Micro Machining of Nonconductive Al2O3 Ceramic on Developed TW-ECSM Setup

2012 ◽  
pp. 167-177
Author(s):  
Alakesh Manna ◽  
Amandeep Kundal
Keyword(s):  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Actual Condition ◽  
Test Results ◽  
Machining Performance ◽  
Machining Processes ◽  
Al2o3 Ceramic ◽  
Advanced Ceramic

Advanced ceramic materials are gradually becoming very important for their superior properties such as high hardness, wear resistance, chemical resistance, and high strength to weight ratio. But machining of advanced ceramic like Al2O3-ceramics is very difficult by any well known and common machining processes. Normally, cleavages and triangular fractures generate when machining of these materials is done by traditional machining methods. It is essential to develop an efficient and accurate machining method for processing advanced ceramic materials. For effective machining of Al2O3-ceramics, a traveling wire electrochemical spark machining (TW-ECSM) setup has been developed. The developed TW-ECSM setup has been utilized to machine Al2O3 ceramic materials and subsequently test results are utilized to analyze the machining performance characteristic. Different SEM photographs show the actual condition of the micro machined surfaces. The practical research analysis and test results on the machining of Al2O3 ceramics by developed TWECSM setup will provide a new guideline to the researchers and manufacturing engineers.

Micro Machining of Nonconductive Al2O3 Ceramic on Developed TW-ECSM Setup

2011 ◽  
Vol 1 (2) ◽  
pp. 46-55
Author(s):  
Alakesh Manna ◽  
Amandeep Kundal
Keyword(s):  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Actual Condition ◽  
Test Results ◽  
Machining Performance ◽  
Machining Processes ◽  
Al2o3 Ceramic ◽  
Advanced Ceramic

Advanced ceramic materials are gradually becoming very important for their superior properties such as high hardness, wear resistance, chemical resistance, and high strength to weight ratio. But machining of advanced ceramic like Al2O3-ceramics is very difficult by any well known and common machining processes. Normally, cleavages and triangular fractures generate when machining of these materials is done by traditional machining methods. It is essential to develop an efficient and accurate machining method for processing advanced ceramic materials. For effective machining of Al2O3-ceramics, a traveling wire electrochemical spark machining (TW-ECSM) setup has been developed. The developed TW-ECSM setup has been utilized to machine Al2O3 ceramic materials and subsequently test results are utilized to analyze the machining performance characteristic. Different SEM photographs show the actual condition of the micro machined surfaces. The practical research analysis and test results on the machining of Al2O3 ceramics by developed TWECSM setup will provide a new guideline to the researchers and manufacturing engineers.

scholarly journals Effect of weld metal composition on impact toughness properties of shielded metal arc welded ultra-high hard armor steel joints

2020 ◽  
Vol 29 (1) ◽  
pp. 186-194
Author(s):  
V. Balaguru ◽  
Visvalingam Balasubramanian ◽  
P. Sivakumar
Keyword(s):  
Impact Toughness ◽  
Weld Metal ◽  
Welded Joints ◽  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Solidification Mode ◽  
Austenitic Phase ◽  
Ferrite Number ◽  
Steel Joints

AbstractNowadays, ultra-high hard armor (UHA) steels are employed in armor tracked vehicle (ATV) construction because of their high hardness, high strength to weight ratio, and excellent toughness. UHA steels are usually welded using austenitic stainless steel (ASS) welding consumables, to avoid hydrogen-induced cracking (HIC). The use of ASS consumables to weld the above steel was the only available remedy because of higher solubility of hydrogen in the austenitic phase. In this investigation, an attempt was made to investigate the effect of ASS consumables (with different Creq/Nieq ratio) on solidification mode, impact toughness and microstructural characteristics of shielded metal arc (SMA) welded UHA steel joints. The welded joints were characterised based on impact toughness properties, hardness, and microstructural features. As the ferrite number increases with an increase in Creq/Nieq ratio result in different solidification mode (A, FA, F). It is also found that ferrite number of weld metal has appreciable influence on impact toughness and has inversely proportional relationship with impact toughness of the welded joints.

Effect of Electrolytes Variation on the Formation of Oxide Layers of Al7075 Alloys by Electrolytic Plasma Processing

2013 ◽  
Vol 378 ◽  
pp. 209-212
Author(s):  
Dong Gun Lee ◽  
Byunh Hyun Ahn ◽  
Je Hyun Lee ◽  
Uk Rae Cho ◽  
Bon Heun Koo
Keyword(s):  
Treatment Process ◽  
Protective Coatings ◽  
Plasma Processing ◽  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Heavy Duty ◽  
Conventional Steel ◽  
Steel Material ◽  
Electrolytic Plasma Processing

Al7075 alloy has typically good mechanical properties. Al7075 alloy has an ultimate tensile strength and yield strength, which is commonly used in the manufacturing of heavy-duty structures requiring good corrosion resistance and in applications requiring high strength to weight ratio, as well as good fatigue resistance. However, as compared to strength and corrosion of conventional steel material, it has some drawbacks. To overcome these disadvantages, Electrolytic plasma processing (EPP) was used. (EPP) is a novel electrochemical and physical surface treatment process for generating protective coatings on light metals. Because, these coating scan present high hardness and continuous barriers, it can offers good protection against abrasion, corrosion and heat as well as electrical insulation. The EPP treatments were carried out under a hybrid voltage of AC 200V (50Hz) combined with DC 260V power supply.

