Investigating Mechanical and Corrosion Behavior of Plain and Reinforced AA1050 Sheets Fabricated by Friction Stir Processing

Malik, Vinayak; Bajakke, Padmakumar A.; Jambagi, Sudhakar C.; Chavana, Nagarjuna; Deshpande, Amruta

doi:10.1007/s11837-020-04323-0

Cited by 17 publications

(4 citation statements)

References 41 publications

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“…Porosity was observed in the coating, which allows the molten salt to penetrate and leads to corrosion. Coating flaws and the impurities on the surface lead to the formation of pitting corrosion. , Sreenivas Rao et al reported a similar observation for plasma-sprayed Cr 2 O 3 –Al 2 O 3 –ZrO 2 multilayer coatings on mild steel. However, depositing dense FA coatings can further improve the corrosion resistance.…”

Section: Resultsmentioning

confidence: 76%

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

2022

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Fly ash (FA), a multicompound mineral, is an industrial waste produced during coal burning in thermal power stations. It has been regarded as the most environmentally hazardous material. Furthermore, handling FA has been a significant challenge for many developing countries. Therefore, researchers have been exhorted to enhance its usage to counter its handling issues. FA is enriched with mullite, silica, and alumina. Having such mineralogy, FA can be envisaged as a promising candidate for combating erosion and corrosion in marine environments. With this motivation, the research aims to deposit as-received FA using the plasma-spraying technique onto a marine-grade steel substrate without additives and assess the performance of such coatings for erosion and corrosion properties. The coating has exhibited more than 100% improvement in microhardness. The erosion resistance was improved by ∼11% compared to that of the uncoated sample, which is attributed to the hardness to elastic modulus ratio ( H / E ) and its unique mineralogy. The minor improvement in erosion resistance was attributed to the coating’s poor fracture toughness. The erosion study shows that slurry concentration and rotational speeds were the most influential parameters. The scar depth was significantly shallower for FA-coated samples. The corrosion resistance has improved only by ∼13.49%, owing to the porous nature of the coating. Therefore, such coatings with appropriate improvements in their properties are expected to assuage both environmental and industrial challenges.

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Section: Resultsmentioning

confidence: 76%

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

2022

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“…Among all the parameters that could be optimized for a tool ascertaining good weld strength, the geometry of the tool plays a crucial role in affecting the amount of heat generation, material flow, torque, axial force as well as the integrity of the weld. A conventional tool used in FSSW is derived from FSW, comprising a fixed pin and shoulder (Bajakke et al , 2020; Malik et al , 2020). This tool is more suitable for butt joint configuration, causing the material to move from one workpiece to another along the horizontal plane of welding, whereas FSSW is applied for lap joints, wherein the same FSW tool causes excessive thinning of the upper sheet.…”

Section: Resultsmentioning

confidence: 99%

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Tiwary,

Padmakumar,

Malik

2023

RPJ

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Purpose Material extrusion (MEX) 3D printers suffer from an intrinsic limitation of small size of the prints due to its restricted bed dimension. On the other hand, friction stir spot welding (FSSW) is gaining wide interest from automobile, airplane, off-road equipment manufacturers and even consumer electronics. This paper aims to explore the possibility of FSSW on Acrylonitrile Butadiene Styrene/Polylactic acid 3D-printed components to overcome the bed size limitation of MEX 3D printers. Design/methodology/approach Four different tool geometries (tapered cylindrical pin with/without concavity, pinless with/without concavity) were used to produce the joints. Three critical process parameters related to FSSW (tool rotational speed, plunge depth and dwell time) and two related to 3D printing (material combination and infill percentages) were investigated and optimized using the Taguchi L27 design of experiments. The influence of each welding parameter on the shear strength was evaluated by analysis of variance. Findings Results revealed that the infill percentage, a 3D printing parameter, had the maximum effect on the joint strength. The joints displayed pull nugget, cross nugget and substrate failure morphologies. The outcome resulted in the joint efficiency reaching up to 100.3%, better than that obtained by other competitive processes for 3D-printed thermoplastics. The results, when applied to weld a UAV wing, showed good strength and integrity. Further, grafting the joints with nylon micro-particles was also investigated, resulting in a detrimental effect on the strength. Originality/value To the best of the authors’ knowledge, this is the first study to demonstrate that the welding of dissimilar 3D-printed thermoplastics with/without microparticles is possible by FSSW, whilst the process parameters have a considerable consequence on the bond strength.

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“…In addition, the grain evolution modes include sub-grain boundaries→sub-grain boundaries, and high angle grain boundaries→high angle grain boundaries. The sub-grain boundaries result in elongated grains, mixed-mode boundaries account for equiaxed grains and oriented grains are the outcome of high angle grain boundaries [35][36][37][38]. Dinaharan et al [22].…”

Section: Friction Stir Processingmentioning

confidence: 99%

Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

Malik

Bajakke

Saxena

et al. 2022

Mater. Res. Express

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The problems associated with the fabrication of in-situ metal matrix composites (MMC) by conventional methods can be avoided by using microwave sintering and friction stirring in combination. The current study investigates the mechanical and electrical properties of pure aluminum (Al-100 wt.%) and Al-Cu MMC. The results showed that excellent ultimate tensile strength, toughness, and electrical conductivity can be acquired simultaneously. The obtained ultimate tensile strength in the case of Al-100wt.% (184.5 MPa) has improved two-fold than that of a typical commercially pure aluminum AA1016 (90 MPa). Similarly, the electrical conductivity of developed pure aluminum (88.87% IACS) is 1.4 times higher compared to AA1016 alloy (62% IACS). For Al-Cu MMC the copper is added in steps of 5 wt.% (5%, 10%, 15%, and 20%). The maximum ultimate tensile strength (205.2 MPa) and the electrical conductivity (71.53% IACS) obtained for Al-10wt.%Cu are higher compared to the AA1016 alloy. The present investigation suggests a novel processing route and opens up new research avenues in the field of solid-state materials processing.

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Investigating Mechanical and Corrosion Behavior of Plain and Reinforced AA1050 Sheets Fabricated by Friction Stir Processing

Cited by 17 publications

References 41 publications

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

Improvement in Slurry Erosion and Corrosion Resistance of Plasma-Sprayed Fly Ash Coatings for Marine Applications

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

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