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
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
