (2011), Pagination: 10-18

Abstract

The effect of rotational speed, welding speed and tool shoulder diameter on the tensile and impact properties of AISI 409M ferritic stainless steel joints made by friction stir welding are investigated. The experiments were conducted based on three-factor five-level central composite rotatable design and empirical relationships were established between the process parameters (rotational speed, welding speed and tool shoulder diameter) and quality characteristics (tensile strength and impact toughness) of friction stir welded ferritic stainless steel joints. Furthermore, the numerical multiobjective optimisation was used to optimise the friction stir welding process parameters.

Keywords

Ferritic Stainless Steel, Tensile Strength, Impact Toughness, Optimisation.

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• Effect of Bonding Temperature on Microstructure and Mechanical Properties of AISI 304 to Ti-6Al-4V Diffusion Bonded Joints

Abstract Views :170  |  PDF Views:3

Authors

A. Arun Negemiya ¹, S. Rajakumar ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar, IN

Source

Manufacturing Technology Today, Vol 16, No 7 (2017), Pagination: 3-10

Abstract

Solid state diffusion bonding (DB) of Ti-6Al-4V and AISI 304 were studied in the temperature range of 600-1000°C with a constant pressure of 12 MPa and holding time of 60 minutes. Micro hardness measurements and the lap shear test were carried out to determine the hardness and strength of the joints respectively. Maximum lap shear strength of 138 MPa was attained in the joint that was diffusion bonded using a temperature of 900°C, holding time of 60 min and a bonding pressure of 12 MPa. Optical microscopy and scanning electron microscopy (SEM) were used to examine the grain growth and the fine details of the interface structure.

Keywords

Titanium, Diffusion Bonding, Dissimilar Joints, Micro Hardness.

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References

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• Process Parameter Selection for Friction Stir Welding of Cast A413 Aluminium Alloy Using Taguchi Experimental Design

Abstract Views :172  |  PDF Views:0

Authors

M. Jayaraman ¹, R. Sivasubramanian ², V. Balasubramanian ³, A. K. Lakshminarayanan ³

Affiliations
1 Dept. of Mechatronics Engg., Kongu Engg. College, Perundurai, Erode, IN
2 Dept. of Mechanical Engg., Coimbatore Institute of Technology, Coimbatore, IN
3 Centre for Materials Joining Research (CEMAJOR), Dept. of Manufacturing Engg., Annamalai University, Annamalai Nagar, IN

Source

Manufacturing Technology Today, Vol 7, No 12 (2008), Pagination: 3-10

Abstract

This paper discusses the use of Taguchi technique for maximizing the tensile strength of friction stir welded cast aluminium alloy A413. The experiments have been conducted using Taguchi's experimental design technique. The friction stir welding (FSW) process parameters namely tool rotational speed, welding speed, axial force play a major role in deciding the weld quality. The effect of process parameters on tensile strength is evaluated and the optimum welding condition for maximizing the tensile strength is determined. The analysis of variance and the signal to noise ratio of robust design are employed to investigate the influence of process parameters on the tensile strength of friction stir welded A413 aluminium alloy. To correlate the process parameters and the measured tensile strength, a mathematical model has been developed by multiple linear regression analysis. The developed mathematical model is found to be very useful for predicting the tensile strength of friction stir welded A413 aluminium alloy.

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• Simulation of Temperature and Residual Stress Field in Friction Stir Welded AISI 304 Stainless Steel Joints

Abstract Views :160  |  PDF Views:0

Authors

S. Sree Sabari ¹, M. Chenchu Giri ¹, V. Balasubramanian ²

Affiliations
1 Dept of Mech Engg., Sree Vidyanikethan Engineering College, Tirupati, AP, IN
2 Centre for Materials Joining Research (CEMAJOR), Dept of Manufacturing Engg., Annamalai University, Annamalai Nagar, TN, IN

Source

Manufacturing Technology Today, Vol 17, No 1 (2018), Pagination: 7-13

Abstract

Three-dimensional nonlinear thermal and thermo-mechanical numerical simulations are conducted for the friction stir welding of AISI 304 stainless steel. The finite element analysis code SYSWELD was used to simulate the results using inverse approach. Defect free welds were made experimentally using a rotational speed, welding speed and shoulder diameter of 800 rpm, 90 mm/min and 20 mm respectively. Residual stress measurement was carried out with X-ray stress analyzer employing C_rK_α radiation. The transient temperature fields were obtained by finite element simulation and the residual stresses in the welded plate are calculated using a three-dimensional elastic–plastic thermo-mechanical simulation. The results of the simulation are in good agreement with that of experimental results.

