New Materials, Processing and Manufacturability

R. Thanigaivelan, PhD, is the principal at AKA Memorial College of Engineering and Technology, Tamilnadu, India. His research fields include micromachining, surface engineering, composites, and biomaterials. He has published more than 90 papers in SCI and SCOPUS-indexed journals and edited two books. Pradeep Kumar Krishnan, PhD, is a senior faculty member of Mechanical and Industrial Engineering, National University of Science and Technology, Muscat, Sultanate of Oman. His research focuses on production processes, characterization, and mechanical behavior of engineering materials. He has authored several publications in international journals and national and international conferences. Kamalakanta Muduli, Ph.D, is an associate professor in the Department of Mechanical Engineering, Papua New Guinea University of Technology, Papua New Guinea. His research interests focus on materials science, manufacturing, sustainable supply chain management, and industry 4.0 applications in operations and supply chains. He is the recipient of the ERASMUS award by the European Union and published more than 70 papers in peer-reviewed international journals. Santosh Kumar Tamang, PhD, is an assistant professor in the Department of Mechanical Engineering, North Eastern Regional Institute of Science & Technology (Deemed to be University), Arunachal Pradesh, India. His research focuses on laser-based manufacturing processes, machining technologies, molecular dynamics simulations, machine learning, optimization and soft computing. Tamang has published more than 50 research papers in peer-reviewed journals.

Preface xvii

1 Aluminum and Its Different Graded Alloys 1
G. Avinash, V. V. N. Sarath and A. Yeswanth

1.1 Introduction 1

1.2 Other Aluminum Materials 7

1.3 Applications 12

1.4 Conclusion 12

1.5 Future Scope 13

2 Cold Spray Additive Manufacturing 21
Jagadeesha T., Arun Prakash J., Avinash Malladi and Seeniappan Kaliappan

2.1 Introduction 21

2.2 Phenomena and Factors Behind CSAM 25

2.3 Different CSAM Techniques 26

2.4 Advantages of CSAM 27

2.5 Disadvantages of CSAM 28

2.6 Numerical Simulation of CSAM of Ti6Al4V Pellets on Ti6Al4V Substrate 30

2.7 Conclusion 32

2.8 Future Scope 32

3 Optimization of Gas Metal Arc Welding (GMAW) Cladding Parameters for Enhanced Weld Integrity in Low-Carbon Steel Plates (EN30) 35
Vivek Singh, Amit Kumar Singh, Akash Deep, Som Ashutosh, M. Chandrasekaran and Bishub Choudhary

3.1 Introduction 36

3.2 Experimental Work 39

3.3 Parametric Study 42

3.4 Taguchi Optimization 46

3.5 Conclusions 53

4 Design and Development of Brake Pedal by Topology Optimization Approach 57
Sivashankar N., Jagadeesha T., Mothilal T. and Natrayan L.

4.1 Introduction 58

4.2 Structure Optimization 60

4.3 Topology Optimization 62

4.4 Optimization Results 63

4.5 Conclusion 68

5 Enhancing Resistance Spot Welding Weld Quality: A Comprehensive Analysis of Influencing Factors and the Role of Modeling and Optimization for Improved Quality 71
Kaushal Jha, Santosh Kumar Tamang, Rajeev Kumar and Bishub Choudhury

5.1 Introduction 72

5.2 Influence of Welding Current and Time 74

5.3 Influence of Resistivity, Surface Preparation, and Cleanliness 78

5.4 Effect of Electrode Force and Electrode Tip Geometry 82

5.5 Modeling and Optimization of RSW Parameters 85

5.6 Conclusion 89

6 Shot-Peening Influence on Corrosion Behavior of SiC Particle Reinforced Aluminum Composite 95
J. Venumurali and S. Rambabu

6.1 Introduction 96

6.2 Experimental Procedure 100

6.3 Results and Discussion 104

6.4 Residual Stress 108

6.5 Hardness Variation 110

6.6 Surface Roughness 111

6.7 Corrosion Behavior 112

6.8 Conclusion 117

7 3D Printing: Fundamentals, Applications, and Future Prospects 123
Sonali Nag, Partha Pratim Borah and Kankan Kishore Pathak

7.1 Introduction 124

7.2 Materials for 3D Printing 125

7.3 Future Prospects of 3D Printing Technology 133

7.4 Conclusions 134

8 Cutting Zone Temperature and Cutting Force in 3D-Milling Operations Using ABAQUS 139
Jagadeesha T., R. Thanigaivelan, Avinash Malladi and Natrayan L.

8.1 Introduction 140

8.2 Literature Review 141

8.3 Objectives 142

8.4 Methodology 142

8.5 Simulation 144

8.6 Milling Conditions 147

8.7 Result and Discussion 149

8.8 Conclusion 153

9 A Rare Ferroelectric Material: Fresnoite (Ba2TiSi2O8) 157
Shiv K. Barbar

9.1 Introduction 158

9.2 Experimental 160

9.3 Characterization Details 161

9.4 Result and Discussion 162

9.5 Conclusion 181

10 Research Progress and Developments in GTAW Process Using Visual Sensing and Weld Penetration Estimation 187
M. Soundarrajan, R. Prakash, D. Deepa, R.Thanigaivelan and P. Suresh

