THE ROLE OF SHIELDING GAS ON MECHANICAL, METALLURGICAL AND CORROSION PROPERTIES OF CORTEN STEEL WELDED JOINTS OF RAILWAY COACHES USING GMAW

This analysis lays emphasis on finding a suitable combination of shielding gas for welding underframe members such as sole bar of Railway Coaches made of corten steel; for improved mechanical, metallurgical and corrosion properties of welds using copper coated solid MIG/MAG welding filler wire size 1.2 mm conforming to AWS/SFA 5.18 ER 70 S in Semi-automatic GMAW process. Solid filler wire is preferred by welders due to less fumes, practically no slag and easy manipulation of welding torch with smooth wire flow during corrosion repair attention, when compared to Flux cored wire. Three joints using Gas metal arc welding (GMAW) with shielding gases viz., Pure CO2, (80% Ar – 20% CO2) and (90% Ar – 10% CO2) were made from test pieces cut from Sole bar material of Railway Coach. Study of Mechanical properties such as tensile strength, hardness and toughness revealed that welded joint made using shielding gas (80% Ar – 20% CO2) has better Mechanical properties compared to the other two shielding gases and comparable to that of Parent metal. Type of Shielding gas used has influence on the chemical composition and macro & micro structures. The Tafel extrapolation study of freshly ground samples in 3.5% NaCl solution revealed that the welded joint made using shielding gas (80% Ar – 20% CO2) has also better corrosion resistance which is comparable to the Parent metal as well as similar commercial steels

Optimization of multipoint incremental sheet metal forming of SS430 sheets using GRA

326-333Incremental sheet metal forming (ISF) is one of the best flexible manufacturing processes used to convert a sheet metal into required final shape using tool movement. In incremental sheet metal forming process, a single pointed forming tool is allowed to move over the sheet metal as per the pre-programmed numerical control of a computer. The advantage of making any complex part without die confirms its importance in the emerging automated industries. But this process has some limitations such as less formability and high surface roughness compared to the conventional forming process. Longer processing time is another drawback of the incremental sheet forming. This paper proposes a newly designed multi-point incremental forming (MPIF) tool to avoid the drawbacks faced by industry in increasing the formability and wall angle of the sheet metal with reduced time. The sheet metal stainless steel (SS) grade 430 has been used for forming process and the outputs obtained from MPIF and single point incremental forming (SPIF) have been compared with respect to wall angle, formability, surface roughness, spring back and forming time. Grey relational analysis (GRA) has been used to find the optimal value for the various responses obtained. The analysis of variance (ANOVA) calculation method has also been used to find the factors that influence the output responses. The responses obtained by the experiment have proved that the multipoint tool results better output

Anionic redox chemistry in Na-rich Na2Ru1−ySnyO3 positive electrode material for Na-ion batteries

The synthesis and Na- electrochemical activity of Na-rich layered Na2Ru1−ySnyO3 compounds is reported. Like their Li-analogue, Na2Ru1−ySnyO3 shows capacities that exceed theoretical capacity calculated from the cationic redox species. The high capacity was found, by means of XPS analysis, to be associated to the accumulation of both cationic (Ru4+/Ru5+) and anionic (O2−/O2n−) redox processes. The structural evolutions during cycling have been followed and found to be associated with the cation disordering and loss of crystallinity on cycling

Multi-response optimization of process parameters for TIG welding of Incoloy 800HT by Taguchi grey relational analysis

Incoloy 800HT which was selected as one of the prominent material for fourth generation power plant can exhibit appreciable strength, good resistance to corrosion and oxidation in high temperature environment. This study focuses on the multi-objective optimization using grey relational analysis for Incoloy 800HT welded with tungsten inert arc welding process with N82 filler wire of diameter 1.2 mm. The welding input parameters play a vital role in determining desired weld quality. The experiments were conducted according to L9 orthogonal array. The input parameter chosen were the welding current, Voltage and welding speed. The output response for quality targets chosen were the ultimate tensile strength and yield strength (at room temperature, 750 °C) and impact toughness. Grey relational analysis was applied to optimize the input parameters simultaneously considering multiple output variables. The optimal parameters combination was determined as A2 B1 C2 i.e. welding current at 110 A, voltage at 10 V and welding speed at 1.5 mm/s. ANOVA method was used to assess the significance of factors on the overall quality of the weldment. The output of the mechanical properties for best and least grey relational grade was validated by the metallurgical characteristics

