Table of contents

PREFACE

The 7^th National Conference on Processing and Characterization of Materials (NCPCM 2017) was organized by the Department of Metallurgical and Materials Engineering, National Institute of Technology Rourkela, India during 08-09 December 2017.

The advanced processing of materials and their subsequent characterization are now-a-days gaining attention owing to the advancement of technology and need of high-quality materials for critical applications. The purpose of the conference was to bring recent developments in materials processing and characterization in the Indian context. About 120 participants and delegates from various organizations in India attended the conference. There were eight technical sessions of about 83 contributory talks along with seven keynote lectures. The conference became a platform for the interaction and exchange of ideas among the scientists, practicing engineers and young researchers from various academic institutions, research laboratories and industries from all over India engaged in frontiers of processing and characterization of conventional as well as advanced materials. This volume contains the selected full-length technical papers presented at the conference NCPCM 2017.

List of Photos are available in this PDF.

Dr. Ashok Kumar Mondal

Department of Metallurgical and Materials Engineering,

National Institute of Technology Rourkela, Rourkela-769008, Odisha, India

Email: mondala@nitrkl.ac.in

Dr. Archana Mallik

Department of Metallurgical and Materials Engineering,

National Institute of Technology Rourkela, Rourkela-769008, Odisha, India

Email: archanam@nitrkl.ac.in

List of Organising Committee and National Advisory Committee are available in this PDF.

• Science and Engineering Research Board (SERB), India

• Council of Scientific and Industrial Research (CSIR), New Delhi, India

• Board of Research in Nuclear Sciences (BRNS), India

• Avadh Rubber Prop Madras Elastomers Limited, Lucknow, India

• AIMIL Ltd., Kolkata, India

• Measure India Corporation Pvt. Ltd., Kolkata

• Spranktronics, Bangalore, India

• Anita Enterprises, Jamshedpur, India

All papers published in this volume of IOP Conference Series: Materials Science and Engineering have been peer reviewed through processes administered by the proceedings Editors. Reviews were conducted by expert referees to the professional and scientific standards expected of a proceedings journal published by IOP Publishing.

Finite element method is employed to determine the effect of variation of residual stress with dimension and the stress generated under its working condition along the Kovar. 3 different dimensions of Alumina-Kovar joint with height to diameter ratio of 3/10, using TiCuSil as a filler material. Transient Structural Analysis is carried out for three different dimensions (diameter × height) (i) 60mm × 20mm (Geometry 1) (ii) 90mm × 20mm (Geometry 2) (iii) 120mm × 20mm (Geometry 3). A comparative study has been carried out between the residual stresses developed in the brazed joint that have undergone 5 thermal cycles subsequent to brazing and that between the brazed joint. The heating and cooling rates from the brazed temperature is 10°C/up to room temperature. The brazing temperature and holding time considered for the analysis are 900°C and 10 minutes. Representative Volume Element (RVE) model is used for simulation. Sparse Matrix Direct Solver method is used to evaluate the results, using Augmented Lagrange method formulation in the contact region. All the simulations are performed in ANSYS Workbench 15.0, using solver target Mechanical APDL. From, the above simulations it is observed high concentration of residual stress is observed along the filler region i.e. in between Alumina and Kovar, as a result of difference in coefficient of thermal expansion between Alumina and Kovar. The residual stress decreases with increasing dimensions of the geometry and upon application of thermal cycles, subsequent to brazing.

This paper describes a new approach towards optimum utilisation of ferrochrome added during stainless steel making in AOD converter. The objective of optimisation is to enhance end blow chromium content of steel and reduce the ferrochrome addition during refining. By developing a thermodynamic based mathematical model, a study has been conducted to compute the optimum trade-off between ferrochrome addition and end blow chromium content of stainless steel using a predator prey genetic algorithm through training of 100 dataset considering different input and output variables such as oxygen, argon, nitrogen blowing rate, duration of blowing, initial bath temperature, chromium and carbon content, weight of ferrochrome added during refining. Optimisation is performed within constrained imposed on the input parameters whose values fall within certain ranges. The analysis of pareto fronts is observed to generate a set of feasible optimal solution between the two conflicting objectives that provides an effective guideline for better ferrochrome utilisation. It is found out that after a certain critical range, further addition of ferrochrome does not affect the chromium percentage of steel. Single variable response analysis is performed to study the variation and interaction of all individual input parameters on output variables.

In present time, developments in reinforced polymer composites have acquired preferential attention for high performance and high precision applications like aerospace, marine and transportation. Fibre reinforced polymer (FRP) composites are being substituted because of their low density, higher strength, stiffness, impact resistance, and improved corrosion resistance. Further laminated composites exhibit superior in-plane mechanical properties that are mostly governed by the fibers. However, laminated FRP composites suffer from poor out of plane properties in some applications. These properties can further be improved by the addition of Nano fillers like carbon nanotube (CNT), graphene and so on. Curing cycle plays a very important role in drawing out the optimum property of glass fiber/epoxy (GE) composite. It is expected that the cure kinetics can further be altered by addition of CNT due to its higher aspect ratio. The main objective of this work is to study the effect of CNT addition on cure kinetics of GE composite as multi-segment adsorption of polymer takes place on the CNT surface. In this study effects of curing parameters on mechanical properties and glass transition temperature of CNT embedded glass fiber/epoxy composite (CNT-GE) has been evaluated. For this study control GE and CNT-GE (with 0.1 wt. %) laminates were fabricated using hand lay-up technique followed by hot compression. The curing parameters that were considered in the present investigation were temperature (80°C, 110°C, and 140°C) and time (0.5 hr, 3 hr and 6 hr). For different combination of above mentioned temperature and time, samples of GE and CNT-GE composites were post cured. Mechanical properties were determined by flexural testing using 3 point bending fixture on INSTRON-5967 and thermal properties i.e. glass transition temperature (Tg) determined by Differential Scanning Calorimeter (DSC) to evaluate the effects of curing parameters. For CNT-GE samples, No much variation observed in flexural modulus with increase in post curing temperature and time, but swift increment was observed in flexural strength at 140°C with increase in post cure time. Elevation in Tg observed with increase in temperature and time duration of post curing; highest Tg noted at 140°C-6hr. Optimum post curing parameters for CNT-GE composite observed to be 140°C-6hr.

Shape memory alloy has a unique capability to return to its original shape after physical deformation by applying heat or thermo-mechanical or magnetic load. In this experimental investigation, desirability function analysis (DFA), a multi-attribute decision making was utilized to find out the optimum input parameter setting during wire electrical discharge machining (WEDM) of Ni-Ti shape memory alloy. Four critical machining parameters, namely pulse on time (T_ON), pulse off time (T_OFF), wire feed (WF) and wire tension (WT) were taken as machining inputs for the experiments to optimize three interconnected responses like cutting speed, kerf width, and surface roughness. Input parameter combination T_ON = 120 μs., T_OFF = 55 μs., WF = 3 m/min. and WT = 8 kg-F were found to produce the optimum results. The optimum process parameters for each desired response were also attained using Taguchi's signal-to-noise ratio. Confirmation test has been done to validate the optimum machining parameter combination which affirmed DFA was a competent approach to select optimum input parameters for the ideal response quality for WEDM of Ni-Ti shape memory alloy.

This paper explores some of the vital machinability characteristics of commercially pure titanium (CP-Ti) grade 2. Experiments were conducted based on Taguchi's L9 orthogonal array. The selected material was machined on a heavy duty lathe (Model: HMT NH26) using uncoated carbide inserts in dry cutting environment. The selected inserts were designated by ISO as SNMG 120408 (Model: K313) and manufactured by Kennametal. These inserts were rigidly mounted on a right handed tool holder PSBNR 2020K12. Cutting speed, feed rate and depth of cut were selected as three input variables whereas tool wear (VBc) and surface roughness (Ra) were the major attentions. In order to confirm an appreciable machinability of the work part, an optimal parametric combination was attained with the help of grey relational analysis (GRA) approach. Finally, a mathematical model was developed to exhibit the accuracy and acceptability of the proposed methodology using multiple regression equations. The results indicated that, the suggested model is capable of predicting overall grey relational grade within acceptable range.