10.1 Introduction 188

10.2 GTAW Process 188

10.3 Sensing Technologies in Welding 190

10.4 Online Vision Inspection 193

10.5 3 Dimensional Image Processing of Weld Pool Geometry Using Dot Matrix 196

10.6 Real-Time Three-Dimensional Measurement of Topside and Backside Width of Weldment 197

10.7 Dynamic Estimation of Weld Pool Geometry 200

10.8 Visual Sensing Based on Supervised Machine Learning Technique 201

10.9 Hybrid Network Model Using Convolutional Neural Network and Long Short-Term Memory 202

10.10 Conclusion 203

11 Simulation of Sulfur Recovery Unit Using Aspen Plus 207
Krati Hardya, V. K. Chandaliya, Pratik Swarup Dash, Barun Kumar Nandi, Deepak Kumar, Bishub Choudhury and Vishnu Kuntal

11.1 Introduction 208

11.2 Process Description 210

11.3 Methodologies 211

11.4 Results and Discussion 215

11.5 Conclusion 222

12 Fabrication of Magnesium Metal Matrix Nanocomposites Using Ultrasonic-Assisted Stir-Casting Method 227
Parthiban K., Balaji E., Durairaj S. and Ashok Kumar R.

12.1 Introduction 228

12.2 Effect of Ultrasound on Magnesium Alloys 234

12.3 Conclusion 242

13 Friction Stir Welding of Dissimilar Magnesium Alloys: Analytical Modeling, Simulation, and Experimental Validation 247
Biswajit Mallick, Jagadeesha T., Mothilal.T.

and Seeniappan Kaliappan

13.1 Introduction 248

13.2 Analytical Modeling 250

13.3 Heat Input Modeling 251

13.4 Experimental Detail 260

13.5 Experimental Setup 260

13.6 Experimental Results 262

13.7 Conclusion 265

14 Advancements in Welding Techniques: Surface and Mechanical Property Insights 269
Jagadeesha T., Manoj Nikam, T. Mothilal and M.D. Raj Kamal

14.1 Introduction 270

14.2 Resistance Welding 277

14.3 Hybrid Welding 281

14.4 Rotary Friction Welding 282

14.5 Friction Stir Welding 282

14.6 Properties of Friction Welding 284

14.7 Future Research Opportunities and Conclusions 284

15 Advanced 3D Printing for Industrial Components: Welded Joint Analysis and Strength Assessment 287
Jagadeesha T., Amith Kumar Gajakosh, Avinash Malladi and Natrayan L.

15.1 Introduction 288

15.2 Material Used for SLM Technology 289

15.3 SLM Technology 3D Component 289

15.4 TIG Welding Method for Joining 290

15.5 ABS and PLA 3D Component Material 291

15.5.1 Fused Deposition Modeling 291

15.6 Welding Method Used for ABS and PLA 292

15.7 Characterisation Techniques 293

15.8 Challenges Faced in the Development Process 294

15.9 Conclusion 295

16 Advancements in Electrochemical Surface Coatings: Innovations, Applications, and Future Prospects 299
Jagadeesha T., Soundarrajan M., Seeniappan Kaliappan and M.D. Raj Kamal

16.1 Introduction 300

16.2 Fundamentals of Electrochemical Process 301

16.3 Types of Electrochemical Surface Coatings 303

16.4 Overview of Surface Preparation Methods 305

16.5 Characterization of Electrochemically Coated Surface 308

16.6 Applications of Electrochemical Surface Coating in Various Fields 308

16.7 Challenges and Limitations of Electrochemical Surface Coating Methods 311

16.8 Conclusions 312

16.9 Future Trends 313

17 Process Variable Impact Analysis in Unconventional Machining: Enhancing MRR, Accuracy, and Surface Quality 317
Jagadeesha T., Manoj Nikam, Seeniappan Kaliappan and Natrayan L.

17.1 Introduction 318

17.2 Nontraditional Machining Processes 319

17.3 Electrochemical Machining 321

17.4 Ultrasonic Machining 323

17.5 Laser Beam Machining (LBM) 328

17.6 Conclusion 330

17.7 Future Research Opportunities 331

18 Pulsed Power Supplies for Surface Coating Applications: Methods, Materials, and Case Studies 335
Jagadeesha T., Amith Kumar Gajakosh, Seeniappan Kaliappan and S. Socrates

18.1 Introduction 336

18.2 Different Coating Materials 338

18.3 Magnetron Sputtering 338

18.4 Ceramic Coatings 339

18.5 Plasma Electrolysis Oxidation 341

18.6 Case Study 1: Aluminum Oxide Coatings by Unbalanced Sputtering 343

18.7 Case Study 2: Power Supply Mode in Plasma Electrolysis Oxidation (Micro-Arc Oxidation Coating) in Magnesium Alloy 345

18.8 Conclusions 346

19 Fabrication and Water Absorption Testing of Banana Fiber-Reinforced Composite 351
Larikynti Massar, Rohan Sarkar, Nako Komo and Nabam Teyi

19.1 Introduction 352

19.2 Materials 354

19.3 Material Preparation 355

19.4 Fabrication Process 356

19.5 Water Absorption Testing 362

19.6 Results and Discussions 363

19.7 Conclusion 365

20 Multi-Objective Optimization of Fusion Welding Parameters Using Non-Dominated Sorting Genetic Algorithm II 369
Monoj Kanti Chakraborty, Arun Jyoti Kalita, Deepty Pandey, Nirsanametla Yadaiah, Md. S. Mujaheed Khan and Nabam Teyi

20.1 Introduction 370

20.2 The Suggested Methodology 372

20.3 Results and Discussions 375

20.4 Conclusion 385

Declaration of Competing Interest 386

References 386

Index 389