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This paper aims to investigate two control mechanisms on the two parameters, namely, spindle speed and tool pin position, while performing friction stir welding (FSW) for aluminium metal matrix composites (Al-MMC) using the concept of system identification.

FSW is a feasible choice for joining of Al-MMC over the fusion welding due to the formation of the narrow heat-affected zone and minimizing the formation of intermetallic compounds at weld interface. The goal in FSW is to generate enough thermal energy by friction between the workpiece and rotating tool. Heat energy is generated due to mechanical interaction because of the difference in velocity between the workpiece and rotating tool. The generated heat is proportional to the tool pin position and the spindle speed. In the present work, a Smith Predictor Control scheme and adaptive control scheme are developed during joining of Al6061/SiC/B4C Al-MMC by FSW. Adaptive controller is developed to control the tool pin position while Smith Predictor control is developed to control the spindle speed. Initially, the Al-MMC plates are prepared at five combinations of SiC and B4C reinforcements and welded at three level parameter settings followed by tensile testing. The experimental data are used in estimating the plant transfer function model using system identification. The control schemes are then developed for the estimated plant model and the same are validated using a standard PID controller. In both the control schemes, PID controller results in a sluggish response. Experimental validations are performed for the developed control schemes followed by microscopic studies of the weldments.

In both the control schemes, PID controller results in a sluggish response. Experimental validations are performed for the developed control schemes followed by microscopic studies of the weldments.

Results from the study concluded that the developed MRAC and Smith predictor scheme effectively controlled the vibrations and spindle speed effectively.

It is observed that the scanning electron microscopy micrographs of the Al-MMC’s welded using developed control schemes resulted in good boding with homogenous distribution of reinforcement particles.

This paper seeks to provide an insight into the design and development of the thermal test model (TTM) of X‐Sat, a 120 kg class micro‐satellite, being developed at the Centre. This model was specifically constructed for carrying out a thermal balance test (TBT) in a 4 m diameter vertical thermal vacuum chamber.

The construction of the thermal model followed a structural mock‐up model which was modified thermally to suit the purpose. Specific and careful consideration was given to the geometry and, more importantly, thermal characteristics such as thermal mass, surface properties, etc. to mimic the actual satellite configuration as closely as possible. Test plans were devised to qualify the fabricated components to meet the out‐gassing and other thermal requirements for the model. Design and qualification of supporting frame and linkages for TBT are also covered.

It is possible to simulate the thermal characteristics of a micro‐satellite in orbit under a different mission scenario through proper scaling and using alternative material options while developing TTM.

The paper discusses in detail the simplified cost‐effective approach of constructing TTM and also outlines the various issues to be considered for a TBT. It provides valuable information needed for micro‐satellite designers.

Since, wear is the one of the most commonly encountered industrial problems leading to frequent replacement of components there is a need to develop metal matrix composites (MMCs) for achieving better wear properties. The purpose of this paper is to fabricate aluminum MMCs to improve the dry sliding wear characteristics. An effective multi-response optimization approach called the principal component analysis (PCA) was used to identify the sets of optimal parameters in dry sliding wear process.

The present work investigates the dry sliding wear behavior of graphite reinforced aluminum composites produced by the molten metal mixing method by means of a pin-on-disc type wear set up. Dry sliding wear tests were carried on graphite reinforced MMCs and its matrix alloy sliding against a steel counter face. Different contact stress, reinforcement percentage, sliding distance and sliding velocity were selected as the control variables and the response selected was wear volume loss (WVL) and coefficient of friction (COF) to evaluate the dry sliding performance. An L25 orthogonal array was employed for the experimental design. Optimization of dry sliding performance of the graphite reinforced MMCs was performed using PCA.

Based on the PCA, the optimum level parameters for overall principal component (PC) of WVL and COF have been identified. Moreover, analysis of variance was performed to know the impact of individual factors on overall PC of WVL and COF. The results indicated that the reinforcement percentage was found to be most effective factor among the other control parameters on dry sliding wear followed by sliding distance, sliding velocity and contact stress. Finally the wear surface morphology of the composites has been investigated using scanning electron microscopy.

Various manufacturing techniques are available for processing of MMCs. Each technique has its own advantages and disadvantages. In particular, some techniques are significantly expensive compared to others. Generally the manufacturer prefers the low cost technique. Therefore stir casting technique which was used in this paper for manufacturing of Aluminum MMCs is the best alternative for processing of MMCs in the present commercial sectors. Since the most important criteria of a dry sliding wear behavior is to provide lower WVL and COF, this study has intended to prove the application of PCA technique for solving multi objective optimization problem in wear applications like piston rings, piston rods, cylinder heads and brake rotors, etc.

