Aluminium, Magnesium and its alloys are preferred wheneverweight reduction is needed without compromising its strength. Both alloys have been used in numerous fields like in aerospace, defence field, automobile wheeling parts and also, they have been used in Medical field because of their biodegradability. In this study, Statistical investigation on surface roughness in Electric discharge machining of aluminium and Magnesium using Taguchi optimization Technique has been reported. Electric discharge machining was carried out under the condition of Current (5, 10, 15 A), Voltage (50, 55, 60 V), Pulse On time (10, 20, 30 µs) and constant flushing pressure of 0.50 Kg/sq.cm. Twenty-seven Experiments are carried out based on L27 orthogonal array. After machining the surface roughness (Ra, Rq, Rz) of the machined surface is measured using SURFTESTSJ-210. Optimizations of the results were done by Taguchi technique and the optimal parameters for the machining operation of aluminium and magnesium are determined. It is found that for Ra, Rq and Rz the most influencing factor is Current followed by the pulse on time, pressure and voltage.
Influence of tungsten disulfide particles (WS2) on the friction and wear behavior of Mg-AZ91 forms the objective of this work. Friction stir processing (FSP) has been used to fabricate FSP AZ91/WS2 composite with various FSP passess. The microstructures were studied using a scanning optical microscope (OM), Electron Backscatter Diffraction (EBSD), and electron microscope (SEM). Hardness is measured using Vickers's microhardness tester. The impact of WS2 on the friction and wear resistance of Mg-AZ91 were evaluated using a pin on disc apparatus under dry sliding conditions. The microstructure showed the grain refinement of FSP AZ91/WS2 composite, due to severe plastic deformation and dynamic recrystallization. An increase in the FSP passess has transformed the grain size from micron to nano level. The hardness of FSP AZ91/WS2 composite is increased to 122 HV, from 62.2 HV0.3 of Mg-AZ91. The improvement in the hardness is due to reinforcement of WS2 and grain refinement. A significant improvement in the friction and wear resistance was achieved for Mg-AZ91 composites in contrast to FSP AZ91 and AZ91. SEM micro images showed the transfer of wear mechanism from severe adhesive wear to mild adhesive wear.
Friction Stir Processing (FSP), a solid-state processing technique employed to modify the microstructure, is based on the principles of friction stir welding. FSP is one of the most promising techniques for the production of surface composites. In this investigation, AZ31 magnesium alloy is reinforced with molybdenum disulfide (MoS2) through a friction stir processing method. Before and after the fabrication of the surface composites the wear tests were conducted by varying the condition of sliding load (25 N & 35 N), sliding distance (1 km & 2 km), and sliding velocity (1 m/s & 2 m/s). Hardness values were measured by using the Brinell hardness tester. Both hardness and wear tests were conducted as per the ASTM standards. After reinforcement, composite material enhances hardness values. The wear rate also reduces as MoS2 acts as a solid lubricant material.
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