Multi-response optimization of process parameters for TIG welding of Incoloy 800HT by Taguchi grey relational analysis

Incoloy 800HT which was selected as one of the prominent material for fourth generation power plant can exhibit appreciable strength, good resistance to corrosion and oxidation in high temperature environment. This study focuses on the multi-objective optimization using grey relational analysis for Incoloy 800HT welded with tungsten inert arc welding process with N82 filler wire of diameter 1.2 mm. The welding input parameters play a vital role in determining desired weld quality. The experiments were conducted according to L9 orthogonal array. The input parameter chosen were the welding current, Voltage and welding speed. The output response for quality targets chosen were the ultimate tensile strength and yield strength (at room temperature, 750 °C) and impact toughness. Grey relational analysis was applied to optimize the input parameters simultaneously considering multiple output variables. The optimal parameters combination was determined as A2B1C2 i.e. welding current at 110 A, voltage at 10 V and welding speed at 1.5 mm/s. ANOVA method was used to assess the significance of factors on the overall quality of the weldment. The output of the mechanical properties for best and least grey relational grade was validated by the metallurgical characteristics

MODELLING AND CHARACTERIZATION OF LASER WELDED INCOLOY 800 HT JOINTS

This study aims at finding the effect of laser welding speed on incoloy 800 HT. This alloy is one of the potential materials for Generation IV nuclear plants. Laser welding has several advantages over arc welding such as low fusion zone, low heat input and concentrated heat intensity. Three different welding speeds were chosen and CO2 laser welding was performed. 2D modeling and simulation were done using ANSYS 15 to find out the temperature distribution at different welding speeds and it was found that an increase in the welding speed decreased the temperature. Mechanical properties such as tensile strength, toughness and hardness were evaluated. The effect of welding speed on metallurgical characteristics was studied using optical microscopy (OM), Scanning Electron Microscopy (SEM) with EDS, X-Ray Diffraction (XRD) technique and fractographic analysis. From the results it was found that high welding speed (1400 mm/min) decreased the joint strength. The M23C6 and Ni3Ti carbides were formed in a discrete chain and in a globular form along the grain boundaries of the weld region which increased the strength of the grain boundaries. Fractographic evaluations of the tested specimens for welding speed (1000 and 1200) mm/min showed deep and wide dimples indicating ductile failures

THE ROLE OF SHIELDING GAS ON MECHANICAL, METALLURGICAL AND CORROSION PROPERTIES OF CORTEN STEEL WELDED JOINTS OF RAILWAY COACHES USING GMAW

This analysis lays emphasis on finding a suitable combination of shielding gas for welding underframe members such as sole bar of Railway Coaches made of corten steel; for improved mechanical, metallurgical and corrosion properties of welds using copper coated solid MIG/MAG welding filler wire size 1.2 mm conforming to AWS/SFA 5.18 ER 70 S in Semi-automatic GMAW process. Solid filler wire is preferred by welders due to less fumes, practically no slag and easy manipulation of welding torch with smooth wire flow during corrosion repair attention, when compared to Flux cored wire. Three joints using Gas metal arc welding (GMAW) with shielding gases viz., Pure CO2, (80% Ar – 20% CO2) and (90% Ar – 10% CO2) were made from test pieces cut from Sole bar material of Railway Coach. Study of Mechanical properties such as tensile strength, hardness and toughness revealed that welded joint made using shielding gas (80% Ar – 20% CO2) has better Mechanical properties compared to the other two shielding gases and comparable to that of Parent metal. Type of Shielding gas used has influence on the chemical composition and macro & micro structures. The Tafel extrapolation study of freshly ground samples in 3.5% NaCl solution revealed that the welded joint made using shielding gas (80% Ar – 20% CO2) has also better corrosion resistance which is comparable to the Parent metal as well as similar commercial steels

Forming Limit Diagram, Void Analysis, Strain Distribution and Surface Roughness for SS430 Sheets During Multipoint Incremental Forming

Single point incremental forming process is a most economical Die-less forming process. The major constraint of it is that it is a time consuming process. In this work, a new attempt was made in incremental forming process using Multipoint tool for SS430 sheets to increase the formability and to reduce forming time. Fractography analysis was made to study the size of voids that were formed during fracture. The forming limit diagrams were drawn and compared for single point incremental forming and the multipoint incremental forming of SS430 sheet. It was proved that the formability of SS430 sheet in the multipoint forming was better than the formability of that in single point forming and the time consumed was reduced. The strain distribution in both processes had also been studied along with surface roughness