Journal of materials & metallurgical engineering (vol4, issue2) by STM Journals Publication

Journal of Materials & Metallurgical Engineering (JoMME)

ISSN : 2321-4236

May - August 2014

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Prof. Bankim Chandra Ray

Chairman, National Institute of Technology Puducherry, India. Former Director, Indira Gandhi Centre for Atomic Research, India.

Professor and Head, Department of Metallurgical and Materials Engineering National Institute of Technology, Rourkela, India.

Dr. Hardev Singh Virk Professor Emeritus, Eternal University, Baru Sahib, India.

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Dr. Pankaj Poddar

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Dr. Nandini Chatterjee Singh Associate Professor, National Brain Research Centre, Manesar, India.

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Dr. Priyavrat Thareja

Dr. Rakesh Kumar

Head, Materials and Metallurgical Engineering Department, PEC University of Technology, Chandigarh, India.

Assistant Professor, Department of Applied Chemistry, BIT Mesra, Patna, India.

Dr. Shankargouda Patil

Dr. Shrikant Balkisan Dhoot

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Prof. Subash Chandra Mishra

Prof. Sundara Ramaprabhu

Professor, Metallurgical & Materials Engineering Department, NIT, Rourkela, India.

Professor, Department of Physics Indian Institute of Technology Madras, India.

Prof. Yuwaraj Marotrao Ghugal

Dr. Amartya Mukhopadhyay

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Dr. R Padmanaban Assistant Professor, Department of Mechanical Engineering, School of Engineering, Coimbatore, India.

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Prof Priyavrat Thareja Head, MME Dept., PEC University of Technology, Chandigarh, 160012 India.

Subash Chandra Mishra Professor, MM Dept., National Institute of Technology, Rourkela, India.

Bankim Chandra Ray Dept. MME, National Institute of Technology Rourkela, India.

Prof. Kantesh Balani Indian Institute of Technology, Kanpur, India.

Asit Kumar Khanra Asst. Prof. Dept. MME, NIT Warangal, India.

Dr. Ashish Garg Indian Institute of Technology Kanpur 208016, India.

Tanmoy Maiti Asst. Prof., Dept. of Materials Science & Engineering, IIT Kanpur, India.

Dr. Sankara Narayanan TSN CSIR-National Metallurgical Laboratory Madras Centre, CSIR Complex Taramani Chennai, India.

Dr. RER. NAT. Ravi Kumar Dept. of MME, Indian Institute of Technology-Madras (IIT Madras), Chennai, India.

Dr. BSS Daniel Dept. of MME, Indian Institute of Technology, Roorkee, India.

Editorial Board

Prof. Sampath-Vedamanickam Dept. of MME, Indian Institute of Technology Madras, Chennai-600 036, India.

Dr. Rupa Dasgupta Senior Principal Scientist, CSIR-AMPRI, Bhopal-462064, India.

Dr. Satyabrata Das Scientist 'G' & Head, Metallic Composite Group Materials Engineering Division CSIR-Advanced Materials and Processes Research Institute, India.

Dr. A. H. Yegneswaran Advanced Materials and Processes Research Institute (AMPRI), CSIR, Hoshangabad Road, India.

Dr. A. Prodhan Sr. Asst. Director, National Metallurgical Laboratory, Jamshedpur-831008.

Dr. J. P. Barnwal Chief Scientist CSIR-AMPRI Bhopal, India.

Dr. Sanjay Srivastava Assoc. Prof. Maulana Azad National Institute of Technology, Bhopal (MP), India.

Ing. Ranjit Singh Solanki The Chief Scientist (Mech. Engg.) & Head of Dept. CSIR - AMPRI, Bhopal (MP), India.

Dr. Gagan Anand Asst. Prof., (Selection Grade)University of Petroleum & Energy Studies, Energy Acres, Dehradun, India.