Bulk graphitic carbon nitride (g-C₃N₄) is synthesized by thermal decomposition of urea and used as an adsorbent for gadolinium ion (Gd³⁺) from aqueous solution. Adsorption capacity of g-C₃N₄ is found to be influenced by initial Gd³⁺ concentration, solution pH and contact time. Adsorbed Gd³⁺is separated from g-C₃N₄ by ultracentrifuge. Initial and Gd ion accumulated g-C₃N₄ adsorbent are characterized by X-ray diffraction technique (XRD) for phase identification, UV-visible and Fourier transform infrared (FTIR) spectroscopy for adsorption characteristics and optical property, scanning electron microscopy (SEM) for morphological behaviour along with energy dispersive X-ray spectroscopy (EDS) for elemental study. HNO₃(0.1M), NaOH (0.1M) and de-ionized water are used for desorption and around 97% quantitative recovery of Gd ion is observed.

Carbon dioxide capture and storage (CCS) is a technique to address the global concern of continuously rising CO₂ level in the atmosphere. Fly ash is considered as a suitable medium for CCS due to presence of metal oxides. The fly ash which has already sequestered carbon dioxide is referred to as carbonated fly ash. Recent research reveals better durability of concretes using carbonated fly ash as part replacement of cement. In the present research pore structure characterization of the carbonated fly ash concrete has been carried out. Mercury Intrusion porosimetry test has been conducted on control concrete and concrete specimens using fly ash and carbonated fly ash at replacement levels of 25% and 40%. The specimens have been water cured for 28 days and 90 days. It is observed that porosity reduction rate is more pronounced in carbonated fly ash concrete compared to control concrete at higher water curing age. Correlation analysis is also carried out which indicates moderately linear relationship between porosity % and pore distribution with particle size and water curing.

In this paper, the effect of corrosion behaviour of aluminium alloy 2014 were studied by potentiodynamic polarization in 1 mole of NaCl solution of aged sample. The experimental testing results concluded that, corrosion resistance of Aluminum alloy 2014 degraded with the increasing the temperature (150°C & 200°C) and time of ageing. Corroded surface of the aged specimens was tested under optical microscopes for microstructures for phase analysis. Optical micrographs of corroded surfaces showed general corrosion and pitting corrosion. The corrosion resistance of lower ageing temperature and lower ageing time is higher because of its fine distribution of precipitates in matrix phase.

An axisymmetric numerical model has been developed to study the laser drilling of a cylindrical work piece under repetitive Gaussian laser pulse. Finite volume method has been used to discretize the energy equation. Convective and radiative heat losses have been considered from the laser irradiated surface. The resulting algebraic equation has been solved with the help of Tri-Diagonal Matrix Algorithm (TDMA) to know the temperature distribution in the work piece. The enthalpy porosity method has been employed to capture the moving solid-liquid interface evolving due to melting of the work piece subjected to laser energy. The laser source irradiated on the work piece has been considered as volumetric laser source instead of surface laser source which is rarely found in the existing literature. The present model is validated first with the existing literature. It has been found that, the results agree well. A parametric analysis has been done to know the effects of different laser parameters such as duty cycle, energy, pulse width and frequency etc. on the temperature field and the size of the melt pool when the work piece is subjected to repetitive laser pulse. The numerical results can provide some guidance for practical laser drilling process.

In recent years, aluminium foams have found use in a wide range of applications. The properties of these foams, as good structural strength with light weight have made them as a promising structural material for aerospace industry. Foaming techniques (direct and indirect) are used to produce these foams. Direct foaming involves blowing of gas to create gas bubbles in the melt whereas indirect foaming technique uses blowing agents as metallic hydrides, which create hydrogen bubbles. Porosity and its distribution in foams directly affect its properties. This demands for more theoretical studies, to control such cellular structure and hence properties. In present work, we have studied the effect of gas bubble rise velocity and melt viscosity, on pore size and its distribution in aluminium foam. A 15 PPI aluminium foam, prepared using indirect foaming technique having porosity ~86 % was used for study. In order to obtain metal foam, the bubble must not escape from the melt and should get entrapped during solidification. Our calculations suggest that bubble rise velocity and melt viscosity are responsible for vertical displacement of bubble in the melt. It is observed that melt viscosity opposes bubble rise velocity and help the bubbles to stay in the melt, resulting in porous structure.

Assessing the mechanical properties of materials through indentation hardness test is an attractive method, rather than obtaining the properties through destructive approach like tensile testing. The present work emphasizes on the relation between hardness and yield strength of Al-Mg-Si alloys considering Tabor type equations. Al-0.5Mg-0.4Si alloy has been artificially aged at various temperatures (100 to 250 °C) for different time durations (0.083 to 1000 h) and the ageing response has been assessed by measuring the Vickers hardness and yield strength. Correlations of the existing data from the open literature have also been reviewed. Lastly, it has been explained that the deviation in obtained relation from Tabor's equation is owing to the dislocation accumulation during indentation.

Characterization and beneficiation studies have been carried out on Brahmagiri placer deposits of Puri, Dist., Odisha. The studies show that this deposit contains potential amount of heavy minerals. The dune sands contain higher heavy minerals than that of beach sand. One of the dune sand samples collected from this deposit shows heavy mineral content of about 29 % also. A composite sand sample is prepared and heavy mineral recovery is studied from this by using gravity table. During recovery of heavy minerals both fresh and sea water are used to see their effect on grade and recovery of concentrate. Sea water rougher gravity table data shows better results than fresh water rougher gravity table. The gravity table study of composite sample shows a yield of 14.8% with a grade of 91.2 % and 93.2 % recovery.

CuCrZr alloys are attractive structural materials for plasma-facing components (PFC) and heat sink element in the International Thermonuclear Experimental Reactor (ITER) fusion reactors. This material has gained so much attention because of its high thermal conductivity and fracture toughness, high resistance to radiation damage and stability at elevated temperatures. The objective of this work is to study the effects of electron beam welding parameters on the mechanical strength of the butt welded CuCrZr joint. Taguchi method is used as the design of experiments to optimize the input parameters, such as accelerating voltage, beam current, welding speed, oscillation amplitude and frequency. The joint strength and ductility are the desired responses, which are measured through ultimate tensile strength and percent elongation, respectively. Accelerating voltage and welding speed are found to have significant influence on the strength. A combination of low amplitude and high-frequency oscillation is suggested for the higher joint strength and ductility. There is a close agreement between Taguchi predicted results and experimental ones. Fractographic analysis of joint and weld zone analysis are carried out to study the failure behaviour and microstructural variation in the weld zone, respectively.