Keywords

Stainless Steel, Friction Stir Welding, Finite Element Analysis, Temperature Distribution, Residual Stress.

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• Tensile Properties of Gas Metal Arc and Cold Metal Transferred Arc Welded AA6061-T6 Aluminium Alloy Joints

Abstract Views :220  |  PDF Views:0

Authors

Addanki Ramaswamy ¹, S. Malarvizhi ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining and Research (CEMAJOR) Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar- 608 002, IN

Source

Manufacturing Technology Today, Vol 18, No 2 (2019), Pagination: 18-27

Abstract

Heat treatable aluminium alloy such as AA6061 finding wide applications especially in the fabrication of door, hood and trunk components in automobile sector. These components are made up of thin sheets of aluminium alloys due to the low density, high strength to weight ratio, excellent weld ability and better corrosion resistance characteristics. Gas metal arc welding (GMAW) process is one of the most widely used welding technologies in the automobile industry, because of its higher productivity. Cold metal transfer (CMT) welding technique, the most advanced variant of GMAW process attracts the automobile manufacturers because of its capabilities such as stable arc, higher welding speed, less spatter and minimum distortion. This paper focuses on the welding of thin sheets of AA6061-T6 aluminium alloys by constant current-gas metal arc welding (CC-GMAW) and cold metal transfer-gas metal arc welding (CMT-GMAW) processes and highlights its tensile properties. The micro hardness variation across the weld joint was recorded by Vickers micro hardness tester. A soft zone is observed in the HAZ region in both the cases, but the relative softening with respect to the base material is less in case of CMT-GMAW joint compared with the CC-GMAW joint. It is also observed that the width of the soft zone in CMT-GMAW joint is less compared with the CC-GMAW joint. It is concluded that the mechanical properties of CMT-GMAW joint are improved compared with the CC-GMAW joint due to the better refinement of grain structure with narrow soft zone formation.

Keywords

Aluminium Alloy, Gas Metal Arc Welding, Cold Metal Transfer Arc Welding, Tensile Properties, Micro Hardness

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References

• Flower, H.M: Light alloys: metallurgy of the light metals, ‘ International Materials Reviews’, Butterworth-Heinemann, Vol. 37, 1992,196-196
• Wang, P; S. Hu; J. Shen; Y. Liang: Characterization the contribution and limitation of the characteristic processing parameters in cold metal transfer deposition of an Al alloy, ‘J. Mater. Process. Technol’. Vol.245, 2017, 122–133.
• Norrish, J; Cuiuri, D: The controlled short circuit GMAW process : A tutorial, ‘J. Manuf. Process’. Vol. 16, 2014, 86–92.
• Wagiman, A; Bin Wahab, MS; Mohid, Z; Mamat, A: Effect of GMAW-CMT Heat Input on Weld Bead Profile Geometry for Freeform Fabrication of Aluminium Parts, ‘Appl. Mech. Mater.’ Vol. 465–466, 2013 ,1370–1374.
• Vargas, JA; Torres, J.E; Pacheco, JA; Hernandez, R.J: Analysis of heat input effect on the mechanical properties of Al-6061-T6 alloy weld joints, ‘Mater. Des.’, Vol.52, 2013, 556–564.
• Y. Liang, J. Shen, S. Hu, H. Wang, J. Pang, Effect of TIG current on microstructural and mechanical properties of 6061-T6 aluminium alloy joints by TIG–CMT hybrid welding, ‘J. Mater. Process. Technol’, Vol. 255, 2018, 161–174.
• Cornacchia,G; Cecchel, S, Panvini , A: A comparative study of mechanical properties of metal inert gas (MIG)-cold metal transfer (CMT) and fiber laserMIG hybrid welds for 6005A T6 extruded sheet, ‘Int. J. Adv. Manuf. Technol’ , Vol.94, 2018, 2017-2030.
• Pinto,H; Pyzalla, AR; Hackl, H; Bruckner, J: A Comparative Study of Microstructure and Residual Stresses of CMT-, MIG- and Laser-Hybrid Welds, ‘Mater. Sci. Forum’. Vol.627, 2006, 524-525.
• Zhang, YM, Pan, C: Male, a. T: Improved microstructure and properties of 6061 aluminum alloy weldments using a double-sided arc welding process, ‘Metall. Mater. Trans. A’,Vol. 31, 2000, 2537–2543.
• Ambriz, RR; Barrera, G.; García, R; López, VH.: A comparative study of the mechanical properties of 6061-T6 GMA welds obtained by the indirect electric arc (IEA) and the modified indirect electric arc (MIEA), ‘Mater. Des’. Vol. 30, 2009, 2446–2453.
• Kuo, TY; Lin, HC: Effects of pulse level of Nd-YAG laser on tensile properties and formability of laser weldments in automotive aluminum alloys, ‘Mater. Sci. Eng. A’. Vol. 416, 2006, 281–289.
• Nie, F; Dong, H; Chen, S; Li, P; Wang L.; Zhao, Z.; Li, X.; Zhang, H.: Microstructure and Mechanical Properties of Pulse MIG Welded 6061/A356 Aluminum Alloy Dissimilar Butt Joints, ‘J. Mater. Sci. Technol’, Vol.34, 2018, 551–560.
• Dutta,I;. Allen S.M; A calorimetric study of precipitation in commercial aluminium alloy 6061, ‘J. Mater. Sci. Lett’, Vol. 10 1991, 323–326

