Metallurgical and Materials Engineering (E-Journal)
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Advanced Motor Design and Optimization for High-Efficiency Industrial Applications
Get PDFObjective: This research combines soft magnetic composite (SMC) material with high-temperature superconductors (HTS) to develop motors with improved efficiency and greater torque output while reducing thermal losses during operation. Regular motors generate large energy waste through magnetic leakage during continuous high torque operation on conveyor systems.
Methods: Using SMCs lowered electricity wastage in motors by 20 percent, which boosted their performance. Special software helped us reach our optimization goals. The modeling tool SolidWorks created perfect shapes, but ANSYS Maxwell performed electromagnetic tests to detect magnetic responses. COMSOL Multiphysics confirmed how heat flow and design strength respond to different function modes. HTS materials improved electric vehicle powertrain design by 25% to deliver higher torque at a smaller size.
Results: Our developed control algorithm through MATLAB/Simulink adjusted naturally to changing loads to save energy. Under industrial production tests, our prototype delivered 15% better energy efficiency than normal motors.
Conclusion: Research shows that advanced materials and computer modeling tools can create better electric motors for industrial and EV environments while guiding us toward environmentally friendly technology
Disaster-Resilient Design And Water Demand Evaluation Of Residential Fire Sprinkler Systems
Get PDFResidential buildings face significant fire hazards due to high occupancy and the presence of combustible materials. Automatic fire sprinkler systems offer a proactive and efficient solution for early fire suppression, significantly reducing life and property loss. This study presents a technical evaluation of water demand for residential sprinkler systems with a focus on disaster-resilient design. A three-story residential building was used as a case study, where fire load calculations were performed based on common household materials. Sprinkler head spacing, discharge flow, and operating pressure were analyzed using NFPA 13D guidelines. Hydraulic calculations, including friction loss and pressure drop, were conducted to ensure system performance. The study concluded that a minimum of 7000 liters of water is required to operate 43 sprinkler heads for 15 minutes, effectively covering a protected area of 474 m². The findings demonstrate that even in resource-constrained residential settings, a scientifically designed sprinkler system can be integrated without excessive water demand. This research supports the implementation of sprinkler systems as a vital component of fire-resilient infrastructure in residential buildings, especially in urban India
Experimental investigation on impact energy of friction stir welded aluminum and copper dissimilar joint using full factorial method
Get PDFThis research work carried out friction stir welding (FSW) of dissimilar aluminum AA3003-H12 and copper C12200-H01, with wide application in the refrigeration and heat exchanger industry. The main aim of this study is to investigate the influence of process parameters, i.e. pin type (PT), weld speed (WS), rotational speed (RPM), and shoulder diameter (SD) on impact energy (IE) of Al-Cu welded joint. The experimental study used the full factorial method with mixed levels of process parameters. Analysis of Variance (ANOVA) determines the significance of process parameters on impact energy. The results of the analysis of variance (ANOVA) shows that rotational speed (RPM) is the most influential process parameter contributing to the impact energy (IE) of dissimilar Al-Cu weld joint. The response optimizer tool in Minitab 18 software gives optimum weld conditions of process parameters for better weld performance. The FSW experiment with a tapered pin, weld speed of 16 mm/min, rotational speed of 1120 rpm, and shoulder diameter of 22.5 mm obtained the maximum impact energy value of 6.5367 J. The fine-grain recrystallization formed intermetallic compounds in the stir zone (SZ). These intermetallic compounds give a maximum microhardness of 382.24 Hv (0.1). The microstructure analysis of the stir zone (SZ) shows an equiaxed grain structure on the Cu side, while the Al side shows a fine recrystallized grain structure
Effects of the tempering temperature on microstructure and mechanical properties of X70 dual phase steel
Get PDFThis study uses direct quenching (DQ) heat treatment at an intercritical annealing temperature (IAT) of 800 °C to form a martensite-ferrite dual phase microstructure of X70 steel. The effects of tempering temperatures ranging from 200 to 500 °C on tensile properties in a dual-phase X70 steel are investigated. Carbon diffusion and redistribution in the microstructure are influenced by tempering. It was discovered that the amount of carbides increases with the tempered temperature, resulting in depleted carbon in martensite. Conversely, increasing the tempered temperature causes a decrease in ultimate tensile strength and yield strength while increasing elongation
Effect of artificial aging treatment on microstructure, mechanical properties and fracture behavior of 2017A alloy
Get PDFThe effect of artificial aging treatment on 2017A aluminum alloy microstructure, mechanical properties, and fracture behavior was investigated. The samples were taken from the as-received alloy and aged at 170 °C for 5, 10, 15, 20, and 30 hours. An optical microscope, scanning electron microscope (SEM), X-ray diffraction (XRD), microhardness and tensile strength tests were used to characterize mechanical and microstructural properties. The microstructural analysis revealed that as the aging treatment duration is increased, the size and density of precipitates grow larger and more numerous. According to X-ray diffraction measurements, the microstructural evolution caused by aging treatments is primarily due to an increase in precipitation of the hardening phase -Al2Cu. According to the tensile test results, the yield stress increases with increasing aging duration. The fracture surface analysis of failed specimens subjected to tensile loading revealed that the aging treatment conditions had a significant impact on the morphology and mode of fracture: the mixed-mode (ductile-brittle) failure was established for intermediate aging durations (aging at 170 °C for 15 and 20 h), and the intergranular fracture was found to be more pronounced when the aging duration is prolonged due to the coalescence of fine precipitates at the grain boundary
