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1 – 10 of 11Suvranshu Pattanayak, Susanta Kumar Sahoo, Ananda Kumar Sahoo, Raviteja Vinjamuri and Pushpendra Kumar Dwivedi
This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc…
Abstract
Purpose
This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire.
Design/methodology/approach
The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions.
Findings
RSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations.
Originality/value
This modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.
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Qiang Sun, Quantong Jiang, Siwei Wu, Chang Liu, Heng Tang, L. Song, Hao Shi, Jizhou Duan and BaoRong Hou
The purpose of this paper is to explore the effect of ZnO on the structure and properties of micro-arc oxidation (MAO) coating on rare earth magnesium alloy under large…
Abstract
Purpose
The purpose of this paper is to explore the effect of ZnO on the structure and properties of micro-arc oxidation (MAO) coating on rare earth magnesium alloy under large concentration gradient.
Design/methodology/approach
The macroscopic and microscopic morphology, thickness, surface roughness, chemical composition and structure of the coating were characterized by different characterization methods. The corrosion resistance of the film was studied by electrochemical and scanning Kelvin probe force microscopy. The results show that the addition of ZnO can significantly improve the compactness and corrosion resistance of the MAO coating, but the high concentration of ZnO will cause microcracks, which will reduce the corrosion resistance to a certain extent.
Findings
When the concentration of zinc oxide is 8 g/L, the compactness and corrosion resistance of the coating are the best, and the thickness of the coating is positively correlated with the concentration of ZnO.
Research limitations/implications
Too high concentration of ZnO reduces the performance of MAO coating.
Practical implications
The MAO coating prepared by adding ZnO has good corrosion resistance. Combined with organic coatings, it can be applied in corrosive marine environments, such as ship parts and hulls. To a certain extent, it can reduce the economic loss caused by corrosion.
Originality/value
The effect of ZnO on the corrosion resistance of MAO coating in electrolyte solution was studied systematically, and the conclusion was new to the common knowledge.
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Abstract
Purpose
The purpose of this paper is to study the effects of voltage on microstructure and properties of micro-arc oxidation (MAO) ceramic coatings formed on AZ31B magnesium alloy under the constant current–constant voltage operation mode.
Design/methodology/approach
The wear and corrosion resistance of MAO coating on AZ31B magnesium alloy was studied by MAO in silicate electrolyte under constant current and constant voltage.
Findings
When the voltage is 360 V, the wear and corrosion resistance of AZ31B magnesium alloy is the best.
Originality/value
The wear and corrosion resistance of MAO coating on AZ31B magnesium alloy was studied by friction wear and electrochemical workstation.
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Zonglin Lei, Zunge Li and Yangyi Xiao
This study aims to investigate the surface modification on 20CrMnTi gear steel individually treated by diamond-like carbon films and nitride coatings.
Abstract
Purpose
This study aims to investigate the surface modification on 20CrMnTi gear steel individually treated by diamond-like carbon films and nitride coatings.
Design/methodology/approach
For this purpose, the mechanical properties of a-C:H, ta-C and AlCrSiN coatings are characterized by nano-indentation and scratch tests. The friction and wear behaviors of these three coatings are evaluated by ball-on-disc tribological experiments under dry contact conditions.
Findings
The results show that the a-C:H coating has the highest coating-substrate adhesion strength (495 mN) and the smoothest surface (Ra is about 0.045 µm) compared with the other two coatings. The AlCrSiN coating shows the highest mean coefficient of friction (COF), whereas the ta-C coating exhibits the lowest one (steady at about 0.16). The carbon-based coatings possess excellent self-lubricating properties compared with nitride ceramic ones, which effectively reduce the COF by about 64%. The major failure mode of carbon-based coatings in dry contact is slight abrasive wear. The damage of AlCrSiN coating is mainly adhesive wear and abrasive wear.
Originality/value
It is suggested that the carbon-based film can effectively improve the friction-reducing and wear resistance performance of the gear steel surface, which has a promising application prospect in the mechanical transmission field.
Peer review
The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0129/
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Muhammad Arif Mahmood, Chioibasu Diana, Uzair Sajjad, Sabin Mihai, Ion Tiseanu and Andrei C. Popescu
Porosity is a commonly analyzed defect in the laser-based additive manufacturing processes owing to the enormous thermal gradient caused by repeated melting and solidification…
Abstract
Purpose
Porosity is a commonly analyzed defect in the laser-based additive manufacturing processes owing to the enormous thermal gradient caused by repeated melting and solidification. Currently, the porosity estimation is limited to powder bed fusion. The porosity estimation needs to be explored in the laser melting deposition (LMD) process, particularly analytical models that provide cost- and time-effective solutions compared to finite element analysis. For this purpose, this study aims to formulate two mathematical models for deposited layer dimensions and corresponding porosity in the LMD process.