• Effect of Constricted Arc Welding on Tensile Properties of Thin Sheets of Aero Engine Grade Titanium Alloy

Abstract Views :217  |  PDF Views:0

Authors

V. Vaithiyanathan ¹, V. Balasubramanian ¹, S. Malarvizhi ¹, Vijay Petley ², Shweta Verma ²

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Dept. of Mfg. Engg., Annamalai University, Annamalai Nagar, Tamilnadu, IN
2 Materials Group (MTG) Gas Turbine Research Establishment (GTRE), Bengaluru, IN

Source

Manufacturing Technology Today, Vol 18, No 4 (2019), Pagination: 3-11

Abstract

Titanium and its alloys have been considered as one of the best engineering materials for aero-engine applications, because they possess many good characteristics such as high specific strength, superior corrosion resistance and good high temperature strength. Gas tungsten arc welding (GTAW) welding process is generally preferred because to repair aero-engine blades of its high versatility and easy applicability. Gas Tungsten Constricted Arc welding (GTCAW) is a new variant of GTAW process. It generates very high frequency (20 kHz) and alters the magnetic field of the arc, thus enabling the control of constriction of arc and leading to less heat input, narrow heat affected zone (HAZ), reduced residual stresses and distortion compared to conventional GTAW process. This paper reports the tensile properties of GTA and GTCA welded thin sheets (1.2 mm) of Ti-6Al-4V alloy used in aero-engine applications. The joints were characterized using optical microscopy, scanning electron microscopy and microhardness survey. From this investigation, it is found that GTCAW joints exhibited superior tensile properties compared to GTAW joints due to reduction of prior beta grain boundary, higher fusion zone hardness and narrow heat affected zone. Hence, it is preferred that GTCAW process can be employed to repair aero-engine components over GTAW process.

Keywords

Titanium Alloy, Gas Tungsten Arc Welding, Gas Tungsten Constricted Arc Welding, Tensile Properties, Microstructure.

