Advances in Micro and Nano Manufacturing and Surface Engineering (eBook)

AIMTDR 2018 Conference’s Core Organizing Committee 6
Patrons 6
President (NAC-AIMTDR) 6
Vice-President (NAC-AIMTDR) 6
Co-patrons 6
Chairman 7
Co-chairman 7
Organizing Secretary 7
Joint Organizing Secretaries 7
International Scientific Committee 7
National Advisory Committee 8
Foreword 10
Preface 11
Contents 12
About the Editors 19
Micro and Nano Manufacturing 20
1 Fabrication and Experimental Investigation of Micro-fluidic Channel-Based Mixing System Using Micro-electric Discharge Machining 21
1.1 Introduction 22
1.2 Experimentation 23
1.2.1 Design of Experiments 23
1.2.2 Experimental Setup 24
1.2.3 Fabrication of Micro-fluidic Channel 25
1.3 Results and Discussion 27
1.3.1 Channel Width 28
1.3.2 Channel Depth 30
1.3.3 Average Surface Roughness (Ra) 31
1.3.4 Flow of Fluids in the Micro-fluidic System 33
1.4 Conclusion 33
References 34
2 Compression and Diametral Tensile Strength Analysis of Graphene–Al2O3 Reinforced AA 2024 and AA 2219 Hybrid Nanocomposites 36
2.1 Introduction 37
2.2 Experimentation and Methods 38
2.2.1 Dispersion of Graphene and Al2O3 38
2.2.2 Composite Preparation 38
2.2.3 Testing and Characterization 38
2.3 Results and Discussion 42
2.4 Conclusion 47
References 48
3 A New Approach for Fabrication of Complex-Shaped Arrayed Micro Electrodes 50
3.1 Introduction 50
3.2 Proposed Technology 54
3.3 LASER Micro machining 54
3.4 Results and Discussions 58
3.4.1 Influence of Pin-Fins Aspect Ratio 58
3.4.2 Heat Transfer Characteristics 61
3.5 Conclusions 62
References 62
4 Fabrication of Micro-holes Array Through Multiple Electrodes with Distributed ?-Pulsed Electrochemical Machining 64
4.1 Introduction 65
4.2 Numerical Simulation of EC Drilling 67
4.3 Experimental Setup 72
4.3.1 Development of the Power Supply 73
4.4 Experimental Results 74
4.5 Conclusions 75
References 77
5 Effect of Water and KOH Aqueous Solution on Micro-slot Grinding of Silicon 78
5.1 Introduction 78
5.2 Experimental Procedure 80
5.2.1 Machining Conditions and Methodology 80
5.2.2 Experimental Setup 81
5.3 Experimental Procedure 82
5.3.1 Grinding Forces 82
5.3.2 Grinding Force Ratio 83
5.3.3 Surface Roughness and Topography 84
5.4 Conclusions 86
References 87
6 Magnetic Effect on High-Speed Electrochemical Discharge (HSECD) Engraving 88
6.1 Introduction 89
6.2 Experimentation 90
6.3 Results and Discussion 93
6.3.1 Effect of Voltage With and Without Magnetic Field 93
6.3.2 Effect of Tool Rotation Speed With and Without Magnetic Field 94
6.3.3 Effect of Feed Rate With and Without Magnetic Field 95
6.4 Conclusions 96
References 97
7 Bactericidal Nanostructured Titanium Surface Through Thermal Annealing 99
7.1 Introduction 99
7.2 Experimental Procedure 100
7.2.1 Materials and Methods 100
7.2.2 Antibacterial Testing 101
7.3 Results and Discussion 101
7.3.1 Samples Characterization 101
7.3.2 Antibacterial Testing 104
7.4 Conclusions 107
References 107
8 A Study on the Effect of Oxalic Acid Electrolyte on Stainless Steel (316L) Through Electrochemical Micro-machining 109
8.1 Introduction 109
8.2 Experimental Arrangement of ECMM 111
8.3 Chemical Reactions of Oxalic Acid Solution on SS (316L) 112
8.4 Results and Discussion 114
8.4.1 Influence of Voltage on Material Removal Rate and Overcut 114
8.4.2 Influence of Duty Cycle on Material Removal Rate and Overcut 115
