New Materials, Processing and Manufacturability

R. Thanigaivelan, PhD, is the principal at AKA Memorial College of Engineering and Technology, Tamilnadu, India. His research fields include micromachining, surface engineering, composites, and biomaterials. He has published more than 90 papers in SCI and SCOPUS-indexed journals and edited two books. Pradeep Kumar Krishnan, PhD, is a senior faculty member of Mechanical and Industrial Engineering, National University of Science and Technology, Muscat, Sultanate of Oman. His research focuses on production processes, characterization, and mechanical behavior of engineering materials. He has authored several publications in international journals and national and international conferences. Kamalakanta Muduli, Ph.D, is an associate professor in the Department of Mechanical Engineering, Papua New Guinea University of Technology, Papua New Guinea. His research interests focus on materials science, manufacturing, sustainable supply chain management, and industry 4.0 applications in operations and supply chains. He is the recipient of the ERASMUS award by the European Union and published more than 70 papers in peer-reviewed international journals. Santosh Kumar Tamang, PhD, is an assistant professor in the Department of Mechanical Engineering, North Eastern Regional Institute of Science & Technology (Deemed to be University), Arunachal Pradesh, India. His research focuses on laser-based manufacturing processes, machining technologies, molecular dynamics simulations, machine learning, optimization and soft computing. Tamang has published more than 50 research papers in peer-reviewed journals.

• Preface xvii1 Aluminum and Its Different Graded Alloys 1G. Avinash, V. V. N. Sarath and A. Yeswanth1.1 Introduction 11.2 Other Aluminum Materials 71.3 Applications 121.4 Conclusion 121.5 Future Scope 132 Cold Spray Additive Manufacturing 21Jagadeesha T., Arun Prakash J., Avinash Malladi and Seeniappan Kaliappan2.1 Introduction 212.2 Phenomena and Factors Behind CSAM 252.3 Different CSAM Techniques 262.4 Advantages of CSAM 272.5 Disadvantages of CSAM 282.6 Numerical Simulation of CSAM of Ti6Al4V Pellets on Ti6Al4V Substrate 302.7 Conclusion 322.8 Future Scope 323 Optimization of Gas Metal Arc Welding (GMAW) Cladding Parameters for Enhanced Weld Integrity in Low-Carbon Steel Plates (EN30) 35Vivek Singh, Amit Kumar Singh, Akash Deep, Som Ashutosh, M. Chandrasekaran and Bishub Choudhary3.1 Introduction 363.2 Experimental Work 393.3 Parametric Study 423.4 Taguchi Optimization 463.5 Conclusions 534 Design and Development of Brake Pedal by Topology Optimization Approach 57Sivashankar N., Jagadeesha T., Mothilal T. and Natrayan L.4.1 Introduction 584.2 Structure Optimization 604.3 Topology Optimization 624.4 Optimization Results 634.5 Conclusion 685 Enhancing Resistance Spot Welding Weld Quality: A Comprehensive Analysis of Influencing Factors and the Role of Modeling and Optimization for Improved Quality 71Kaushal Jha, Santosh Kumar Tamang, Rajeev Kumar and Bishub Choudhury5.1 Introduction 725.2 Influence of Welding Current and Time 745.3 Influence of Resistivity, Surface Preparation, and Cleanliness 785.4 Effect of Electrode Force and Electrode Tip Geometry 825.5 Modeling and Optimization of RSW Parameters 855.6 Conclusion 896 Shot-Peening Influence on Corrosion Behavior of SiC Particle Reinforced Aluminum Composite 95J. Venumurali and S. Rambabu6.1 Introduction 966.2 Experimental Procedure 1006.3 Results and Discussion 1046.4 Residual Stress 1086.5 Hardness Variation 1106.6 Surface Roughness 1116.7 Corrosion Behavior 1126.8 Conclusion 1177 3D Printing: Fundamentals, Applications, and Future Prospects 123Sonali Nag, Partha Pratim Borah and Kankan Kishore Pathak7.1 Introduction 1247.2 Materials for 3D Printing 1257.3 Future Prospects of 3D Printing Technology 1337.4 Conclusions 1348 Cutting Zone Temperature and Cutting Force in 3D-Milling Operations Using ABAQUS 139Jagadeesha T., R. Thanigaivelan, Avinash Malladi and Natrayan L.8.1 Introduction 1408.2 Literature Review 1418.3 Objectives 1428.4 Methodology 1428.5 Simulation 1448.6 Milling Conditions 1478.7 Result and Discussion 1498.8 Conclusion 1539 A Rare Ferroelectric Material: Fresnoite (Ba2TiSi2O8) 157Shiv K. Barbar9.1 Introduction 1589.2 Experimental 1609.3 Characterization Details 1619.4 Result and Discussion 1629.5 Conclusion 18110 Research Progress and Developments in GTAW Process Using Visual Sensing and Weld Penetration Estimation 187M. Soundarrajan, R. Prakash, D. Deepa, R.Thanigaivelan and P. Suresh10.1 