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The purpose of this study is to investigate the tribological performance of the developed self-healing Al6061 composite and to optimize the operating conditions for enhanced tribo-performance of the developed material.

A unique procedure has been adopted to convert the sand casted Al6061 into self-healing material by piercing a low melting point solder material with and without MoS₂. Taguchi-based L9 orthogonal array has been used to optimize the number of experiments and analyze the influence of operating parameters such as speed, sliding distance and load on material wear.

The results reveal that the paper shows the self-healing and self-repair is possible in metal through piercing low melting point alloy. Then, the load has a significant influence over other input parameters in predicting the wear behavior of developed material. Moreover, addition of MoS₂ does not affect the tribo-performance of the developed material. The study concludes that the developed self-healing Al6061 has huge potential to be used in mechanical industry.

The concept of self-healing in metals are very challenging task due to very slow diffusion rate of atoms at room temperature. Therefore, researchers are encouraged to explore the other new techniques to create self-healing in metals.

The self-healing materials had shown huge potential to be used in mechanical industry. The current investigation established a structural fabrication and testing procedure to understand the effects of various parameters on wear. The conclusion from the experimentation and optimization helps researchers to developed and create self-healing in metals.

The previous research works were not focused on the study of tribological property of self-healing metal composite. With the best of author’s knowledge, no one has reported tribological study, as well as optimization of parameters such as speed, load and sliding distance on wear in self-healing metals composite.

The purpose of this paper is to present the determination of critical stress intensity factor (K_C) both by experimental method and three-dimensional (3D) finite element simulations.

CT specimens of different compositions of Al6061-TiC composites (3wt%, 5wt% and 7wt% TiC) with variable crack length to width (a/W=0.3-0.6) ratios are machined from as-cast composite block. After fatigue pre-cracking the specimens to a required crack length, experimental load vs crack mouth opening displacement data are plotted to calculate the K_C value. Elastic 3D finite element simulations have been conducted for CT specimens of various compositions and a/W ratios to compute K_C. The experimental results indicate that the magnitude of K_C depends on a/W ratios, and significantly decreases with increase in a/W ratios of the specimen.

From 3D finite element simulation, the K_C results at the centre of CT specimens for various Al6061-TiC composites and a/W ratios show satisfactory agreement with experimental results compared to the surface.

The research work contained in this manuscript was conducted during 2015-2016. It is original work except where due reference is made. The authors confirm that the research in their work is original, and that all the data given in the article are real and authentic. If necessary, the paper can be recalled, and errors corrected.

Fiber-reinforced polymers (FRP) contain critical electrical conductivity for high-intensity radiated fields such as lightning strike susceptibility, electromagnetic energy from radar, airborne radio frequency transmitter. To provide high-intensity radiated field protection (HIRFP) for the electric and electronic aircraft system and defied the EMI effect on it, metal matrix composite was conquered. To provide the dynamic ever-increasing requirement of industries, it is necessary that Al6061 metal matrix composite assisted with AL₂O₃ and fly ash is used to construct the aircraft to provide HIRFP. The thickness of the material can be maintained as low as possible to use it as a coating material for the aircraft surface. X-band for oblique incidence is used to measure electromagnetic and mechanical safeguarding properties of composites.

Day by day, the applications of aerospace are becoming digital and automated. Proper shielding techniques are required to operate digital electronic devices without electromagnetic interference. It leads to a rapid rise in temperature, thermal ablation, delamination, and adverse effects on the electric and electronic aircraft system. Fly ash, a metal matrix material composite AL6061 with different percentages of reinforcement of Al₂O₃, was contemplated and experimented with for mechanical properties like tensile strength, density and hardness.

The obtained results compared with adjusted values and an improvement of 0.19, 0.18, 0.14 g/cm³ for density of MMC-1, MMC-2, MMC-3.31, 11 MPa for tensile strength of MMC-1, MMC-2. 24, 27, 23 BHN for hardness of MMC-1, MMC-2, MMC-3. With regard to the shielding effectiveness the results compared with adjusted values and obtained 11.36, 14.56, 19.47 dB better value than it. According to the above results, fabricated MMC’s provide superior results for a defined application like HIRFP(Surface material of aircraft).