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References

• G. Lutjering and J. C. Williams: ‘Titanium’, 177–232; 2003, Berlin, Springer-Verlag.
• R.R. Boyer An overview on the use of titanium in the aerospace industry: ’Material Science and Engineering A’ Vol.213, 1996, 103–114
• Wang, RR, Welsch, GE: Joining titanium materials with tungsten inert gas welding, laser welding and infrared brazing, ‘J Prosthet Dent’, Vol - 74(5), 1995, 521–530
• Malinov S, Sha W Application of artificial neural networks for modeling correlations in titanium alloy, ’Material Science and Engineering A’ Vol-365, 2004, 202–211
• Yunlian Qi, Deng Ju, Quan Hong, Liying Zeng: Electron beam welding, laser beam welding and gas tungsten arc welding of titanium sheet, ‘Materials Science and Engineering A’, Vol-280, 2000, 177–181
• S.H. Wang, M.S. Wei: Tensile properties of gas tungsten arc weldments in CP, Ti-6Al-4V and Ti-15V-3Al-3Sn-3Cr alloys at different strain rates, ‘Science and Technology of Welding and Joining’, Vol- 9, 2004, 415-422
• Becker DW, Adams CM Jr: The role of pulsed GTA welding variables in solidification and grain refinement, ‘Weld research supplement’, 1979, 143–152
• Ram, G.D.J., Mitra, T.K., Shankar, V., Sundaresan, S: Microstructural refinement through inoculation of type 7020 Al–Zn–Mg alloy welds and its effect on hot cracking and tensile properties, ‘Journal of materials processing technology’, Vol- 142, 2003, 174–181
• Rao, K.P., Angamuthu, K., Bala Srinivasan: Fracture toughness of electron beam welded Ti-6Al-4V, ‘Journal of materials processing technology’, Vol-199, 2008, 185–192
• Sundaresan S, Janaki Ram GD, Madhusudhan Reddy ,G: Microstructural refinement of weld fusion zones in alpha–beta titanium alloy using pulsed current welding, ’Material Science and Engineering A’, Vol-262, 1999, 88–100
• Prasad Rao ,K: Fusion zone grain refinement in GTA welds using magnetic arc oscillation and current pulsing. RAMP; 2001, 176–196
• Shinoda T, Ueno Y, Masumoto I: Effect of pulsed welding current on solidification cracking in austenitic stainless steel weldsjournal of the japan welding society’, vol-7, 1989, 245-249
• Madhusudhan Reddy G, Gokhale AA, Prasad Rao K: Optimization of pulse frequency in pulsed current gas tungsten arc welding of Al–lithium alloysteels, ‘material science and technology’, Vol- 14, 1998, 61–66
• Simpson, RP: Refinement of weld fusion zones in alpha-beta titanium alloys, ‘Weld Journal’ 1977, 56–67
• Kishore BN, Ganesh SRS, Mythili R: Correlation of microstructure with mechanical properties of TIG weldments of Ti-6Al-4V made with and without current pulsing, ‘Materials Characterization’, Vol- 58, 2007, 581–587
• Naveen Kumar P, Bhaskar Y, Mastanaiah P: Study on dissimilar metals welding of 15CDV6 and SAE 4130 steels by Inter pulse gas tungsten arc welding, ‘Procedia materials Science’ Vol-5, 2014, 2382-2391
• Leary R, Merson E, Birmingham,K: Microstructural and microtextural analysis of InterPulse GTCAW welds in Cp-Ti and Ti–6Al–4V, ‘Materials Science Engineering A’, Vol- 527, 2010, 7694-7705.
• V. Vaithiyanathan, V. Balasubramanian, S. Malarvizhi: Identification of Optimized Gas Tungsten Constricted Arc Welding Parameters to attain Minimum Fusion Zone Area in Ti-6Al-4V alloy sheets used in Aero Engine Components, ‘Journal of Advanced Microscopy Research’, Vol-13, 2018, 354-362

• Effect of Delta Current on the Microstructure and Tensile Properties of Gas Tungsten Constricted Arc Welded Inconel 718 Alloy Joints

Abstract Views :228  |  PDF Views:0

Authors

Tushar Sonar ¹, V. Balasubramanian ¹, S. Malarvizhi ¹, T. Venkateswaran ², D. Sivakumar ²

Affiliations
1 Centre for Material Joining and Research (CEMAJOR), Dept. of Mfg. Engg., Annamalai University, Annamalai Nagar, Tamilnadu, IN
2 Vikram Sarabhai Space Centre (VSSC), ISRO, Thiruvananthapuram, IN

Source

Manufacturing Technology Today, Vol 18, No 5 (2019), Pagination: 48-60

Abstract

Inconel 718 is a nickel-based superalloy which is of potential interest in high temperature applications in rocket and gas turbines. This alloy is mostly joined by Gas Tungsten Arc Welding (GTAW) process for clean and precise welds and it is economical and shop friendly. However, due to the high heat input associated with this process, the joints are more prone for metallurgical problems such as coarse dendritic structure and segregation in weld metal region and liquation cracking in heat affected zone (HAZ) which significantly reduces the mechanical properties of the welded joints. To overcome these shortcomings, a recently developed Gas Tungsten Constricted Arc Welding (GTCAW) process is used for joining Inconel 718 alloy. It is the advanced variant of GTAW process with magnetic arc constriction achieved by introducing high frequency pulsing Current (known as Delta Current). Delta Current pulsing at a very high frequency is controlling factor for the rise and fall of magnetic arc constriction during welding. The main objective of this investigation is to make the potential use of Magnetic Arc Constriction to reduce the heat input for minimizing metallurgical problems and enhancing the mechanical properties of the joints. To achieve this, main effect of Delta Current on tensile properties and microstructural characteristics of Inconel 718 alloy is investigated.

Keywords

Gas Tungsten Constricted Arc Welding (GTCAW), Delta Current, Tensile Properties, Microstructural Characteristics.

