Isaac Dinaharan

Friction stir welding (FSW) exhibits significant advantages to join titanium and its alloys compared to other welding methods. FSW of 3mm thick titanium alloy Ti–6Al–4V sheets was carried out using a lanthanated tungsten alloy tool. The traverse speed was varied from 40mm/min to 200mm/min in steps of 80mm/min by keeping other parameters constant. T...

Friction stir processing (FSP) has emerged as an effective secondary processing technique to improve the microstructure and properties of aluminum matrix composites (AMCs). Al/(0–15 wt.%) Al2Cu AMCs were prepared by adding pure copper powder to molten aluminum and subjected to FSP. The microstructural changes before and after FSP were studied using...

Friction stir processing (FSP) was applied to develop pure titanium (Ti) particulate reinforced AZ31B magnesium matrix composites (MMCs). Machined groove strategy was used to pack the Ti particulates initially and FSP was carried out using a conventional vertical milling machine. Traverse speed, number of passes and volume fraction of Ti particulat...

Conventional ceramic particulate reinforcements cause a major loss in ductility of magnesium matrix composites (MMCs). Metallic particles possessing higher melting point can offer a solution to this issue. Titanium (Ti) particles (0,7,14 and 21 vol.%) were reinforced into magnesium alloy AZ31 using friction stir processing (FSP) performed by a conv...

This research work investigated the role of fly ash particles (0, 5, 10, 15 and 20 wt.%) on the microstructural evolution and the wear resistance under dry sliding conditions of copper matrix composites (CMCs), prepared through powder metallurgy (PM) route. Copper and fly ash particles were initially mixed in a twin-shell blender, compacted in a di...

Fly ash particles were reinforced into AA6061 aluminum in semisolid state to produce aluminum matrix composites (AMCs). The prepared AMCs were subjected to turning operation using a tool made of polycrystalline diamond. Fly ash particles were spread across the aluminum matrix in homogenous manner. The incorporation of fly ash particle had a remarka...

Industries increasingly pay attention to hot wire assisted gas tungsten arc welding (HWGTAW) in the present decade for joining several materials. Limited works were reported on HWGTAW of nickel and its alloys. In this investigation, HWGTAW was applied to weld pure nickel tubes (Ni 200 grade) having a thickness of 4 mm and an outer diameter of 44 mm...

Ti–6Al–4V sheets of 3 mm thickness were joined via friction stir welding (FSW) technique using industrial purpose I-STIR machine. Since the welding speed is a key parameter in production, it was varied from 40 to 200 mm/min in steps of 40 mm/min. Sound joints were obtained without macroscopic defects using a lanthanated tungsten tool. The microstru...

Activating flux tungsten inert gas (A-TIG) welding has drawn intense research focus in the present material era to overcome the wide bead geometry and shallow penetration of conventional TIG welding. This work is devoted to investigating the role of halide-based flux on the bead geometry and the microstructural evolution of 7-mm-thick pure titanium...

This study produced silicon carbide (SiC) and aluminum oxide (Al2O3) particulates using an in situ reaction system of silicon dioxide (SiO2)+ carbon (C)+ aluminum (A)l with a molten aluminum alloy. The reaction system was examined through differential scanning calorimetry (DSC). The in situ-fabricated aluminum matrix composites (AMCs) were analyzed...

Magnetically impelled arc butt (MIAB) welding is being used in industries for joining metallic tubes and pipes. This research work reported MIAB welding of AISI 409 ferritic stainless steel tubes of 4 mm thickness. Joints were obtained by varying arc rotation current and characterized using various microscopic techniques. An increase in arc rotatio...

Magnetically impelled arc butt (MIAB) welding is the modern version of the ancient forge welding. The abutting edges are preheated by a rotating arc and upset subsequently. This research work is focused on joining 4-mm thick AISI 409 ferritic stainless steel (FSS) tubes using MIAB welding. Three process parameters namely arc rotation current, upset...

