New Materials, Processing and Manufacturability: Fabrication and Processing of Advanced Materials

✍ Scribed by R. Thanigaivelan; Pradeep Kumar Krishnan; Kamalakanta Muduli; Santosh Kumar Tamang

• Publisher: Wiley
• Year: 2024
• Tongue: English
• Leaves: 413
• Edition: 1
• Category: Library

✦ Synopsis

The book focuses on multiple areas of manufacturing, including cutting-edge material processing technologies, custom-made materials, metallic and non-metallic materials, new engineering experiments, contemporary machining, joining, surface modification, and process optimization techniques. Readers will find in this volume an extensive exploration of various advanced manufacturing and material engineering topics. It includes a detailed examination of aluminum grades and their applications, an overview of cold spray additive manufacturing, and a discussion on Gas Metal Arc Welding (GMAW) for cladding low-carbon steel plates. The volume also presents innovative approaches to brake pedal design using topology optimization, analysis of resistance-spot welding quality, and the impact of shot peening on the corrosion behavior of SiC Particle Reinforced Aluminum Composite. It highlights crucial factors in 3D printed component strength, reviews 3D milling operations with ABAQUS, and delves into the rare ferroelectric material Fresnoite. The book surveys visual sensing technologies for weld pool analysis, simulates Claus Sulfur Recovery Units with Aspen Plus, and discusses ultrasonic-assisted stir casting for metal matrix nanocomposites. It also covers the joining of dissimilar magnesium alloys, advancements in electrochemical surface coatings, unconventional machining techniques, surface coating processes using pulsed power systems, natural fiber-reinforced composite fabrication, and process parameter optimization in laser beam welding using NSGA-II. Audience The book will interest researchers in academia and industry engineers in advanced manufacturing, materials science, surface science, adhesion and coatings, production engineering, civil engineering, and welding.

✦ Table of Contents

Cover
Series Page
Title Page
Copyright Page
Contents
Preface
Chapter 1 Aluminum and Its Different Graded Alloys
1.1 Introduction
1.1.1 AA1XXX Series
1.1.2 AA2XXX Series
1.1.3 AA3XXX Series
1.1.4 AA4XXX Series
1.1.5 AA5XXX Series
1.1.6 AA6XXX Series
1.1.7 AA7XXX Series
1.1.8 AA8XXX Series
1.2 Other Aluminum Materials
1.3 Applications
1.4 Conclusion
1.5 Future Scope
References
Chapter 2 Cold Spray Additive Manufacturing
2.1 Introduction
2.2 Phenomena and Factors Behind CSAM
2.3 Different CSAM Techniques
2.4 Advantages of CSAM
2.5 Disadvantages of CSAM
2.6 Numerical Simulation of CSAM of Ti6Al4V Pellets on Ti6Al4V Substrate
2.7 Conclusion
2.8 Future Scope
References
Chapter 3 Optimization of Gas Metal Arc Welding (GMAW) Cladding Parameters for Enhanced Weld Integrity in Low-Carbon Steel Plates (EN30)
3.1 Introduction
3.2 Experimental Work
3.2.1 Dilution Calculation Procedure
3.3 Parametric Study
3.3.1 Influences on PSF
3.3.2 Influences on RFF
3.3.3 Influence on D
3.4 Taguchi Optimization
3.4.1 Determination of Optimal Cladding Conditions
3.4.2 Maximization of PSF
3.4.3 Minimization of RFF
3.4.4 Minimization of D
3.5 Conclusions
