In recent years, among all the aluminium alloys, Al6061 is gaining much popularity as a matrix material to prepare MMCs owing to its excellent mechanical properties and good corrosion resistance. Fly ash cenospheres are primarily a by-product in power generation plants. Research is in progress to effectively use this byproduct to produce new usable and profitable materials as they pose major disposal and environmental problems. In the light of the above, the present investigation is aimed at development of metal coated cenosphere reinforced Al6061 composites and to characterize their mechanical properties. Al6061 nickel coated composites have been prepared by liquid metallurgy route by varying percentage of nickel coated cenospheres between 2–10% by weight in steps of 2%. Density, hardness and tensile behaviour of the composites is carried out. It is observed that there is an increase in the values of hardness, density of the composite with an increasing percentage of the nickel coated cenosphere reinforcements. There is also a notable increase in the tensile strength as well as reduction in ductility of the prepared composite. Fractographs to indicate the behaviour of the composites have also been depicted in the paper.
This research work aims at investigating the performance of the gas tungsten arc welded dissimilar AISI 304 and AISI 310S when subjected to cyclic hot corrosion in air oxidation and in the molten salt environment of K2SO4 + 60% NaCl environment at 600°C. The weldments are characterized for its mechanical and metallurgical properties. Tensile strength of the weldment is found to be 529 Mpa. Further the hot corrosion studies are performed on the various zones of the weldment and the corrosion products are characterized by the combined techniques of optical microscopy, XRD and SEM/EDAX analysis.
The effect of welding parameters (current, electrode diameter) on the impact of low carbon steel specimens was investigated in this work. Two different geometries namely square butt welded joint and double V welded joint were created. The welding operation was carried out at three different current for welding currents of 90, 110 and 130 amps and electrode diameters of 2.5, 3.2 and 4mm respectively. A Charpy impact testing machine was used to evaluate the impact of the welded samples. It was observed that a low current of 90 Amps for all the welding electrode diameters produced high impact values for both the welding geometries. Also, the 3.2 mm electrode diameter was found to be more suitable for welding the square butt and the double V geometry as it yielded higher impact values. Additionally, the double V geometry showed better performance when compared to the square butt geometry for all the combinations of welding currents and electrode diameters.
Cenosphere fly ash is one of the most inexpensive and low-density material which is abundantly available as a solid waste by-product of coal combustion in thermal power plants. Aluminium metal matrix composites with Nickel coated cenospheres as the reinforcement is prepared by stir casting route. The composites are prepared with varying percentages of cenospheres in the percentage of 2-10% by weight of the composite. Immersion corrosion tests are conducted on the composites in three different medium and for three different time durations. It is evident from the test results as well as the microstructure images that the weight loss of samples with 8% Nickel coated cenospheres has shown least corrosion or the highest corrosion resistance when compared to the counterparts.
A case study of the comparison of the properties of conventional foundry sand and light weight cenosphere/microsphere particles has been undertaken. This analysis was initiated by the preparation of their respective specimens, followed by the actual testing of these samples. Properties such as Compression strength, Shear strength, Permeability and Hardness were determined. In addition the grain form and microstructure of the specimens prepared was also analyzed. This analysis clearly indicates the possibility of the usage of cenospheres as a replacement of foundry sand.
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