Magnetically impelled arc butt (MIAB) welding has been the focus of several industries to weld metals in tubular form. 4 mm thick AISI 409 ferritic stainless steel tubes were joined effectively using MIAB welding. The arc duration was varied (4s–8s with an increment of 1s) during welding and all other process parameters such as arc rotation current...

Friction stir welding (FSW) process is an appropriate welding process to successfully join the aluminum matrix composites (AMCs) reinforced with ceramic particles. In this study, AA6061 AMCs reinforced with 10 and 20 weight percentages of aluminum nitride particles (AlNp) were welded by FSW process. The effect of FSW on microstructure, microhardnes...

Titanium alloy Ti-6Al-4V particles were used as reinforcement for AZ31B magnesium metal matrix composites (Mg MMCs) which were synthesized via friction stir processing (FSP). Ti-6Al-4V particulates were packed in the machined grooves at first and subsequently processed by means of a traditional machine used for vertical milling. The processing spee...

Laser beam welding (LBW) of AA6061/10 wt% ZrB2 aluminum matrix composites (AMCs) demonstrated substantial benefits compared to other welding processes. In this research work, 4 mm thick AA6061/10 wt% ZrB2 composite plate was effectively joined using Nd:YAG LBW. The welding was carried out using varied scanning speed in the range of 1.7–2.5 m/min by...

Incoloy alloy 800 is a superalloy particularly suited to aggressive corrosive environments. Both weld quality and productivity may be enhanced when joining parts by laser beam welding (LBW). The current paper describes joining of Incoloy alloy 800 plates (4 mm thickness) by laser welding (Nd :YAG). The laser scan speed was varied between 0.5 to 2 m...

Dual phase brass was reinforced with industrial residue fly ash particles (0 to 18 vol.%) to produce surface composites through friction stir processing (FSP). Micrographs revealed uniformly dispersed fly ash particles. The interface made a strong bond with the brass matrix because of the absence of pores or any undesirable compounds. Fracture of f...

Poor ductility is the primary concern of magnesium matrix composites (MMCs) inflicted by non-deformable ceramic particle reinforcements. Metal particles which melt at elevated temperature can be used as reinforcement to improve the deformation characteristics. Ti–6Al–4V particles reinforced AZ31 MMCs were produced through friction stir processing (...

The interest in hot wire gas tungsten arc welding (HWGTAW) process is increasing in industrial sector in the current decade. Pure nickel (Ni 200) tubes having 4-mm-thickness and 44-mm-outer diameter were effectively joined by HWGTAW. The heating current of the filler wire was varied from 80 amps to 120 amps in steps of 10 amps. The joint microstruc...

Tool rotation speed is one of the most important processing parameters that govern the performance of the friction stir welds. In this study, a novel variant of friction stir welding for T-joints, which is termed as corner stationary shoulder friction stir welding (CSSFSW), is investigated regarding the effect of tool rotation speed on the microstr...

There is a renewed interest to utilize the advantages of hot wire gas tungsten arc welding (HWGTAW) process in industrial area. This manuscript reports HWGTAW of pure nickel tubes of 4 mm thickness. Design of experiment (DoE) approach was adopted to bring down the number of the joints. Welding plan was executed according to 3 factors, 5 levels cent...

The application of artificial neural network (ANN) to predict the wear rate of the surface composites produced using a solid-state technique called friction stir processing (FSP) is presented in this work. The copper surface composites were prepared by incorporating different sort of ceramic particles such as SiC, TiC, Al2O3, WC and B4C. The design...

Casting route is preferred highly to produce metal matrix composites (MMCs) because of simplicity, low cost and applicability for mass production. The process involves melting the metallic matrix using a furnace, incorporating the reinforcements and allowing the composite melt to solidify. The physical and chemical properties of the reinforcement p...

Accumulative roll bonding (ARB) is a popular severe plastic deformation method which was used to produce ultrafine grain materials and bimetallic composite strips. ARB was discoved to produce metal matrix composites a decade ago by incorporating reinforcement particles between the sheets prior to roll bonding. The severe deformation and the plastic...

