Materials and Manufacturing Processes (MATER MANUF PROCESS )

Publisher: Taylor & Francis


Materials and Manufacturing Processes deals with issues that result in better utilization of raw materials and energy, integration of design and manufacturing activities requiring the invention of suitable new manufacturing processes and techniques, unmanned production dependent on efficient and reliable control of various processes including intelligent processing, introduction of new materials in industrial production necessitating new manufacturing process technology, and more. Information is offered in various formats, including research articles, letter reports, review articles, conference papers, applied research, book and conference reviews, patent reports, and entire issues devoted to symposia.

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    Materials and manufacturing processes (Online)
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    • Publisher last contacted on 25/03/2014
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Publications in this journal

  • Shifeng Huang, Min Sun, Meijuan Zhou, Dongyu Xu, Qinggang Li, Xin Cheng
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    ABSTRACT: This study demonstrated the preparation of 1-3 piezoelectric composite transducers by using 1-3 piezoelectric composites as the active phases, air as the backing layer and polyurethane as the matching layer. The composite electrode was produced by electroless nickel coating and the effect of the matching layer on transducer performance was investigated in detail. The results showed that the matching layer could improve the receiving sensitivity of the transducer significantly. The receiving response value of the transducer at first increased and then decreased with the increase of the matching layer thickness. This receiving response had the largest head-wave amplitude value when the thickness of the matching layer was about 2.2 mm, which was in good agreement with the theoretical value. The resonance frequency of the transducer in water showed a tendency of low frequencies, and the bandwidth of the transducer in water became much wider than that in air. The reasonable matching layer could improve performance of the transducer effectively.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • S. Amini, H. Khakbaz, A. Barani
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    ABSTRACT: In this study, improvement of near-dry machining (NDM) and its effect on tool wear in turning of AISI 4142 by carbide tool (DNMG 150608-PM) is investigated. First, the preparation of experimental setup was carried out, and then, some experiments to study the process were performed. Surface roughness was used as the criterion of finding the optimal conditions of fluid flow rate and frequency, and position and angle of nozzle. After optimization of the process, some experiments were performed to study tool life. Machining force, roughness, and tool wear were chosen as the criteria to determine the tool life. Obtained results show that the tool life in NDM is longer than that in dry machining.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Ya-Qiang Liu, Xue-Liang Du, Zen-Lian An
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    ABSTRACT: As-prepared epoxy resin samples were surface fluorinated using a F2/N2 mixture. The fluorination resulted in a remarkable increase in surface conductivity of the epoxy sample by over three orders of magnitude. Corona charges deposited on the fluorinated surface could not be stored even at room temperature. Obvious dependence of surface conductivity and steady state surface current on ambient humidity was found for the fluorinated sample. ATR-IR analysis and SEM imaging of surface and cross-section demonstrated substantial changes in surface layer chemical composition and morphology due to the fluorination, which are responsible for the changes in surface electrical properties.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Karali Patra, Ravi Shankar Anand, Markus Steiner, Dirk Biermann
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    ABSTRACT: This article presents an experimental investigation on microdrilling of austenitic stainless steel which is a difficult material for machining because of its properties like high strain-hardening rate, low thermal conductivity, and high fracture toughness. Microholes are produced on X5CrNi18-10 austenitic stainless steel workpiece using 0.5 mm diameter solid carbide microdrills. Two factors (cutting speed and feed) and three levels (low–center–high) full-factorial design of experiment are performed. Response surface methodology is used to developed mathematical models (quadratic and bilinear regression models) for cutting forces in microdrilling. The experimental analysis shows that feed affects the cutting force components (radial and thrust) significantly. Additionally, it also shows that there are only minor effects from cutting speed, square of cutting speed, square of feed and product of speed, and feed on the cutting forces. Finally, the optimized cutting conditions are proposed for minimum cutting forces.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Chen Fei, Tian Zuzhi, Wu Xiangfan
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    ABSTRACT: To obtain high-performance magnetorheological fluid, first, the effectiveness of single surfactant including oleic acid, sodium dodecyl benzene sulfonate, OP4 emulsifier and Tween80 are analyzed by testing the sedimentation stability and viscosity. And then, according to the research results, a novel preparation process, that is the compounding of different surfactants, is proposed. Finally, the effect of surfactants compounding type and content on the properties of magnetorheological fluid are also researched. It is found that the properties of MR fluids can be improved effectively by compounding of oleic acid and sodium dodecyl benzene sulfonate, and the most appropriate compounding content relationship is 4.0 g: 4.0 g.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • M. Hernández-Hernández, W. Cruz-Mendez, C. González-Rivera, M. A. Ramírez-Argáez