In the present study, first ever attempt has been made to develop physically functionalized multiwalled carbon nanotube (MWCNT) reinforced Al-11 5Si alloy nanocomposites synthesized via novel consolidation technique viz spark plasma sintering (SPS). There is a recent trend in employing carbon nanotubes (CNTs), an allotrope of carbon, as reinforcement for high strength structural metallic composite materials, as these cylindrical nano-fibers poses extremely unique mechanical properties such as very high elastic modulus (~ 300 GPa to 1.5 TPa) as well as tensile strength (~150 GPa). However, it has remained as an ever-existing problem to achieve a porosity-free nanocrystalline matrix with homogenously dispersed CNTs, owing to the very high coagulation tendency of CNTs. The gas-atomized, spherical Al-11.5Si alloy powders (1-8 μm) were subjected to high energy ball milling for the purpose of achieving nanocrystallinity in the powders. The improvement in MWCNT dispersion was effort by treating the MWCNTs with a physical surfactant, sodium dodecyl sulfate (SDS). The nano-grained ball-milled Al-Si powders with varying MWCNT content (0.5 and 1 wt%) were consolidated via spark plasma sintering in order to retain the nano-sized grains in the Al-Si matrix, attributed to the faster and highly effective sintering kinetics of the sintering techniques. FESEM study shows problem of MWCNT agglomeration persists by addition of non-SDS treated as pristine MWCNT in the composite. After treated with SDS, MWCNTs are well separated out from each other and as a result of that good morphological and mechanical property such as high hardness value obtained after analysis. Detailed TEM study of the 0.5wt% MWCNT reinforced SPS nanocomposite revealed that the distribution of CNTs in the matrix. Mechanical analysis study of the nanocomposite attributes higher hardness in case of SDS treated CNT reinforced nanocomposite owing to less agglomeration problem of the CNT in the matrix. Nano-tribological data attributed variation of surface roughness after consolidated by SPS.

The Carbon fiber (CF)/epoxy composites are being used in the automotive and aerospace industries owing to their high specific mechanical strength to weight ratio compared to the other conventional metal and alloys. However, the low interfacial adhesion between fiber and polymer matrix results the inter-laminar fracture of the composites. Effects of different carbonaceous nanomaterials i.e., carbon nanotubes (CNT), graphene nanosheets (GNPs), graphene oxide (GO) etc. on the static mechanical properties of the composites were investigated in detail. Only a few works focused on the improvement of the dynamic mechanical of the CF/epoxy composites. Herein, the effect of thermally reduced grapheme oxide (TRGO) on the dynamic mechanical properties of the CF/epoxy composites was investigated. At first, GO was synthesized using modified Hummers method and then reduced the synthesized GO inside a vacuum oven at 800 °C for 5 min. The prepared TRGO was dispersed in the epoxy resin to modify the epoxy matrix. Then, a number of TRGO/CF/epoxy laminates were manufactured incorporating different wt% of TRGO by vacuum assisted resin transfer molding (VARTM) technique. The developed laminates were cured at room temperature for 24 h and then post cured at 120 °C for 2 h. The dynamic mechanical analyzer (DMA 8000 Perkin Elmer) was used to examine the dynamic mechanical properties of the TRGO/CF/epoxy composites according to ASTM D7028. The dimension of the specimen was 44×10×2.4 mm³ for the DMA test. This test was carried out under flexural loading mode (duel cantilever) at a frequency of 1 Hz and amplitude of 50 μm. The temperature was ramped from 30 to 200 °C with a heating rate of 5 °C min^-1. The dynamic mechanical analysis of the 0.2 wt% TRGO incorporated CF/epoxy composites showed ~ 96% enhancement in storage modulus and ~ 12 °C increments in glass transition temperature (T_g) compared to the base CF/epoxy composites. The fiber-matrix interaction was studied by Cole-Cole plot analysis. It proved the homogeneous dispersion of the epoxy resin and TRGO. The homogeneous dispersion of the TRGO in the epoxy matrix increased the overall enhancement of the dynamic mechanical properties of the hybrid composites.

In this present work, single walled wavy carbon nanotube reinforced into composite has been studied to predict the effective directional strength of the nanocomposite. The effect of waviness on the overall Young's modulus of the composite has been analysed using three dimensional finite element model. Waviness pattern of carbon nanotube is considered as periodic cosine function. Both long (continuous) and short (discontinuous) carbon nanotubes are being idealized as solid annular tube. Short carbon nanotube is modelled with hemispherical cap at its both ends. Representative Volume Element models have been developed with different waviness, height fractions, volume fractions and modulus ratios of carbon nanotubes. Consequently a micromechanics based analytical model has been formulated to derive the effective reinforcing modulus of wavy carbon nanotubes. In these models wavy single walled wavy carbon nanotubes are considered to be aligned along the longitudinal axis of the Representative Volume Element model. Results obtained from finite element analyses are compared with analytical model and they are found in good agreement.

In this article, the dynamic response of the carbon nanotube-reinforced functionally graded sandwich composite plate has been studied numerically with the help of finite element method. The face sheets of the sandwich composite plate are made of carbon nanotube- reinforced composite for two different grading patterns whereas the core phase is taken as isotropic material. The final properties of the structure are calculated using the rule of mixture. The geometrical model of the sandwich plate is developed and discretized suitably with the help of available shell element in ANSYS library. Subsequently, the corresponding numerical dynamic responses computed via batch input technique (parametric design language code in ANSYS) of ANSYS including Newmark's integration scheme. The stability of the sandwich structural numerical model is established through the proper convergence study. Further, the reliability of the sandwich model is checked by comparison study between present and available results from references. As a final point, some numerical problems have been solved to examine the effect of different design constraints (carbon nanotube distribution pattern, core to face thickness ratio, volume fractions of the nanotube, length to thickness ratio, aspect ratio and constraints at edges) on the time-responses of sandwich plate.

This work investigates on the single step electrodeposition of quality CuInSe₂ (CIS) thin film absorber layer for photovoltaics applications. The electrodeposition was carried using an aqueous acidic solution with a pH of 2.25. The deposition was carried using a three electrode system in potentiostatic conditions for 50 minutes. The as-deposited and nitrogen (N₂) annealed films were characterized using XRD, FE-SEM and Raman spectroscopy. It has been observed that the SDS has the tendency to suppress the copper selenide (Cu_xSe) secondary phase which is detrimental to the device performance.

In this article, we investigate the thermomechanical deflection characteristics of the debonded composite plate structure using an isoparametric type of higher-order finite element model. The current formulation is derived using higher-order kinematic theory and the displacement variables described as constant along the thickness direction whereas varying nonlinearly for the in-plane directions. The present mid-plane kinematic model mainly obsoletes the use of shear correction factor as in the other lower-order theories. The separation between the adjacent layers is modeled via the sub-laminate technique and the intermittent continuity conditions imposed to avoid the mathematical ill conditions. The governing equation of equilibrium of the damaged plate structure under the combined state of loading are obtained using the variational principle and solved numerically to compute the deflection values. Further, the convergence test has been performed by refining the numbers of elements and validated through comparing the present results with available published values. The usefulness of the proposed formulation has been discussed by solving the different kind of numerical examples including the size, location and position of delamination.

The incorporation of nano fillers in Fibre reinforced polymer (FRP) composites has been a source of experimentation for researchers. Addition of nano fillers has been found to improve mechanical, thermal as well as electrical properties of Glass fibre reinforced polymer (GFRP) composites. The in-plane mechanical properties of GFRP composite are mainly controlled by fibers and therefore exhibit good values. However, composite exhibits poor through-thickness properties, in which the matrix and interface are the dominant factors. Therefore, it is conducive to modify the matrix through dispersion of nano fillers. Creep is defined as the plastic deformation experienced by a material for a temperature at constant stress over a prolonged period of time. Determination of Master Curve using time-temperature superposition principle is conducive for predicting the lifetime of materials involved in naval and structural applications. This is because such materials remain in service for a prolonged time period before failure which is difficult to be kept marked. However, the failure analysis can be extrapolated from its behaviour in a shorter time at an elevated temperature as is done in master creep analysis. The present research work dealt with time-temperature analysis of 0.1% SiO₂-based GFRP composites fabricated through hand-layup method. Composition of 0.1% for SiO₂nano fillers with respect to the weight of the fibers was observed to provide optimized flexural properties. Time and temperature dependence of flexural properties of GFRP composites with and without nano SiO₂ was determined by conducting 3-point bend flexural creep tests over a range of temperature. Stepwise isothermal creep tests from room temperature (30°C) to the glass transition temperature T_g (120°C) were performed with an alternative creep/relaxation period of 1 hour at each temperature. A constant stress of 40MPa was applied during the creep tests. The time-temperature superposition principle was followed while determining the Master Curve and cumulative damage law. The purpose of a Master Curve was to determine the variation of compliance with respect to increase in time and temperature of the specimen. The shift factors at any reference temperature were determined by Arrhenius activation energy method at a far lower temperature than T_g (Glass transition temperature) and by manual shift method at a temperature near T_g (Glass transition temperature).