8.4.3 Influence of Electrolyte Concentration on Material Removal Rate and Overcut 116
8.5 Conclusions 118
References 118
9 Inkjet Printing-Based Micro-manufacturing of the Thin Film Electrodes for Flexible Supercapacitor Applications 120
9.1 Introduction 121
9.2 Experimental 122
9.2.1 Preparation of the Conducting Layer and Electrode Layer Inks 122
9.2.2 Fabrication of the Device 122
9.2.3 Characterization 123
9.3 Calculations 123
9.4 Results and Discussion 124
9.4.1 Material Characterization 124
9.4.2 Micro-Manufacturing of the Thin Film Electrodes 125
9.4.3 Electrochemical Analysis 125
9.5 Conclusions 128
References 128
10 Multiresponse Optimization of Electrochemical Micro-machining Process Parameters of Micro-dimple Using TOPSIS Approach 129
10.1 Introduction 129
10.2 Experimental System and Experimental Methods 131
10.2.1 Experimental Setup 131
10.2.2 Process Parameters 131
10.2.3 Selection of Electrolyte and Electrolyte Concentration 132
10.2.4 Experimental Results 133
10.3 Multiresponse Optimization 134
10.3.1 Optimization Steps Using TOPSIS Approach 134
10.4 Results and Discussion 137
10.4.1 Fabrication of micro-dimple 137
10.4.2 Effect of Applied Voltage on Micro-Dimple 138
10.4.3 Effect of Duty Ratio on Micro-Dimple 138
10.4.4 Effect of Feed Rate on Micro-dimple 139
10.4.5 Surface Roughness Profile of Micro-Dimple 139
10.5 Conclusions 140
References 141
11 Investigations into Micro-Hole Drilling on SS-304 by Sequential Electro-Micro Machining 142
11.1 Introduction 142
11.2 Experimental Details 145
11.3 Experimental Planning 146
11.3.1 Tool Electrode and Workpiece Specifications 147
11.4 Results and Discussion 148
11.5 Conclusions 152
References 153
12 Experimental Investigations to Evaluate Machining Accuracy of Ultrasonic-Assisted Milling on Thin-Walled Structures 154
12.1 Introduction 154
12.2 Design and Fabrication of Experimental Setup and Design of Experiments 156
12.3 Measurement and Comparison 159
12.4 Conclusions 162
References 163
13 High-Speed Conduction-Mode Micro-Laser Welding of Thin SS-304 Sheets: Modeling and Experimental Validation 165
13.1 Introduction 165
13.2 Experimental Procedure 167
13.3 Model Description 167
13.3.1 Governing Transport Equations 168
13.3.2 Boundary and Initial Conditions 170
13.3.3 Numerical Implementation 170
13.4 Results and Discussion 171
13.4.1 Experimental Results 171
13.4.2 Modeling Results 171
13.4.3 Model Validation 173
13.5 Conclusions 176
References 176
14 Surface Roughness Improvement by Removal of Recast Layer on Wire Electrical Discharge Machined Surface Through Abrasive Flow Finishing Machine 178
14.1 Introduction 178
14.2 Experimental Work 180
14.2.1 Abrasive Flow Finishing Machine 180
14.2.2 Abrasive Polymer Media 180
14.2.3 Work-Holding Fixture 181
14.2.4 Component 181
14.2.5 Experimental Procedure 182
14.3 Results and Discussion 183
14.3.1 Micro-hardness Analysis 184
14.3.2 Scanning Electron Microscopic Analysis 184
14.3.3 EDS Analysis 186
14.4 Conclusions 186
References 187
15 Investigations on the Influence of Size Effect on Surface Characteristics During Micro-End Milling of Inconel 718 188
15.1 Introduction 188
15.2 Experimental Work 191
15.2.1 Workpiece Material 191
15.2.2 Cutting Tool 191
15.2.3 Experimental Setup 191
15.3 Results and Discussion 193
15.3.1 Areal Surface Roughness 193
15.3.2 Surface Defect 194
