Effect of III-Pass on Microstructure, Micro Hardness and Static Immersion Corrosion Resistance of AA6061-T6/SiCp Surface Composite Fabricated by Friction Stir Processing

In this current investigation, SiC particles 20μm in average size were incorporated into the commercially AA6061-T6 to prepare surface composite by using Friction stir processing (FSP). The morphology of the reinforcement inside the Al matrix has been evaluated from scanning electron microscope (SEM) and the corrosion characteristics of the resulted composite were evaluated using static immersion corrosion (SIC) behavior in 3.5% NaCl aqueous solution at various regimes. From the results, it observed that the SiC particles were distributed uniformly inside the stir zone (SZ) in both first and third-pass of FSP. The micro hardness of stir zone with SiC particles of I-pass was higher compared to III-pass and as-received Al alloy. In static immersion corrosion test the FSP AA6061-T6/SiCp exhibited significantly greater corrosion resistance in I-pass than compared to the III-pass and as-received Al alloy

Influence of Rotary Assisted Electrical Discharge Machining of 17-4PH StainlessSteel Using Taguchi Technique

The current investigation has study the material removal rate, surface roughness and electrode wear rate in rotary toolassisted EDM of 17-4 PH stainless steel. 17-4 PH SS has widely used in aerospace, marine, nuclear, and chemicalprocessing due to their characteristic high strength to weight ratio and corrosion resistance properties. This paper primarilyfocuses on enhancing the flushing efficiency of dielectric fluid in the EDM process and to improve the machiningperformance characteristics. A custom designed rotating electrode attachment has fabricated and used to assist with theEDM process. The experiments are designed and planned using Taguchi L27 Orthogonal array technique.The experimentsare planned for four input factors and each parameter is varied at three levels. Current, pulse on time, pulse off time andElectrode Rotation Speed are input factors. ANOVA test is conducted to find out the significance of factors and theirpercentage contribution on the performance characteristics like Material Removal Rate, Surface Roughness and ElectrodeWear Rate. The resultsconcluded that Electrode Rotation Speed has more influence on Material Removal Rate and ElectrodeWear Rate. An individual percentage and interaction percentage of parameters from ANOVA confirm that their effectsare higher in Material Removal Rate (MRR) compared to Surface roughness (Ra) and Electrode Wear Rate (EWR). Finally,surface morphology studies revealed that significantly less cracks and voids had formed on the EDM’ed sample at optimumcondition

Dry Sliding Wear And Static Immersion Corrosion Resistance of Aluminum Alloy 6061-T6/SiCp Metal Matrix Composite Prepared Via Friction Stir Processing

In this experiment, SiC particles 20μm in average size were incorporated into the commercially Aluminum alloy 6061-T6 to form particulate metal matrix composite produced by using Friction Stir Processing (FSP). After the preparation of composite, the homogeneity of the particles distribution inside Al matrix has been observed by optical microscope (OM) and scanning electron microscope (SEM). Dry sliding wear test was conducted by using pin on disk equipment and Static immersion corrosion (SIC) resistance was evaluated in 3.5% NaCl aqueous solution at various regimes. From the results, it observed that the SiC particles are well distributed homogenously inside the nugget zone without any defects, obtained good bonding between the SiC particles and Al matrix alloy. The micro hardness of nugget zone with SiC particles is more compare to the as-received Al alloy due to the dispersion of SiC particles. It found that, exhibited superior dry sliding wear resistance and significant improvement SIC resistance of FSPed Aluminum alloy 6061-T6/SiCp composite is compare with as-received Al alloy

Tensilel Properties of AA6061-T6/SiCp Surface Metal Matrix Composite Produced By Friction Stir Processing

In this experiment, Friction stir process (FSP) was attempted to incorporate micron-sized SiC particles 20μm in average size into the commercially AA6061-T6 to form surface particulate metal matrix composite. Microstructure observations were carried out by scanning electron microscope (SEM) in the nugget zone. Mechanical properties include micro hardness behavior and tensile properties were evaluated. From the results, SEM microstructure shows that the SiC particles are uniformly distributed in nugget zone without any defect. The micro hardness of nugget zone with SiC particles is higher than the as-received Al alloy. Tensile properties of the FSPed composite were reduced as compared to the as-received Al alloy

Influence of volume percentage of NanoTiB2 particles on tribological & mechanical behaviour of 6061-T6 Al alloy nano-surface composite layer prepared via friction stir process