Introduction 18810.2 GTAW Process 18810.3 Sensing Technologies in Welding 19010.4 Online Vision Inspection 19310.5 3 Dimensional Image Processing of Weld Pool Geometry Using Dot Matrix 19610.6 Real-Time Three-Dimensional Measurement of Topside and Backside Width of Weldment 19710.7 Dynamic Estimation of Weld Pool Geometry 20010.8 Visual Sensing Based on Supervised Machine Learning Technique 20110.9 Hybrid Network Model Using Convolutional Neural Network and Long Short-Term Memory 20210.10 Conclusion 20311 Simulation of Sulfur Recovery Unit Using Aspen Plus 207Krati Hardya, V. K. Chandaliya, Pratik Swarup Dash, Barun Kumar Nandi, Deepak Kumar, Bishub Choudhury and Vishnu Kuntal11.1 Introduction 20811.2 Process Description 21011.3 Methodologies 21111.4 Results and Discussion 21511.5 Conclusion 22212 Fabrication of Magnesium Metal Matrix Nanocomposites Using Ultrasonic-Assisted Stir-Casting Method 227Parthiban K., Balaji E., Durairaj S. and Ashok Kumar R.12.1 Introduction 22812.2 Effect of Ultrasound on Magnesium Alloys 23412.3 Conclusion 24213 Friction Stir Welding of Dissimilar Magnesium Alloys: Analytical Modeling, Simulation, and Experimental Validation 247Biswajit Mallick, Jagadeesha T., Mothilal.T.and Seeniappan Kaliappan13.1 Introduction 24813.2 Analytical Modeling 25013.3 Heat Input Modeling 25113.4 Experimental Detail 26013.5 Experimental Setup 26013.6 Experimental Results 26213.7 Conclusion 26514 Advancements in Welding Techniques: Surface and Mechanical Property Insights 269Jagadeesha T., Manoj Nikam, T. Mothilal and M.D. Raj Kamal14.1 Introduction 27014.2 Resistance Welding 27714.3 Hybrid Welding 28114.4 Rotary Friction Welding 28214.5 Friction Stir Welding 28214.6 Properties of Friction Welding 28414.7 Future Research Opportunities and Conclusions 28415 Advanced 3D Printing for Industrial Components: Welded Joint Analysis and Strength Assessment 287Jagadeesha T., Amith Kumar Gajakosh, Avinash Malladi and Natrayan L.15.1 Introduction 28815.2 Material Used for SLM Technology 28915.3 SLM Technology 3D Component 28915.4 TIG Welding Method for Joining 29015.5 ABS and PLA 3D Component Material 29115.5.1 Fused Deposition Modeling 29115.6 Welding Method Used for ABS and PLA 29215.7 Characterisation Techniques 29315.8 Challenges Faced in the Development Process 29415.9 Conclusion 29516 Advancements in Electrochemical Surface Coatings: Innovations, Applications, and Future Prospects 299Jagadeesha T., Soundarrajan M., Seeniappan Kaliappan and M.D. Raj Kamal16.1 Introduction 30016.2 Fundamentals of Electrochemical Process 30116.3 Types of Electrochemical Surface Coatings 30316.4 Overview of Surface Preparation Methods 30516.5 Characterization of Electrochemically Coated Surface 30816.6 Applications of Electrochemical Surface Coating in Various Fields 30816.7 Challenges and Limitations of Electrochemical Surface Coating Methods 31116.8 Conclusions 31216.9 Future Trends 31317 Process Variable Impact Analysis in Unconventional Machining: Enhancing MRR, Accuracy, and Surface Quality 317Jagadeesha T., Manoj Nikam, Seeniappan Kaliappan and Natrayan L.17.1 Introduction 31817.2 Nontraditional Machining Processes 31917.3 Electrochemical Machining 32117.4 Ultrasonic Machining 32317.5 Laser Beam Machining (LBM) 32817.6 Conclusion 33017.7 Future Research Opportunities 33118 Pulsed Power Supplies for Surface Coating Applications: Methods, Materials, and Case Studies 335Jagadeesha T., Amith Kumar Gajakosh, Seeniappan Kaliappan and S. Socrates18.1 Introduction 33618.2 Different Coating Materials 33818.3 Magnetron Sputtering 33818.4 Ceramic Coatings 33918.5 Plasma Electrolysis Oxidation 34118.6 Case Study 1: Aluminum Oxide Coatings by Unbalanced Sputtering 34318.7 Case Study 2: Power Supply Mode in Plasma Electrolysis Oxidation (Micro-Arc Oxidation Coating) in Magnesium Alloy 34518.8 Conclusions 34619 Fabrication and Water Absorption Testing of Banana Fiber-Reinforced Composite 351Larikynti Massar, Rohan Sarkar, Nako Komo and Nabam Teyi19.1 Introduction 35219.2 Materials 35419.3 Material Preparation 35519.4 Fabrication Process 35619.5 Water Absorption Testing 36219.6 Results and Discussions 36319.7 Conclusion 36520 Multi-Objective Optimization of Fusion Welding Parameters Using Non-Dominated Sorting Genetic Algorithm II 369Monoj Kanti Chakraborty, Arun Jyoti Kalita, Deepty Pandey, Nirsanametla Yadaiah, Md. S. Mujaheed Khan and Nabam Teyi20.1 Introduction 37020.2 The Suggested Methodology 37220.3 Results and Discussions 37520.4 Conclusion 385Declaration of Competing Interest 386References 386Index 389