15.3.3 Microhardness 196
15.4 Conclusions 197
References 198
16 Machining of Borosilicate Glass Using Micro-End Milling 199
16.1 Introduction 199
16.2 Brittle to Ductile Mode Transition Mechanism 201
16.3 Experimental Setup 202
16.4 Results and Discussion 203
16.5 Conclusions 209
References 210
17 Parametric Optimization of Micro-electrical Discharge Drilling on Titanium 211
17.1 Introduction 211
17.2 Materials and Methods 213
17.3 Results and Discussion 215
17.3.1 Machining Time 215
17.3.2 Diameter at Entry and Exit 216
17.3.3 Analysis of Variance 218
17.3.4 Confirmation Test 218
17.4 Conclusions 219
References 220
18 Numerical Simulation of Micro-EDM Process by Incorporating a Novel Approach of Multi-sparks 221
18.1 Introduction 222
18.2 Multi-sparks in the EDM Process 223
18.3 Model Description 224
18.3.1 Boundary Conditions 225
18.3.2 Thermal Conduction Model 226
18.3.3 Thermal Ablation Model 226
18.4 Results and Discussion 227
18.4.1 Results of the Crater Formed Due to Single Spark 228
18.4.2 Results of Multi-spark Micro-EDM Simulation 230
18.5 Conclusions 233
References 233
19 Analysis of Fiber Laser Micro-grooving on 316 L Stainless Steel 235
19.1 Introduction 235
19.2 Experimental Plan 237
19.3 Experimental Results 238
19.3.1 Effect of Laser Power on Kerf Width and Surface Roughness, Ra 238
19.3.2 Effect of Pulse Frequency on Kerf Width and Surface Roughness, Ra 240
19.3.3 Effect of Cutting Speed on Kerf Width and Surface Roughness, Ra 242
19.4 Conclusions 244
References 245
20 Characterization of Cutting Edge Radius of a Single Crystal Diamond Tool by Atomic Force Microscopy 246
20.1 Introduction 246
20.2 Least Square Method (LSM) of Circle Fitting with Error Minimization 248
20.3 Experimentation 250
20.3.1 Equipment Specifications 250
20.3.2 Diamond Tool Specifications 250
20.3.3 Experimental Setup 250
20.3.4 Scanning of Cutting Edge Radius 250
20.4 Result and Discussion 251
20.4.1 Data Processing 251
20.4.2 Characterization of Cutting Edge Radius 251
20.5 Conclusion 256
References 257
21 Effect of Different Electrodes on Micro-feature Fabrication in Biomedical Co-29Cr-6Mo Alloy Machined Using µ-EDM Process 258
21.1 Introduction 258
21.2 Experimentation 260
21.3 Results and Discussion 262
21.3.1 Material Removal Rate 262
21.3.2 Tool Wear Rate 263
21.3.3 Overcut 264
21.4 Conclusions 265
References 266
22 Micro-tool Fabrication and Micro-ED Milling of Titanium Nitride Alumina Ceramic–Composite 267
22.1 Introduction 267
22.2 Materials and Methods 269
22.3 Experimentations 270
22.4 Results and Discussion 273
22.5 Conclusions 274
References 275
23 Experimental Investigations on the Effect of Energy Interaction Durations During Micro-channeling with ECDM 276
23.1 Introduction 276
23.2 Materials and Methods 278
23.3 Results and Discussion 279
23.4 Conclusions 283
References 283
24 Influence of Chip Thickness Models on Deflection Aspects of an End Mill Cutter and a Spindle Bracket of a Miniaturized Machine Tool 285
24.1 Introduction 285
24.2 Chip Thickness Models 286
24.2.1 Tooth Position Angle ( ?) Calculation 286
24.3 Cutting Force Models 287
24.3.1 Specific Cutting Force Model 287
24.3.2 Cutting Force Model with Cutter Stiffness Included 288
24.4 Tool Deflection of a Micro End Mill 288
24.4.1 Path of Cutter Tooth—Circular 289
24.4.2 Trajectory of Cutter Tooth—Trochoidal 290
