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Devendra Pratap Singh, Vijay Kumar Dwivedi and Mayank Agarwal
The purpose of this study is to investigate and evaluate the impact of varying proportions of reinforcement on the mechanical properties of a modified Al2O3-LM6 cast composite…
Abstract
Purpose
The purpose of this study is to investigate and evaluate the impact of varying proportions of reinforcement on the mechanical properties of a modified Al2O3-LM6 cast composite under self-pouring temperature conditions. This study aims to determine the optimal mixture proportion of fine powders of Al, Si and xAl2O3 (with x values of 2%, 3% and 4%) through the application of design of experiment (DoE) and statistical analysis using the Minitab software. This study also involved evaluating the microstructural estimation and other physical properties of the cast composite to understand the combined effect of the reinforcement proportion on the material’s properties.
Design/methodology/approach
The researchers initially mixed the powders through ball milling and then compacted the moisture-free powder mix in a closed steel die. The resulting preforms were heated at the self-pouring temperature in an inert environment to fabricate the final cast composite. By applying DoE and performing an analysis of variance (ANOVA), the researchers sought to optimize the mixture proportion that would yield the best mechanical properties.
Findings
The experimental results indicated that a mixture combination of 83.5% Al blended with 12.5% Si and 4% Al2O3 led to the greatest improvement in mechanical properties, specifically in terms of increased density, hardness and impact strength. The ANOVA further supported the interaction effect of each processing parameter on the observed results. The results of this study offer valuable insights for the fabrication of modified Al2O3-LM6 cast composites under self-pouring temperature conditions. The identified optimal mixture proportion provides guidance for manufacturing processes and material selection to achieve improved mechanical properties in similar applications.
Originality/value
This study focuses on a specific composite material consisting of modified Al2O3 and LM6. Although Al2O3 and LM6 have been studied individually in various contexts, the combination of these materials and their impact on mechanical properties under self-pouring temperature conditions is a novel aspect of this research. The researchers use DoE methodology, along with statistical analysis using Minitab software, to optimize the mixture proportion and analyze the data. This systematic approach allows for a comprehensive exploration of the parameter space and the identification of significant factors that influence the mechanical properties of the composite.
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Rania Abdel Gwad Eloriby and Hamdy Mohamed Mohamed
This study aims to assess the efficacy of nano-alumina (nano-Al2O3) in improving the performance of epoxy adhesives used to assemble archaeological glass. The conservators face a…
Abstract
Purpose
This study aims to assess the efficacy of nano-alumina (nano-Al2O3) in improving the performance of epoxy adhesives used to assemble archaeological glass. The conservators face a significant problem in assembling this type of artifact. Therefore, the assembling process is considered one of the important stages that must be taken care of to preserve these artifacts from damage and loss.
Design/methodology/approach
To evaluate the stability of adhesives, the samples were subjected to artificial aging under varying environmental conditions. Some investigative techniques and mechanical testing were used in this study to evaluate the selected materials. It includes a transmission electron microscope, X-ray diffraction, visual assessment, digital microscope, scanning electron microscopy (SEM), color change and tensile strength test.
Findings
The visual evaluation and the digital microscope results showed that the epoxy/nano-Al2O3 greatly resisted artificial aging. Although slight yellowing was present, it did not significantly affect the general appearance of the samples. On the other hand, the pure epoxy sample showed cracks of different sizes on its surface due to aging, as evidenced by SEM examination. Furthermore, epoxy/nano-Al2O3 has a better tensile strength (11.27 MPa) and slight color change (ΔE = 2.06).
Originality/value
The main objective of the experimental study was to identify appropriate adhesive materials that possess key properties such as non-yellowing and improved tensile strength by conducting various tests and evaluations. Ultimately, the goal was to identify materials that could serve as effective adhesives for assembling the archaeological glass.
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Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…
Abstract
Purpose
As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.
Design/methodology/approach
Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.
Findings
In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.
Originality/value
With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.
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Jian Sun, Zhanshuai Fan, Yi Yang, Chengzhi Li, Nan Tu, Jian Chen and Hailin Lu
Aluminum alloy is considered an ideal material in aerospace, automobile and other fields because of its lightweight, high specific strength and easy processing. However, low…
Abstract
Purpose
Aluminum alloy is considered an ideal material in aerospace, automobile and other fields because of its lightweight, high specific strength and easy processing. However, low hardness and strength of the surface of aluminum alloys are the main factors that limit their applications. The purpose of this study is to obtain a composite coating with high hardness and lubricating properties by applying GO–PVA over MAO coating.
Design/methodology/approach
A pulsed bipolar power supply was used as power supply to prepare the micro-arc oxidation (MAO) coating on 6061 aluminum sample. Then a graphene oxide-polyvinyl alcohol (GO–PVA) composite coating was prepared on MAO coating for subsequent experiments. Samples were characterized by Fourier infrared spectroscopy, X-ray diffraction, Raman spectroscopy and thermogravimetric analysis. The friction test is carried out by the relative movement of the copper ball and the aluminum disk on the friction tester.
