Exploring the intricacies of machine learning-based optimization of electric discharge machining on squeeze cast TiB2/AA6061 composites: Insights from morphological, and microstructural aspects in the surface structure analysis of recast layer formation and worn-out analysis

Journal of Materials Research and Technology, Journal Year: 2023, Volume and Issue: 26, P. 8569 - 8603

Published: Sept. 1, 2023

Aluminium (Al) Alloy-6061/TiB2 was developed with Squeeze casting while varying composite quantities titanium diboride (TiB2). The metallographic structure of the investigated using EDS and scanning electron microscopy (SEM). machining is challenging conventional methods due to higher tool wear surface roughness (Ra). This study analyses output responses, machinability TiB2 15% volume reinforced AA6061 composites Electrical Discharge Machining (EDM). EDM operation variables such as current, pulse on time, voltage gap were utilized examine material removal rate (MRR), (TWR) Ra employing Box–Behnken design experiments. MRR, TWR data acquired from various experiments optimized considering single multiple objectives by a hybrid approach. Machine learning (ML) applied predict responses linear regression (LR), decision tree (DT) random forest (RF). samples' recast layer examined SEM, thickness also documented. Al6061 alloy's SEM micrographs reveal deep equiaxed dimples its fracture surface, indicating high level plastic deformation before failure. evenly distributed darker particles in Al-matrix alloy no directional-orientation. Al6061-15 wt% composites' surfaces display dimples, ductile-fracture for deformation, cleavage facets some areas. aluminum pattern depicts long, extensive ploughing grooves short cracks parallel sliding direction at grooves' bottom. recast-layer formation have reported that molten metal ligaments break into droplets during flushing, exposing fresh surfaces. groove width larger compared composites. Thus, it can be observed tracks base are deeper comparison Al- 15 presence hard particles. Also, may advantageous wear-resistant properties. has importance an industry where components slide each other used disc brakes automobiles. Compared standards, single-objective optimization considerably enhanced outcomes: MRR increased 10.61%, enriched 25.91%, 17.60%. According ANOVA, peak current contributed 87.88%, 98.18%, 95.80% respectively TWR, Ra. It requisite investigate multi-objective owing diverse optimal factor combinations responses. slightly 1.14% simultaneous utilizing techniques Equal Entropy weights, which diminished 11.74% 11.66%. ML, particularly DT, improves performance assisting productivity, durability, cost-efficiency under changeable circumstances raising forthcoming possibilities.

Language: Английский

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Unveiling of grain structure, porosity, phase distributions, microstructural morphology, surface hardness, and tribo-corrosion characteristics of nickel, and titanium dioxide-based SS-304 steel microwave composite coatings cladding

Journal of Materials Research and Technology, Journal Year: 2023, Volume and Issue: 28, P. 4299 - 4316

Published: Dec. 30, 2023

The microstructure, homogeneity, and tribo-corrosion behavior of microwave-developed Nickel as well titanium dioxide SS-304 cladding surfaces are the primary emphasis this research. study includes assessing hardness enhancement from Ni TiO2 particles in surface. investigation additionally evaluates surface wear rates, friction coefficients, resistance to corrosion under tribological conditions. with developed by microwave energy were investigated study. microstructure was being examined validate uniformly homogeneous dispersion particles, XRD employed determine phases. evaluated, a pin-on-disk tribometer has assessed behavior. Tribo-corrosion tested 3.5-percent NaCl solution. To enhance cladding's efficiency, hybrid heating (MHH) utilising charcoal susceptor been employed. Findings exhibited that analysis showed had uniform distribution compact microstructure. significantly improved about 37.68% due incorporation 10% particles. FeNi3, NiSi2, Ni3C, NiC, Ni2Si, FeNi, phases seen on conditions also evaluated using tribometer. outcomes have decreased rates coefficients compared uncoated substrate. Moreover, 3.5% rate coefficient measured be 0.00412 mm3/m 0.297, respectively. results indicated enhanced

Language: Английский

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AA5754–Al2O3 Nanocomposite Prepared by Friction Stir Processing: Microstructural Evolution and Mechanical Performance

