In this research work, AA2024/5Al2O3/5Gr hybrid composites fabricated through stir casting were machined utilising an electric discharge machine (EDM). Experiments were performed by varying current, pulse on time (POT), gap voltage (GV), and Al2O3 powder concentration (PC). The experiments were designed using response surface methodology in which material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) were recorded as responses. The addition of Al2O3 particles has a positive impact on MRR and Ra, whereas it has a negative impact on TWR. The interaction impact of process parameters (p-p) on responses was thoroughly analyzed using contour plots. A mathematical model was developed and validated for all the responses. The experimental results were compared with the predicted values. It was found that all the values have a maximum deviation of 3.5%. The ANOVA table reveals that the PC was the most influential factor followed by the current.
The current research has been aimed to study densification of Al-Mg alloy which was made with optimum sized Nanopowders through Equal Channel Angular Pressing (ECAP) technique. Al-Mg alloy nanopowder was synthesized through high energy ball milling process in the optimised condition. XRD was used to analyze the crystallite sizes of powders prepared at 10, 20, 30, 40 and 50 hrs in ball mill and the minimum crystallite size of 20.388nm achieved at 30hrs was found to be the best milling time. Consolidated specimens were prepared at three working conditions; without back pressure, with back pressure and with back pressure at high temperature (250°C). At each working condition, two passes were made to get better densification in the specimen. The specimens were analyzed for hardness, density, and microstructure. It was found that 92.11% of dense material was formed with a hardness of 64HRB.
Using stir-casting, the hybrid aluminium metal matrix composites are prepared with the reinforcement of SiC and graphite particulates by varying equally 2%, 4%, 6%, and 8% by weight. The wear and frictional force for the prepared specimens were investigated through pin on disc wear testing machine. Exercising ANOVA technique, the wear rate and coefficient of friction was accomplished with the impact of applied load, sliding speed and sliding distance. Using Taguchi technique, experiments have been performed depending on the design of experiments. For analysis of data L9 Orthogonal array was preferred. Wear resistance and frictional force were influenced majorly with the reinforcement of graphite. The morphology of the depleted surfaces and the wear fragments were analysed to recognize the wear property. Distinguished to other percentages of reinforcements, 6% wt. of SiC and 6% wt. of graphite has demonstrated high wear resistance.
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