Research on the Advanced Ceramic Die Materials and Their Properties

2008 ◽  
Vol 375-376 ◽  
pp. 133-137 ◽  
Author(s):  
Chong Hai Xu ◽  
Guang Chun Xiao ◽  
Rong Bo Zhang ◽  
Yu Mei Feng
Keyword(s):  
Mechanical Property ◽  
High Hardness ◽  
Ceramic Materials ◽  
High Wear Resistance ◽  
Ceramic Surface ◽  
Temperature Property ◽  
Nano Composite ◽  
Advanced Ceramic ◽  
Die Materials ◽  
High Temperature Property

The composition, processing technology, mechanical property and engineering performance of ceramic materials such as cermet, ZTA, TZP, TZP/Al2O3, PSZ, Si3N4 and Sialon, etc, have been predominantly summarized when they are used as die materials in various operations such as drawing, extrusion, punching and stamping etc. The problems existed in the research and application of ceramic die materials are discussed, and the perspectives in the application of ceramic die materials are pointed out. It is concluded that advanced ceramic material is one of the most promising die materials because of its high hardness, high wear resistance, superior high-temperature property and chemical stability and good engineering performance, compared with other die materials such as die steel and cemented carbides. It is proposed that nano composite and functionally gradient ceramic, surface modification technology with ceramic, optimal design of die structures and die reliability research, etc. are all the potential and effective methods in the improvement of mechanical property and engineering performance of ceramic die materials.

BEHAVIOR OF HIGH STRENGTH FIBER REINFORCED CONCRETE SQUARE COLUMNS WITH HYBRID BARS

2020 ◽  
Vol 7 (1) ◽  
Author(s):  
Saad Al-Taan ◽  
Abduljalil Aldoski
Keyword(s):  
Reinforced Concrete ◽  
Weight Ratio ◽  
High Strength ◽  
Concrete Cover ◽  
Fiber Reinforced Concrete ◽  
Steel Fibers ◽  
Test Results ◽  
Fiber Reinforced ◽  
High Strength Fiber ◽  
And Behavior

The paper presents test results on 20 high-strength fiber reinforced concrete square columns subjected to concentric and eccentric loading. The study aim was to examine the effect of the weight of steel fibers on the strength and behavior of HSC columns under concentric and eccentric loading. All columns were longitudinally reinforced with 4 GFRP bars 6 mm diameter, and two steel bars 10 mm diameter, making the reinforcement ratio (ρg = 0.0181), and steel ties at 64 mm spacing. The studied test variables included the steel fiber weight ratio and the eccentricity. To prevent premature spalling in the concrete cover, it was discovered that it helps to add steel fibers to HSC mixtures in concrete columns. In addition, this also increases the strength of eccentrically loaded reinforced columns compared to that for concentrically loaded columns. The strength and behavior were predicted also by the proposed method. The predicted and the experimental results found to be in a good agreement.

scholarly journals An innovative tubular standing support incorporating PVC and FRP composites: laboratory tests

2021 ◽  
Author(s):  
Baisheng Zhang ◽  
Hongchao Zhao
Keyword(s):  
Weight Ratio ◽  
High Strength ◽  
Test Results ◽  
Compression Tests ◽  
Frp Composites ◽  
Frp Composite ◽  
Reinforced Polymer ◽  
Deformation Ability ◽  
Fibre Reinforced Polymer ◽  
Infill Material

Abstract With the depletion of shallow resources, the drawbacks of conventional bolting system in sustaining the integrity of the roadway have drawn much attention. Developing the innovative secondary standing support is therefore to be urgent. This paper presents a hybrid tubular standing support, which consists of an exterior container made of PVC and fibre-reinforced polymer (FRP) composites and the infill material made of coal rejects and high flowable cementitious grout material. Compared with other marketable standing support, the combination application of the large rupture strain PVC tube and the FRP composite with high strength-to-weight ratio can provide the effective confinement to infill material, which may result in the strain hardening behaviour. The use of coal reject to generate the backfill material is believed to be effective and thus is attractive from the design aspect. To verify these mentioned advantages, a series of compression tests were conducted on this FRP-PVC tubular standing support (FPTSS) with different thickness of the FRP jacket. In addition, the compression tests were also conducted to investigate the compressive behaviour of FRP tubular standing support (FTSS) and PVC tubular standing support (PTSS). Test results indicated that the combination of FRP and PVC composite achieve the superior behaviour either in terms of the compressive strength or the deformation ability.

scholarly journals Manufacturing and Mechanical Behavior of (Al/SiC) Functionally Graded Material using Powder Metallurgy Technique