24.5 Static Deflection of Spindle Bracket of a MMT 290
24.6 Results and Discussion 292
24.7 Conclusions 292
References 293
25 Micro-hardness Improvement of HSS Using Tungsten Tool Through Micro-electrical Discharge Process 294
25.1 Introduction 294
25.2 Methodology 295
25.3 Results and Discussion 297
25.3.1 Micro-hardness 297
25.3.2 EDS Analysis 299
25.3.3 XRD Analysis 299
25.3.4 Diffusion 299
25.4 Conclusions 300
References 302
26 Nano-finishing of Internal Surface of Power Steering Housing Cylinder Using Rotational Magnetorheological Honing Process 303
26.1 Introduction 303
26.2 Design of Magnetorheological Honing Tool and Experimental Setup 305
26.3 Experimentation 306
26.4 Results and Discussion 308
26.5 Conclusions 310
References 311
27 Investigation and Evaluation of Erosion Efficiency in Micro-EDM Dressing of Biocompatible Ti6Al7Nb Material 312
27.1 Introduction 312
27.2 Experimental Details 313
27.3 Errosion Efficiency of Micro-EDM Dressing 315
27.3.1 Assumptions 315
27.3.2 Theoretical Modeling 316
27.4 Results and Discussion 318
27.4.1 Erosion Efficiency of Normal Pulses 318
27.4.2 Erosion Efficiency of Effective Pulse 319
27.5 Conclusions 319
27.6 Future Directions 320
References 320
28 Correlation Between Mechanical Properties and Microstructure of Fe-Ti-Zn Alloys Fabricated by Powder Metallurgy 321
28.1 Introduction 321
28.2 Experimental Work 322
28.2.1 Manufacture of Alloy Using Powder Metallurgy 322
28.2.2 Mixing of Powders 323
28.2.3 Compacting the Mixture 324
28.2.4 Sintering 324
28.2.5 Testing of the Alloy 325
28.3 Results and Discussion 326
28.3.1 XRD Results 326
28.3.2 Microstructure 327
28.3.3 Hardness Test Results 327
28.3.4 Impact Test Results 328
28.4 Conclusions 328
References 329
29 Experimental Investigations into Wire Electrical Discharge Machining Process for the Machining of Ti-6Al-4V 330
29.1 Introduction 330
29.2 Experimental Details 331
29.3 Results and Discussion 332
29.3.1 Variation of Average Cutting Rate with Discharge Energy and Feed Rate 332
29.3.2 Variation of Average Kerf Loss with Discharge Energy and Feed Rate 333
29.3.3 Effect of Wire Speed 334
29.4 Comparative Assessment of Micro-slit Machining at Different Inclination Angles 335
29.5 Machining of Micro-slits with Thin Wall 336
29.6 Conclusions 337
References 338
30 Design and Development of Tool Electrode for Electrochemical Micromachining Using Reverse EMM Technique 339
30.1 Introduction 339
30.2 Experimentation Details 341
30.3 Results and Discussion 342
30.3.1 Effect of Electrolyte Concentration (2 and 2.5 g/l) on Tool Shape—Without Reciprocating Feed 342
30.3.2 Effect of Electrolyte Concentration (2–2.5 g/l) on Tool Shape—With Reciprocating Feed 343
30.3.3 Surface Roughness Profile of Micro Tools 344
30.3.4 Machining of Micro Holes on 304 SS 344
30.4 Conclusions 345
References 347
31 Micro-dimple Array Fabrication by Through Mask Electrochemical Micromachining 348
31.1 Introduction 349
31.2 Experimentation 350
31.2.1 Experimental Conditions 350
31.2.2 Experimental Planning 351
31.2.3 Measurement of Experimental Outcomes 352
31.3 Taguchi’s Robust Methodology and Investigation of the Machining Parameters 352
31.3.1 Orthogonal Array Selection 353
31.3.2 Analysis of Signal-to-Noise (S/N) Ratio 353
31.3.3 Analysis of Variance (ANOVA) 355
31.3.4 Confirmation Tests 357
31.4 Conclusions 358
References 359
