Miniaturization drives the need for developing appropriate technology for microproducts of extremely small geometric features with high tolerances. In this work, the authors have investigated the material behavior and size effect in microextrusion of pure copper and aluminum with different grain sizes. A forward microextrusion assembly has been developed in the first phase of work to investigate the grain size effects. The experimental results are then compared to finite element simulation to quantify force displacement response. It has been found that the simulated deformation load is comparable with experimental results. The influence of size effect in both copper and aluminum showed that the extrusion load and average microhardness of 38 μm and 34 μm are higher when compared to 204 μm and 124 μm. In the second phase of work, an attempt has been made to fabricate the copper microgear (m = 0.416 mm) by the developed extrusion setup. The findings of this work are essential for further development of micro-formed parts and will facilitate in introducing microextrusion for mass production of industrial components.
Micro scale deformational behavior of metals is improved upon increasing the room temperature. Further, the drawbacks of micro forming caused by size effects are reduced significantly. In the current work, investigation on the material behavior of copper at elevated temperature ranging from room temperature to 200 ℃ is conducted. On the experimental part, a novel micro extrusion die set assembly has been developed along with temperature assistance, where the specimen is heated within the die assembly to study deformation behavior. When the forming temperature is raised, an enlargement of the forming limits is achieved along with a significant reduction in extrusion force. Further, the flow of material inside the die orifice was more uniform, and the micro pin showed a good replication of the die dimensions with homogeneous material deformation. During the increase of extrusion temperature and lubrication conditions (diamond-like carbon coating), the micro pin is more complete with higher dimensional accuracy and surface finish. The investigation on the influence of temperature showed that there is a reduction in microhardness of samples compared to the hardness of samples extruded at room temperature. However, there is a significant reduction of scattering due to homogenizing effect.
Nanoparticles of titanium diboride (TiB2) coated with a conductive polymer and subjected to an oxidizing agent was carried out in this research. TiB2 nanoparticles coated with polypyrrole (PPy) were studied using XRD and TEM techniques. Nitrogen adsorption and desorption properties of nanoparticles are covered with modified polypyrrole to understand better the surface zone, structural features, and pore geometries of the nanoparticles. The water-based hazardous anionic Congo red (CR) dye was removed using polypyrrole-coated titanium diboride (PPy@TiB2) nanoparticles. Numerous cutting-edge experimental techniques, including FTIR, FE-SEM, EDXS, and element mapping analysis, were used to confirm the CR color’s adhesion to the PPy@TiB2 nanoadsorbent study. While conducting batch experiments, coated TiB2 nanoadsorbents with polypyrrole enhanced the adsorption behaviour. One of the factors evaluated in the adsorption tests was pH; another was contact time, and a third was dose. At
pH
=
4
, 98.75% of Congo red dye was detached using 60 mg of PPy-coated TiB2 nanoadsorbent. Several sorption-desorption cycles were performed on this nanoadsorbent to determine its reusability. An excellent adsorption capacity for water treatment is reported in PPy-coated TiB2 nanoadsorbent.
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