Design/methodology/approach
In this study, analytical models have been proposed. Initially, deposited layer dimensions, including layer height, width and depth, were calculated based on the operating parameters. These outputs were introduced in the second model to estimate the part porosity. The models were validated with experimental data for Ti6Al4V depositions on Ti6Al4V substrate. A calibration curve (CC) was also developed for Ti6Al4V material and characterized using X-ray computed tomography. The models were also validated with the experimental results adopted from literature. The validated models were linked with the deep neural network (DNN) for its training and testing using a total of 6,703 computations with 1,500 iterations. Here, laser power, laser scanning speed and powder feeding rate were selected inputs, whereas porosity was set as an output.
Findings
The computations indicate that owing to the simultaneous inclusion of powder particulates, the powder elements use a substantial percentage of the laser beam energy for their melting, resulting in laser beam energy attenuation and reducing thermal value at the substrate. The primary operating parameters are directly correlated with the number of layers and total height in CC. Through X-ray computed tomography analyses, the number of layers showed a straightforward correlation with mean sphericity, while a converse relation was identified with the number, mean volume and mean diameter of pores. DNN and analytical models showed 2%–3% and 7%–9% mean absolute deviations, respectively, compared to the experimental results.
Originality/value
This research provides a unique solution for LMD porosity estimation by linking the developed analytical computational models with artificial neural networking. The presented framework predicts the porosity in the LMD-ed parts efficiently.
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Shekhar Srivastava, Rajiv Kumar Garg, Anish Sachdeva, Vishal S. Sharma, Sehijpal Singh and Munish Kumar Gupta
Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a…
Abstract
Purpose
Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process.
Design/methodology/approach
The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS.
Findings
A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively.
Originality/value
To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
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Donghui Hu, Shenyou Song, Zongxing Zhang and Linfeng Wang
This paper aims to figure out the conundrum that the corrosion resistance longevity of steel wires for bridge cables was arduous to meet the requirements.
Abstract
Purpose
This paper aims to figure out the conundrum that the corrosion resistance longevity of steel wires for bridge cables was arduous to meet the requirements.
Design/methodology/approach
The “two-step” hot-dip coating process for cable steel wires was developed, which involved first hot-dip galvanizing and then hot-dip galvanizing of aluminum magnesium alloy. The corrosion rate, polarization curve and impedance of Zn–6Al–1Mg and Zn–10Al–3Mg alloy-coated steel wires were compared through acetate spray test and electrochemical test, and the corrosion mechanism of Zn–Al–Mg alloy-coated steel wires was revealed.
Findings
The corrosion resistance of Zn–10Al–3Mg alloy-coated steel wires had the best corrosion resistance, which was more than seven times that of pure zinc-coated steel wires. The corrosion current of Zn–10Al–3Mg alloy-coated steel wires was lower than that of Zn–6Al–1Mg alloy-coated steel wires, whereas the capacitive arc and impedance value of the former were higher than that of the latter, making it clear that the corrosion resistance of Zn–10Al–3Mg was better than that of Zn–6Al–1Mg alloy coating. Moreover, the Zn–Al–Mg alloy-coated steel wires for bridge cables had the function of coating “self-repairing.”
Originality/value
Controlling the temperature and time of the hot dip galvanizing stage can reduce the thickness of transition layer and solve the problem of easy cracking of the transition layer in the Zn–Al–Mg alloy coating due to the Sandelin effect.
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Ferhat Ceritbinmez, Yusuf Kanca, Ahmet Tuna and Erdoğan Kanca
FeNi36 (Invar-36) alloy is widely used in the fabrication of molding tools in aerospace industries but there remains a need to improve its wear and friction performance due to its…
Abstract
Purpose
FeNi36 (Invar-36) alloy is widely used in the fabrication of molding tools in aerospace industries but there remains a need to improve its wear and friction performance due to its relatively low hardness. The formation of a heat affected zone (HAZ) on the surface of Invar-36 cut by wire electric discharge machining (WEDM) is promising to enhance its tribological properties. This study aims to investigate the tribological performance of WEDM-treated Invar-36 via a ball-on-disk tribometer in dry-sliding conditions.