Director's Desk

STM JOURNALS

I take the privilege to present the hard copy compilation for the [Volume 4 Issue (2)] of Journal of Materials and Metallurgical Engineering(JoMME). The intension of JoMME is to create an atmosphere that stimulates creativeness, research and growth in the area of Material & Metallurgical Engineering. The development and growth of the mankind is the consequence of brilliant Research done by eminent Scientists and Engineers in every field. JoMME provides an outlet for Research findings and reviews in areas of Material and Metallurgical Engineering found to be relevant for National and International recent developments & research initiatives. The aim and scope of the Journal is to provide an academic medium and an important reference for the advancement and dissemination of Research results that support high level learning, teaching and research in the domain of Material and Metallurgical Engineering. Finally, I express my sincere gratitude and thanks to our Editorial/ Reviewer board and Authors for their continued support and invaluable contributions and suggestions in the form of authoring writeups/ reviewing and providing constructive comments for the advancement of the journals. With regards to their due continuous support and co-operation, we have been able to publish quality Research/Review findings for our customers base. I hope you will enjoy reading this issue and we welcome your feedback on any aspect of the Journal.

Dr. Archana Mehrotra Director STM Journals

Journal of Materials & Metallurgical Engineering

Contents

1. Correlating the Damage Behaviour of Polymer Composites with the Potential Energy of the Impactor K. Mohamed Kaleemulla, K.G. Satish

2. Effect of Tool Tilt on Formation of Tunnel in Friction Stir Welded 5083 Joints: An Experimental Study S.K. Tiwari, D.K. Shukla, Rakesh Chandra

3. A Study of Improvement of Mechanical Properties of Aluminum by Conventional Casing and Deformation Process Hafiz Abdul Ahad Qazi

4. Evaluation of Mechanical Property and Optimization of the Dry Sliding Wear Behavior of Carbon BlackAlumina-Epoxy-Glass Composite by using Design of Experiments Amith V., Sudrashan Rao, Sushilendra Mutalikdesai

5. Micro Crack Formation in High Frequency-Electric Resistance Welding Raghu Shant, Gokul Thummuluru, Anil Mahajan, Rajesh K. Goyal, T. S. Kathayat

Journal of Materials and Metallurgical Engineering ISSN: 2231-3818 (online), ISSN: 2321-4236 (print) Volume 4, Issue 2 www.stmjournals.com

Correlating the Damage Behaviour of Polymer Composites with the Potential Energy of the Impactor K. Mohamed Kaleemulla*, K.G. Satish Department of Mechanical Engineering, University B.D.T. College of Engineering, Davangere 577004, India Abstract Design of structures using composites requires comprehensive evaluation and characterization of mechanical properties in both undamaged and damaged state. Composite laminates undergo combinations of mechanical loading resulting into microdamage accumulation in the plies. The first mode of damage is usually intralaminar cracking with the crack plane transverse to the middle plane of the laminate, spanning the whole width of the laminate. The density of cracks in a ply depends on layer orientation with respect to the load direction, laminate lay-up, ply thickness, material fracture toughness and certainly, potential energy of the impactor. This article addresses the issues related to damage under impact loading. An investigation of damage initiation and experimentation on a woven glass/satin epoxy composite material was performed for different potential energies of the impactor. Plain weave glass/textile satin epoxy laminate with (0/90)s orientation was investigated. Experimental data for laminate are summarized to establish a relationship between potential energy of the impactor and severity of damage.

Keywords: Woven composites, damage, potential energy, laminates, glass fabric

Journal of Materials and Metallurgical Engineering ISSN: 2231-3818 (online), ISSN: 2321-4236 (print) Volume 4, Issue 2 www.stmjournals.com

Effect of Tool Tilt on Formation of Tunnel in Friction Stir Welded 5083 Joints: An Experimental Study S.K. Tiwari*, D.K. Shukla, Rakesh Chandra Department of Mechanical Engineering, National Institute of Technology, Jalandhar, India Abstract Friction stir welding (FSW) being a solid-state joining process is immune to the various defects faced in traditional fusion welding process. However, defects such as voids, joint line remnants and tunnel defects are common imperfections in FSW. In the present study, an attempt has been made to investigate the effect of tool tilt on the formation of tunnel defect, while keeping all other process parameters constant. Tool tilt is a significant parameter as it influences the flow patterns of the stir zone, frictional forces and the heat generated. The study has shown that the tool tilt can alter the flow of plasticized material in the stir zone and for that reason can control the quality of weld.

