Assessment of erosion rate on AA7075 based surface hybrid composites fabricated through friction stir processing by taguchi optimization approach

Suganeswaran, K.; Rathinasamy, Parameshwaran; Nithyavathy, N.; Karumalai, Deepandurai; Mohanraj, T.; Palaniappan, M.

doi:10.1080/01694243.2021.1929018

Cited by 36 publications

(11 citation statements)

References 56 publications

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“…Fine grain size increases the hardness of the SCs based on Hall petch relation. Dispersion strengthening [36][37][38] and hindering dislocation mechanism by emery and FA reinforcements [39][40][41] is also accountable for the increased hardness. Difference in thermal expansion coefficient values of the reinforcement particulates and parent matrix brings quench hardening effect into action.…”

Section: Microhardnessmentioning

confidence: 98%

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Suganeswaran

Parameshwaran

Sathiskumar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The novel friction stir technology is adopted in modern automotive industries to meet the desired properties like hardness, impact toughness and tribological behaviour over the conventional techniques like stir casting, compo casting, squeeze casting, electroplating and infiltration methods. AA7075 surface composites fabricated with different volume fractions of fly ash and emery particles is said to enhance the aforementioned properties. The composites are processed through friction stir process (rotational speed −1200 rpm, transverse speed – 56 mm/min, tool tilt angle – 2 °). During characterization, the Microstructural examination of surface composites depicts fine and homogenous distribution of reinforcements in the friction stir process region owing to severe plastic deformation and dynamic recrystallization process. Substantially, good interface is formed between the reinforcement particulates and base substrate. Inclusion of Fe3O4, Al2O3 and SiO2 constituents through fly ash and emery reinforcements associated with the homogenous dispersion strengthening mechanism favours for the superior hardness of surface hybrid composite specimen 50E50FA. Decremented grain size and load bearing capacity of the reinforcements is beneficial for the crack propagation resistance that enhances the impact toughness behaviour (17.4 J/cm2) of the same specimen. Wear rate of the specimens are evaluated through pin on disc tribometer. The decrease in the wear rate of hard specimen 50E50FA is observed due to the reduced contact area between its surface and counter disc. The morphology of worn specimens using SEM analysis shows the combined abrasive and adhesive wear as the worn mechanism.

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Section: Microhardnessmentioning

confidence: 98%

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Suganeswaran

Parameshwaran

Sathiskumar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…Furthermore, Kandasamy et al [32] minimized the erosion rate of friction-stirred fabricated aluminum hybrid composite using the Taguchi design technique. Erosion rate as a cost component is not the only essential component because the material quality in terms of finishing and machining efficiency is important, which subsequently gives a holistic view of the production cost analysis.…”

Section: Related Work and Findingsmentioning

confidence: 99%

Cost and Quality Optimization Taguchi Design with Grey Relational Analysis of Halloysite Nanotube Hybrid Composite: CNC Machine Manufacturing

Esangbedo

Abifarin

2022

Materials

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Researchers who work on manufacturing hybrid composites have significant concerns about holistically optimizing more than one performance characteristic, as in the case of cost and quality optimization. They usually trade off one for the other. Hence, this study employed statistical tools and grey relational analyses (GRA) design to model and optimize the surface roughness and cutting force of Computer Numerical Control (CNC) machine settings to manufacture halloysite nanotube hybrid composite. In this paper, the GRA was able to address the multiple optimization complications by producing 0.6 mm depth of cut, 1500 rpm spindle speed, and 40 mmpm feed rate as the CNC machine settings for high-quality and low-cost hybrid composite. It was noticed that the mathematical and interaction modeling of surface roughness, cutting force, and grey relational grade (GRG) allowed different CNC machines to manufacture hybrid composites. This can assist researchers and production engineers of CNC machines. Variance analysis and delta statistical characteristics revealed that the depth of a cut is the most significant machine setting, with a contribution of 49.12%. This paper outlines the possible CNC machine settings for high-quality composite manufacturing. In future studies, it is recommended for researchers in the field of CNC machine manufacturing to consider the modeling analysis aspect of the optimization, which comprehensively provides the opportunity for the adjustment of CNC machines for better material performance, which has been lacking in the literature.

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“…12 FSP is used to create AA7075 Surface Hybrid Composites (SHCs) using reinforcements like silicon carbide and aluminum oxide. 13 During FSP, processing parameters need to be controlled for required grain refinement and good distribution of the reinforcements in the matrix. 14,15 Mishra et al 16 reported on the production of surface Al matrix composites with the addition of ceramics across the plunger to form a particle.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the microstructure, mechanical and wear performance of friction stir-processed AA6061-T6 plate reinforced with B₄C particles surface composite

Abdelhady

Elbadawi²,

Zoalfakar

2023

Journal of Composite Materials

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In this work, friction stir processing (FSP) was used to successfully embed boron carbide (B4C) particles into an aluminum matrix (AA6061-T6). Four specimens of aluminum 6061 composite reinforced with 4%, 6%, 8%, and 10% volume fraction of B4C were manufactured. The effects of B4C particles volume fraction on microstructure, mechanical and wear properties are investigated. The microstructural investigations demonstrated that a rise in the volume % of reinforcement greatly decreased the matrix grain size. The manufactured AA6061-T6 loaded with B4C surface composites demonstrated homogeneous B4C particle dispersion, with no significant particle clustering in the stir zone. In addition, it was established that increasing the volume fraction of B4C particles promoted grain refinement, increased hardness, and tensile strength. X-ray diffraction (XRD) was used to identify the reinforcement dispersion. For AA6061-T6 with 10% B4C particles, a maximum hardness value of 163 HV was obtained in the stir zone. Maximum yield strength of 165 MPa and ultimate tensile strength of 220 MPa were attained by AA6061-T6 with 10% B4C particles, which is an improvement of 21% over the specimen FSP without reinforcement. The strengthening of the grain refining was attributed for the increase in hardness and strength. The ductility was reduced by the incorporation of more B4C particles. Comparing the surface composite loaded with B4C to unreinforced friction stir processing and AA6061-T6 as received, it demonstrated superior wear resistance.

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Assessment of erosion rate on AA7075 based surface hybrid composites fabricated through friction stir processing by taguchi optimization approach

Cited by 36 publications

References 56 publications

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Cost and Quality Optimization Taguchi Design with Grey Relational Analysis of Halloysite Nanotube Hybrid Composite: CNC Machine Manufacturing

Investigation of the microstructure, mechanical and wear performance of friction stir-processed AA6061-T6 plate reinforced with B₄C particles surface composite

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Assessment of erosion rate on AA7075 based surface hybrid composites fabricated through friction stir processing by taguchi optimization approach

Cited by 36 publications

References 56 publications

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

Cost and Quality Optimization Taguchi Design with Grey Relational Analysis of Halloysite Nanotube Hybrid Composite: CNC Machine Manufacturing

Investigation of the microstructure, mechanical and wear performance of friction stir-processed AA6061-T6 plate reinforced with B4C particles surface composite

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Investigation of the microstructure, mechanical and wear performance of friction stir-processed AA6061-T6 plate reinforced with B₄C particles surface composite