Acknowledgement
References
Chapter 4 Design and Development of Brake Pedal by Topology Optimization Approach
4.1 Introduction
4.2 Structure Optimization
4.3 Topology Optimization
4.4 Optimization Results
4.5 Conclusion
References
Chapter 5 Enhancing Resistance Spot Welding Weld Quality: A Comprehensive Analysis of Influencing Factors and the Role of Modeling and Optimization for Improved Quality
5.1 Introduction
5.2 Influence of Welding Current and Time
5.3 Influence of Resistivity, Surface Preparation, and Cleanliness
5.4 Effect of Electrode Force and Electrode Tip Geometry
5.5 Modeling and Optimization of RSW Parameters
5.6 Conclusion
References
Chapter 6 Shot-Peening Influence on Corrosion Behavior of SiC Particle Reinforced Aluminum Composite
6.1 Introduction
6.2 Experimental Procedure
6.2.1 Fabrication of Composite
6.2.2 Microstructure Analysis
6.2.3 Shot-Peening Process
6.2.4 Surface Characteristics
6.2.5 Residual Stress Measurement
6.2.6 Microhardness Measurement
6.2.7 Immersion Corrosion Test
6.3 Results and Discussion
6.3.1 Microstructure of AA6061- SiCP MMC
6.3.2 Surface Morphology
6.3.3 X-Ray Diffraction
6.4 Residual Stress
6.5 Hardness Variation
6.6 Surface Roughness
6.7 Corrosion Behavior
6.8 Conclusion
References
Chapter 7 3D Printing: Fundamentals, Applications, and Future Prospects
7.1 Introduction
7.2 Materials for 3D Printing
7.2.1 Stages Involved in the Process of 3D Printing
7.2.2 3D Printing Technologies
7.2.3 Applications of 3D Printing
7.2.4 Advantages of 3D Printing
7.2.5 Disadvantages of 3D Printing
7.3 Future Prospects of 3D Printing Technology
7.4 Conclusions
References
Chapter 8 Cutting Zone Temperature and Cutting Force in 3D-Milling Operations Using ABAQUS
8.1 Introduction
8.2 Literature Review
8.3 Objectives
8.4 Methodology
8.5 Simulation
8.5.1 Geometry
8.5.2 Boundary Conditions
8.5.3 Meshing Details
8.5.4 Step Information
8.6 Milling Conditions
8.7 Result and Discussion
8.7.1 Effect of Cutting Parameters on Force Distribution
8.7.2 Effect of Cutting Parameters on Stress Distribution
8.8 Conclusion
References
Chapter 9 A Rare Ferroelectric Material: Fresnoite (Ba2TiSi2O8)
9.1 Introduction
9.2 Experimental
9.2.1 Materials and Methods
9.3 Characterization Details
9.3.1 Powder X-Ray Diffraction
9.3.2 Scanning Electron Microscope
9.3.3 Raman Spectroscopy
9.3.4 DC Conductivity and Dielectric
9.3.5 Modulated Differential Scanning Calorimetry
9.4 Result and Discussion
9.4.1 X-Ray Diffraction Analysis
9.4.2 Morphological Analysis
9.4.3 Raman Spectroscopic Analysis
9.4.4 Electrical Analysis
9.4.5 Thermal Analysis
9.5 Conclusion
References
Chapter 10 Research Progress and Developments in GTAW Process Using Visual Sensing and Weld Penetration Estimation
10.1 Introduction
10.2 GTAW Process
10.2.1 Current
10.2.2 Speed
10.2.3 Voltage
10.2.4 Shielding Gas
10.3 Sensing Technologies in Welding
10.3.1 Sensor-Based Technology
10.3.2 Acoustic Emission Technology
10.3.3 Several Sensor Information Fusion Techniques
10.4 Online Vision Inspection
10.4.1 Inspection Sensors
10.4.2 Vision Inspection Contents
10.4.3 Camera Calibration Techniques
10.5 3 Dimensional Image Processing of Weld Pool Geometry Using Dot Matrix
10.5.1 Image Processing
10.6 Real-Time Three-Dimensional Measurement of Topside and Backside Width of Weldment