Findings
Results showed that the friction coefficient of MAO samples was reduced by 80% after treated with GO–PVA composite film.
Originality/value
This research has made a certain contribution to the surface hardness and tribological issues involved in the lightweight design of aluminum alloys.
Peer review
The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0427/
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Ch Kapil Ror, Vishal Mishra, Sushant Negi and Vinyas M.
This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced…
Abstract
Purpose
This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced bio-composites. The mechanical properties and fracture morphology behavior are evaluated to establish the relationships between layer spacing–microstructural characteristics–mechanical properties of CBF/RPET composite.
Design/methodology/approach
This study uses RPET filament developed from post-consumer PET bottles and CBF extracted from agricultural waste banana sap. RPET serves as the matrix material, while CBF acts as the reinforcement. The test specimens were fabricated using a customized fused deposition modeling 3D printer. In this process, customized 3D printer heads were used, which have a unique capability to extrude and deposit print fibers consisting of a CBF core coated with an RPET matrix. The tensile and flexural samples were 3D printed at varying layer spacing.
Findings
The Young’s modulus (E), yield strength (sy) and ultimate tensile strength of the CBF/RPET sample fabricated with 0.7 mm layer spacing are 1.9 times, 1.25 times and 1.8 times greater than neat RPET, respectively. Similarly, the flexural test results showed that the flexural strength of the CBF/RPET sample fabricated at 0.6 mm layer spacing was 47.52 ± 2.00 MPa, which was far greater than the flexural strength of the neat RPET sample (25.12 ± 1.94 MPa).
Social implications
This study holds significant social implications highlighting the growing environmental sustainability and plastic waste recycling concerns. The use of recycled PET material to develop 3D-printed sustainable structures may reduce resource consumption and encourages responsible production practices.
Originality/value
The key innovation lies in the concept of in-nozzle impregnation approach, where RPET is reinforced with CBF to develop a sustainable composite structure. CBF reinforcement has made RPET a superior, sustainable, environmentally friendly material that can reduce the reliance on virgin plastic material for 3D printing.
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Fatih Selimefendigil and Hakan F. Oztop
Multiple encapsulated phase change materials (PCMs) are used in a wide range of applications, including convective drying, electronic cooling, waste heat recovery and air…
Abstract
Purpose
Multiple encapsulated phase change materials (PCMs) are used in a wide range of applications, including convective drying, electronic cooling, waste heat recovery and air conditioning. Therefore, it is important to understand the performance of multiple PCMs in channels with flow separation and develop methods to increase their effectiveness. The aim of the study is to analyze the phase transition dynamics of multiple encapsulated PCMs mounted in a U-shaped tube under inclined magnetic field by using ternary nanofluid.
Design/methodology/approach
The PCMs used in the upper horizontal channel, vertical channel and lower horizontal channel are denoted by M1, M2 and M3. Magnetic field is uniform and inclined while finite element method is used as the solution technique. Triple encapsulated-PCM system study is carried out taking into account different values of Reynolds number (Re, ranges from 300 to 1,000), Hartmann number (Ha ranges from 0 and 60), magnetic field inclination (between 0 and 90) and solid volume fraction of ternary nanofluid (between 0 and 0.03). The dynamic response of the liquid fraction is estimated for each PCM with varying Re, Ha and t using an artificial neural network.
Findings
It is observed that for PCMs M2 and M3, the influence of Re on the phase transition is more effective. For M2 and M3, entire transition time (t-F) lowers by approximately 47% and 47.5% when Re is increased to its maximum value, whereas it only falls by 10% for M1. The dynamic characteristics of the phase transition are impacted by imposing MGF and varying its strength and inclination. When Ha is raised from Ha = 0 to Ha = 50, the t-F for PCM-M2 (PCM-M3) falls (increases) by around 30% (29%). For PCMs M1, M2 and M3, the phase transition process accelerates by around 20%, 30% and 28% when the solid volume fraction is increased to its maximum value.
Originality/value
Outcomes of this research is useful for understanding the phase change behavior of multiple PCMs in separated flow and using various methods such as nano-enhanced magnetic field to improve their effectiveness. Research outputs are beneficial for initial design and optimization of using multiple PCMs in diverse energy system technologies, including solar power, waste heat recovery, air conditioning, thermal management and drying.
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Anand Mohan Pandey, Sajan Kapil and Manas Das
Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the…
Abstract
Purpose
Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the substrate form metallurgical bonding, so separating them from the substrate is an unsolved issue. Therefore, this paper aims to propose a method for separating the deposited micro parts from a sacrificial substrate. Furthermore, single and multi-bead optimization is performed to fabricate microparts with varying density.