Machinability study on Al7075/Al2O3-SiC hybrid composites
Get PDFIn the present research, the effects of volume fraction of SiC+Al2O3 particles and aging temperature on the machinability of stir-casted Al7075 metal matrix composites (MMC) have been investigated. The hybrid composites were fabricated using the liquid metallurgy route. Al7075 was reinforced with different wt. % of SiC (3%, 6%, and 9%) and Al2O3 (2%, 4%, and 6%) which were used to fabricate the hybrid metal matrix composites. The samples were aged at different temperatures (140 ºC, 160 ºC, and 180 ºC) for 4 h and cooled at furnace temperature (27 ºC). The machinability of hybrid metal matrix composites was studied by carrying out L27 orthogonal array experiments. Three process parameters were selected, such as 0.2 mm/min of the depth of cut, 0.1 mm/min of feed rate, and 1500 rpm of spindle speed. The obtained results indicate that the surface roughness and machining force of MMCs increase with an increase in weight percentage of Al2O3/SiC and decrease with the increase in aging temperature. Optimum machining force and surface roughness were obtained at 2% Al2O3 + 3 % SiC and 180°C of aging temperature
Failure analysis of fractured dental implants
Get PDFThe success and predictability of titanium implants over long periods of time are well established, and there has been a tremendous increase in implant popularity among patients and clinicians over the last four decades. However, complications can occur, resulting in the loss of both the implant and the prosthesis. Dental implant fracture is uncommon; however, implants or abutment screws can fracture and cause significant problems for both the clinician and the patient. Improper design, overload, fatigue, and corrosion are all potential causes of implant fracture. Six retrieved fractured dental implants of varying diameter and thread design were collected on a regular basis to characterize their fracture behavior by SEM and assess the fracture mechanism. The majority of the implants were fractured as a result of fatigue crack initiation and propagation from the thread roots
Mathematical and experimental examination of the effect of the stepped pin tool profile on the characterization of AA 6061-T6 underwater friction stir welding
Get PDFThis research paper presents the mathematical model to design a stepped pin profile tool and its durability index. A mathematical model is being developed by considering tools that should generate the same heat as conventional conical tools and stepped tools by varying the shoulder to pin diameter ratio (D/d). Aluminum alloy AA6061-T6 with a thickness of 6 mm fabricated using a butt-type weld configuration and newly developed conical stepped pin profile tools with water as a cooling medium. The result shows that a conical stepped tool shows better mechanical properties of the welded joints compared with a conventional conical tool. When compared to other stepped conical pin profile tools, one with a (D/d) of 3 has superior mechanical and microstructural properties and as the D/d ratio increases, the tool pin durability index falls
Simultaneous improvement of corrosion and mechanical properties of AA 5083 aluminum alloy
Get PDFIn this study, the effects of cold-rolling and annealing on the structural, electrochemical, and mechanical properties of AA5083 in a simulated seawater environment are investigated. The results demonstrated that annealing temperature significantly affects the alloy's mechanical and corrosion properties. According to potentiodynamic results, the rate of corrosion decreased after annealing. Compared to the cold-rolled sample, the heat treatment doubles the electrochemical impedance, indicating that the corrosion resistance of AA5083 alloy is suitable at 50°C annealing. Approximately twice as much ductility was added to the materials as compared to the as-received materials. Additionally, the mechanical testing revealed the Portevin-Le Chatelier (PLC) Effect Type B band, which reflected the smaller grain size
Wear characterization of Al 7075 alloy hybrid composites
Get PDFAluminium alloy hybrid composites are in high demand for advanced scientific applications due to their high strength, low weight, and enhanced tribological properties. A hybrid composite of aluminium alloy (Al7075) and aluminium oxide (Al2O3) and E-glass shot fibres was produced using a sand moulding technique in an electric resistance furnace. The objective of this research was to look at the wear characteristics of Al7075-Al2O3-E-glass hybrid composites with various Al2O3 (3-12%) and E-glass weight percentages (2-6 percent). The sliding distance (500, 1000, and 1500 m), load (10, 20, and 30N), Al2O3 (3, 6, and 9 %), and E-glass (2-6 %) are the wear characteristics that are considered. Wear testing is carried out using pin-on-disc equipment (WTE 165 model, Version-EV00) in line with the Taguchi L9 orthogonal array. Taguchi analysis was done on the collected data to find SN plots. Regression analysis was done along with ANOVA to find relationships between different factors selected. In order to reduce the wear rate of hybrid composites, the optimal wear parameters are determined. As the percentage of reinforcements increased, the rate of deterioration decreased. SEM scans revealed the attachment and displacement of unintended wear debris, as well as the uniform distribution of Al2O3/E-glass particles