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    ABSTRACT: Mathematical and physical models of water deoxidation in a batch aluminum degassing reactor using the rotor-injector technique were developed. The mathematical model was successfully validated against measured degassing kinetics. The physical model was employed to perform a process analysis using a two-level factorial experimental design to determine the influence of gas flow rate, impeller angular velocity, and gas injection points on gas consumption efficiency and degassing kinetics. A combination of higher rotor speeds and gas flow rates results in fast degassing kinetics. However, moderate gas flow rates are recommended to save gas.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Vinod Mishra, Neha Khatri, Keshva Nand, Karanvir Singh, RamaGopal V Sarepaka
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    ABSTRACT: Single point diamond turning is one of the ultraprecision methods to generate high quality surfaces with highest possible profile accuracies. However, diamond turning process also introduces some unique errors which affect the surface finish. Some of these errors are controllable, while some are noncontrollable. Controllable parameters need proper selection, whereas uncontrollable parameters require adequate understanding of the process behavior. In this study only the effect of uncontrollable parameters on surface finish is explored. Tool overhang results tool–workpiece vibration whereas dynamic unbalance of vacuum responsible for workpiece wobble and both affect the surface finish considerably. Chipping of tool edge, improper extraction of chips, and slipping of workpiece on vacuum chuck are the main reasons of random scratch marks on surface and are contributing factors for degradation of surface finish.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Pervaiz Ahmad, Mayeen Uddin Khandaker, Yusoff Mohd Amin, Ziaul Raza Khan
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    ABSTRACT: Boron nitride microtubes are synthesized in a dual zone quartz tube furnace at 1200°C with ammonia as a reaction atmosphere. Field emission scanning electron microscopy (FE-SEM) results show a unique cone-like morphology of the tubes with larger internal space and thin walls structure. The diameters of the tubes were found to be in the range of 1 to ∼2 µm with the walls thickness estimated to be from 10 to 100 nm. XPS survey shows N 1 s and B 1 s peaks at 398.7 and 191 eV, respectively, that represent h-BN in the sample. Raman spectroscopy indicates a high-intensity peak at 1372.53 (cm−1) that corresponds to the E2g mode of h-BN. Along with the novel tubular morphology of boron nitride microtubes, the present work also explains a mechanism for the formation of boron nitride nanosheets (from boron nitride microtubes) found in the FE-SEM results of the current sample.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Alexander V. Perig, Alexander F. Tarasov, Iaroslav G. Zhbankov, Sergey N. Romanko
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    ABSTRACT: This article mainly focusses on the improvement of metal forming die tooling for equal channel angular extrusion (ECAE) processes through nonrectangular 2-dies of classical Segal geometry. The technological appropriateness of workpiece deformation through 2-dies using inclined oblique 2-punches has been evaluated with the introduction of physical simulation techniques. It has been shown experimentally that for the best efficiency, the geometric condition required for the taper angle of the inclined oblique punch is equal to the 2 angle between the inlet and outlet channels of the angular die. Physical simulation shows that the application of an oblique inclined 2-punch provides workpiece dead zone area downsizing and macroscopic rotation reduction during ECAE. The use of numerical finite element modeling simulation also confirms the usefulness of the oblique inclined 2-punch for increase of the utilization ratio and decrease of the maximum deformation and unevenness of deformation distribution.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • M. Amutha Surabi, J. Chandradass, Seong-Ju Park
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    ABSTRACT: Thin film transistors (TFTs) were fabricated on a glass substrate using zinc oxide material as a channel layer. The layers were grown by radio frequency magnetron sputtering method at a temperature of 100°C. The output characteristics of a TFT device showed that there is a reduction in drain current at increased drain-source voltage and gate-source voltage. This evidenced the existence of self-heating effect which may be due to increased donor type point defects. The electrical characteristics of a device show an improved intrinsic channel mobility of 4 cm2/Vs, threshold voltage of 12 V, sub-threshold swing of 1 V/decade, and very much decreased off current of the order 10−12 A.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Kejian Li, Yinsheng He, In Shik Cho, Chang Soon Lee, In Gyu Park, Jung-il Song, Cheol-Woong Yang, Je-Hyun Lee, Keesam Shin
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    ABSTRACT: Specimens of Inconel 690 were investigated after ultrasonic nanocrystalline surface modification (UNSM) using microhardness tests, electron backscattered diffraction, and transmission electron microscopy (TEM). After UNSM treatment, a 60% increase of hardness up to ∼310 µm in depth was observed. Layer-by-layer TEM analysis showed well-refined grains and twins in addition to the high dislocations density. The mechanism of the microstructure refinement was attributed to the development of nano-grains, twin structures, and dislocations.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • A. M. Chelladurai, K. A. Gopal, S. Murugan, S. Venugopal, T. Jayakumar
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    ABSTRACT: A systematic parametric study has been made in pulsed Nd:YAG laser welding to understand the energy transfer modes. Four different energy transfer zones, namely conduction, transition, penetration, and keyhole, have been identified. The traditional classification of energy transfer modes based on the power density value of 106 W/cm2 is not strictly applicable as the transfer mode varies with pulse duration. The threshold power density to form keyhole is not constant, but the threshold energy density has been found to be invariant around 2.4 kJ/cm2. The pulse duration has been optimized to be of about 8 ms to achieve welds of higher aspect ratio.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Mohammad Faizan
