This present investigation focusing on preparation of Al-based hybrid composites in which Al6082 is engaged as the main alloy reinforced with two reinforcements of ZrSiO₄/TiC. The combination of the stir-squeeze process helps to make different specimen by change of four parameters such as stir speed, stir time, reinforcements, and squeeze pressure. In this process, two reinforcements are reserved as constant about 7.5 wt%. The four levels of each parameter are stir speed (300, 400, 500, and 600 rpm), stir time (10, 15, 20, and 25 min), reinforcement (2.5, 5, 7.5, and 10 wt%), and squeeze pressure (50, 60,70, and 80 MPa). According to the L16 orthogonal array Taguchi design, the specimens are created to analyze the mechanical properties of tensile strength and hardness along with porosity. In addition, the optimization technique is used to determine the optimal parameter on improving tensile strength. The optimization process can be assisted by the software namely Minitab-17 which helps to study analysis of variance, regression model, and contour plots. The observed result of ANOVA showed that stir speed (41.8%) is the maximum influenced parameter that increases TS, followed by squeeze pressure (25.7%), stir time (12.7%), and reinforcement (1.96%), and optimum tensile strength is found at the parameters of stir speed 600 rpm, stir time 10 min, reinforcement 2.5 wt%, and squeeze pressure 80 MPa. The fractured surface of tensile strength also examined by the SEM test. The combined parameters of S4-T1-R1-P4 achieve the highest TS, and it is observed that there are nearly no pore defects and good diffusion as a result of the reinforcements to be properly mixed. It is noticeable that the TiC and Al 6082 matrix, as well as the various ZrSiO4 exhibit stronger bonds.
Friction stir welding (FSW) is the solid state welding technique which is mostly utilized to join similar and dissimilar Al, Cu, Mg, and their alloys. This research investigated that the tensile strength of FSW dissimilar Al6262 and Al5456 of 4 mm thickness is carried out using an H-13 tool pin along with different process variables such as tool rotational speed (TRS), welding speed (WS), and tool tilt angle (TTA). The selected parameters are set as TRS of 900, 1100, and 1400 rpm, WS of 20, 30, and 40 mm/min with TTA of 2, 2.5, and 3° to find out significant parameters on tensile strength (TS). The Taguchi L27 method is taken to create a number of experiments to recognize the optimal level of each parameter to accomplish the highest TS value. From the experimental results witnessed, the extreme TS (202.44 MPa) is acquired at sample 22 when maintaining TRS-1400 rpm, WS-30 mm/min, and TTA-2 degree, whereas minimum TS (165.88 MPa) is attained at sample 15 of TRS-1100 rpm, WS-30 mm/min, and TTA-3 degree. The ANOVA outcome revealed that TRS is the most significant factor (23.24%) which improves the tensile property of joints, followed by a weld speed of 21.7% and a combination of tool speed and weld speed (16.17%). The increment in the tool tilt angle does not play a vital role in improving the TS value, and MINITAB -17 software helped to find a relation between the parameters in the regression equation.
AA6262 and AA5456 alloys are welded through friction stir weld (FSW) with process parameters of tool speed of 1200 rpm, welding speed of 25 mm/min, and tool angle of 3 degree. A cylindrical shape HSS-13 tool is used to perform the welding process To improve mechanical properties of tensile strength (TS), yield strength (YS), elongation%, hardness, and wear behavior, postweld heat treatment was conducted on the FSW sample at di erent temperatures from 300 °C to 500 °C. e in uence of heat treatment (HT) changes the material characteristics. It is observed that the maximum TS (209 MPa) and YS (178 MPa) are identi ed when maintaining temperature 350 °C on the FSW sample. e reduction in elongation of as-welded joints is entirely improved by HT, and the elongation percentage is almost increased to 5% when increasing temperature on the heat treatment process, and hardness test results exhibited that the increased hardness value (120Hv) is found at HT-300 °C nugget zone distance of 0 to 5 mm range.
In the present work, the preparation of AA-6082/ZrSiO4/TiC hybrid composite is studied along with an analysis of the effects of electrochemical machining parameters such as feed rate of electrode (FE), voltage (VO), electrolyte concentration (EL), and electrolyte discharge (ED) rate on the output responses of the material removal rate (MRR) and surface roughness (SR) for Al hybrid composites. The experiments are carried out based on the Taguchi L16 orthogonal array and the important process parameters are found for MRR and SR. Each parameter contains four different levels that are FE (0.10, 0.15, 0.20, and 0.25 mm/min), VO (10, 15, 20, and 25 V), EL (15, 20, 25, and 30 g/lit), and ED (1.5, 2, 2.5, and 3 lit/min).The optimization software, namely, Minitab-17 version helps to find the contribution of each parameter on MRR and SR. The ANOVA result reveals that the feed rate of electrode is the highest contributing parameter, trailed by the electrolyte discharge rate and other process parameters for MRR and SR. A linear model of regression and interaction plots is also included to show the relationship between the parameters. From the observational results, the highest MRR (0.00953 mg/min) is attained by the parameter combination level of the feed rate of electrode of 0.20 mm/min, voltage of 25 V, electrolyte concentration of 20 g/lit, and electrolyte discharge rate of 1.5 g/, whereas the lowest MRR is found at FE of 0.10 mm/min, VO of 10 V EL-15 g/lit and ED of 2.5 g/litre. For SR, the maximum and minimum are recognized at FE2-VO4-EL3-ED2 (0.15 mm/min, 25 V, 25 g/lit, and 2 lit/min) and FE1-VO1-EL1-ED1 (0.10 mm/min, 10 V, 15 g/lit, and 1.5 lit/min), respectively. Finally, the increment of MRR and SR values is mostly dependent on the feed rate of the electrode.
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