Journal of Manufacturing and Materials Processing, Journal Year: 2024, Volume and Issue: 8(2), P. 58 - 58

Published: March 8, 2024

The utilization of Al2O3 nanopowder to reinforce AA5754 aluminum alloy through blind holes employing the friction stir processing (FSP) technique produce an matrix nanocomposite is explored in this paper. Motivated by necessity enhance strength and ductility welded joints, impacts varying tool rotational speed (rpm) hole diameter on microstructure mechanical properties joints are investigated. Experimental characterization techniques including SEM, optical microscopy, microhardness, tensile tests were employed analyze produced under different parameters (tool speeds 910, 1280, 1700 rpm, diameters 0, 1, 1.5, 2 mm). Comparative analyses conducted against base metal without reinforcement powder. It was found that addition resulted a decrease maximum generated heat during FSP, while also reducing zone size compared samples nanopowder. Moreover, enhancements both observed with incorporation nanoparticles. optimal combination welding conditions, at 1280 rpm 1.5 mm diameter, yielded remarkable ultimate 567 MPa, accompanied hardness 45 HV. These results underscore potential nano-Al2O3 significantly improving nanocomposite, implications for advancing performance structures various engineering applications.

Language: Английский

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Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21st century

Journal of Magnesium and Alloys, Journal Year: 2024, Volume and Issue: 12(6), P. 2091 - 2146

Published: June 1, 2024

Rising concerns about climate change drive the demand for lightweight components. Magnesium (Mg) alloys are highly valued their low weight, making them increasingly important in various industries. Researchers focusing on enhancing characteristics of Mg and developing Metal Matrix Composites (MMCs) have gained significant attention worldwide over past decade, driven by global shift towards materials. Friction Stir Processing (FSP) has emerged as a promising technique to enhance properties produce Mg-MMCs. Initially, FSP adapted refine grain size from micro nano level accelerated development MMCs due its solid-state nature synergistic effects microstructure refinement reinforcement, improving strength, hardness, ductility, wear resistance, corrosion fatigue strength. However, producing defect-free sound FSPed Mg-MMCs requires addressing several variables interdependencies, which opens up broad range practical applications. Despite existing reviews individual Mg, alloys, MMCs, an attempt been made analyze latest research these three aspects collectively understanding, application, effectiveness derivatives. This review article discusses literature, classifies importance provides historical background, explores developments potential applications alloys. It focuses novel fabrication methods, reinforcement strategies, machine tool design parameters, material characterization, integration with other methods enhanced properties. The influence process parameters emergence defects examined, along specific mono hybrid composites evolution. study identifies materials highlights gaps production. concludes recommendations further exploration, reflecting ongoing advancements this field.

Language: Английский

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The influence of tool shape on the microstructure evolution and tribological properties during friction stir processing of AlCoCrFeNi high entropy alloys particle reinforced AA7075 aluminum alloy

Vacuum, Journal Year: 2024, Volume and Issue: 229, P. 113540 - 113540

Published: Aug. 8, 2024

Language: Английский

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Fabrication of the novel hybridized AZ31B Mg/CeO2+ZrO2 composites via multiple pass friction stir processing

Journal of Materials Research and Technology, Journal Year: 2023, Volume and Issue: 24, P. 9984 - 10004

Published: May 1, 2023

The mixture of the rare-earth CeO2 and ZrO2 particulates was used for fabricating hybridized AZ31BMg/(CeO2+ZrO2)p composites by utilizing friction stir processing with a multiple-tool pass strategy. structure, mechanical properties (tensile strength hardness), tribological performances (wear properties) corrosion behaviours hybrid were examined. findings reveal elimination tunnel-like defects clustering CeO2+ZrO2 particles in composite after multiple passes tool due to successive stirring-assisted material flow. rise reduced mean grain sizes (7.91–3.02 μm), particle (5.47–2.28 average coefficient (0.45–0.18) specific wear rate (4.26 × 10−5–2.17 10−5 mm3/Nm) composite. tensile (172–239 MPa), performance also improved via Multiple is thus recommended fabrication Mg-based composites.