Application of multi-response optimization technique for evaluation of tribological characteristics for Aluminum MMCs made up of graphite particulates is a first-of-its-kind approach in literature. Hence PCA method can be successfully used for multi-response optimization of dry sliding wear process.

The purpose of this study is to present a comprehensive review of the fundamental concepts and terminologies pertaining to different types of aluminium metal matrix composites, their joining techniques and challenges, friction stir welding (FSW) process, post-welding characterizations and basic control theory of FSW, followed by the discussions on the research reports in these areas.

Joining of aluminium metal matrix composites (Al-MMC) poses many challenges. These materials have their demanding applications in versatile domains, and hence it is essential to understand their weldability and material characteristics. FSW is a feasible choice for joining of Al-MMC over the fusion welding because of the formation of narrow heat affected zone and minimizing the formation of intermetallic compounds at weld interface. The goal in FSW is to generate enough thermal energy by friction between the workpiece and rotating tool. Heat energy is generated by mechanical interaction because of the difference in velocity between the workpiece and rotating tool. In the present work, a detailed survey is done on the above topics and an organised conceptual context is presented. A complete discussion on significance of FSW process parameters, control schemes, parameter optimization and weld quality monitoring are presented, along with the analysis on relation between the interdependent parameters.

Results from the study present the research gaps in the FSW studies for joining of the aluminium-based metal matrix composites, and they highlight further scope of studies pertaining to this domain.

It is observed that the survey done on FSW of Al-MMCs and their control theory give an insight into the fundamental concepts pertaining to this research area to enhance interdisciplinary technology exploration.

The main purpose of the present work is to study the multi response optimization of dissimilar friction stir welding (FSW) process parameters using Taguchi-based grey relational analysis and desirability function approach (DFA).

The welded sheets were fabricated as per Taguchi orthogonal array design. The effects of tool rotational speed, transverse speed and tool tilt angle process parameters on ultimate tensile strength and hardness were analyzed using grey relational analysis, and DFA and optimum parameters combination was determined.

The tensile strength and hardness values were evaluated from the welded joints. The optimum values of process parameters were estimated through grey relational analysis and DFA methods. Similar kind of optimum levels of process parameters were obtained through two optimization approaches as tool rotational speed of 1150 rpm, transverse speed of 24 mm/min and tool tilt angle of 2° are the best process parameters combination for maximizing both the tensile strength and hardness. Through these studies, it was confirmed that grey relational analysis and DFA methods can be used to find the multi response optimum values of FSW process parameters.

In the present study, the FSW is performed with L9 orthogonal array design with three process parameters such as tool rotational speed, transverse speed and tilt angle and three levels.

Aluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property.

Very limited work had been carried out on multi objective optimization techniques such as grey relational analysis and DFA on friction stir welded joints made with dissimilar aluminium alloys sheets.

The objective of the paper is to evaluate the fabrication process and to study the influence of process parameters of friction stir processing of 6061-TiB₂-Al₂O₃ Aluminum alloy surface composite on microhardness tensile strength, and microstructure.

Friction stir processing method is used for attaining the desired mechanical properties, and selectively processed reinforcements to fabricate the samples. The Taguchi technique was used to optimize rotational speed, travel speed and volume percentage of reinforcement particles to enhance the mechanical properties of 6061-TiB₂-Al₂O₃ Aluminum alloy composite.

The fabrication of surface composites through FSP allows new inventions in terms of material with enhanced surface layers without changing the base metal.

To examine the behavior of the surface of the composites in the different zones, the practical implication consists of the use of different characterization techniques like optical microscopy and scanning microscopy for microstructural behavior and the measurement of hardness and tensile tests for mechanical behavior.

The research work consists of tool design and process parameters, which can affect the final product (microstructural changes), and the performance of the modified surface layer behavior was studied and presented.

The deposition of particles onto a substrate during the cold spraying (CS) process relies on severe plastic deformation, so there are various micro-defects induced by insufficient deformation and severe crushing. To solve the problems, many post-treat techniques have been used to improving the quality by eliminating the micro-defects. This paper aims to help scholars and engineers in this field a better and systematic understand of CS technology by summarizing the post-treatment technologies that have been investigated recently years.