32 Parametric Optimize and Surface Characterisation of Micro Electrical Discharge Machining Drilling Process 360
32.1 Introduction 360
32.2 Experimental Procedure 361
32.3 Results and Discussions 364
32.4 Conclusions 367
References 368
33 Experimental Study of Nanosecond Fiber Laser Micromilling of Ti6Al4V Alloy 369
33.1 Introduction 369
33.2 Experimental Setup 371
33.3 Experimental Plan Based on Response Surface  Methodology 372
33.4 Results and Discussion 373
33.4.1 Parametric Influence on Depth 373
33.4.2 Mathematical Regression Model 374
33.4.3 Roughness Measurement Inside Groove 376
33.5 Conclusions 376
References 378
34 Evaluation of Side Wall Roughness and Material Removal Rate in Vibration Assisted Powder Mixed Micro-EDM Drilling on Inconel 718 379
34.1 Introduction 379
34.2 Experimental Setup 381
34.3 Results and Discussion 382
34.3.1 Analysis of Material Removal Rate 382
34.3.2 Analysis of Surface Roughness Along Sidewall 384
34.3.3 Multi-objective Optimization of MRR and SWR 385
34.4 Conclusions 386
References 386
35 Analysis of Effect of Heat Treatment on Machining Characteristics During Micro-end Milling of Inconel 718 388
35.1 Introduction 389
35.2 Experimental Work 390
35.2.1 Workpiece Material 390
35.2.2 Cutting Tool 391
35.2.3 Experimental Setup 391
35.3 Results and Discussion 392
35.3.1 Effect of Grain Size on Heat-Treated Samples 392
35.3.2 Effect of Microhardness on Heat-Treated Samples 393
35.3.3 Effect of Heat Treatment on Areal Surface Roughness 393
35.3.4 Effect of Heat Treatment on Cutting Force 394
35.4 Conclusions 395
References 396
36 Modeling of Mechanical Residual Stresses in Micro-End Milling of Ti-6Al-4V Alloy 397
36.1 Introduction 397
36.2 Elastic Loading 399
36.3 Loading Beyond Yielding 399
36.4 Increment in Plastic Strain Due to Plastic Loading 400
36.5 Relaxation Procedure 402
36.6 Simulations and Validation 403
36.7 Conclusions 404
References 405
37 Machining of High-Quality Microchannels on Ti6Al4V Using Ultra-Short Pulsed Laser 406
37.1 Introduction 406
37.2 Experimental Setup 408
37.2.1 Experimental Setup and Materials 408
37.2.2 Characterization of Microfeatures 408
37.3 Results and Discussions 409
37.3.1 Micro Channel—Slot 410
37.3.2 Microchannel—Circular 412
37.4 Conclusion 415
References 416
38 Investigation of Electrochemical Micromachining Process Using Ultrasonic Heated Electrolyte 418
38.1 Introduction 419
38.2 Experimental Method 420
38.3 MOORA (Multi-objective Optimization on the Basis of Ratio Analysis) Optimization Method 421
38.4 Result and Discussion 423
38.4.1 Input Parameters Effect on MRR 423
38.4.2 Input Parameters Effect on OC 424
38.4.3 MOORA 425
38.4.4 ANOVA Table for MOORA 425
38.5 SEM Analysis 426
38.6 Conclusion 427
References 428
Surface Engineering 430
39 Microstructure and Mechanical Properties of Atmospheric Plasma Sprayed 8YSZ Thermal Barrier Coatings 431
39.1 Introduction 431
39.2 Experimental Procedure 433
39.2.1 Preparation of TBCs 433
39.2.2 Characterization 435
39.3 Results and Discussion 435
39.3.1 Microstructure 435
39.3.2 Mechanical Properties 439
39.4 Conclusions 440
References 440
40 Decoding the Grinding Zone—A Study on Track Grinding Wheels 441
40.1 Introduction 441
40.2 Experiments 443
40.2.1 Diagnostic Tool 445
40.2.2 Derivatives of Power and Material Removal 445
40.3 Results and Discussion 449