Temperature generation in cutting tools is one of the major causes of tool failure especially during hard machining where machining forces are quite high resulting in elevated temperatures. Thus, the present work investigates the temperature generation during hard machining of AISI 52100 steel (62 HRC hardness) with uncoated and PVD AlTiN coated Al₂O₃/TiCN mixed ceramic cutting tools. The experiments were performed on a heavy duty lathe machine with both coated and uncoated cutting tools under dry cutting environment. The temperature of the cutting zone was measured using an infrared thermometer and a finite element model has been adopted to predict the temperature distribution in cutting tools during machining for comparative assessment with the measured temperature. The experimental and numerical results revealed a significant reduction of cutting zone temperature during machining with PVD AlTiN coated cutting tools when compared to uncoated cutting tools during each experimental run. The main reason for decrease in temperature for AlTiN coated tools is the lower coefficient of friction offered by the coating material which allows the free flow of the chips on the rake surface when compared with uncoated cutting tools. Further, the superior wear behaviour of AlTiN coating resulted in reduction of cutting temperature.

Generation of fines is common in mining, sizing, and beneficiation and also in high-temperature metallurgical processes as the disintegration of agglomerate/compact occurs. Extraction of metallic iron from ore fines is one of the challenging aspects of iron making industries as the liberation of fines blocks, the charge burden porosity and hence hinders the reduction rate. Along with size factor, mineral composition plays a vital role in the extraction process; particularly silica. As silica has the very high tendency towards iron oxide, at comparatively low temperature, the activity of silica should be suppressed to prevent silicate phases. Adjustment of such conditions is controlled by addition of lime, but sometimes excessive slag generation increases the cost of production. In the present work, carbothermic reduction of partially reduced iron bearing pellets has been melted through 20 KW DC arc plasma furnace, and a comparative study has been made for considering different slag chemistry approaches. Pellets as aforementioned are made available from Patnaik Steel and Alloys Ltd, Odisha, having high silica content ore fines (of about 8.6%) as obtained from the chemical analysis. X-Ray analysis and optical image analyzer result of sinter thus obtained reveal that fayalite phase has major fractional value. Smelting works were done for sinter with/without adjustment of slag chemistry, where argon and nitrogen were used as plasma forming gases. A range of recovery rates (between 87-94%) is achieved by charge composition, ionizing gases, and smelting duration. It is observed that use of nitrogen as plasma forming gas increases the recovery rate than that of using only argon plasma; due to high energy flux of nitrogen which increases the enthalpy due to its diatomicity. A maximum recovery rate of about 94% is achieved for process duration of 13minutes utilizing nitrogen plasma. Smelting of charge with the addition of hydrated lime targeting melilite as final slag resulted in the formation of metallic iron as confirmed from XRD and XRF analyses. In the other hand, ferrosilicon is liberated in the metallic parts where smelting of charge was done without adjustment of slag chemistry. Both metal and slag thus obtained are characterized by XRD, XRF, microhardness and wet chemical analysis suitably.

Thermo mechanical treatments have the ameliorated impacts on the mechanical and tribological properties of powder metallurgy components. In this investigation an aluminium matrix composite (AMC) {Al (92) + Mg (5) + Gr (1) + Ti (2)} has been prepared by following powder metallurgy technique, with double axial compaction and ulterior sintering. Secondary thermo-mechanical treatment i.e. hot extrusion through mathematical contoured cosine profiled die was considered. The die causes minimum velocity relative differences across the extrusion exit cross-section, which provides smooth material flow. Comparative result analysis for the mechanical and tribological characteristics of the specimen before and after extrusion was concentrated. Extrusion engenders significant amount of improvements of the properties those are attributed to excellent bond strength and uniform density distribution due to high compressive stress. Oxidative and delaminated wear mechanisms were found predominating type. To furnish the suitable explanation scanning electron microscopies have been performed for the wear surfaces.

Ultrasonic welding is one of the promising solid state welding methods which have been widely used to join highly conductive materials like aluminum and copper. Despite these applications in the automotive field, other industries also have a strong interest to adopt this process for joining of various advanced alloys. In some of its applications, poor weld strength and sticking of the workpiece to the tool are issues. Thus, an attempt has been taken in the present study to overcome these issues by performing experiments with a suitable range of weld parameters. The major objectives of this study are to obtain a good joint strength with a reduced sticking phenomenon and microstructure of Al-Cu weld coupons. The results uncovered the mechanical strength of the joint increased up to 0.34 sec of weld time and afterward, it gradually decreased. Meantime, the plastic deformation in the weld zone enhanced the formation of an intermetallic layer of 1.5 μm thick, and it is composed of mainly Al₂Cu compound. The temperature evolved during the welding process is also measured by thermocouples to show its relationship with the plastic deformation. The present work exemplifies a finer understanding of the failure behavior of joints and provides an insight of ultrasonic welding towards the improvement in the quality of weld.

Extraction and separation of individual rare earth elements has been a challenge as they are chemically very similar. Solvent extraction is the most suitable way for extraction of rare earth elements. Acidic, basic, neutral, chelating are the major classes of extractants for solvent extraction of rare earth elements. The coordination complex of chelating extractants is very selective with positively charged metal ion. Hence they are widely used. Hydroxyamide is capable of forming chelates with metal cations. In this present study interactions of hydroxyamide ligand with lanthanum have been investigated using density functional theory (DFT). Two different functional such as raB97XD and B3LYP are applied along with 6-31+G(d,p) basis set for carbon, nitrogen, hydrogen and SDD basis set for lanthanum. Stability of formed complexes has been evaluated based on calculated interaction energies and solvation energies. Frontier orbital (highest occupied molecular orbital or HOMO and lowest unoccupied molecular orbital or LUMO) energies of the molecule have also been calculated. Electronegativity, chemical hardness, chemical softness and chemical potential are also determined for these complexes to get an idea about the reactivity. From the partial charge distribution it is seen that oxygen atoms in hydroxyamide have higher negative charge. The double bonded oxygen atom present in the hydroxyamide structure has higher electron density and so it forms bond with lanthanum but the singly bonded oxygen atom in the hydroxyamide structure is weaker donor atom and so it is less available for interaction with lanthanum.

Owing to the persistent quest of renewable energy technology, piezoelectric energy harvesters are gathering considerable research interest due to their potential in driving microelectronic devices with small power requirement. Electrical energy (milli to microwatt range) is generated from mechanical counterparts such as vibrations of machines, human motion, flowing water etc. based on the principles of piezoelectricity. Flexible high piezoelectric constant (d33) ceramic/polymer composites are crucial components for fabricating these energy harvesters. The polymer composites composed of gallium ferrite nanoparticles and polyvinylidene fluoride (PVDF) as the matrix have been synthesized by solvent casting method. First, 8 wt. % PVDF was dissolved in DMF and then different compositions of GaFeO₃ or GFO (10, 20, 30 wt. %) (with respect to PVDF only) nanocomposites were synthesized. The phase of the synthesized nanocomposites were studied by X- Ray diffraction which shows that with the increase in the GFO concentration, the intensity of diffraction peaks of PVDF steadily decreased and GFO peaks became increasingly sharp. As the concentration of GFO increases in the PVDF polymer matrix, band gap is also increased albeit to a small extent. The maximum measured output voltage and current during mechanical pressing and releasing conditions were found to be ~ 3.5 volt and 4 nA, respectively in 30 wt % GFO-PVDF composite, comparable to the available literature.

