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

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