It can be used to protect electronic devices under a high-intensity radiated field, mainly in aircraft design to protect from lightning effect.

For a better approximation of the signal toward the practical case, the oblique incidence was considered with a different combination of Al₂O₃ and fly ash, reinforced to pure AL6061 to get better shielding and mechanical properties.

To fabricate and characterise novel heat sinks manufactured by selective laser melting (SLM). The investigation explores features of SLM produced heat sinks that may be exploited to improve their heat transfer capability.

The study was conducted on heat sinks manufactured from 316L stainless steel and aluminium 6061. The heat transfer devices' thermal and pressure drop performances were determined by experimental test.

The research demonstrates the performance enhancements that can be realised by using novel heat sink designs, fabricated by SLM, over conventional pin fin arrays. aluminium 6061 is used with the process to illustrate the improvement in heat transfer provided by higher conductivity feedstock materials.

Although the manufacturing technique is still in the development stage and the heat transfer devices that have so far been manufactured should not be considered optimal, the potential for creative new designs and applications is clear. This study highlights the need to develop the SLM process parameters to allow the repeatable production of heat transfer devices from higher conductivity metals with controllable surface finishes.

This paper outlines the design issues and performance of novel heat transfer devices fabricated using SLM. A new material, aluminium 6061, is introduced to the family of materials that can be processed with SLM and example heat sinks are tested.

Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works have indicated the minimum quantity lubrication (MQL) system is used to achieve near dry machining of alloys and hard materials. This study aims to provide an experimental analysis of the grinding process during machining of aluminium alloy (Al6061-T6). MQL nanofluid was used as the lubricant for the grinding operations. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality was studied. Adaptive neuro-fuzzy inference system (ANFIS) prediction modelling was used to predict the specific normal force, specific tangential force and surface quality, the ANFIS models were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further study shows that both the specific grinding forces and surface roughness are inversely proportional to the nanofluid concentration. Also, the depth of cut and table feed rate were found to have a directly proportional relationship with both the grinding forces and surface roughness. Moreover, higher MQL air pressure was found to offer better delivery of the atomised nanofluid into the grinding region.

Grinding experiments were performed using MQL nanofluid as the lubricant. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality has been studied.

The grinding process parameters were optimised using Taguchi S/N ratio analysis, whereas the prediction of the response parameters was done using ANFIS modelling technique. The developed ANFIS models for predicting the specific normal force, specific tangential force and surface quality were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further findings show that both the specific grinding forces and surface roughness are inversely proportional to the percentage of nanoparticle concentration in the lubricant. Also, the depth of cut and table feed rate were found to exhibit a direct proportional relationship with both the grinding forces and surface roughness, while high MQL air pressure was observed to offer more efficient delivery of the atomised nanofluid into the grinding region.

The work can applied into manufacturing industries to prevent unnecessary trials and material wastages.

The purpose of this study is to develop an artificial intelligent model for predicting the outcomes of MQL grinding of the aluminium alloy material using ANFIS modelling technique.

The purpose of this paper is to investigate the influence of most predominant heat-treatment parameters on the wear behavior of Al6061 hybrid composite reinforced with 10 weight per cent SiC and 2 weight per cent graphite particles.

The aluminum hybrid composite was produced using stir casting process. Wear testing of heat-treated samples was carried out using a pin-on-disc apparatus. Experiments were conducted by applying design of experiments (DOE) technique. The experimental values were used for formulation of a mathematical model. The wear surfaces of composite specimens were analyzed using scanning electron microscope (SEM).

The volume loss of heat-treated composite initially decreased with increasing aging duration. This was followed by the attainment of a minimum and then a reversal in the trend at longer aging times. SEM micrographs of the wear surfaces of the composite show that the wear mechanisms were abrasion, delamination and adhesion.

In this paper, the hybrid composite was produced using stir casting route, and its wear properties after heat treatment were tested using pin-on-disc apparatus. It was found that heat treatment had a profound effect on the wear behaviour of the developed composite.

The main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.

The welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.

Tensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.

In the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.

Aluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.