The present study focuses on the evaluation of microstructure and mechanical properties of reduced activation ferritic-martensitic (RAFM) steel (9Cr-1W-0.06Ta) subjected to thermo-mechanical treatment (TMT) in ferritic phase field. The results obtained were compared with the steel in conventional normalised plus tempered (N+T) condition. The microstructure of the steel in N+T and TMT conditions was assessed by optical and scanning electron microscopes. Hardness, tensile and creep studies were carried out and the results were correlated with the microstructural studies. While the TMT processed steel resulted in coarser prior austenite grains and exhibited ferritic microstructure with large distribution of fine M₂₃C₆ and MX precipitates, the N+T steel reveals tempered martensitic structure with finer prior austenitic grains with coarser M₂₃C₆ and MX precipitates. Although ferritic structure is present in TMT processed steel, it exhibits better tensile and creep rupture strengths than N+T steel due to the presence of increased dislocation density and finer distribution of precipitates.

In this paper, we present a lucid understanding about the deformation behaviour of nanocrystalline (NC) Ni with and without defects subjected to tensile followed by compressive loading using molecular dynamic (MD) simulations. The embedded atom method (EAM) potential have been incorporated in the simulation for three kinds of samples-i.e. for NC Ni (without any defect), porous NC Ni and NC Ni containing a centrally located void. All the three samples, which have been prepared by implementing the Voronoi method and using Atom Eye software, consist of 16 uniform grains. The total number of atoms present in NC Ni, porous NC Ni and NC Ni containing a void are 107021, 105968 and 107012 respectively. The stress-strain response of NC Ni under tensile followed by compressive loading are simulated at a high strain rate of 10⁷ s^-1 and at a constant temperature of 300K. The stress-strain curves for the NC Ni with and without defects have been plotted for three different types of loading: (a) tensile loading (b) compressive loading (c) forward tensile loading followed by reverse compressive loading. Prominent change in yield strength of the NC Ni is observed due to the introduction of defects. For tensile followed by compressive loading (during forward loading), the yield point for NC Ni with void is lesser than the yield point of NC Ni and porous NC Ni. The saw tooth shape or serration portion of the stress-strain curve is mainly due to three characteristic phenomena, dislocation generation and its movement, dislocation pile-up at the junctions, and dislocation annihilation. Both twins and stacking faults are observed due to plastic deformation as the deformation mechanism progresses. The dislocation density, number of clusters and number of vacancy of the NC sample with and without defects are plotted against the strain developed in the sample. It is seen that introduction of defects brings about change in mechanical properties of the NC Ni. The crystalline nature of NC Ni is found to decrease with introduction of defects. The findings of this work can thus be extended in bringing a whole new insight related to the deformation behaviour and properties of Nano- materials during cyclic deformation at various temperatures.

Development of Aluminum Metal Matrix Co mposites (AMMCs) has been one of the major requirements in engineering applicat ions due to their excellent mechanical properties, light weight and high strength. In the present investigation, Stir casting technique has been used for fabrication of co mposites, taking Alu miniu m as parent metal, Silicon Carbide (SiCp) of 7 vol. % of 220 mesh size and 1.75 vol. % of graphite as reinforcements. The Zirconia content was varied as 2.75, 4.5 and 6 vol. % to fabricate three d ifferent types of hybrid composites. The tensile strength and hardness were measured in UTM and Vickers hardness tester respectively and the wear characteristics were studied in a pin on disc friction monitor under dry sliding condition against steel counter face. The tensile strength was found to be 90 MPa, 120 MPa, 130 MPa and hardness 80.25 VHN, 103.22 VHN, 103.77 VHN for 2.75, 4.5 and 6vol. % of Zirconia respectively. Fro m the above investigation, it is recommended that composition with Al, 7 %-SiCp, 1.75 % -Gr and 6 vol %-ZrO2 showed better mechanical p roperties i.e . h igh tensile strength (130MPa) and reasonably good hardness (103.77 VHN) . The co mposite with Al, 7 % - SiCp, 1.75 % -Gr and 6 %-ZrO2 is good for short run frictional applicat ion and the composite with Al, 7 %- SiCp, 1.75 % -Gr and 4.5 %- ZrO2 may be used for long run frictional applicat ions after testing.

Minimizing the residual stress build-up in metal-based additive manufacturing plays a pivotal role in selecting a particular material and technique for making an industrial part. In beam-based additive manufacturing, although a great deal of effort has been made to minimize the residual stresses, it is still elusive how to do so by simply optimizing the processing parameters, such as beam size, beam power, and scan speed. Amid different types of additive manufacturing processes, Direct Metal Laser Sintering (DMLS) process uses a high-power laser to melt and sinter layers of metal powder. The rapid solidification and heat transfer on powder bed endows a high cooling rate which leads to the build-up of residual stresses, that will affect the mechanical properties of the build parts. In the present work, the authors develop a numerical thermo-mechanical model for the measurement of residual stress in the AlSi10Mg build samples by using finite element method. Transient temperature distribution in the powder bed was assessed using the coupled thermal to structural model. Subsequently, the residual stresses were estimated with varying laser power. From the simulation result, it found that the melt pool dimensions increase with increasing the laser power and the magnitude of residual stresses in the built part increases.

In this article, the acoustic radiation characteristics of laminated and sandwich composite spherical panels subjected to harmonic point excitation under thermal environment are investigated. The finite element (FE) simulation model of the vibrating panel structure is developed in ANSYS using ANSYS parametric design language (APDL) code. Initially, the critical buckling temperatures of the considered structures are obtained and the temperature loads are assorted accordingly. Then, the modal analysis of the thermally stressed panels is performed and the thermo-elastic free vibration responses so obtained are validated with the benchmark solutions. Subsequently, an indirect boundary element (BE) method is utilized to conduct a coupled FE-BE analysis to compute the sound radiation properties of panel structure. The agreement of the present sound power responses with the existing results available in the published literature establishes the validity of the proposed scheme. Finally, the current standardised scheme is extended to solve several numerical examples to bring out the influence of various parameters on the thermo-acoustic characteristics of laminated composite panels.

The paper reports on development and characterization of epoxy based composites filled with micro-sized mine overburden material. Coal mine overburden material is typically highly heterogeneous and is considered as waste material. For excavating each ton of coal, roughly 5 tons of overburden materials are removed and is dumped nearby occupying large space. Gainful utilization of this waste is a major challenge. In the present work, this material is used as filler materials in making a new class of epoxy matrix composites. Composites with different weight proportions of fillers (0, 10, 20, 30 and 40) wt. % are prepared by hand layup technique. Compression tests are performed as per corresponding ASTM standards to assess the compressive strength of these composites. Further, dry sliding tests are performed following ASTM G99 standards using a pin on disk machine. A design of experiment approach based on Taguchi's L₁₆ orthogonal arrays is adopted. Tests are performed at different sliding velocities for multiple sliding distances under varying normal loads. Specific wear rates of the composites under different test conditions are obtained. The analysis of the test results revealed that the filler content and the sliding velocity are the most predominant control factors affecting the wear rate. This work thus, opens up a new avenue for the value added utilization of coal mine overburden material.