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References

• Lippold, J; DuPont, JC; DuPont, JN; Kiser, SD: Welding metallurgy and weldability of nickel base alloys, 'John Wiley and Sons, Inc.', New Jersey, 2009.
• Agilan, M; Krishna Chenna, S; Manwatkar, Sushant, K; Vinayan, EG; Sivakumar, Bhanu, D Pant: Effect of welding processes (GTAW & EBW) and solutionizing temperature on microfissuring tendency in Inconel 718 welds, 'Materials Science Forum', vol. 710, 2004, 603-607.
• Gordine, J: Some problems in welding Inconel 718, 'Welding Journal', 1970, 480-484.
• Madhusudan Reddy, G; Srinivasa Murthy, CV; Srinivasa Rao, K; Prasad Rao, K: Improvement of mechanical properties of Inconel 718 electron beam welds— influence of welding techniques and post weld heat treatment, 'International Journal of Advanced Manufacturing Technology', vol. 43, 2009, 671 - 680.
• Janki Ram, G; Reddy, A; Prasad Rao, K; Reddy G; Sarin Sundar, J: Microstructure and tensile properties of Inconel 718 pulsed Nd-Yag laser welds, 'Journal of Materials Processing Technology', vol. 167, 2005, 73 - 82.
• Sivaprasad, K; Sundra Raman, G: Influence of weld cooling rate, on microstructure and mechanical properties of Alloy 718 weldments, 'Metallurgical and Materials Transactions A', vol. 39A, 2008, 2115 - 2127.
• Sudarshan Rao, G; Saravanan, K; Harikrishnan, G; Sharma, VMJ; Ramesh Narayan, P; Sreekumar, K; Sinha, P: Local deformation behaviour of Inconel 718 TIG weldments at room temperature and 550°C, 'Materials Science Forum', vol. 710, 2012, 439 - 444.
• Sivaprasad, K; Ganesh Sundara Raman, S; Mastanaiah, P; Madhusudhan Reddy, G; Influence of magnetic arc oscillation and current pulsing on microstructure and high temperature tensile strength of alloy 718 TIG weldments, 'Materials Science and Engineering A', vol. 428, 2006, 327 - 331.
• Janaki Ram, GD; Venugopal Reddy, A; Prasad Rao, K; Madhusudhan Reddy, G: Control of Laves phase in Inconel 718 GTA welds with current pulsing, 'Science and Technology of Welding and Joining', vol. 9, no. 5, 2004, 390-398.
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• Establishing Relationship Between Welding Current And Weld Metal Deposition Rate (productivity) for Metal Cored Tubular (MCT) Wire in Submerged Arc Welding Process

Abstract Views :181  |  PDF Views:0

Authors

R. Bashkar ¹, V. Balasubramanian ¹, C. Mani ²

Affiliations
1 Annamalai University, Annamalai Nagar, Tamilnadu, IN
2 Consolidated Contractors Company Ltd (CCC), Musaffah Industrial Area, Abu Dhabi, AE

Source

Manufacturing Technology Today, Vol 19, No 11 (2020), Pagination: 3-12

Abstract

Submerged arc welding (SAW) process is used to weld large, heavy metal deposition jobs that warrant critical requirements, and this metal joining process alone is used to weld approximately 10% of the deposited weld metal worldwide. Any augmentation in productivity of SAW process, will immensely benefit the welding industry, as this process is widely used on variety of common metals & alloys. This paper focusses on establishing relationship between welding current and productivity (in terms of weld metal deposition rate as an index), for a given filler wire diameter. Productivity rates of three most commonly used SAW wire sizes Metal Cored Tubular wires were studied, at different current values, covering full current range through bead-on-plate experiments. At each current value, the bead was optimized for acceptable visual quality, by varying arc travel speed and voltage, then the wire feed rate making acceptable bead was noted. The current density, the heat input and corresponding weld metal deposition rate were calculated for establishing an empirical relationship. The established relationship can be effectively used, to estimate the productivity from the current values, for a given wire diameter.

Keywords

Submerged Arc Welding (SAW), Carbon Steel, Metal Cored Tubular (MCT) Wire, Bead on Plate (BoP) Trials, Weld Metal Deposition Rate (WMDR), Productivity, Heat Input (HI), Current Density.

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• Mechanical Properties and Microstructural Characteristics of Rotating Arc Gas Metal Arc Welded Carbon Steel Joints

Abstract Views :283  |  PDF Views:1

Authors

N. Sankar ¹, S. Malarvizhi ¹, V. Balasubramanian ¹

Affiliations
1 Annamalai University, Annamalainagar (P.O), Tamilnadu, IN

Source

Manufacturing Technology Today, Vol 20, No 5-6 (2021), Pagination: 21-30

Abstract

Low carbon steels are widely used in the manufacturing sectors due to their easy weldability than other carbon steels. Usually, the welding processes like shielded metal arc welding (SMAW), and gas metal arc welding (GMAW) are used for welding thick low carbon steel plates. Recently, a novel “rotary arc” or “spin arc” technique is developed with a rotary motion of filler wire that can change the flow of the weld puddle. In this investigation, an attempt has been made to join 12mm thick carbon steel plates made by stationary arc gas metal arc welding (SA-GMAW) and rotating arc gas metal arc welding (RA-GMAW) processes. The objective of present paper is to study the influence of rotating arc on mechanical properties and microstructural characteristics of GMA welded carbon steel joints. The results indicated that the arc rotation of GMAW process yielded 15% improvement in joint efficiency than the conventional stationary arc process.