Language: Английский

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Achieving high mechanical and wear properties in the AZ31/(CeO2+ZrO2)p surface composite using friction stir processing: Application of vibration

Vacuum, Journal Year: 2023, Volume and Issue: 218, P. 112654 - 112654

Published: Sept. 30, 2023

Language: Английский

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Effect of processing environment during friction stir processing of AZ31/(ZrO2+CuO)p surface composite on the mechanical and tribological performance

Journal of Materials Research and Technology, Journal Year: 2023, Volume and Issue: 28, P. 1891 - 1899

Published: Dec. 9, 2023

In this work, the AZ31 Mg alloy was subjected to friction stir processing (FSP) by adding CuO and ZrO2 particles. The main aim of study increase tribological mechanical behavior AZ 31/(CuO + ZrO2)p surface composite in air water. influence media on microstructural modification properties developed composites is assessed via optical microscopy (OM), scanning electron (SEM), transmission (TEM), shear punch testing (SPT) Vickers hardness testing. It had been found that finer grains are produced zone due reduction heat input for water-cooled relative air-cooled composite. Indeed, water-cooling system acted as a hamper suppressed grain growth, which consequently resulted enhancement

Language: Английский

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Assessment of microstructure, biocompatibility and in-vitro biodegradation of a biomedical Mg-Hydroxyapatite composite for bone tissue engineering

Journal of Materials Research and Technology, Journal Year: 2023, Volume and Issue: 27, P. 852 - 875

Published: Sept. 27, 2023

In the present study, an Mg-based biomedical composite is fabricated by addition of Hydroxyapatite bioactive nanoparticles into a substrate bioabsorbable WE43 Mg alloy using multi pass friction stir processing (FSP). The findings indicate that applying 6 passes FSP leads to decrease grain size over 93%, crushing and redistribution secondary phase particles within matrix, improved homogeneity reduction in their agglomeration. vitro Biodegradation tests prove as number increases, weight loss bio-composites biodegradation rate simulated body fluid (SBF) decrease. Bioactivity assessed immersion SBF for 28 days. Biomineralization process shows all Mg-Hydroxyapatite exhibit bone-like apatite forming ability, cauliflower-shaped crystals form on surface. Moreover, increasing uniformity stimulates formation denser crystals, which improves biocompatibility bio-composites. Biocompatibility also evaluated MTT assay DAPI staining. Mg-HA-6P demonstrates highest healthy flattened spindle shaped L-929 fibroblast cells with 83.36% cell viability after 5 days incubation compared other samples. Increasing causes high bioactivity, low homogenous distribution particles, turn improve cells. Furthermore, increase passes, yield strength values samples increase, reaching 212 MPa 226 Mg-6P Mg-6P-HA samples, respectively.

Language: Английский

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Effect of Ni addition on the behavior of dissimilar A356-AZ91/CeO ₂ aluminum-magnesium based composite fabricated by friction stir process technique

Composite Interfaces, Journal Year: 2023, Volume and Issue: 31(3), P. 305 - 330

Published: Sept. 18, 2023

ABSTRACTIn the present study, Behavior of Dissimilar A356-AZ91/CeO2 Aluminum-Magnesium Based Composite Fabricated by Friction Stir Process Technique was observed. The Macrostructure A356-AZ91/5%CeO2/2% Ni showed a defect-free and crack-free composite. Microstructural examination revealed that FSP effectively distributed CeO2 particles within matrix, resulting in refined microstructure. Tensile strength A356-AZ91 matrix material improved about 38.04% after addition 5% CeO2. However, with 2% to A356-AZ91/5% composite displaying further enhancement. alloy through 44.78% improvement tensile strength. There an hardness adding Ni- found 41.66%. Hardness A356-AZ91-5% only 28.33% without Ni. Wear testing aluminum carried out using pin-on-disc apparatus. wear rate decreased 70% particles. 61.66% particles.KEYWORDS: Interfacial layermacrostructureFSP techniquefatigue strengthwear Disclosure statementNo potential conflict interest reported author(s).

Language: Английский

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