Laser beam welding (LBW) has many advantages to join high strength low alloy (HSLA) steels compared with conventional fusion welding processes. The present work is focused on joining HSLA plates of 2 mm thickness efficiently through the application of Nd:YAG laser source. Only one process variable i.e. the welding speed was operated between 70 mm/s...

The conventional alloys do not always provide the required properties under all service conditions which are over-come by reinforcing those alloys with ceramic particles. Such reinforced metallic alloys are universally known as metal matrix composites (MMCs). MMCs have received considerable attention in the present material world owing totheir high...

Metal matrix composites (MMCs) provide a range of desirable properties which make them to gradually phase out existing monolithic materials. It is inevitable to join MMCs for structural and industrial applications to expand the usage. It is a challenging task to obtain sound joints due to the presence of hard particle reinforcements. This chapter s...

The widely accepted casting routes to produce metal matrix composites (MMCs) presented lot of challenges and defects which include inhomogeneous dispersion, interfacial reaction, porosity and poor wettablily. Friction stir processing (FSP) has become a popular method to produce bulk and surface MMCs. FSP was developed based on the working principle...

Friction stir processing (FSP) is used as a secondary processing technique that has been Q3 employed to enhance the microstructure and other attributes of aluminum matrix composites (AMCs). Al/(0-15 wt.%) Al 3 Ni AMCs were created using pure nickel powder, which was Q4 added to molten aluminum. The composite was then subjected to FSP. The AMC micro...

In the current work, 4 mm thick HSLA steel plates were joined by Nd:YAG laser welding. The scanning speed of the laser was varied in the range of 1.5–3.5 m/min while maintaining constant laser power. The microstructure evolution was observed using conventional and advanced microscopic techniques. The geometry of the fusion zone resembled a classic...

Purpose Friction stir processing (FSP) as a solid-state process has the potential for the production of effective aluminum matrix composites (AMCs). In this investigation, various ceramic particles including B 4 C, TiC, SiC, Al 2 O 3 and WC were incorporated as the dispersed phase within AA6082 aluminum alloy by FSP. The wear rate of the composite...

The present research work examines the impact of temperature on the dry sliding wear behaviour of AA7075 aluminum strengthened zirconium diboride (ZrB2) particulate composite (0, 3, 6, 9 and 12 wt.%). AA7075/ZrB2 aluminum matrix composites (AMCs) were prepared by the in-situ reaction of K2ZrF6 and KBF4 to liquid aluminum. The in-situ formed AMCs we...

This work is focussed on developing AA2124/4wt. B4C nano composite coatings on Ti-6Al-4V using friction surfacing to improve the wear resistance. The composite was produced using conventional stir casting method and coatings were laid using an indigenously developed friction surfacing machine. The rotational speed of the mechtrode was varied. The c...

Submicron and Nanometric sized ceramic particles provide an enhanced performance of aluminum matrix composites (AMCs) to that of commonly used micron sized particles. B4C particles (~250 nm) were effectively reinforced (0,1,2,3 and 4 wt.%) into AA2124 aluminum alloy using conventional stir casting technique using an arrangement to pour the molten m...

Utilizing fly ash (FA) as reinforcement for magnesium matrix composites (MMCs) brings down the production cost and the land pollution. Magnesium alloy AZ31 was reinforced with FA particles (10 vol.%) successfully by two different processing methods namely conventional stir casting and friction stir processing (FSP). The microstructural features wer...

This paper presents an investigation to establish the link between friction welding process parameters and the ultimate tensile strength (UTS) of friction-welded titanium joints by application of an artificial neural network (ANN) technique. The experimental matrix is based on a central composite design with parameters varied at five levels. The UT...

Friction stir processing (FSP) has emerged as an effective secondary processing technique to improve the microstructure and properties of aluminum matrix composites (AMCs). Al/(0–15 wt%) Al3Fe AMCs were prepared by adding pure iron powder to molten aluminum and subjected to FSP. The microstructural changes before and after FSP were studied using OM...