Keywords

Carbon Steel, Rotating Arc Welding, Tensile Properties, Impact Toughness and Microstructural Characteristics.

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References

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• Indian Railways on Fast Track with Welding Industry 4.0 : Application of Internet of Things and Artificial Intelligence

Abstract Views :102  |  PDF Views:1

Authors

Tushar Sonar ¹, V. Balasubramanian ², S. Malarvizhi ², Namita Dusane ³, V. Sivamaran ⁴, C. Rajendran ⁵

Affiliations
1 G. S. Mandal's Maharashtra Institute of Technology, Aurangabad, Maharashtra, IN
2 Annamalai University, Annamalai Nagar, Tamil Nadu, IN
3 Hinduja College of Commerce, Mumbai, Maharashtra, IN
4 Audisankara College of Engineering & Technology (Autonomous), Gudur, Andhra Pradesh, IN
5 Sri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, IN

Source

Manufacturing Technology Today, Vol 20, No 11-12 (2021), Pagination: 10-20

Abstract

The objective of this paper is to explain about application of Internet of Things (IoT) and Artificial Intelligence (AI) in welding of Indian Railways. The introduction of welding technology has also been followed by the country’s economic growth. Indian Railways has long been the single most significant infrastructure entity in India, with the railway track network expanding for many years. The new manufacturing sector is speeding the transition to digital and intelligent manufacturing, with the ongoing growth and maturity of cloud computing, big data, IoT and other innovations. Welding methods are also one of the fields where AI is tested and used early, with the help of information technology. Train maintenance and repair is usually carried out in demanding working conditions and frequently under demand from time. In such high demand and dynamic activities, it helps to decrease human error. In the welding of rail tracks and machine parts, IoT and AI will certainly offer many advantages in less time and with greater accuracy and precision. It will allow the Indian Railways to become more profitable and effective.

Keywords

Indian Railways, Internet of Things, Artificial Intelligence, Welding 4.0.

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References

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• Porosity and metallurgical characteristics of AA5356 aluminum alloy cylindrical components made by wire arc additive manufacturing process

Abstract Views :150  |  PDF Views:2

Authors

B. Prasanna Nagasai ¹, S. Malarvizhi ¹, V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Annamalai University, Annamalainagar, Tamilnadu, India, IN

Source

Manufacturing Technology Today, Vol 21, No 7-8 (2022), Pagination: 3-12

Abstract

AA5356 (Al-Mg) alloys can reach medium strength without a solid solution and quenching treatment, thereby avoiding product distortion caused by quenching, which has attracted the attention of wire arc additive manufacturing (WAAM) researchers. However, challenges during the additive manufacturing of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with low heat input. This paper presents metallurgical characteristics and mechanical properties of wire arc additive manufactured AA5356 alloy cylindrical components fabricated by Gas Metal Arc Welding (GMAW) and Cold Metal Transferred (CMT) arc welding processes. Herein, comparison between the welding processes and the resulting heat input show the effect on resulting microstructural characteristics of additively manufactured AA5356 parts. Firstly, the influence of heat input on the porosity was analyzed. Subsequently, the effect of heat input on the microstructural characteristics of the components was studied. The component produced by CMT process exhibits fewer and smaller pores with finer grains and reduced segregation of β-(Al3Mg2) phases than the GMAW process.

Keywords

Wire Arc Additive Manufacturing, Al-Mg Alloy, Porosity, Metallurgical Characteristics.

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References

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• Donghong, D., Zengxi, P., & Dominic, C. (2015). A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robotics and Computer- Integrated Manufacturing, 31(2), 101-110.
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• Gierth, M., Henckell, P., Ali, Y., Scholl, J., & Bergmann, J.P. (2020). Wire Arc Additive Manufacturing (WAAM) of aluminum alloy AlMg5Mn with energy-reduced Gas Metal Arc Welding (GMAW). Materials, 13(12), 1-9.
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• Xiong, J., Lei, Y., Chen, H., & Zhang, G. (2017). Fabrication of inclined thin-walled parts in multi-layer single-pass GMAW-based additive manufacturing with flat position deposition. Journal of Materials Processing Technology, 240, 397-403.
• Zhang, C., Li, Y., Gao, M., & Zeng, X. (2018). Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source. Materials Science and Engineering: A, 711(1), 415-423.

