Poly(ether ether ketone) is a semicrystalline organic polymer. It has widely been used as high-performance engineering plastic owing to its high melting point (343 °C), excellent mechanical strength, and outstanding chemical resistance. Therefore, poly(ether ether ketone) and its composites have shown lots of applications in aerospace and medical fields. However, its application is restricted due to poor strength at the mechanically joint components. Thus, this scope leads us to study an alternative method of the joint process that will lead to finding a new joining process for poly(ether ether ketone)-based materials. In this study, a solid-state joining process was conducted to join two poly(ether ether ketone) rods by a friction welding process. Here, we statistically optimized the values of forge load, friction load, and friction welding time as 100 N, 450 N, and 8 s, respectively, which have more influence on tensile stress and hardness of the material after the friction welding process. It has been found that the forge load had the highest influence and the forge time had the least influence on tensile strength. Their optimal values were calculated after considering the trend in hardness values by statistical analysis using Minitab software. However, after the optimal values, the above parameter showed a negative effect on the high tensile stress due to the change in crystallinity of the friction welding processed poly(ether ether ketone) as confirmed by X-ray diffraction and thermal analyses.
Nowadays it’s difficult to use a metal with high corrosion resistant properties in required applications. Monel 400 is one nickel based alloy having required property to be applicable in such scenarios. It is used in highly corrosive environments such as marine, chemical and aerospace industries as it has the property of maintaining its toughness over a range of temperature, however machining of this Monel alloy is relatively tough due to its characteristic work hardening properties. To tackle the mentioned issues, Abrasive water jet machining is used which is a widely known nontraditional machining technique. The process parameters and the response variables were chosen depending on the machine specifications, and parameter combinations were made using Minitab statistical software. The parameters and their interactions like the cut quality on the alloy, nozzle diameters effects, and water pressure were also studied. Response surface model and various statistical algorithms such as S-N ratio, ANOVA and regression equations were utilized for formation of the design of experiment, optimization of process parameters for the machining process were done using Grey relations. Reduction of surface roughness, maximization of Material removal rate while simultaneously reducing the cycle time for the operation was the primary objective. The results thus obtained indicates that the quality of cut was the most influential factor in the machining process followed by water-jet pressure value.
In friction welding, welding takes place due to exterior pressure applied on the cylindrical rods. Both the specimen to be welded are having a linear motion or a rotary motion. The main benefit of friction welding, is that it produces low distortion. The other advantage is absence of defects and comparatively high weld strength. It can also be employed to weld materials that are considered difficult to weld by older welding methods. Friction welded specimen do not require any external auxiliary such as tools or filler rods and thus helps to save cost. Also, this method requires relatively lesser welding times as compared to other welding processes. Using this technology, we can achieve welding of a large number of materials which have distinct mechanical properties and chemical composition. Friction Welding also helps to reduce the costs of process by a significant amount. This also has shown prominent reduction in overall weight of the component. This study encapsulates the work done in friction welding, presents the summary of the testing done in this field till date in brief. The identification of proper welding parameters such as Friction Load, Friction Time and Forge Load is an important task. The problem of obtaining good weldability as well as high weld strength is tackled and dealt with hereby. Friction welding could be a discovery in production technology, a leap which will profit a large variety of industries, as well as the aviation, naval industries. It also has use in manufacturing drilling tools.
This paper studies the surface tribology and mechanical properties of AA6061 graded aluminum alloy matrix composite, reinforcing Silicon Carbide and Boron Carbide. In this work, the AA6061 graded aluminum alloy is reinforced with 3%, 6%, 9% (By weight) of B4C with constant 5% (By weight) of SiC under stir casting and producing three test samples A, B and, C respectively. The Samples were subjected to wear test, tensile test, impact test, and hardness test calculating wear loss, wear rate, coefficient of friction, ultimate tensile strength, impact strength, and brinell hardness. From analyzing the results from the test conducted, it is inferred that maintaining the optimum B4C composition between 3% and 6% in Al-SiC produces better mechanical properties and wear resistance.
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