Friction stir processing (FSP) has emerged as an effective secondary processing technique to improve the microstructure and properties of aluminum matrix composites (AMCs). Al/(0–15wt.%) Al⁠3Zr AMCs were prepared by adding zirconium powder to molten aluminum and subjected to FSP. The microstructural changes before and after FSP were studied using O...

Fusion welding of austenitic stainless steels (ASSs) causes undesirable metallographic changes. An attempt has been made to join 3-mm-thick 316L ASS plates using friction stir welding and correlate the microstructural evolution and the mechanical properties under various welding conditions. Tungsten alloy (W-Re) tool was employed for welding. Succe...

The reinforcement of ceramic particles in aluminum matrix composites (AMCs) restricts the plastic flow of the matrix and causes a loss in ductility. The reported research work demonstrates an improvement in tensile strength without losing appreciable ductility by reinforcing vanadium particles (~18 µm) into AA6063 AMCs by friction stir processing (...

The dry sliding wear behaviour of in-situ formed TiC particulate in aluminium alloy AA6061 was investigated at ambient temperature using a pin-on-disc wear testing machine. Aluminium alloy AA6061 reinforced with different mass fractions of (0, 2.5, 5, 7.5 & 10 weight percentage) TiC particles was fabricated by the in-situ reaction process. The in-s...

Aluminum matrix composites (AMCs) are difficult to machine due to increased tool wear. AA7075/(0–12wt.%) TiB2 in situ AMCs were prepared and turned in a modified conventional lathe using polycrystalline diamond (PCD) cutting tool. A central composite rotatable design comprising of four process parameters and five levels was utilized to limit the ac...

The microstructure and mechanical properties of friction and laser beam welded Grade 2 titanium tubes (wall thickness of 3.9 mm and outer diameter of 60 mm) are compared in the present investigation. Friction welding (FW) was conducted on a vertical friction processing system. Laser beam welding (LBW) was accomplished by utilizing a 4 KW Nd:YAGlase...

Rutile (TiO2) particle-reinforced aluminum matrix composites were prepared by friction stir processing. The microstructure was studied using conventional and advanced characterization techniques. TiO2 particles were found to be dispersed uniformly in the composite. Clusters of TiO2 particles were observed at a higher particle content of 18 vol%. Th...

The relatively new severe plastic deformation method, friction stir processing (FSP) is a cutting-edge process to synthesize surface and bulk metal matrix composites. The present work is focused to produce Cu/TiC copper matrix composites (CMCs) and investigate the microstructure and sliding wear behavior at room temperature without lubrication. In...

Fly ash (FA) is a cheaper reinforcement which will bring down the production cost of metal matrix composites (MMCs). This paper reports FA reinforced MMCs based on aluminum alloy AA6061, magnesium alloy AZ31 and copper. The composites were synthesized using the novel and latest method friction stir processing (FSP). The microstructure was examined...

TiB2 and Al2O3 particulates reinforced AA6061 aluminum matrix composites (AMCs) were synthesized by in-situ reaction of titanium (Ti) and boric acid (H3BO3) powders with molten aluminum. AMCs were fabricated using an electric stir casting furnace under a controlled environment. Heat flow curves of differential thermal analysis (DTA) showed that the...

Friction stir welding (FSW) is an ideal process to join brass to avoid the evaporation of zinc. In the present investigation, 6-mm-thick dual-phase brass plates were joined efficiently using FSW at various tool rotational speeds. The microstructures were studied using optical microscopy, electron backscattered diffraction and transmission electron...

This paper investigates the machining characteristics of AA7075/(0–12wt.%) TiB⁠2 aluminum matrix composites (AMCs) during dry turning using polycrystalline diamond cutting tool. AMCs were produced using in situ reaction between inorganic salts K⁠2TiF⁠6 and KBF⁠4 with molten aluminum. TiB⁠2 particles were observed to be uniformly distributed in the...