10.7 Dynamic Estimation of Weld Pool Geometry
10.8 Visual Sensing Based on Supervised Machine Learning Technique
10.9 Hybrid Network Model Using Convolutional Neural Network and Long Short-Term Memory
10.10 Conclusion
References
Chapter 11 Simulation of Sulfur Recovery Unit Using Aspen Plus
11.1 Introduction
11.2 Process Description
11.3 Methodologies
11.3.1 Description of Simulation Flow Sheet
11.3.2 Validation of Simulation Model
11.4 Results and Discussion
11.4.1 Effect of Acid Gas/Air Molar Flow Ratio on Sulfur Recovery and Tail Gas Ratio
11.4.2 Effect of H2S Concentration in Acid Gas Stream on Sulfur Recovery and Tail Gas Ratio
11.5 Conclusion
Acknowledgments
References
Chapter 12 Fabrication of Magnesium Metal Matrix Nanocomposites Using Ultrasonic-Assisted Stir-Casting Method
12.1 Introduction
12.1.1 Ultrasound Equipment
12.1.2 Ultrasonication-Assisted Stir-Casting Technique (UASCT)
12.1.3 Nanocomposites Processing
12.2 Effect of Ultrasound on Magnesium Alloys
12.2.1 AlN Reinforcement
12.2.2 Al2O3 Reinforcement
12.2.3 SiC Reinforcement
12.2.4 TiB2 Reinforcement
12.3 Conclusion
References
Chapter 13 Friction Stir Welding of Dissimilar Magnesium Alloys: Analytical Modeling, Simulation, and Experimental Validation
13.1 Introduction
13.2 Analytical Modeling
13.3 Heat Input Modeling
13.3.1 Calculation of Heat Generation
13.3.2 Heat Flux Modeling
13.4 Experimental Detail
13.4.1 Tool Preparation
13.4.2 Work Material
13.5 Experimental Setup
13.5.1 Tensile Test
13.5.2 Microhardness Test
13.6 Experimental Results
13.6.1 Weldments
13.6.2 Tensile Test Results
13.6.3 Hardness Test Results
13.7 Conclusion
References
Chapter 14 Advancements in Welding Techniques: Surface and Mechanical Property Insights
14.1 Introduction
14.1.1 Arc Welding Processes
14.1.2 Tungsten Inert Gas Welding
14.1.3 Metal Inert Gas Welding
14.1.4 Submerged Arc Welding
14.1.5 Flux-Cored Arc Welding
14.2 Resistance Welding
14.2.1 Spot Welding Processes
14.2.2 Projection Welding
14.2.3 Seam Welding
14.2.4 Butt Welding
14.3 Hybrid Welding
14.4 Rotary Friction Welding
14.5 Friction Stir Welding
14.6 Properties of Friction Welding
14.7 Future Research Opportunities and Conclusions
References
Chapter 15 Advanced 3D Printing for Industrial Components: Welded Joint Analysis and Strength Assessment
15.1 Introduction
15.2 Material Used for SLM Technology
15.3 SLM Technology 3D Component
15.4 TIG Welding Method for Joining
15.5 ABS and PLA 3D Component Material
15.5.1 Fused Deposition Modeling
15.6 Welding Method Used for ABS and PLA
15.6.1 Solvent Welding
15.6.2 Mechanical Fastening
15.6.3 Adhesive Bonding
15.7 Characterisation Techniques
15.7.1 Examining the Base Material’s Porosity
15.7.2 Analysis of Mechanical Properties
15.8 Challenges Faced in the Development Process
15.8.1 Due to the Solvent Welding
15.8.2 Due to Mechanical Fastening
15.8.3 Due to Adhesive Bonding
15.8.4 Method to Avoid Issue
15.9 Conclusion
References
Chapter 16 Advancements in Electrochemical Surface Coatings: Innovations, Applications, and Future Prospects
16.1 Introduction
16.2 Fundamentals of Electrochemical Process
16.2.1 Electrode Kinetics
16.2.2 Faraday’s Laws of Electrolysis
16.3 Types of Electrochemical Surface Coatings
16.3.1 Electrodeposition