40.3.1 Needle Shaped Versus Blocky Shaped Grains 449
40.3.2 Varying the Dresser Feed Rate 452
40.4 Conclusions 453
References 454
41 Three Turn ECAP Processing of AA6061 Alloy: Microstructure and Mechanical Properties 455
41.1 Introduction 455
41.2 Experimental Setup 456
41.3 Limitations in Conventional Single Turn Ecap Process 457
41.3.1 Labour Intensive Process 457
41.3.2 Reduction in Billet Size 458
41.4 Three Turn ECAP 459
41.4.1 Tensile Testing 462
41.4.2 Microstructural Analysis 463
41.5 Conclusions 466
References 466
42 Wear Performance Evaluation of AlCrN Based Coating Deposited by PVD Technique Under Dry and Cryogenic Environments 467
42.1 Introduction 467
42.2 Experimental Details 468
42.2.1 Coating Deposition 468
42.2.2 Machining Test 469
42.2.3 Tool Wear Characterization 469
42.3 Results and Discussion 470
42.3.1 Coating Morphology and Composition 470
42.3.2 Flank Wear Studies 471
42.3.3 Rake Wear Studies 474
42.4 Conclusions 475
References 475
43 Numerical and Experimental Analysis of Plasma Nitrided XM-19 Stainless Steel 477
43.1 Introduction 477
43.2 Experimental Procedure 479
43.2.1 Hardness Measurement 480
43.2.2 Simulation Problem 481
43.3 Outcomes and Discussion 481
43.3.1 Physical Appearance 481
43.3.2 Optical Microscopy 482
43.3.3 Hardness Measurement and Profile Plot 483
43.3.4 Case Depth Hardness Measurement Graph of PN Treated Specimens 484
43.3.5 Numerical Simulation 487
43.3.6 Results Comparisons 487
43.4 Conclusions 488
References 493
44 Study on Actuation Characteristics of NiTiCu SMA Thin Film Deposited on Flexible Substrate 495
44.1 Introduction 495
44.2 Experimental Setup 497
44.3 Results and Discussion 498
44.4 Conclusions 500
References 501
45 Influence of Laser Shock Peening on Wire Arc Additive Manufactured Low Carbon Steel 503
45.1 Introduction 503
45.2 Materials and Methods 505
45.2.1 Materials 505
45.2.2 Methods 505
45.3 Result 507
45.3.1 Optical Microscope 507
45.3.2 X-Ray Diffraction 508
45.4 Conclusion 509
References 510
46 Fluidity of A206 Cast Alloy with and Without Scrap Addition Using Thin Cross-Sectional Fluidity Test: A Comparison 511
46.1 Introduction 511
46.2 Experimental Procedure 512
46.3 Experimental Results 514
46.3.1 Fluidity Results of the A206 Alloy at Without Addition of Scrap 514
46.3.2 Fluidity Results of the A206 Alloy with 15% A206 Alloy Scrap Addition 515
46.3.3 Fluidity Results of the A206 Alloy with 15% A206 Alloy Scrap Addition 516
46.4 Discussions 517
46.5 Conclusions 518
References 518
47 Study on the Aesthetic Behavior of Anodic Oxidation in ADC12 Aluminum Alloy 520
47.1 Introduction 520
47.2 Methodology 522
47.2.1 Materials Used 522
47.2.2 Process Improvements Outcome 523
47.2.3 Corrosion Testing 526
47.3 Conclusion 527
References 528
48 Development and Correlative Microstructural-Nanoindentation Investigation on Ni-Based + 10% Al2O3 Nanocomposite Microwave Clad on Hydroturbine Steel 529
48.1 Introduction 529
48.2 Experimental Procedure 530
48.2.1 Material Selection 530
48.2.2 Experimental Setup 532
48.2.3 Characterization of the Nanocomposite Clad 532
48.3 Results and Discussion 533
48.3.1 Microstructure Analysis 533
48.3.2 Nano Hardness 535
48.4 Conclusions 537
References 537
49 Evaluation of Surface Characteristics of PTAW Hardfacing Based on Energy and Powder Supplied 539
49.1 Introduction 539
49.2 PTAW Hardfacing Technique 540
49.3 Experimentations 541