Electrical discharge machining (EDM) is a non-traditional machining process which is widely used in machining of difficult-to-machine materials. EDM process can produce complex and intrinsic shaped component made of difficult-to-machine materials, largely applied in aerospace, biomedical, die and mold making industries. To meet the required applications, the EDMed components need to possess high accuracy and excellent surface finish. In this work, EDM process is performed using Nitinol as work piece material and AlSiMg prepared by selective laser sintering (SLS) as tool electrode along with conventional copper and graphite electrodes. The SLS is a rapid prototyping (RP) method to produce complex metallic parts by additive manufacturing (AM) process. Experiments have been carried out varying different process parameters like open circuit voltage (V), discharge current (Ip), duty cycle (τ), pulse-on-time (Ton) and tool material. The surface roughness parameter like average roughness (Ra), maximum height of the profile (Rt) and average height of the profile (Rz) are measured using surface roughness measuring instrument (Talysurf). To reduce the number of experiments, design of experiment (DOE) approach like Taguchi's L₂₇ orthogonal array has been chosen. The surface properties of the EDM specimen are optimized by desirability function approach and the best parametric setting is reported for the EDM process. Type of tool happens to be the most significant parameter followed by interaction of tool type and duty cycle, duty cycle, discharge current and voltage. Better surface finish of EDMed specimen can be obtained with low value of voltage (V), discharge current (Ip), duty cycle (τ) and pulse on time (Ton) along with the use of AlSiMg RP electrode.

Composite electrodes composed of silicon nanoparticles (SiNPs) in accommodation with graphene oxide (GO) synthesized by the ultra-sonication method can be used as a Li-ion battery anode. SiNPs wrapped with graphene is found to be used as an advanced material for Li- ion anode battery because of the high charge storage capacity, low cost, large surface area, cyclic stability, and reliability in comparison to the conventional planner Si particle. The SiNPs coated with graphene can accommodate the volume expansion problem of Si during lithiation without any fracture. The graphene-wrapped SiNPs morphology and dimension were characterized by high-resolution transmission electron microscopy (HRTEM).

Thermal buckling strength of smart sandwich composite structure (bonded with shape memory alloy; SMA) examined numerically via a higher-order finite element model in association with marching technique. The excess geometrical distortion of the structure under the elevated environment modeled through Green's strain function whereas the material nonlinearity counted with the help of marching method. The system responses are computed numerically by solving the generalized eigenvalue equations via a customized MATLAB code. The comprehensive behaviour of the current finite element solutions (minimum buckling load parameter) is established by solving the adequate number of numerical examples including the given input parameter. The current numerical model is extended further to check the influence of various structural parameter of the sandwich panel on the buckling temperature including the SMA effect and reported in details.

Molecular dynamics (MD) simulations are performed for nanoindentation on metal (Al)-metallic glass (Cu₅₀Zr₅₀) reinforced composites to investigate the mechanical properties and the effects of volume percentage on behavior of the load-displacement curves. The interaction among Al-Cu-Zr is modelled using a EAM (Embedded Atom Method) potential. Simulation box size of 100 Å (x) × 100 Å (y) × 100 Å (z) is modelled for investigating the properties of the sintered models by altering the volume percentage on the scale of 5%-20%. Nanoindentation is done along y-direction with a spherical diamond indenter at temperature of 300 K with constant indentation speed of 100 m/s. NVT ensemble is used with a timestep of 0.002 ps. Investigations on the effect of volume percentage show that as volume percentage of Metallic Glass (MG) increases, the corresponding Load required to penetrate inside the sample also increases. As a result of this Hardness also increase as volume percentage varies from 5% to 20%.

Nano Y₂O₃ and Al₂O₃ dispersed W-Ni alloys with nominal composition of W₈₉Ni₁₀ (Y₂O₃)₁ (alloy A), W₈₉Ni₁₀ (Al₂O₃)₁ (alloy B) were mechanically alloyed for 10 h followed by compaction at 0.5 GPa pressure with 5 min of dwell time and conventional sintering at 1400°C with 2 h soaking time in Ar atmosphere with Ar flow rate of 100 ml/min. The microstructure of milled and sintered alloy was investigated using X-ray Diffraction (XRD), Scanning electron Microscopy (SEM), Energy dispersive spectroscopy (EDS) and Elemental mapping. Minimum crystallite size of 31.9 nm and maximum lattice strain, dislocation density of 0.23%, 9.12(10¹⁶/m²) respectively was found in alloy A at 10 h of milling. Uneven and coarse particles at 0 h of milling converted to elongated flake shape at 10 h of milling. Bimodal (fine and coarse) particle size distribution is revealed in both the alloys and minimum particle size of 0.69 μm is achieved in 10 h milled alloy A. Evidences of formation of intermetallic phases like Y₂WO₆, Y₆WO₁₂ and Y₁₀W₂O₂₁ in sintered alloy A and Al₂(WO₄)₃, NiAl₁₀O₁₆, NiAl₂O₄ and AlWO₄ in sintered alloy B were revealed by XRD pattern and SEM micrograph. Minimum grain size of 1.50 μm was recorded in sintered alloy A. Both faceted and spherical W matrix is evident in both the alloys which suggests occurrence of both solid phase and liquid phase sintering. Maximum % relative sintered density and hardness of 85.29% and 5.13 GPa respectively was found in alloy A. Wear study at 20N force at 25 rpm for 15 min on ball on plate wear tester revealed that minimum wear depth (48.99 μm) and wear track width (272 μm) was found for alloy A as compared to alloy B.

The evolution of texture in commercially pure (CP) titanium during uniaxial tension and compression through VPSC (Visco-plastic self-consistent) simulation is reported in the present study. CP-titanium was subjected to both uniaxial tension and compression upto 35% deformation. During uniaxial tension, tensile twin of $\{10\bar{1}2\}\unicode{x003C;}\bar{1}011\unicode{x003E;}$ type and compressive twin of $\{11\bar{2}2\}\unicode{x003C;}11\bar{2}\bar{3}\unicode{x003E;}$ type were observed in the samples. However, only tensile twin of $\{10\bar{1}2\}\unicode{x003C;}\bar{1}011\unicode{x003E;}$ type and compressive twin of type was observed in the samples during uniaxial compression. Volume fractions of the twins were increased linearly as a function of percentage deformation during uniaxial tension. Whereas, during uniaxial compression the twinning volume fraction was increased up to 20% deformation and then decreased rapidly on further increasing the percentage deformation. During uniaxial tension, the general t-type textures were observed in the samples irrespective of the percentage deformation. The initial non-basal texture was oriented to split basal texture during uniaxial compression of the sample. VPSC formulation was used for simulating the texture development in the material. Different hardening parameters were estimated through correlating the simulated stress-strain curve with the experimental stress-strain data. It was observed that, prismatic slip $\{10\bar{1}0\}\unicode{x003C;}11\bar{2}0\unicode{x003E;}$ operated as the primary deformation mode during uniaxial tension whereas basal slip $\{0001\}\unicode{x003C;}11\bar{2}0\unicode{x003E;}$ acquired the leading role during deformation through uniaxial compression. It was also revealed that active deformation modes were fully depending on percentage deformation, loading direction, and orientation of grains.

Plasma arc cutting (PAC) is a high temperature thermal cutting process employed for the cutting of extensively high strength material which are difficult to cut through any other manufacturing process. This process involves high energized plasma arc to cut any conducting material with better dimensional accuracy in lesser time. This research work presents the effect of process parameter on to the dimensional accuracy of PAC process. The input process parameters were selected as arc voltage, standoff distance and cutting speed. A rectangular plate of 304L stainless steel of 10 mm thickness was taken for the experiment as a workpiece. Stainless steel is very extensively used material in manufacturing industries. Linear dimension were measured following Taguchi's L16 orthogonal array design approach. Three levels were selected to conduct the experiment for each of the process parameter. In all experiments, clockwise cut direction was followed. The result obtained thorough measurement is further analyzed. Analysis of variance (ANOVA) and Analysis of means (ANOM) were performed to evaluate the effect of each process parameter. ANOVA analysis reveals the effect of input process parameter upon leaner dimension in X axis. The results of the work shows that the optimal setting of process parameter values for the leaner dimension on the X axis. The result of the investigations clearly show that the specific range of input process parameter achieved the improved machinability.