16.3.2 Anodization
16.3.3 Electrophoretic Deposition
16.3.4 Electroless Plating
16.4 Overview of Surface Preparation Methods
16.4.1 Cleaning
16.4.2 Degreasing
16.4.3 Surface Activation
16.4.4 Surface Roughening
16.5 Characterization of Electrochemically Coated Surface
16.6 Applications of Electrochemical Surface Coating in Various Fields
16.6.1 Automotive
16.6.2 Aerospace
16.6.3 Biomedical Application
16.6.4 Application in Dental Implants
16.6.5 Microelectronics
16.7 Challenges and Limitations of Electrochemical Surface Coating Methods
16.8 Conclusions
16.9 Future Trends
References
Chapter 17 Process Variable Impact Analysis in Unconventional Machining: Enhancing MRR, Accuracy, and Surface Quality
17.1 Introduction
17.2 Nontraditional Machining Processes
17.2.1 Electro-Discharge Machining
17.2.2 Parameters Affecting the MRR in EDM
17.2.3 Parameters Affecting the Surface Quality and Accuracy in EDM
17.3 Electrochemical Machining
17.3.1 Parameters Affecting the MRR in ECM
17.3.2 Parameters Affecting the Surface Quality and Accuracy in ECM
17.4 Ultrasonic Machining
17.4.1 Parameters Affecting the MRR in USM
17.4.2 Parameters Affecting the Surface Quality and Accuracy in USM
17.4.3 Abrasive Jet Machining (AJM)
17.4.4 Parameters Affecting the MRR in AJM
17.4.5 Parameters Affecting the Surface Roughness and Accuracy in AJM
17.5 Laser Beam Machining (LBM)
17.5.1 Parameters Affecting the MRR in LBM
17.5.2 Parameters Affecting the Surface Roughness and Accuracy in LBM
17.6 Conclusion
17.7 Future Research Opportunities
References
Chapter 18 Pulsed Power Supplies for Surface Coating Applications: Methods, Materials, and Case Studies
18.1 Introduction
18.2 Different Coating Materials
18.3 Magnetron Sputtering
18.4 Ceramic Coatings
18.4.1 Specific Types of Ceramic Coatings
18.5 Plasma Electrolysis Oxidation
18.5.1 Properties of Plasma Electrolytic Oxide
18.6 Case Study 1: Aluminum Oxide Coatings by Unbalanced Sputtering
18.7 Case Study 2: Power Supply Mode in Plasma Electrolysis Oxidation (Micro-Arc Oxidation Coating) in Magnesium Alloy
18.7.1 Process Parameters
18.7.2 Advantages of the Process
18.7.3 Disadvantages of Process
18.8 Conclusions
References
Chapter 19 Fabrication and Water Absorption Testing of Banana Fiber–Reinforced Composite
19.1 Introduction
19.2 Materials
19.3 Material Preparation
19.3.1 Banana Fiber
19.3.2 Epoxy Resin
19.3.3 Hardener
19.4 Fabrication Process
19.5 Water Absorption Testing
19.6 Results and Discussions
19.6.1 Observation on Fabrication of the Composite
19.6.2 Results of the Water Absorption Test
19.7 Conclusion
Declaration of Competing Interest
References
Chapter 20 Multi-Objective Optimization of Fusion Welding Parameters Using Non-Dominated Sorting Genetic Algorithm II
20.1 Introduction
20.2 The Suggested Methodology
20.2.1 Genetic Algorithm
20.2.2 Non-Dominated Sorting Genetic Algorithm
20.2.3 A Fast and Elitist Multi-Objective Genetic Algorithm: NSGA-II
20.3 Results and Discussions
20.3.1 Process Variable Considered for Optimization
20.3.2 Optimization of Penetration Depth, Bead Thickness, and Welding Irregularity by Regression Analysis
20.3.3 Validation of Results with Experimental Result
20.3.4 Pareto Frontier Chart
20.4 Conclusion
Declaration of Competing Interest
References
Index
EULA