Preparing aluminum matrix composites (AMCs) using in situ method results in many desirable benefits. This paper is focused on preparing AA2024/(0, 2.5, 5, 7.5 and 10 wt%) ZrB2 AMCs by Al–K2ZrF6–KBF4 reaction system. The inorganic salts were added to molten aluminum alloy at an elevated temperature of 850OC. The prepared AMCs were studied by applyin...

Grade 2 titanium tubes of outer diameter 60 mm and wall thickness 3.9 mm were effectively joined by Nd:YAG laser. The welding speed was varied in five levels (2.50, 2.75, 3.00, 3.25 and 3.50 m/min). The microstructure evolution was studied using optical microscopy and advanced characterization techniques. The bead geometry changed from parallel sha...

Aluminum-rich intermetallic particles are potential reinforcements for aluminum matrix composites (AMCs) due to several desirable properties including low density and coefficient of thermal expansion, high modulus and melting temperature, and good potential for recycling. This chapter focuses on the liquid metallurgy processing of AMCs reinforced w...

Friction welding is a near ideal process to join thin metallic tubes. Grade 2 titanium tubes of outer diameter 60 mm and wall thickness 3.9 mm were joined by friction welding. The effect of rotational speed on microstructure was evaluated for five different speeds. The process parameters were recorded during welding. The microstructure was observed...

The poor wear performance of copper is improved by reinforcing hard ceramic particles. The present work reports the fabrication of Cu/TiB2 (0, 6, 12, 18 vol.%) copper matrix composites (CMCs) using friction stir processing (FSP). TiB2 particles were initially packed together into a machined groove and were subjected to FSP under a constant set of p...

In the present work, dissimilar friction stir welding of aluminium alloy 5754 and C11000 copper plates were carried out and the residual stresses were characterised. Hole drilling technique was employed to measure the residual stress at various directions. The dissimilar joints were produced by varying the major process parameters such as tool rota...

Aluminum nitride (AlN) is a potential ceramic particle to improve the wear resistance of copper surface. The present work is focused on synthesizing Cu/AlN (0,6,12,18 vol%) copper matrix composites (CMCs) on pure copper substrates through friction stir processing (FSP). AlN particles were compacted into grooves machined on the surface of the copper...

Rice husk ash (RHA) is an economical reinforcement to improve the poor wear behavior of pure copper. This work concentrates on the preparation of Cu/RHA (0,6,12,18 vol.%) copper matrix composites (CMCs) by friction stir processing (FSP). Grooves were machined on the copper plates to deposit RHA particles and were friction stir processed at a chosen...

This work concentrates on the preparation of AA6061/(0, 2, 4, 6, 8 wt.%) rice husk ash (RHA) aluminum matrix composites (AMCs) using compocasting and investigation of the dry sliding wear behavior by means of pin-on-disc apparatus at room temperature. The microstructures of the composites were studied using scanning electron microscopy and electron...

Fly ash particle reinforced aluminum matrix composite (AMCs) has been fabricated using a stir casting furnace by employing compocasting technique. The presence of fly ash particles in the compocast fabricated AMCs has been tested by X-ray diffraction and scanning electron microscopy (SEM). The wear behaviour of compocast fabricated AMCs and matrix...

Brass is difficult to join using conventional fusion welding processes due to the loss of zinc during fusion. The relatively new friction stir welding (FSW) is a promising process to join brass without loss of zinc. The aim of the present work is to join 6-mm-thick Cu–38.55Zn brass using FSW and investigate the microstructure using color metallogra...

In this study a welding window was constructed for the relatively new welding process of friction-stir welding (FSW) to join the 6-mm-thick dissimilar aluminium alloys AA5083-H111 and AA6351-T6. The dissimilar joints were fabricated using different combinations of tool rotational speeds and welding speeds. The effect of the process parameters on th...