This paper reports on the dielectric and thermal properties of hair fibers reinforced epoxy composites. Hair is an important part of human body which also offers protection to the human body. It is also viewed as a biological waste which is responsible for creating environmental pollution due to its low decomposition rate. But at the same time it has unique microstructural, mechanical and thermal properties. In the present work, epoxy composites are made by solution casting method with different proportions of short hair fiber (SHF). Effects of fiber content on the thermal conductivity and dielectric constant of epoxy resin are studied. Thermal conductivities of the composites are obtained using a Unitherm^TM Model 2022 tester. An HIOKI-3532-50 Hi Tester Elsier Analyzer is used for measuring the capacitance of the epoxy-SHF composite, from which dielectric constant (D_k) of the composite are calculated. A reduction in thermal conductivity of the composite is noticed with the increase in wt. % of fiber. The dielectric constant value of the composites also found to be significantly affected by the fiber content.

In the present paper, the structural and electronic properties of ordered face-centered cubic (L1₂) γ'-Ni₃Al and body-centered tetragonal (D0₂₂) γ"-Ni₃Nb are investigated by density functional theory calculation within projector augmented wave (PAW) potentials. The structures are optimized for both the phases and the results are found in good agreement with the experimental and theoretical data. In the geometrical optimization, all the forces on each atom are converged to less than 10³ eV/Å, and the total energy less than 10^-6 eV/atom. The Methfessel–Paxton smearing width of 0.2 eV is used here. The formation energy of γ'-Ni₃Al and γ"-Ni₃Nb phases are calculated and the values are found to be -40.67 kJ/mol and -27.55 kJ/mol respectively. The bonding character is analyzed based on the density of states (DOS).

Five layer W-Cu functionally graded material (FGM) for components in nuclear fusion application was fabricated by a one-step resistance sintering process, known as spark plasma sintering (SPS). In this study effect of sintering temperature (T_s) on physical, mechanical and surface property was investigated. Detailed microstructural study revealed that the graded structure of the composite layers with varying composition from 0 to 100 wt% W and Cu in opposite directions could be well densified after the SPS process. It also indicates that the fine microstructure within functionally graded layers can be maintained because of short sintering time. The sample sintered at 1050°C shows more than 90% theoretical density, hardness greater than 239±5 Hv and excellent surface scratch resistance. The result demonstrates that SPS is promising and more suitable process for fabrication of W-Cu FGM.

In this work, eutectic Al-12.6Si alloy with and without manganese (Mn) have been developed through gravity casting route. The effect of Mn concentration (0.0 wt.%, 1 wt%, 2 wt% and 3 wt%) on microstructural morphology and hardness property of the alloy has been investigated. The eutectic Al-12.6 Si alloy exhibits the presence of combine plate, needle and rod-like eutectic silicon phase with very sharp corners and coarser primary silicon particles within the α-Al phase. In addition of 1wt.% of Mn in the eutectic Al-12.6Si alloy, sharp corners of the primary Si and needle-like eutectic Si are became blunt and particles size is reduced. Further, increase in Mn concentration (2.0 wt.%) in the Al-12.6Si alloy, irregular plate shape Al₆(Mn,Fe) intermetallics are formed inside the α-Al phase, but the primary and eutectic phase morphology is similar to the eutectic Al-12.6Si alloy. The volume fraction of Al₆(Mn,Fe) increases and Al₆(Mn,Fe) particles appear as like chain structure in the alloy with 3 wt.% Mn. An increase in Mn concentration in the Al-12.6Si alloys result in the increase in bulk hardness of the alloy as an effects of microstructure modification as well as the presence of harder Al₆(Mn,Fe) phase in the developed alloy.

In this work we have systematically studied the optical characteristics of synthesized wurzite zinc oxide thin films exhibiting (002) orientation. Using sol gel spin coating technique zinc oxide thin films are grown on pre cleaned fused quartz substrates. Structural properties of the films are studied using X-ray diffraction analysis. Micro structural analysis and thickness of the grown samples are analyzed using field emission scanning electron microscopy. With an aim to investigate the optical characteristics of the grown zinc oxide thin films the transmission and reflection spectra are evaluated in the ultraviolet-visible (UV-VIS) range. Using envelope method, the refractive index, extinction coefficient, absorption coefficient, band gap energy and the thickness of the synthesized films are estimated from the recorded UV-VIS spectra. An attempt has also been made to study the influence of crystallographic orientation on the optical characteristics of the grown films.

Direct metal laser sintering is one of the very efficient processes which comes under the field of additive manufacturing and is capable of producing products of good mechanical and physical properties. The process parameters affect the physical and mechanical properties of the final products. Rapid solidification plays an important role in the consolidation kinetics as the powdered material sinters and forms a polycrystalline structure. In the recent times, the enormous use of computational modeling has helped in examining the utility of final products in a wide range of applications. In this study, a phase field model has been implemented to foresee the consolidation kinetics during the liquid state sintering. Temperature profiles have been used to study the densification behavior and neck growth which is caused by the surface diffusion of particles at initial stage. Later, importance of grain boundary and the volume diffusion during densification process is analyzed. It is also found that with rise in temperature, neck growth also increases rapidly due to the interaction of adjacent grains through grain boundary diffusion and stabilization of grain growth.

The present work emphasizes the influence of Er₂O₃ addition on the microstructure and nonlinear current-voltage characteristics of ZnO based varistors prepared by mixing in a high energy ball mill followed by compaction and sintering at a temperature of 1100 °C for duration ranging from 0.5 to 8 h. Increasing sintering time is found to enhance the size of ZnO grains of the sintered pellets and thereby, degrades the electrical properties. However, Er₂O₃ addition retards the grain growth of ZnO due to the generation of secondary spinel phases (ErVO₄ and Er-rich) at grain boundaries and triple points that restrict the grain boundary migration. Er₂O₃ modified ZnO varistor sintered at 1100 °C for 0.5 h exhibits considerably improved electrical property with nonlinear exponent and breakdown field of 27 and 3880 V cm^-1, respectively.

Many practical situations may be encountered under which a GFRP (Glass fibre reinforced polymer) composite, during its service life, is exposed to the severities of sudden temperature fluctuations. Moisture absorption of GRE (Glass fibre reinforced epoxy) composites followed by various gradients of temperature fluctuations may cause thermo- mechanical degradation. It is on this context, the hand layed GRE composite samples are exposed to up-thermal shock (-40°C to +50°C) and down-thermal shock (+50°C to -40°C) for various time interval after several periods of moisture (hydrothermal/hygrothermal) conditioning. The thermally shocked GRE specimens are put to 3-point bend test to divulge inter laminar shear strength (ILSS). Least ILSS values are recorded for the samples with maximum period of moisture treatments under with both up-thermal and down-thermal shock conditions. Lower glass transition temperature (T_g) values, as revealed through the low temperature DSC test, are exhibited at maximum durations of both up-thermal and down-thermal shock for the samples with higher periods of hygrothermal/hydrothermal treatments. SEM fractographs of representative GRE specimens after optimum period of moisture treatments and thermal shock show the various modes of failures.