Keywords: Friction stir welding, tunnel defects, tool tilt

Journal of Materials and Metallurgical Engineering ISSN: 2231-3818 (online), ISSN: 2321-4236 (print) Volume 4, Issue 2 www.stmjournals.com

A Study of Improvement of Mechanical Properties of Aluminum by Conventional Casing and Deformation Process Hafiz Abdul Ahad Qazi* Mehran University of Engineering and Technology, Jamshoro, Pakistan Abstract Nowadays, Aluminum-Zinc alloy system are the major and rapid development in the field of automotive and aerospace industries for growing demand of efficient vehicles and aircrafts to reduce energy consumption and air pollution. Aluminum is a very soft metal by nature. Different alloying elements were added in the past to increase its strength and toughness. Zinc is considered as a major alloying element in aluminum to increase its strength and toughness. Present experimental work was conducted to determine the appropriate amount of zinc to be added in pure aluminum to increase its mechanical properties. A wide range of experimental work was conducted on pure aluminum to determine the appropriate amount of zinc to be added to develop Al-Zn alloy using conventional foundry method. Pure aluminum was mixed with different percentages of zinc with constant percentage of magnesium and copper. The molten alloys were cast in metal mold. Wrought alloys have high strength as compared to cast alloy so after casting, the alloy was subjected to mechanical rolling. Standard samples were prepared for tensile tests and a number of samples were age hardened. Various characterization techniques were used to investigate the chemical composition, tensile strength, ductility (elongation), and hardness. It has been observed that the alloy containing 5% Zn and 2% Mg, gives highest strength, and have good ductility in heat-treated condition.

Keywords: Aluminum-Zinc alloy, foundry method, mechanical rolling

Journal of Materials and Metallurgical Engineering ISSN: 2231-3818 (online), ISSN: 2321-4236 (print) Volume 4, Issue 2 www.stmjournals.com

Evaluation of Mechanical Property and Optimization of the Dry Sliding Wear Behavior of Carbon Black-AluminaEpoxy-Glass Composite by using Design of Experiments Amith V.1*, Sudrashan Rao1, Sushilendra Mutalikdesai2 1

Department of Mechanical Engineering, Vivekananda College of Engineering and Technology, Puttur, Karnataka, India 2 Department of Mechanical Engineering, Dr. M. V. Shetty Institute of Technology, Moodabidri, Karnataka, India

Abstract The research work is mainly focused on investigating the effects of wear parameters: filler content (0%, 4% CB, 4% Al2O3, and 2% CB + 2% Al2O3), applied load (4.905, 9.810, 14.710, and 19.62 N), sliding distance (20, 30, 40, and 50 mm) by using Design of Experiments (DOEs) approach. The experimental results were analyzed using MINITAB V16 scientific graphical and data analysis software. Signal-to-Noise (S/N) ratio, analysis of variance (ANOVA) proved that the most influencing factor is filler and load and the minimum value of wear rate is obtained in 4% Al2O3 and moderate wear rate is shown by 2% CB + 2% Al2O3, specimen and it as a very good tensile strength of 20,759.785 N, and has a very minimum absorption of 0.784%. So finally (2% CB + 2% Al2O3) specimen is a very good wear resistance, tensile, and also absorption property. The overall improvement in the material property is achieved due to the very good dispersion and also establishment of interfacial bond between carbonblack and aluminium oxide nanopowder in epoxy resin filler. So it is a very economic and next generation material with highly improved properties which has a lot of applications.

Keywords: Carbon black CB, aluminium oxide Al2O3, wear, ANOVA, S/N ratio, GFRP

Journal of Materials and Metallurgical Engineering ISSN: 2231-3818 (online), ISSN: 2321-4236 (print) Volume 4, Issue 2 www.stmjournals.com

Micro Crack Formation in High Frequency-Electric Resistance Welding Raghu Shant*, Gokul Thummuluru, Anil Mahajan, Rajesh K. Goyal, T. S. Kathayat Welspun City, Survey No. 665, Village Varsamedi, Taluka Anjar, Dist. Kutch, Gujarat, India

Abstract The present paper discusses about the formation of micro cracks in base metal adjacent to the weld area during High Frequency-Electric Resistance Welding (HF-ERW) of 10'' outside diameter pipe. The micro crack formation has been analyzed with respect to chemical composition, microstructure, inclusion level, welding parameters and angle of weld flow lines.

Keywords: Electric resistance welding, pearlitic banding, sulphide inclusions, HAZ