Aluminum matrix composites (AMCs) reinforced with various ceramic particles suffer a loss in ductility. Hard metallic particles can be used as reinforcement to improve ductility. The present investigation focuses on using molybdenum (Mo) as potential reinforcement for Mo(0,6,12 and 18 vol.%)/6082Al AMCs produced using friction stir processing (FSP)...

Aluminum matrix composites (AMCs) reinforced with various ceramic particles usually exhibit poor ductility. One solution to increase ductility is the usage of hard metallic or alloy particles as reinforcements. An attempt was made to reinforce stainless steel (SS) particles to prepare AA6082/ (0,6,12 and 18 vol. %) SS AMCs via friction stir process...

Friction welding is a useful technique to join tubes, including titanium tubes, without the presence of certain common defects encountered with conventional fusion welding. Grade 2 titanium tubes with an outer diameter of 60 mm and wall thickness of 3.9 mm were effectively joined by friction welding. An empirical relationship was developed to inves...

Copper is very difficult to be spot welded with conventional fusion-welding techniques due to a high thermal diffusivity. Friction-stir spot welding (FSSW) is a novel solid-state welding process, suitable and effective for spot welding copper. Commercially pure copper sheets of 3 mm thickness were spot welded using an industrial friction-stir weldi...

In situ synthesis of aluminum matrix composites (AMCs) has become a popular method due to several advantages over conventional stir casting method. In the present study, AA7075/ZrB2 AMCs reinforced with various content of ZrB2 particulates (0, 3, 6, 9 and 12 wt.%) were synthesized by the in situ reaction of molten aluminum with inorganic salts K2Zr...

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld paramete...

Friction stir processing (FSP) has been accepted as a potential method to produce aluminum matrix composites (AMCs) without the drawbacks of liquid metallurgy methods. The present work focuses on the development of AMCs reinforced with quartz (SiO2) particles using FSP. Grooves with various dimensions were machined on AA6063 plates and compacted wi...

Stir casting is an economical method to produce aluminum matrix composites. In the present work, composites of aluminum alloy AA6061 reinforced with various amounts (0, 5, 10 and 15 wt.%) of TiC particles were prepared by stir casting technique. X-ray diffraction patterns of the prepared composites clearly revealed the incorporation of TiC particle...

Aluminum alloys AA6061 reinforced with various amounts (0, 2.5% and 5%, mass fraction) of TiC particles were synthesized by the in situ reaction of inorganic salt K2TiF6 and ceramic particle SiC with molten aluminum. The casting was carried out at an elevated temperature and held for a longer duration to decompose SiC to release carbon atoms. X-ray...

In the present study AA6061 aluminium alloy composites containing 0, 4, 8 and 12 wt.% of fly ash particles have been fabricated by the compocasting process. The dry sliding wear behaviour of unreinforced alloy and composites are studied using pin-on-disc machine. The dry sliding wear test was conducted under a load of 4.9, 9.8, 14.7, 19.6, and 24.5...

Friction stir processing (FSP) was successfully applied to synthesize AA6082/(TiB2 + BN) hybrid aluminum matrix composites (AMCs) and compared with AA6082, AA6082/TiB2 AMC and AA6082/BN AMC. TiB2 and BN particles were compacted into a groove and FSP was carried out at optimized parameters. The microstructure was investigated by optical, scanning el...

Stir casting was used to produce AA6061/15%TiC (mass fraction) aluminum matrix composites (AMCs). An empirical relationship was developed to predict the effect of stir casting parameters on the ultimate tensile strength (UTS) of AA6061/TiC AMCs. A central composite rotatable design consisting of four factors and five levels was used to minimize the...

Friction stir processing (FSP) was applied to produce aluminum matrix composites (AMCs). Aluminum alloy AA6082 was used as the matrix material. Various ceramic particles, such as SiC, Al2O3, TiC, B4C and WC, were used as reinforcement particle. AA6082 AMCs were produced using a set of optimized process parameters. The microstructure was studied usi...