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ISSN : 2321-4236(JoMME)

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Journal of Materials &Metallurgical Engineering

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Industrial Tribology Machine Dynamics & Maintenance

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Prof Priyavrat TharejaHead, MME Dept., PEC

University of Technology, Chandigarh, 160012 India.

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Institute of TechnologyRourkela, India.

Asit Kumar Khanra Asst. Prof. Dept. MME,

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Kanpur 208016, India.

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Tanmoy MaitiAsst. Prof., Dept. of Materials

Science & Engineering, IIT Kanpur, India.

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CSIR Complex Taramani Chennai, India.

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Chennai, India.

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Technology, Roorkee, India.

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Prof. Sampath-VedamanickamDept. of MME, Indian Institute

of Technology Madras, Chennai-600 036, India.

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Group Materials Engineering Division CSIR-Advanced Materials and

Processes Research Institute, India.

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Dr. Gagan Anand Asst. Prof., (Selection Grade)University

of Petroleum & Energy Studies,Energy Acres, Dehradun, India.

I take the privilege to present the hard copy compilation for the [Volume 4 Issue (2)] of Journal of

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Dr. Archana Mehrotra

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STM JOURNALS

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

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 10

3. A Study of Improvement of Mechanical Properties of Aluminum by Conventional Casing and Deformation ProcessHafiz Abdul Ahad Qazi 16

4. Evaluation of Mechanical Property and Optimization of the Dry Sliding Wear Behavior of Carbon Black-Alumina-Epoxy-Glass Composite by using Design of ExperimentsAmith V., Sudrashan Rao, Sushilendra Mutalikdesai 21

5. Micro Crack Formation in High Frequency-Electric Resistance WeldingRaghu Shant, Gokul Thummuluru, Anil Mahajan, Rajesh K. Goyal, T. S. Kathayat 32

ContentsJournal of Materials & Metallurgical Engineering

JoMME (2014)© STM Journals 2014. All Rights Reserved

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

JoMME (2014)© STM Journals 2014. All Rights Reserved

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

JoMME (2014)© STM Journals 2014. All Rights Reserved

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

JoMME (2014) © STM Journals 2014. All Rights Reserved

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-Alumina-

Epoxy-Glass Composite by using Design of Experiments

Amith V.1*, Sudrashan Rao

1, Sushilendra Mutalikdesai

2

1Department of Mechanical Engineering, Vivekananda College of Engineering and Technology,

Puttur, Karnataka, India 2Department 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

JoMME (2014) © STM Journals 2014. All Rights Reserved

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