The current research paper discusses the characterization and machining (turning) operation of aluminium (Al) and silicon carbide nano particle (SiCp) nano composite. The paper reveals proper distribution of silicon carbide nano particles (25nm) with aluminium metal matrix. Initially, tensile test has been carried on metal matrix nano composite to study its different properties. It was noticed that the properties of Al-SiCp increases by increasing the weight percentage of SiCp. Viker hardness test has also been conducted to find out the hardness of metal matrix nano composites. Different techniques i.e. Optical microscopy EDX-Analysis were utilized to find out various ingredients of the nano-composite material. The experimental study was carried out using Taguchi L 16 orthogonal array by taking three different factors at four different levels each. The response parameters i.e. flank wear of coated carbide insert and surface roughness of Al-SiCp has been optimized by using Principal Component Analysis (PCA). Various graphs like main effect plot and normal probability plot have been plotted and studied properly. Different optical images of coated insert carbide tools (Insert CNMG 12040822TN 6010) at different runs were conducted to visualize the effects of process and response parameters. From the ANOVA table, it was found that cutting speed as well as depth of cut are found to the most vital parameters in influencing the responses for VBc and depth of cut and feed are found to the most significant parameters in influencing the responses for Ra.
Ultrasonic welding is one of the promising solid state welding methods which have been widely used to join highly conductive materials like aluminum and copper. Despite these applications in the automotive field, other industries also have a strong interest to adopt this process for joining of various advanced alloys. In some of its applications, poor weld strength and sticking of the workpiece to the tool are issues. Thus, an attempt has been taken in the present study to overcome these issues by performing experiments with a suitable range of weld parameters. The major objectives of this study are to obtain a good joint strength with a reduced sticking phenomenon and microstructure of Al-Cu weld coupons. The results uncovered the mechanical strength of the joint increased up to 0.34 sec of weld time and afterward, it gradually decreased. Meantime, the plastic deformation in the weld zone enhanced the formation of an intermetallic layer of 1.5 μm thick, and it is composed of mainly Al2Cu compound. The temperature evolved during the welding process is also measured by thermocouples to show its relationship with the plastic deformation. The present work exemplifies a finer understanding of the failure behavior of joints and provides an insight of ultrasonic welding towards the improvement in the quality of weld.
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