Design/methodology/approach
The untreated and WEDM-treated Invar-36 surfaces were reciprocated against an alumina ball at a sliding velocity of 40 mm/s, a stroke length of 10 mm and a sliding duration of 125 min under loads of 5, 10 and 20 N. The worn surfaces were characterized using a 2D profilometry and a scanning electron microscope equipped with energy-dispersive spectroscopy.
Findings
The results showed that the WEDM-treated surface had a superior friction coefficient and wear resistance in comparison to the untreated surface, due to the grown HAZ. There was found to be a 9.3%–11.4% decrease in the friction coefficient and a 47%–57% reduction in the wear volume after the WEDM treatment. Both the untreated and WEDM-treated Invar-36 surfaces found abrasion and plastic deformation as the dominant wear mechanisms.
Originality/value
Previous works have not focused on the tribological performance of the WEDM-treated Invar-36 extensively used for molding tools in aerospace industries. Our findings provide compelling evidence that the WEDM treatment improved the wear and friction performance of Invar-36 alloy because of the grown HAZ.
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İdris Tuğrul Gülenç, Mingwen Bai, Ria L. Mitchell, Iain Todd and Beverley J. Inkson
Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This…
Abstract
Purpose
Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This study aims to develop a cost-effective Ti6Al4V-carbon feedstock, which preserves the parent Ti6Al4V particle’s flowability, and produces in situ TiC-reinforced Ti6Al4V composites with superior traits.
Design/methodology/approach
Ti6Al4V particles were directly mixed with graphite flakes in a planetary ball mill. This composite powder feedstock was used to manufacture in situ TiC-Ti6Al4V composites using various energy densities. Relative porosity, microstructure and hardness of the composites were evaluated for different SLM processing parameters.
Findings
Homogeneously carbon-coated Ti6Al4V particles were produced by direct mixing. After SLM processing, in situ grown 100–500 nm size TiC nanoparticles were distributed within the α-martensite Ti6Al4V matrix. The formation of TiC particles refines the Ti6Al4V β grain size. Relative density varied between 96.4% and 99.5% depending on the processing parameters. Hatch distance, exposure time and point distance were all effective on relative porosity change, whereas only exposure time and point distance were effective on hardness change.
Originality/value
This work introduces a novel, cost-effective powder feedstock preparation method for SLM manufacture of Ti6Al4V-TiC composites. The in situ SLM composites achieved in this study have high relative density values, well-dispersed TiC nanoparticles and increased hardness. In addition, the feedstock preparation method can be readily adapted for various matrix and reinforcement materials in future studies.
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Murat Isik, Isa Emami Tabrizi, Raja Muhammad Awais Khan, Mehmet Yildiz, Eda Aydogan and Bahattin Koc
In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and…
Abstract
Purpose
In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare the structural and mechanical properties of additively manufactured and conventionally machined IFs.
Design/methodology/approach
In this study, mechanical and microstructural properties of Inconel 718 (Inc718) alloy internal features, manufactured either as-built with AM or machining of additively manufactured (AMed) part thereafter were investigated.
Findings
The results showed that the average ultimate tensile strength (UTS) of additively manufactured center internal feature (AM-IF) is almost analogous to the machined internal feature (M-IF). However, the yield strength of M-IF is greater than that of AM-IF due the greater surface roughness of the internal feature in AM-IF, which is deemed to surpass the effect of microstructure on the mechanical performance. The results of digital image correlation (DIC) analysis suggest that AM-IF and M-IF conditions have similar strain values under the same stress levels but the specimens with as built IF have a more locally ductile region around their IF, which is confirmed by hardness test results. But this does not change global elongation behavior. The microstructural evolution starting from as-built (AB) and heat-treated (HT) samples to specimens with IF are examined. The microstructure of HT specimens has bimodal grain structure with d phase while the AB specimens display a very fine dendritic microstructure with the presence of carbides. Although they both have close values, machined specimens have a higher frequency of finer grains based on SEM images.
Originality/value
It was shown that the concurrent creation of the IF during AM can provide a final part with a preserved ultimate tensile strength and elongation but a decreased yield strength. The variation in UTS of AM-IF increases due to the surface roughness near the internal feature as compared to smooth internal surfaces in M-IF. Hence, the outcomes of this study are believed to be valuable for the industry in terms of determining the appropriate production strategy of parts with IF using AM and postprocessing processes.
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