No abstract

No abstract

In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.

In this investigation, the development of an empirical relationship to determine the porosity and microhardness of the coatings through low-pressure cold-sprayed (LPCS) aluminum alloy/alumina metal matrix composite (MMC) deposit. Spray parameters like temperature, standoff distance (SOD), and powder feed rate play an essential part in the determination of the coating effectiveness. In this study, 3 variables, 5 levels of central composite rotatable design (CCD) were used to decrease the total count of the experimentation. A mathematical model has been developed to evaluate the porosity and hardness of the coated samples along with LPCS spray parameters, and the model’s applicability was inspected by ANOVA. Utilizing response surface methodology, spray parameter optimization was carried out. The deposit developed by optimal spray parameters produces the lowest surface porosity of 3.31 vol.% and a higher hardness of 137.21 HV compared with other coated samples. It is validated through the response graph. As a result, the optimized parameters for aluminum alloy/alumina metal matrix composite (MMC) coatings via LPCS are 500 degrees Celsius, 10 mm SOD, and 20 grams/min powder feed rate.

Lanthanum zirconate (LZ) has emerged as a novel thermal barrier coating (TBC) material because of its higher temperature phase stability, and low sintering ability than the current standard yttria-stabilized zirconia (YSZ). In order to combine the advantages, LZ and YSZ feedstock powders are blended with predetermined weight ratios (50:50) as composite coatings. The leading issue in developing the composite coating using the atmospheric plasma spray method (APS) is finding the optimum range of input parameters to attain the desired coating properties. This issue can be resolved by developing empirical relations to find the porosity and micro hardness of the coating by the atmospheric plasma spray method (APS). Spray parameters such as input power, spray distance, and powder feed rate play a vital part in determining the coating quality. Three variables and five levels of central composite rotatable design (CCD) to reduce the overall run of the experiment were utilized in the research. The empirical relations were predicted to find the porosity and micro hardness of the specimens with APS process parameters, and the empirical relations were examined through ANOVA. Optimizing the plasma spray parameters was done using response surface methodology (RSM), which provides the minimum porosity and maximum hardness. It is validated using the surface response graphs, contour plots, and overlay plots. As a result, the input power has the greatest impact on the coating properties among the three variables, and the standoff distance and powder feed rate are the subsequent important spray parameters.