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    ABSTRACT: Besides the popular reflow soldering practice, wave soldering is another established technique in the electronic packaging industry for obtaining the solder joints. In this study the dissolution behavior of copper and the growth of intermetallic compound (IMC) during wave soldering process have been investigated. The study involved two different solder compositions, viz. pure Sn and eutectic Sn–Ag solder. Dipping experiments were conducted for the temperature range of 221–300 °C and for dwell time starting form 5 s to 6 min. The average thickness of the intermetallic compound formed and the amount of copper dissolved was determined. Experimental results indicated that the amount and rate of copper dissolution were strongly affected by temperature of molten solder and dwell time. The initial rate of copper dissolution was very high but it decreased with time. Based on the experimental results, the kinetic parameters governing the dissolution of copper and growth of the IMC were determined for the two solders.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • A. J. Jegadeesan, L. Karunamoorhty, N. Arunkumar
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    ABSTRACT: The capability of hot-staking in providing mechanical as well as electrical joints along with its versatility and cost effectiveness makes it a process of preference in electrical and electronics appliances. However, the effectiveness of the process depends only on the mechanical contact and there is no welding or fusion between the joining surfaces. This necessitates proper selection and control of process parameters. This study investigates using Taguchi experiments the importance of process parameters for hot-staked joints in armatures of DC motors. Results show that the electrode material, geometry, and its position are significantly important. Based on the findings, a hypothesis is reasoned about process-product relationship to enable evolving in joint strength.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • S. Rajendran, M. Sakthivel, S. Dharamalingam
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    ABSTRACT: The formation and spherical form of the resolidified layer on T90Mn2W50Cr45 tool surface processed using wire electrical discharge machine was investigated and analysis was done in detail for optimization by response surface methodology. The surface layer modification was examined by scanning electron microscope.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Zhanshu He, Dalei Li, Lianduo Cao, Yong Tang
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    ABSTRACT: A new method for fabricating CCMPMPs, namely multi-cutter milling, is proposed and the fabrication principle is discussed. Then, a study of three microchannel parameters, the microchannel depth H c, width W c, and interval W s, and two CCMPMP parameters, the porosity P and the total surface area per unit volume S V, is presented. Furthermore, 3D FEM has been adopted to study the effective stress distribution, the metal flow velocity distribution, and the cutting forces. The results show that CCMPMPs can be successfully machined. H c, W c, and W s can be controlled by the radial depth of cut a e, the slotting cutter thickness E t, and the gasket thickness E g, while P and S V can be changed by adjusting H c, W c, and W s. Moreover, as a e increases, the average resultant force increases, and the friction between chip and the side face of the machined microchannel, and between chip and the rake face, plays an increasingly important role in it.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Lanying Xu, Qiang Wu, Yong Tang, Gui Qu, Xiaodan Wu
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    ABSTRACT: In this study, a simple and flexible transplantation device of electric heating drilling is developed for hard-to-cut materials. Based on this device, small holes (diameter of 1–3 mm) are drilled for stainless steel 1Cr18Ni9Ti and high manganese steel ZGMn13 adopting hard carbide twist drill YG6A. In the process of electric heating drilling, the dynamic change in drilling force (including axial force and torque) is discussed with the change in variant heating current, cutting speed, and feed. Experimental data show that axial force and torque increase with increasing cutting speed and feed, and with increasing heating current, total drilling force is obviously reduced in the initial stage, then it increases slightly over time. The heating current helps to reduce axial force and torque, which shows that electric hot drilling is effective in hard-to-cut materials.
    Materials and Manufacturing Processes 02/2015; 30(2).
  • Ning Yang, Zhan-Xiang Sun, Liang-Shan Feng, Mu-Zi Zheng, Dao-Cai Chi, Wei-Zhong Meng, Zhi-Yan Hou, Wei Bai, Kai-Yu Li
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    ABSTRACT: The dramatic increase in plastic film mulching in water-efficient agriculture is primarily due to its versatile nature that has proven to be very beneficial over the last decade in the arid region. However, as carelessly used plastic mulch films lead to agro-environmental pollution, there has been vigorous research recently to develop degradable film materials for mulching. This review describes the use of plastic film for mulching in water-efficient agriculture practices with special reference to progress made in degradable film materials. Moreover, this review includes water-efficient mechanisms and techniques of mulching film cultivation, photodegradable and biodegradable plastic polymers (PHA, PCL etc. synthetic- and natural-based polymers films), their degradation process and developmental deficiencies, and an outlook of degradable film materials. There exists great potential for the further development of water-efficient agriculture; however, it is dependent upon effective research and the wide-spectrum applications of degradable film materials.
    Materials and Manufacturing Processes 02/2015; 30(2).
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    ABSTRACT: This work reports results of silicon carbide plates, disks, pipes, and pipe–disk couples bonded by a spark plasma sintering apparatus. The joining was conducted at 1900 °C for 30 min with a 35 MPa uniaxial pressure. The samples were analyzed by Scanning acoustic microscopy, which in turn revealed a low amount of small defects at the samples’ periphery. Scanning acoustic microscopy results were verified through scanning electron microscopy and nanoindentation. It was concluded that Spark Plasma Sintering technique may serve as a valid and effective tool for diffusion bonding of high-temperature-resistant silicon carbide with different geometries.
    Materials and Manufacturing Processes 01/2015; 30(1).