2019 ◽  
Vol 8 (9) ◽  
pp. 1835-1839 ◽  
Keyword(s):  
Powder Metallurgy ◽  
Functionally Graded Materials ◽  
Pure Aluminum ◽  
Weight Ratio ◽  
Mesh Size ◽  
High Hardness ◽  
High Strength ◽  
Functionally Graded ◽  
Graded Materials ◽  
Wide Range

This research focuses on manufacturing and mechanical characterization of functionally graded materials using powder metallurgy techniques. Owing to its low density and high strength to weight ratio, pure aluminum with mesh size No. 200 is chosen as the matrix. Silicon carbide with mesh size No. 220, which has a wide range of applications due to its high hardness, is selected as reinforcement. Specimens of two functionally graded materials(FGM) with 4 layers (0%, 3%, 7%, 10%)(FGM-1) and 5 layers (10%, 20%, 30%, 40%, 50%) (FGM-2) are sintered by varying the SiC composition from layer to layer. From the microstructure, it is clearly evident that four layered specimens achieved more homogeneous mixture than five layered. Also, mechanical properties of four layered specimens attained better results than five layered specimens.

Nanocrystalline Diamond Coated Tool Performance in Machining of LM6 Aluminium Alloy/Alumina MMC

2015 ◽  
Author(s):  
Ramasubramanian Kannan ◽  
Arunachalam Narayanaperumal ◽  
Mamidanna Sri Ramachandra Rao
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Weight Ratio ◽  
High Hardness ◽  
High Strength ◽  
Matrix Composites ◽  
Aerospace Applications ◽  
Coated Tools ◽  
Nano Crystalline ◽  
Improved Performance

Aluminium based metal matrix composites (MMC) gain its importance in automotive and aerospace applications due to their high strength to low weight ratio, which leads to reduced fuel consumption and improved performance. However the usage of MMC is limited due to its poor machinability. The presence of hard reinforcing particles in MMC makes these materials difficult to machine. A cutting tool with high hardness and low coefficient of friction is required for machining this MMC material effectively. In this paper a comparative study on machinability of different coated tools on LM6 aluminum alloy/alumina MMC are conducted and presented. Experimental results on tool wear, cutting force and surface finish indicate that nano-crystalline diamond coated tools (NCD) outperform the other commercially available coated tools for machining this metal matrix composites.

Silicon Nitride Ceramics

2008 ◽  
Vol 606 ◽  
pp. 27-41 ◽  
Author(s):  
Stuart Hampshire
Keyword(s):  
Silicon Nitride ◽  
Glass Phase ◽  
Structural Engineering ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Liquid Phase Sintering ◽  
High Fracture ◽  
Boundary Chemistry ◽  
Good Creep Resistance

Silicon nitride is one of the major structural ceramics that has been developed following many years of intensive research. It possesses high flexural strength, high fracture resistance, good creep resistance, high hardness and excellent wear resistance. These properties arise from the processing of the ceramic by liquid phase sintering and the development of microstructures in which high aspect ratio grains and intergranular glass phase lead to excellent fracture toughness and high strength. The glass phase softens at high temperature and controls the creep rate of the ceramic. The purpose of this review is to examine the development of silicon nitride and the related sialons and their processing into a range of high-grade structural ceramic materials. The development of knowledge of microstructure–property relationships in silicon nitride materials is outlined, particularly recent advances in understanding the effects of grain boundary chemistry and structure on mechanical properties. This review should be of interest to scientists and engineers concerned with the processing and use of ceramics for structural engineering applications.

scholarly journals Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2377
Author(s):  
Ankit D. Oza ◽  
Abhishek Kumar ◽  
Vishvesh Badheka ◽  
Amit Arora ◽  
Manoj Kumar ◽  
...  
Keyword(s):  
Removal Rate ◽  
Gas Bubbles ◽  
Hydrogen Gas ◽  
Test Results ◽  
Machining Performance ◽  
Machining Processes ◽  
Exploratory Investigation ◽  
Industrial Performance ◽  
Quartz Substrates ◽  
Traveling Wire

Many microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and brittleness. The key objective of the current study was to demonstrate the fabrication of microslits on quartz material through a magnetohydrodynamics (MHD)-assisted traveling wire-electrochemical discharge micromachining process. Hydrogen gas bubbles were concentrated around the entire wire surface during electrolysis. This led to a less active dynamic region of the wire electrode, which decreased the adequacy of the electrolysis process and the machining effectiveness. The test results affirmed that the MHD convection approach evacuated the gas bubbles more rapidly and improved the void fraction in the gas bubble scattering layer. Furthermore, the improvements in the material removal rate and length of the cut were 85.28% and 48.86%, respectively, and the surface roughness was reduced by 30.39% using the MHD approach. A crossover methodology with a Taguchi design and ANOVA was utilized to study the machining performance. This exploratory investigation gives an unused strategy that shows a few advantages over the traditional TW-ECDM process.

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