• Predicting the load-bearing capability of resistance spot welded advanced high strength DP-1000 steel spot joints for automotive structural and body frame applications

Abstract Views :127  |  PDF Views:0

Authors

P. Rajalingam ¹, S. Rajakumar ², V. Balasubramanian ², Tushar Sonar ³, S. Kavitha ⁴

Affiliations
1 4Centre for Materials Joining and Research (CEMAJOR), Annamalai University, Annamalai Nagar, Tamil Nadu, India., IN
2 Centre for Materials Joining and Research (CEMAJOR), Annamalai University, Annamalai Nagar, Tamil Nadu, India., IN
3 Centre for Welding and Additive Manufacturing (C-WAM), G. S. Mandal’s Maharashtra Institute of Technology, Aurangabad, Maharashtra, India., IN
4 Department of Electronics and Instrumentation Engineering, Annamalai University, Annamalai Nagar, Tamil Nadu, India., IN

Source

Manufacturing Technology Today, Vol 21, No 7-8 (2022), Pagination: 13-22

Abstract

Resistance spot welding (RSW) is used to overcome the issues in fusion welding of DP-1000 steel such as softening in heat affected zone (HAZ), solidification cracking, high thermal residual stresses and distortion. The main objective of this investigation is to develop the empirical relationships to predict the tensile shear fracture load bearing capability of spot joints for automotive applications. The three factor – three level box-behnken design (3X3-BBD) consisting ofless experiments was chosen for developing the experimental matrix. The lap tensile shear fracture load (LAP-TSFL) and cross tensile shear fracture load (CROSS-TSFL) tests were performed to determine the load bearing capability of spot joints. The empirical relationships of LAP-TSFL and CROSS-TSFL of spot joints were developed using polynomial regression equations incorporating the process parameters in coded form. Analysis of Variance (ANOVA) was executed to check the viability of developed empirical relationships for LAP-TSFL and CROSS-TSFL. The empirical relationship accurately predicted the LAP-TSFL and CROSS-TSFL capability of spot joints with less than 1% error at 95% confidence level.

Keywords

DP-1000 Steel, Resistance Spot Welding, Optimization, Tensile Shear Fracture Load.

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References

• Alves, P. H. O. M., Lima, M. S. F., Raabe, D., Sandim, H. R. Z. (2018). Laser beam welding of dual-phase DP1000 steel. Journal of Materials Processing Technology, 252,498-510.
• Aydin, H. (2015). The mechanical properties of dissimilar resistance spot-welded DP600– DP1000 steel joints for automotive applications. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 229(5), 599-610.
• Chabok, A., Galinmoghaddam, E., De Hosson, J. T. M., Pei, Y. T. (2019). Micromechanical evaluation of DP1000-GI dual-phase high-strength steel resistance spot weld. Journal of materials science, 54(2), 1703-1715.
• Chabok, A., Van der Aa, E., De Hosson, J. T. M., Pei, Y. T. (2017). Mechanical behavior and failure mechanism of resistance spot welded DP1000 dual phase steel. Materials & design, 124, 171- 182.
• Khraisat, W., Abu Jadayil, W., Al-Zain, Y., Musmar, S. E. (2018). The effect of rolling direction on the weld structure and mechanical properties of DP 1000 steel. Cogent Engineering, 5(1), 1491019.
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• Pizzorni, M., Lertora, E., Mandolfino, C., Gambaro, C. (2019). Experimental investigation of the static and fatigue behavior of hybrid ductile adhesive-RS Welded joints in a DP 1000 steel. International Journal of Adhesion and Adhesives, 95, 102400.
• Rajarajan, C., Sivaraj, P., Sonar, T., Raja, S., Mathiazhagan, N. (2022). Resistance spot welding of advanced high strength steel for fabrication of thin-walled automotive structural frames. Forces in Mechanics, 7, 100084.
• Rocha, I. C. L., Machado, I. G. and Mazzaferro, C. C. P. (2015). Mechanical and metallurgical properties of DP 1000 steel square butt welded joints with GMAW. International journal of engineering & technology, 4(1), 26-34.
• Xue, X., Pereira, A. B., Amorim, J., Liao, J. (2017). Effects of pulsed Nd: YAG laser welding parameters on penetration and microstructure characterization of a DP1000 steel butt joint. Metals, 7(8), 292.

