No abstract

ECAP (Equal Channel Angular Pressing) is a technique used to enhance the strength of material by grain refinement. In this research, an aerospace grade aluminum alloy-6061 is investigated. The specimens were pressed through ECAP die channels, intersecting each other at an angle of 90oC where a shear plane of 45oC was developed, that results grains refinement. Fatigue strengths and CGR (Crack Growth Rate) for the stress ratio R 0.7 and 0.1 are found and compared with the as-received material.It was observed that the CGR is slower at stress ratio R=0.1, as compared to stress ration R=0.7. An electric furnace was embedded with ECAP die to regulate the material flow through this die. The temperature of the die was maintained at 450oC during ECAP pressing and the specimens were also preheated at this temperature using another furnace. The ECAP die consists of two channels intersecting at 90o provided with safe inner and outer corner radius to avoid scaling.The microstructural observations revealed that the deformation was perfectly plastic. The ECAPed and as-received materials were also characterized by tensile tests, micro-hardness tests, and 3-point bend fatigue tests.

EDMed (Electric Discharge Machined) surfaces are unique in their appearance and metallurgical characteristics, which depend on different parameter such as electric parameters, flushing method, and dielectric type. Conventionally, in static workpiece method the EDM (Electric Discharge Machining) is performed by submerging both of the tool and workpiece in dielectric liquid and side flushing is provided by impinging pressurized dielectric liquid into the gap. Another flushing method has been investigated in this study, in which, instead of side flushing the rotation motion is provided to the workpiece. Surface characteristics for both flushing methods are determined and compared in this study. The investigated surface characteristics are: surface roughness, crater size, surface morphology, white layer thickness and composition. These investigations are performed using optical and SEM (Scanning Electron Microscope). Statistical confidence limits are determined for scattered data of surface roughness. It is found that the white layer thickness and surface roughness are directly proportional to discharge current for both flushing methods. The comparison has shown that the side flushing of statics workpiece gives thicker white layer and lower surface finish as compared to the flushing caused by the rotation of workpiece.