49.3.1 Hardfacing Alloy 542
49.4 Result and Discussion 542
49.4.1 Effects of Energy Supplied Per Unit Track of Deposition 543
49.4.2 Effects of Powder Supplied Per Unit Track of Deposition 545
49.5 Conclusions 548
References 549
50 Electroless Nickel–Phosphorus Plating on SS304 Substrate with Al2O3 and WS2 Powder Suspended in Electrolytic Solution 551
50.1 Introduction 551
50.2 Literature Review 552
50.3 Methodology 553
50.3.1 Materials Used 553
50.3.2 Experimental Set-Up 554
50.4 Result and Discussions 556
50.4.1 Microhardness 556
50.4.2 Coating Thickness 557
50.4.3 EDS Study 557
50.4.4 Surface Morphology 558
50.4.5 XRD Analysis 561
50.5 Conclusions 561
References 562
51 Influence of Heat Input on Corrosion Resistance of Duplex Stainless Steel Cladding on Low-Alloy Steel by FCAW 563
51.1 Introduction 563
51.2 Experimental Procedure 565
51.2.1 Calculation of Heat Input, Creq, Nieq, Ferrite No., and PREN 566
51.2.2 Corrosion Test 566
51.2.3 Metallographic Study 567
51.2.4 Chemical Composition 567
51.3 Results and Discussion 567
51.4 Conclusions 572
References 573
52 Study of Sliding Abrasive Wear Behaviour of TiC–TiB2 Composite Coating Fabricated on Titanium Alloy by TIG Cladding Method 574
52.1 Introduction 574
52.2 Experimental Planning and Procedure 575
52.3 Results and Discussion 577
52.4 Conclusions 582
References 582
53 Effect of Test Conditions on Tribological Behavior of NiTi–TiN-Coated Ti–6Al–4V Alloy Fabricated by TIG Cladding Method 583
53.1 Introduction 583
53.2 Materials and Methodology 584
53.3 Results and Discussion 586
53.4 Conclusions 590
References 590
54 Sliding Abrasive and Adhesive Wear Behavior of TIG-Cladded NiTi–W Coating Deposited on Ti–6Al–4V Alloy 592
54.1 Introduction 592
54.2 Materials and Methodology 593
54.3 Results and Discussion 594
54.3.1 Sliding Abrasive Wear Test 594
54.3.2 Sliding Adhesive Wear Test 596
54.3.3 COF for Adhesive Wear 599
54.4 Conclusions 599
References 600
55 Investigation of Surface Coating on Inconel 718 Alloy with Silicon Carbide Powder 601
55.1 Introduction 601
55.1.1 Electrical Discharge Alloying 602
55.1.2 Inconel 718 Alloy 602
55.1.3 Silicon Carbide 603
55.1.4 Surface Roughness 603
55.2 Experimental Details 603
55.2.1 Working Procedure 604
55.2.2 Observation 605
55.3 Results and Discussion 606
55.3.1 Surface Roughness 606
55.3.2 SN Ratio 606
55.3.3 Main Effects Plots 607
55.3.4 Surface Morphology 608
55.3.5 Energy-Dispersive X-Ray Spectroscopy 609
55.4 Conclusion 609
References 610
56 Effect of Sensitization on Electroless Nickel Plating of MoS2 Nanoparticles 611
56.1 Introduction 611
56.2 Experimentation 612
56.2.1 Pretreatment of MoS2 Surface 612
56.3 Results and Discussion 614
56.3.1 Structural Information 614
56.4 Conclusions 618
References 618
57 Laser Beam Treatment of Nimonic C263 Alloy: Study of Mechanical and Metallurgical Properties 620
57.1 Introduction 620
57.2 Experimental Procedure 622
57.2.1 Experimental Setup 622
57.2.2 Workpiece Material 623
57.2.3 Experimentation 623
57.2.4 Characterization of Samples 625
57.3 Results and Discussion 625
57.3.1 Effect of Process Parameters on Bead Geometry 625
57.3.2 Microstructure and Heat Affected Zone (HAZ) at Weld Bead Cross Section 627
57.3.3 X-Ray Diffraction (XRD) Analysis 630
57.3.4 Effect of Laser Power on Micro-Hardness 631
57.4 Conclusion 632
References 632