• Role of plasma gas flow rate on the microstructural and mechanical aspects of plasma arc welded titanium alloy joints

Abstract Views :65  |  PDF Views:0

Authors

T. Pragatheswaran ¹, S. Rajakumar ², V. Balasubramanian ¹

Affiliations
1 Centre for Materials Joining & Research (CEMAJOR), Annamalai University, Annamalai Nagar, Tamil Nadu, India, IN
2 Centre for Materials Joining & Research (CEMAJOR), Annamalai University, Annamalai Nagar, Tamil Nadu, India., IN

Source

Manufacturing Technology Today, Vol 21, No 5-6 (2022), Pagination: 15-22

Abstract

In the present investigation, the effect and role of plasma gas flow rate on the formation of microstructure during plasma arc welding of Ti6Al4V titanium alloy were studied using microscopic observation, energy dispersive spectroscopic analysis, tensile tests and microhardness measurements. Plasma gas flow rate influences the arc pressure, arc constriction, and stability. The transformation of plasma arc from conduction mode to keyhole mode causes severe changes to the microstructural characteristics of the titanium welds. This transformation takes place with slight variations of PGFR. Weld geometries increase with an increase in the PGFR. The microstructural examination shows that there are various phases formed during the variation in PGFR. Fusion zone had acicular α and widmanstätten α. Mechanical properties (i.e) strength and hardness of the joints increase with an increase in plasma gas flow rate. In the joint welded with 1 L/min, there is the formation of α-case which is an oxygen rich brittle subsurface structure and found detrimental to the ductility of the joints.

Keywords

Plasma Arc Welding, Titanium Alloy, Microstructure, Defects, Tensile, Hardness.

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References

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• Baruah, M., & Bag, S. (2016). Microstructural Influence on Mechanical Properties in Plasma Microwelding of Ti6Al4V Alloy. Journal of Materials Engineering and Performance, 25(11), 4718-4728. https://doi.org/10.1007/ s11665-016-2333-8
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• Effect of copper electrode pressure on nugget diameter and mechanical performance of resistance spot welded thin DP800 steel sheets

Abstract Views :69  |  PDF Views:0

Authors

C. Rajarajan ¹, Tushar Sonar ², P. Sivaraj ³, V. Balasubramanian ³

Affiliations
1 Meenakshi Ramaswamy Engineering College, Thathanur, Tamil Nadu, India, IN
2 G. S. Mandal’s Maharashtra Institute of Technology, Aurangabad, Maharashtra, India, IN
3 Centre for Materials Joining & Research (CEMAJOR), Annamalai University, Annamalai Nagar, Tamil Nadu, India, IN

Source

Manufacturing Technology Today, Vol 21, No 5-6 (2022), Pagination: 23-30

Abstract

DP800 is an advanced high strength steel containing duplex microstructure of ferrite and martensite phases. It is broadly used in automotive structural frame applications owing to its high strength to weight ratio. DP steel is mainly joined by resistance spot welding (RSW) to avoid the problems of solidification cracking and severe HAZ softening. In this study, the effect of copper electrode pressure on nugget diameter and mechanical performance of resistance spot welded 1.2 mm thick DP800 steel sheets are investigated. The tensile shear strength (TSS) properties were evaluated in straight lap (SL-TSS) and cross lap (CL-TSS) joint configuration. Results showed that the DP-800 steel spot joints developed using the electrode pressure of 4.0 MPa exhibited superior SL-TSS of 830 MPa and CL-TSS of 684 MPa. It is attributed to the evolution of finer martensitic needles in nugget zone.

Keywords

Dual-Phase Steel, Resistance Spot Welding, Tensile Shear Strength, Microstructure, Electrode Pressure.

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References

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• Rajarajan, C., Sivaraj, P., & Balasubramanian, V. (2020). Role of welding current on mechanical properties and microstructural characteristics of resistance spot welded dual phase steel joints. Physics of Metals and Metallography, 121(14), 1447-1454.
• Rajarajan, C., Sivaraj, P., Sonar, T., Raja, S., & Mathiazhagan, N. (2022). Resistance spot welding of advanced high strength steel for fabrication of thin-walled automotive structural frames. Forces in Mechanics. 7, 100084.
• Rajarajan, C., Sivaraj, P., Sonar, T., Raja, S., & Mathiazhagan, N. (2022). Investigation on microstructural features and tensile shear fracture properties of resistance spot welded advanced high strength dual phase steel sheets in lap joint configuration for automotive frame applications.Journal of the Mechanical Behavior of Materials, 31(1), 52-63.
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