Journal of Advancements in Material Engineering

Mechanical and Wear Behavior Investigation of AZ91 Magnesium Alloy-Based Surface Composites

Kamal Basha K. — 2024-04-16

The study presents an in-depth investigation into the mechanical and wear behaviour of surface composites based on the AZ91 magnesium alloy. With the ever-growing demand for lightweight materials with superior mechanical properties, magnesium alloys have emerged as promising candidates across diverse industrial applications. However, their intrinsic limitations, such as low wear resistance, hinder their widespread adoption. Surface composites offer a strategic solution to address these shortcomings by enhancing the surface properties of magnesium alloys through the incorporation of rein for cement materials. The research encompasses a systematic experimental approach aimed at comprehensively evaluating the mechanical performance and wear resistance of AZ91 magnesium alloy-based surface composites. Key mechanical properties, including tensile strength, hardness, and impact resistance, are meticulously characterized to assess the effectiveness of various reinforcement materials and fabrication techniques in augmenting the overall performance of the composites. A range of reinforcement materials, such as ceramic particles, fibers, and nanoparticles, are investigated for their potential to enhance the mechanical properties of the AZ91 magnesium alloy. Additionally, diverse fabrication methods, including stir casting, powder metallurgy, and laser cladding, are explored to tailor the microstructure and distribution of reinforcement phases within the composite matrix. Furthermore, wear tests are conducted under controlled conditions to evaluate the wear resistance of the surface composites. The investigation delves into the influence of parameters such as load, sliding velocity, and environmental conditions on the tribological performance of the composites. The findings of this study contribute to a deeper understanding of the mechanical and wear behavior of AZ91 magnesium alloy-based surface composites, elucidating the intricate relationships between microstructure, reinforcement characteristics, and performance properties. These insights hold significant implications for the optimization of surface composite design and fabrication processes, paving the way for the development of lightweight materials with enhanced mechanical strength and wear resistance for diverse industrial applications, including automotive, aerospace, and biomedical engineering.

Manufacturing and Testing of Polymer Matrix Composites (PMCs): A Review

Rajkumar D. Patil — 2024-03-02

Polymer Matrix Composites (PMCs) have garnered considerable interest in several engineering domains owing to their exceptional strength, low weight, and customizable mechanical attributes. It is essential to comprehend PMC torsional behaviour while developing and optimizing structures that are subjected to rotating loads. The torsional characteristics of polymer matrix composites are reviewed in this work, along with a thorough examination of their mechanical behaviour under torsional loads. The kind of polymer matrix, reinforcing fibers, fiber orientation, volume percentage, and manufacturing procedures are some of the major parameters that are explored in the torsional behaviour of PMCs. These variables' impacts on PMCs' shear modulus, shear strength, and shear strain are investigated to provide light on the material's resistance to rotational deformation. Ultimately, the topic of torsional characteristics of PMCs has both opportunities and challenges, which sets the stage for the next study initiatives. The goal of this review is to give readers a thorough grasp of polymer matrix composites' torsional behaviour, making it an invaluable tool for scientists, engineers, and designers working on the creation and use of these cutting-edge materials.

Development of Special Purpose Machine for Keyways and Slot

Pratik S. Awati — 2024-02-09

In manufacturing and machining, the demand for precision and efficiency is ever-increasing. Developing specialized machinery tailored to specific machining tasks has become imperative to meet these demands. This research paper presents the development and assembly of a Special Purpose Machine (SPM) dedicated to machining keyways and slots. The motivation behind this research stems from the need for a dedicated solution that can streamline the machining keyways and slots, which are crucial features in various mechanical components such as gears, shafts, and pulleys. Conventional machining methods often need more precision and speed for high-volume production or intricate designs, leading to inefficiencies and quality issues.

The proposed SPM integrates precision controls to achieve optimal performance in keyway and slot machining operations. The development process involved rigorous theoretical analysis of machining requirements and selecting appropriate components to ensure accuracy, repeatability, and productivity. The research methodology encompasses theoretical modeling, Computer-Aided Design (CAD), prototype development, and assembly. Overall, this research contributes to the advancement of manufacturing technology by introducing a specialized solution for keyway and slot machining processes. The developed SPM offers manufacturers a competitive edge by enabling cost-effective, high-precision production of components essential to various industries.

Review on Composition of Natural and Synthetic Material

Jeevan R. — 2024-03-19

Since composite materials are thought to be better than alloys and metals in comparison to traditional materials, they are essential in the field of materials science and engineering. A composite material is made up of two distinct materials with dissimilar characteristics combined. Compared to metals and alloys, composite materials are lighter, have a longer lifespan, and don't experience wear and tear. Due to their superior mechanical qualities and evolving application dynamics, composite materials are becoming increasingly popular. Conventional methods for making and characterizing composite materials are well-established technologies. However, it has been discovered that using modest amounts of fillers in addition to conventional reinforcing fibers and resins is a better option for improving the mechanical, chemical, and physical properties of composite materials. Hybrid composites made from natural fibers such as banana fibers and synthetic fibers such as carbon fibers and e-glass fibers are stronger, lighter, cheaper, biodegradable, and environmentally friendly than traditional metals. As a result, scientists and researchers are searching for renewable, biodegradable composite materials that are reinforced with natural fibers. Unquestionably, natural fibers have advantages over synthetic fibers, including reduced density, comparable durability, non-toxicity, lower cost, and less waste disposal issues. Scientists have directed various examinations to research the potential purposes of normal strands. However, during this long period, filaments like banana, jute, bagasse, and sisal additionally acquired significance. After the fruit is harvested, banana fibers which are derived from the steam created by banana plants—are discarded. Polymer composites' mechanical, chemical, and physical properties have been improved as a result of the use of banana fiber as a reinforcing material. This study provides a comprehensive overview of banana fiber-reinforced composites and their potential applications. This study addresses various aspects that influence the performance of banana fiber-reinforced polymer composites, including Banana Fiber length, orientation and composition, humidity, temperature and surface treatment.

Optimizing and Redesigning the Vertical Milling Fixture for Friction Stir Welding of Aluminium Alloy (Al 6061)

Daya Shankar Diwakar — 2024-03-01

Friction stir welding is a kind of solid-state fusion process for welding like or unlike metals. Established and patented by “The Institute of Welding” in the UK in December 1991, it involves using a compressive force applied by a conventional milling machine to make contact with work-pieces. The work-pieces are one or the other revolving or moving proportional to a pin tool, generating the heat necessary for atomic diffusion and thereby uniting the material at the edges. FSW can be functional in a variety of materials, together with stainless steel, aluminium, and various alloys. The process typically takes place on vertical milling machines, requiring a vertical milling fixture to firmly hold the plates being welded. In this paper, vertical milling holding setup and fixture for FSW procedures on vertical milling machines are established. Materials such as aluminium and aluminium alloy (Al 6061) are analyzed for their suitability in FSW operations, to identify the best material for the process. Additionally, there is potential for extending the FSW process to plastics and similar materials. Friction stir welding offers significant advantages in terms of weld quality, strength, and versatility across a range of industries, making it a versatile option for solid-state joining processes.