Metal Additive Manufacturing Using Friction Stir Engineering
Authors - Sandeep Rathee, Manu Srivastava, Pulak Mohan Pandey, Abhishek Mahawar, Siddhant Shukla
Publisher - Elsevier
Description - Solid state metal additive manufacturing (SS-MAM) techniques based on friction stir engineering (FSE) have gained significant attention since the last decade and act as a bridge for many existing MAM shortfalls. In this article, SS-MAM techniques based upon FSE especially additive friction stir (AFS) and friction stir additive manufacturing (FSAM) are discussed. There is meagre research with respect to tooling associated with these processes since they involve expertise in two fields i.e., AM and FSE. The current article bridges this gap with a detailed discussion on all relevant fundamentals of AFS and FSAM. The recent developments with respect to tooling design and parameters are discussed in-depth. Also, this article discusses metallurgy, microstructural aspects and mechanical properties of deposited layers via these techniques. A detailed timeline summarizing the development with respect to these techniques.
Fabrication of AI 5059/SIC Composite
Authors - Manu Srivastava, Sandeep Rathee
Publisher - Elsevier
Description - Friction stir additive manufacturing (FSAM) is a novel friction based additive manufacturing technology that can be effectively utilized to fabricate fully dense components in solid state with improved structural performance. In this work, Al5059/SiC composite component of approximately 20 mm height was developed using FSAM technique. Microstructural and microhardness characterization of fabricated component was done to evaluate the microstructural changes and, bonding between subsequent layers of fabricated build. Results reflected that fabricated build exhibits smaller grain size and higher micro-hardness as compared to base metal. A maximum enhancement of ∼62% in micro-hardness of the build was achieved as compared to base metal.
Incorporation of SiC particles during friction stir welding of Al 5059 alloy
Authors - Manu Srivastava, Sandeep Rathee
Publisher - Springer Netherlands
Description - Friction stir welding (FSW) was performed in the current research on Al 5059 alloy. Nano-sized SiC (n-SiC) particles were incorporated during FSW for improving mechanical characteristics of welds. Effect of tool rotating speed and multiple FSW passes was studied on SiC dispersion, micro structural changes and mechanical characteristics of composite joints. Results reflected that rotational speed and multiple FSW passes have significant impact over the distribution of SiC reinforcement. Further, the pattern of SiC distribution in the base metal strongly affects the micro structural evolution and mechanical characteristics of welds. An increase of ~55% in microhardness values was achieved in the stir zone of composite joint. Correspondingly, higher ultimate tensile strength (342 MPa) value was obtained as compared to base metal (321 MPa). The increase in mechanical characteristics is mainly owing to grain
Influence of activated flux on micro-structural
Authors - Anand Baghel, Chaitanaya Sharma, Sandeep Rathee, Manu Srivastava
Publisher - Elsevier
Description - The strength of weld joint largely depends on depth of penetration of metal at fusion zone. The present study aims to investigate effect of five activated fluxes, viz. Al2 (SO4)3, NaOH, Na2CO3, NaHCO3, and borax in MIG welding on depth of penetration and mechanical properties of AISI 1018. Results reflected that use of flux had paramount influence on the microstructure and hardness of the bead on plate welds. It helps in increasing depth of penetration via reverse Marangoni effect. Out of all five fluxes, Borax flux had provided higher depth of penetration, external and internal aspect ratio and hardness than other fluxes used as well as than without flux.
Parametric Optimization of Friction Stir Welding
Authors - Nasir Khan, Sandeep Rathee, Manu Srivastava
Journal - Yugoslav Journal of Operations Research
Description - Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction, and so on. In this work, newly developed friction stip
Activated flux TIG welding
Authors - Anand Baghel, Chaitanaya Sharma, Sandeep Rathee, Manu Srivastava
Publisher - Elsevier
Description - Low depth of penetration limits the use of favored tungsten inert gas (TIG) welding process for joining of ferrous and non-ferrous metals, demanding weld bead profile of high quality. This article aims to study the effect of chloride and oxide fluxes viz. calcium chloride (CaCl2) and ferric oxide (Fe2O3) on micro-structural and mechanical properties of TIG welded joints of dissimilar SS304 and SS202 steels. Results reflected that use of oxide and chloride fluxes significantly affects the weld bead geometry, bead dimensions and penetration. The use of oxide flux resulted in complete penetration and approximately linear root of weld with good fusion of both the base metals. Fusion zone showed columnar dendritic cast grain structure while coarse grain structure was obtained in heat-affected zone. Fusion zone hardness was higher than SS304 base metal and an opposite trend observed for SS202 irrespective of welding.
Functionally Graded Materials
Authors - Ashish Yadav, Pushkal Badoniya, Manu Srivastava, Prashant K Jain, Sandeep Rathee
Publisher - CRC Press
Description - Functionally graded materials (FGMs) or tailor-made materials offer a vast research domain and have various intriguing applications. Immense developments have been witnessed in the field of FGMs over the past few decades. These include advancements in processing techniques as well as applications. Various processing techniques have been discussed in this book and their applications have also been discussed in detail in respective chapters. This chapter presents a summary of different applications, challenges, and future trends. The objective of this chapter is to help the readers in drawing meaningful conclusions on the different aspects of FGM and not to provide a detailed description in order to avoid any replication of concepts already covered in the previous chapters of this book.
Effect of tool rotational speed on weld quality
Authors - Nasir Khan, Sandeep Rathee, Manu Srivastava, Chaitanaya Sharma
Publisher - Elsevier
Description - Friction stir welding (FSW) is one of the best suitable solid state welding techniques for joining of light weight metallic materials such as aluminium, magnesium, etc. Several process parameters such as rotational speed, travel speed, tilt angle of tool, etc. affect the performance of FSW. In this research work, an attempt was made to analyze the effect of rotation speed of tool (TRS) on the weld quality of friction stir welded joints of AA6061 alloy. RST was varied in the range of 700 to 1120 rpm keeping other parameters as constant throughout the experimentation. Results reflected that RST significantly affects the weld quality, microstructural evolution and mechanical properties of welds.
Layout Optimization for FDM Process
Authors - Sandeep Rathee, Manu Srivastava
Publisher - Springer, Cham
Description - This chapter presents an overview of various aspects for quantitatively optimizing the fused deposition modelling (FDM) layout process. After initial introductory sections, a case study for utilizing hybrid optimization strategy by combining response surface methodology (RSM) with grey relational analysis (GRA) for optimizing multiple responses to acheive improved cost effectiveness for FDM process is presented. Spatial orientation (SO), air gap (AG), raster angle (RA) and contour width (CW) are taken as process variables. Also, build time (BT), model material volume (MV) and support material volume (SV) are considered as response in present work. Thirty experiments were performed for acrylo butadiene styrene (ABS) P400 on FDM machine for conical-shaped constructive solid geometry (CSG) primitives. Aim of the current case study is establishing a scientific reference for optimizing BT, MV and SV