The aim of present study is to analyze the influence of volume percentage (vol.%) of nano-sized particles (TiB2: average size is 35 nm) on microstructure, mechanical and tribological behavior of 6061-T6 Al alloy surface nano composite prepared via Friction stir process (FSP). The microstructure of the fabricated surface nanocomposites is examined using optical microscopy (OM) and scanning electron microscope (SEM) for distribution of TiB2 nano reinforcement particles, thickness of nano composite layer formed on the Aluminum alloy substrate and fracture features. The depth of surface nano composite layer is measured as 3683.82 μm along the cross section of stir zone of nano composite perpendicular to FSP. It was observed that increase in volume percentage of TiB2 particles, the microhardness is increased up to 132 Hv and it is greater than as-received Al alloy's microhardness (104 Hv). It is also observed that at 4 volume percentage higher tensile properties exhibited as compared with the 2 and 8 vol. %. It is found that high wear resistance exhibited at 4 volume percentage as-compared with the 2 and 8 vol. %. The observed wear and mechanical properties are interrelated with microstructure, fractography and worn morphology

Influence of Rotary Assisted Electrical Discharge Machining of 17-4PH Stainless Steel Using Taguchi Technique

801-808The current investigation has study the material removal rate, surface roughness and electrode wear rate in rotary tool assisted EDM of 17-4 PH stainless steel. 17-4 PH SS has widely used in aerospace, marine, nuclear, and chemical processing due to their characteristic high strength to weight ratio and corrosion resistance properties. This paper primarily focuses on enhancing the flushing efficiency of dielectric fluid in the EDM process and to improve the machining performance characteristics. A custom designed rotating electrode attachment has fabricated and used to assist with the EDM process. The experiments are designed and planned using Taguchi L27 Orthogonal array technique.The experiments are planned for four input factors and each parameter is varied at three levels. Current, pulse on time, pulse off time and Electrode Rotation Speed are input factors. ANOVA test is conducted to find out the significance of factors and their percentage contribution on the performance characteristics like Material Removal Rate, Surface Roughness and Electrode Wear Rate. The resultsconcluded that Electrode Rotation Speed has more influence on Material Removal Rate and Electrode Wear Rate. An individual percentage and interaction percentage of parameters from ANOVA confirm that their effects are higher in Material Removal Rate (MRR) compared to Surface roughness (Ra) and Electrode Wear Rate (EWR). Finally, surface morphology studies revealed that significantly less cracks and voids had formed on the EDM’ed sample at optimum condition

Electrical Discharge Machining of SiC Reinforced 6061-T6 Aluminum Alloy Surface Composite Fabricated by Friction Stir Processing

Engineered materials with high hardness, great wear tolerance, high high-temperature power, and a low thermal expansion coefficient are aluminum-based composites. These materials are widely used in the automotive and aerospace industries. Friction stir processing (FSP) method used to prepare SiC reinforced aluminium alloy surface composite. Material removal rate (MRR) and surface roughness (SR) are measured with the impact of pulse on time, discharge current, and pulse off time (add one or two outcomes remark at SR and MRR optimal condition) is examined. For each of the three machining parameters, L9 orthogonal arrays (OA) of three levels were used in conducting the experiments. The validity of the Aluminum Surface Composite experiment programme is determined using MINITAB

Wear and mechanical properties of 6061-T6 aluminum alloy surface hybrid composites [(SiC+Gr) and (SiC+Al2O3)] fabricated by friction stir processing

AbstractIn this investigation, the influence of tool rotational speed on wear and mechanical properties of aluminum alloy based surface hybrid composites fabricated via Friction stir processing (FSP) was studied. The fabricated surface hybrid composites have been examined by optical microscope for dispersion of reinforcement particles. Microstructures of all the surface hybrid composites revealed that the reinforcement particles (SiC, Gr and Al2O3) are uniformly dispersed in the nugget zone. It was observed that the microhardness decreases when increasing the rotational speed and showed higher microhardness value in Al–SiC/Al2O3 surface hybrid composite due to presence and pining effect of hard SiC and Al2O3 particles. It was also observed that high wear resistance exhibited in the Al–SiC/Gr surface hybrid composites due to presence of SiC and Gr acted as load bearing elements and solid lubricant respectively. The observed wear and mechanical properties have been correlated with microstructures and worn micrographs