Very limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

This paper aims that optimization parameters depending on machining processes examine to define for the milling process of AL 6061-T6 aluminum alloy used in the aviation industry.

The Taguchi method was used to study the optimal parameters. Furthermore, the effects of machining parameters on surface roughness were also evaluated by performing variance analysis. Optimum parameter levels were determined by Signal/Noise analysis.

It was determined that the parameter levels that optimize the surface roughness were “4000 rev/min for the rotational speed of the cutting tool, 0.4 mm for the cutting depth and the optimum value for the feedrate 500 mm/min.”

It is limited by the precision of the manufacturing processes, the desired geometry and the exactness of the measurement make the machine productivity valuable in the production of parts.

By improving the optimal production parameters, reducing part production costs and waste amount in aviation has been seen as an important gain.

Improving production methods and optimization parameters in production technologies will ensure the minimization of loss and waste. These developed parameters with optimizing the surface roughness will add value in this context.

It was determined that the parameter levels that optimize the surface roughness of aluminum considering manufacturing processes. Especially as process parameters, optimum feed rate has been developed for effective rotation speed and cutting depth for cutting tools.

This research outlines the development and characterization of advanced composite materials and their potential applications in the aerospace industry for interior applications. Advanced composites, such as carbon-fiber-reinforced polymers and ceramic matrix composites, offer significant advantages over traditional metallic materials in terms of weight reduction, stiffness and strength. These materials have been used in various aerospace applications, including aircraft, engines and thermal protection systems.

The development of design of experiment–based hybrid aluminum composites using the stir-casting technique has further enhanced the performance and cost-effectiveness of these materials. The design of the experiment was followed to fabricate hybrid composites with nano cerium oxide (nCeO₂) and graphene nanoplatelets (GNPs) as reinforcements in the Al-6061 matrix.

The Al6061 + 3% nCeO2 + 3% GNPs exhibited a high hardness of 119.6 VHN. The ultimate tensile strength and yield strength are 113.666 MPa and 73.08 MPa, respectively. A uniform distribution of reinforcement particulates was achieved with 3 Wt.% of each reinforcement in the matrix material, which is analyzed using scanning electron microscopy. Fractography revealed that brittle and ductile fractures caused the failure of the fractured specimens in the tensile test.

The manufactured aluminum composite can be applied in a range of exterior and interior structural parts like wings, wing boxes, motors, gears, engines, antennas, floor beams, etc. The fan case material of the GEnx engine (currently using carbon-fiber reinforcement plastic) for the Boeing 7E7 can be another replacement with manufactured hybrid aluminum composite, which predicts weight savings per engine of close to 120 kg.

The development of hybrid reinforcements, where two or more types of reinforcements are used in combination, is also a novel approach to improving the properties of these composites. Advanced composite materials are known for their high strength-to-weight ratio. If the newly developed composite material demonstrates superior properties, it can potentially be used to replace traditional materials in aircraft manufacturing. By reducing the weight of aircraft structures, fuel efficiency can be improved, leading to reduced operating costs and environmental impact. This allows for a more customized solution for specific application requirements and can lead to further advancements in materials science and technology.

The purpose of this paper is to produce Al6061 metal matrix composites reinforced with silicon carbide (SiC) and graphite particulates and study their wear behavior and also to develop artificial neural network model to predict the mass loss of hybrid composites.

The hybrid composites were produced by using stir casting process. The experiments were conducted based on the central composite rotatable design matrix using pin‐on‐disc wear testing machine. The set of data collected from the experimental values were used to train a back propagation (BP) learning algorithm with one hidden layer network. In artificial neural network (ANN) training module, four input vectors were used in the construction of proposed network namely, weight percentage of SiC particles, weight percentage of graphite particles, applied load and sliding distance. Mass loss was the output to be obtained from the proposed network. After training process, the test data collected from the experimental values were used to check the accuracy of proposed ANN model.

The results show that the well trained one hidden layer network have smaller training errors and much better generalization performance and can be successfully used for the prediction of mass loss of hybrid aluminium metal matrix composites.

In this paper the ANN method was adopted to predict the mass loss of hybrid composites. It was found that artificial neural network can be successfully used for prediction of mass loss of composites.