58 Evaluation of Mechanical Properties of Ti6Al4V Built by Composite Coating of WS2, CNT, Ni, and Ti6Al4V Powders Through Laser Cladding Process 634
58.1 Introduction 634
58.2 Experimental Details 636
58.2.1 Setup for the Experiment 636
58.2.2 Material Selection and Powder Preparation 637
58.2.3 Experimental Procedure 637
58.2.4 Characterization of the Coated Layer 639
58.3 Results and Discussions 640
58.3.1 EDX Analysis of Clad Layer 640
58.3.2 XRD Analysis of Clad Layer 641
58.3.3 Microstructure 642
58.3.4 Microhardness of the Clad Layer 643
58.3.5 Clad Layer Thickness 644
58.3.6 Wear Analysis 645
58.4 Conclusion 647
References 647
59 Towards Extending ECAP Technology from Lab Scale to Manufacturing by Enhanced Multipass Continuous ECAP Process 649
59.1 Introduction 649
59.2 Experimental Set-up 650
59.3 Mechanical Properties and Microstructure 651
59.3.1 Limitations of Conventional ECAP 653
59.4 Finite Element Analysis of Continuous ECAP 655
59.5 Conclusions 657
References 657
60 The Effect of Normal Load and Sliding Frequency on the Reciprocating Friction Behavior of Nanocrystalline CuO-Based Alumina Ceramics 658
60.1 Introduction 658
60.2 Experimental Work 659
60.2.1 Materials 659
60.2.2 Synthesis of Nanocrystalline CuO Powder 659
60.2.3 Sample Preparation 660
60.2.4 Test Procedure 660
60.3 Results and Discussions 661
60.3.1 Effect of Reciprocating Frequency on Friction Coefficient 661
60.3.2 Effect of Normal Load on Friction Coefficient 663
60.4 Conclusions 664
References 665
61 Increase in Hardness and Wear Resistance of Ti-6Al-4V Surface by In Situ Laser Coating of Ti- and Al-Based Hard Ceramics 667
61.1 Introduction 668
61.2 Experimental Detail 669
61.3 Result and Discussion 670
61.3.1 Microstructural Analysis 670
61.3.2 Hardness Analysis of the Coating 672
61.3.3 Wear Analysis 673
61.3.4 Coefficient of Friction Analysis 674
61.4 Conclusions 674
References 675
62 Effect of Sigma Phase on Dry Sliding Wear Resistance and Surface Roughness of ASTM A890 Grade 6A Duplex Stainless Steels 676
62.1 Introduction 676
62.2 Experimental Procedure 677
62.3 Results and Discussion 678
62.4 Conclusions 683
References 684
63 Investigation on the Structural and Wear Characteristics of Mg AZ91/Fly Ash Surface Composites Fabricated by Friction Stir Processing 685
63.1 Introduction 685
63.2 Experimental Details 686
63.3 Results and Discussion 689
63.4 Conclusions 691
References 692
64 Atmospheric Plasma Sprayed 25 wt.% WO3-75wt.% SnO2 Composite Coating: Investigations on Ethanol and Acetone Sensing Characteristics 693
64.1 Introduction 693
64.2 Experimental 694
64.3 Results and Discussion 694
64.4 Conclusions 699
References 700
65 Microstructural and Size Accuracy Study of Electrochemical Machined Aluminium Alloy Features 702
65.1 Introduction 703
65.2 Experimental Details 704
65.3 Methodology 705
65.4 Results and Discussion 707
65.5 Conclusions 709
References 710
66 Establishing EDM as a Method for Inducing Hydrophobicity on SS 304 Surfaces 711
66.1 Introduction 711
66.2 Materials and Methodology 713
66.2.1 Materials 713
66.2.2 Electrical Discharge Machining Process 713
66.2.3 Contact Angle Measurement 714
66.2.4 Surface Roughness Measurement 714
66.3 Results and Discussion 714
66.3.1 Contact Angle Analysis 714
66.3.2 Correlation Between MCA and Surface Roughness Parameters 716
66.4 Conclusions 717
References 719