Design/methodology/approach
A typical SJED process consists of a nozzle (to establish a column of electrolytes) retrofitted on a machine tool (to provide relative motion between substrate and nozzle) that deposits material atom-by-atom on a conductive substrate.
Findings
A comprehensive study of process parameters affecting the layer height, layer width and morphology of the deposited micro-parts has been provided. The uniformity in the deposited parts can be achieved with the help of low applied voltage and high scanning speed. Multi-bead analysis for the flat surface condition is experimentally performed, and the flat surface condition is achieved when the centre distance between two adjacent beads is kept at half of the width of a single bead.
Originality/value
Although several literatures have demonstrated that the SJED process can be used for the fabrication of parts; however, part fabrication through multi-bead optimization is limited. Moreover, the removal of the fabricated part from the substrate is the novelty of the current work.
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Kai Deng, Liang Zhang, Chen Chen, Xiao Lu, Lei Sun and Xing-Yu Guo
This study aims to explore the feasibility of adding Si3N4 nanoparticles to Sn58Bi and provides a theoretical basis for designing and applying new lead-free solder materials for…
Abstract
Purpose
This study aims to explore the feasibility of adding Si3N4 nanoparticles to Sn58Bi and provides a theoretical basis for designing and applying new lead-free solder materials for the electronic packaging industry.
Design/methodology/approach
In this paper, Sn58Bi-xSi3N4 (x = 0, 0.2, 0.4, 0.6, 0.8, 1.0 Wt.%) was prepared for bonding Cu substrate, and the changes in thermal properties, wettability, microstructure, interfacial intermetallic compound and mechanical properties of the composite solder were systematically studied.
Findings
The experiment results demonstrate that including Si3N4 nanoparticles does not significantly impact the melting point of Sn58Bi solder, and the undercooling degree of solder only fluctuates slightly. The molten solder spreading area reached a maximum of 96.17 mm2, raised by 19.41% relative to those without Si3N4, and the wetting angle was the smallest at 0.6 Wt.% of Si3N4, with a minimum value of 8.35°. When the Si3N4 nanoparticles reach 0.6 Wt.%, the solder joint microstructure is significantly refined. Appropriately adding Si3N4 nanoparticles will slightly increase the solder alloy hardness. When the concentration of Si3N4 reaches 0.6 Wt.%, the joints shear strength reached 45.30 MPa, representing a 49.85% increase compared to those without additives. A thorough examination indicates that legitimately incorporating Si3N4 nanoparticles into Sn58Bi solder can enhance its synthetical performance, and 0.6 Wt.% is the best addition amount in our test setting.
Originality/value
In this paper, Si3N4 nanoparticles were incorporated into Sn58Bi solder, and the effects of different contents of Si3N4 nanoparticles on Sn58Bi solder were investigated from various aspects.
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Masume Khodsuz, Amir Hamed Mashhadzadeh and Aydin Samani
Electrical characteristics of transformer oil (TO) have been studied during normal and thermal aging conditions. In this paper, breakdown voltage (BDV), partial discharge (PD)…
Abstract
Purpose
Electrical characteristics of transformer oil (TO) have been studied during normal and thermal aging conditions. In this paper, breakdown voltage (BDV), partial discharge (PD), heat transfer results and the physical mechanisms considering the impact of varying the diameter of Al2O3 nanoparticles (NPs) have been investigated. Different quantities of the two sizes of Al2O3 were added to the oil using a two-step method to determine the positive effect of NPs on the electrical and thermal properties of TO. Finally, the physical mechanisms related to the obtained experimental results have been performed.
Design/methodology/approach
The implementation of nanoparticles in this paper was provided by US Research Nanomaterials, Inc., USA. The provided Al2O3 NPs have an average particle size of 20–80 nm and a specific surface area of 138 and 58 m2/g, respectively, which have a purity of over 99%. Thermal aging has been done. The IEC 60156 standard has been implemented to calculate the BDV, and a 500-mL volume test cell (Apar TO 1020) has been used. PD test is performed according to Standard IEC 60343, and a JDEVS-PDMA 300 device was used for this test.
Findings
BDV tests indicate that 20 nm Al2O3 is more effective at improving BDV than 80 nm Al2O3, with an improvement of 113% compared to 99% for the latter. The analysis of Weibull probability at BDV indicates that 20 nm Al2O3 performs better, with improvements of 141%, 125% and 112% at probabilities of 1, 10 and 50%, respectively. The results of the PD tests using the PDPR pattern also show that 20 nm Al2O3 is superior. For the heat transfer test, 0.05 g/L of both diameters were used to ensure fair conditions, and again, the advantage was with 20 nm Al2O3 (23% vs 18%).
Originality/value
The effect of Al2O3 NP diameter (20 and 80 nm) on various properties of virgin and aged TO has been investigated experimentally in this paper to examine the effect of proposed NP on electrical improvement of TO.
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