This review summarizes the types of micro-defects and introduces the effect of micro-defects on the properties of CS coating/additive manufactured, illustrates the post-treatment technologies and its effect on the microstructure and performances, and finally outlooks the future development trends of post-treatments for CS.

There are significant discoveries in post-treatment technology to change the performance of cold spray deposits. There are also many limitations for post-treatment methods, including improved performance and limitations of use. Thus, there is still a strong requirement for further improvement. Hybrid post-treatment may be a more ideal method, as it can eliminate more defects than a single method. The proposed ultrasonic impact treatment could be an alternative method, as it can densify and flatten the CS deposits.

It is the first time to reveal the influence factors on the performances of CS deposits from the perspective of microdefects, and proposed corresponding well targeted post-treatment methods, which is more instructive for improving the performances of CS deposits.

Recent trends in material science show a considerable interest in the manufacturing of metal matrix composites to meet the stringent demands of lightweight, high strength and corrosion resistance. Aluminium is the popular matrix metal currently in vogue that can be reinforced with ceramic materials such as particulates to meet the desired property. The purpose of this paper is to fabricate hybrid metal matrix composites to improve the dry sliding wear resistance and to study of the effect of sliding speed, load and reinforcement (alumina and graphite) on wear properties, as well as its contact friction.

The present study addresses the dry sliding wear behaviour of Al‐Si10Mg alloy reinforced with 3, 6 and 9 wt% of alumina along with 3 wt% of graphite. Stir casting method was used to fabricate the composites. Mechanical properties such as hardness and tensile strength have been evaluated. A pin‐on‐disc wear test apparatus was used to evaluate the wear rate and coefficient of friction by varying the loads of 20, 30 and 40 N, sliding speeds of 1.5 m/s, 2.5 m/s and 3.5 m/s at a constant sliding distance of 2100 m.

Mechanical properties of hybrid metal matrix composites (HMMCs) have shown significant improvement. The wear rate and coefficient of friction for alloy and composites decreased with increase in sliding speed and increased with increase in applied load. Temperature rise during wearing process for monolithic alloy was larger than that of HMMCs and Al/9% Al₂O₃/3% Gr composite showing the minimum temperature rise.The worn surfaces of the composites were investigated using scanning electron microscope.

The paper shows that aluminium composites can improve strength and wear resistance.

HMMCs has proven to be useful in improving the dry sliding wear resistance.

The paper aims to examine the mechanical and wear performance of A356/Al₂O₃ (alumina) nanocomposites. The correlation between wear performance and the microstructural properties that result from various mechanical milling periods was investigated.

The production of nano alumina reinforced (1 Wt.%) A356 aluminum nanocomposite specimens was carried out using the traditional powder metallurgy method, incorporating three different mechanical milling times (1, 2 and 4 h). Subsequently, mechanical and wear performance assessments were conducted using hardness, compression and pin-on-disc wear tests.

Although the specimens subjected to the most prolonged mechanical milling (4 h) demonstrated superior hardness and compressive strength properties, they exhibited a remarkable weight loss during the wear tests. The traditional evaluation, which supports that the wear performance is generally correlated with hardness, does not consider the microstructural properties. Since the sample milled for 1 h has a moderate microstructure, it showed better wear performance than the sample with higher hardness.

The originality of the paper is demonstrated through its evaluation of wear performance, incorporating not only hardness but also the consideration of microstructural properties resulted from mechanical milling.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-02-2023-0031/

This paper aims to investigate the wear behaviors of aged metal matrix composites and of the as-cast Al-Si alloy by using a pin-on-disk wear testing machine at room temperature.

Hypoeutectic (Al-7Si) alloy reinforced with low volume fractions of SiC particles (SiC_p) and graphite (Gr) particles were prepared by the stir-casting process. It was found that the addition of 9 Wt.% of SiC_p and 3 Wt.% of Gr particles conferred a beneficial effect in reducing the wear rate of the composites.

The worn-out surfaces of the specimens were examined using scanning electron microscopy (SEM); the extensive micro cracking occurs on the surface of the Al-7Si alloy tested at lower loads. The growth of these microcracks finally led to the delamination of the base alloy surface. The reinforcements (SiCp and Gr) particles tended to reduce the extent of plastic deformation in the surface layer, thereby reducing extensively the occurrence of micro cracking in the composites.

From the results, it is revealed that the quantity of wear rate was less for aged specimens compared to the as-cast specimens. The worn-out surfaces were studied using electron dispersive spectroscopy, and wear debris was analyzed using SEM.