The size, volume fraction and distribution of primary as well as eutectic silicon affect the mechanical properties of the Al-Si hypereutectic alloys. It is very difficult for the simultaneous refinement and modification of primary and secondary Si particles in hypereutectic Al-Si alloys through traditional processes. This paper explores the role of γ-Al₂O₃ nanoparticles on Si particles in the course of solidification in hypereutectic Al-Si alloys at particular pouring temperature. The present study involves incorporation of varying contents dispersed γ-Al₂O₃ nanoparticles into a molten base metal during stir casting and followed by solidification. It has been reported that the synthesized composites having good interfacial bonding (wetting) between the dispersed phase and the liquid matrix was achieved in order to provide improved mechanical properties of the composite. The cast product of hypereutectic Al-16Si alloy with the reinforcement of nanoparticles, illustrated a significant improvement in both wear behaviour and hardness. The dry sliding wear test has been performed on a group of specimens with varying parameters (different loads and sliding velocities) in a pin on disc wear testing machine. Moreover, the wear rate and specific wear rate also affected in different load and different sliding velocities. However in XRD analysis of the samples, the enhancement of wear resistance as well as hardness was due to the formation of brittle phases like SiO₂, Al₂O₃ and Al-rich intermetallic compounds. The hardness value of the materials increases nearly 6% in addition to increase in the density of only 0.8%. As per literature, the large plate eutectic Si particles were modified in to the fine core particles and it acquires enough potential for various applications.

PLK rock classified in to two products after a selective grinding to a particular size fraction. PLK rocks ground to below 45-micron size which is followed by a classifier i.e. hydrocyclone. The ground product classified in to different sizes of apex and vortex finder. The pressure gauge was attached for the measurement of the pressure. The production of fines is also increasing with increase in the vortex finder diameter. In order to increase in the feed capacity of the hydrocyclone, the vortex finder 11.1 mm diameter and the spigot diameter 8.0 mm has been considered as the best optimum condition for recovery of fines from PLK rock sample. The overflow sample contains 5.39% iron oxide (Fe₂O₃) with 0.97% of TiO₂ and underflow sample contains 1.87% Fe₂O₃ with 2.39% of TiO₂. The cut point or separation size of overflow sample is 25 μm. The efficiency of separation, or the so-called imperfection I, is at 6 μm size. In this study, the iron oxide content in underflow sample is less than 2% which is suitable for making of refractory application. The overflow sample is very fine which can also be a raw material for ceramic industry as well as a cosmetic product.

In the present work the wear behavior and mechanical properties of as cast A16082 and A16086-T6 were compared and analyzed using statistical analysis. The as cast Al6082 alloy was solutionized at 550°C, quenched and artificially aged at 170°C for 8hrs. Metallographic examination and XRD analysis revealed the presence of intermetallic compounds Al₆Mn.Hardness of heat treated Al6082 was found to be more than as cast sample. Wear tests were carried out using Pin on Disc wear testing machine according to Taguchi L9 orthogonal array. Experiments were conducted under normal load 10-30N, sliding speed 1-3m/s, sliding distance 400,800,1200m respectively. Sliding speed was found to be the dominant factor for wear in both as cast and aged Al 6082 alloy. Sliding distance increases the wear rate up to 800m and then after it decreases.

Different types of erosion resistant coatings are applied/deposited on aero components, depending on the operating/working temperatures. Nickel based coating are applied on the air craft (compressor) components, which can sustain up to working temperature of 650°C. In the present investigation, to improve the compatibility between substrate (i.e. the machine component) and the top coat, application of bond coat is there. The application of Nickel based coating by thermal plasma spray technique has proven to be a satisfactory means of producing acceptable sealing surface with excellent abradability. Before the corrosion study, coated sample is subjected to hardness, thickness and porosity testing. Hence the result is being evaluated. The corrosion behavior of coating was studied by sea water immersion with a time period of 16 weeks. It is observed that, up to 9 weeks increase in weight of coating occurs in a sharp trend and then takes a decreasing trend. The weight gain of the samples has varied from 37.23% (with one week immersion in sea water) to a maximum of about 64.36% for six weeks immersion. Coating morphology and composition analysis of the coatings are studied using SEM and EDS. This behavior shows adsorption/deposition of the foreign particles with polygonal shape on the coating surface by sea water interaction. Foreign particles with polygonal shape deposited on the coating and with increase in immersion/treatment time, washing out of the deposited materials starts, which reflects the decreasing trend of weight gain of the specimen.

Direct Metal Laser Sintering (DMLS) process is a laser based additive manufacturing process, which built complex structures from powder materials. Using high intensity laser beam, the process melts and fuse the powder particles makes dense structures. In this process, the laser beam in terms of heat flux strikes the powder bed and instantaneously melts and joins the powder particles. The partial solidification and temperature distribution on the powder bed endows a high cooling rate and rapid solidification which affects the microstructure of the build part. During the interaction of the laser beam with the powder bed, multiple modes of heat transfer takes place in this process, that make the process very complex. In the present research, a comprehensive heat transfer and solidification model of AlSi10Mg in direct metal laser sintering process has been developed on ANSYS 17.1.0 platform. The model helps to understand the flow phenomena, temperature distribution and densification mechanism on the powder bed. The numerical model takes into account the flow, heat transfer and solidification phenomena. Simulations were carried out for sintering of AlSi10Mg powders in the powder bed having dimension 3 mm × 1 mm × 0.08 mm. The solidification phenomena are incorporated by using enthalpy-porosity approach. The simulation results give the fundamental understanding of the densification of powder particles in DMLS process.

The environment is being contaminated with advancement of new technology, day by day. One of the primary sources for this contamination is the industrial waste. Industrialization is the prime reason behind the prosperity of any country to meet the materialistic demand. To run the industries, a huge amount of (electric) power is needed and hence need for thermal power plants to serve the purpose. In present scenario, coal fired thermal power plants are set up which generates a huge quantity of Fly ash. Consumption of industrial waste (Fly ash), continually a major concern for human race. In recent years, fly ash is being utilized for various purposes i.e. making bricks, mine reclamation, production of cements etc. The presence of Silica and Alumina in fly ash makes it useful for thermal barrier applications also. The plasma spray technology has the advantage of being able to process any types of metal/ceramic mineral, low-grade-ore minerals etc. to make value-added products and also to deposit ceramics, metals and a combination of these to deposit composite coatings with desired microstructure and required properties on a range of substrate materials. The present work focuses on utilization of fly ash mixing with bauxite (ore mineral) for a high valued application. Fly ash with 10 and 20% bauxite addition is used to deposit plasma spray overlay coatings at different power levels (10-20kW) on aluminum and mild steel substrates. Adhesion strength and surface roughness of the coatings are evaluated. Phase composition analysis of the coatings were done using X-ray diffraction analysis. Surface morphology of the coatings was studied using a scanning electron microscope (SEM). Maximum adhesion strength of 4.924 MPa is obtained for the composition fly ash and bauxite (10%), coated on mild steel at 16kW torch power level. The surface roughness (Ra) of the coatings is found to vary between 10.0102 to 17.2341 micron.

Bamboo is a typical plant native in Asia, been used in many sectors, which also produces a large volume of leaves which goes waste and not find its application for any useful purposes; is often considered as a bio-waste and normally incinerated or dumped; as its applications are not yet fully explored. However, some research work done on bamboo fibers for use as a reinforcement in making polymer matrix composite. In the present piece of research work, the influence of burning/carbonization of bamboo leaves (at different temperatures) have been studied and characterized. Proximate analysis gave the fixed carbon content (of ~nearly21%). X-Ray diffraction results revealed the presence of various phases viz. cristobalite (SiO₂), Calcite (Ca₂O₃) etc. accompanied with changes in crystal structures. Fourier transform infrared spectroscopy results showed various modes of vibrations viz. O-H stretching bending of other bonds; (for aromatic benzene derivatives) etc. Scanning Electron Microscopic observation (of morphology) showed irregular stacking arrangements between the randomly spaced lamellae structure, with variation in carbonizing temperature. Results revealed the advantages of pyrolysis process in biochar production/formation. It appears that, the bamboo biochar can have suitable properties for its use as an alternative energy source and also for agricultural applications. Its high porosity and carbon content suggest its application as activated carbon also; after physical or chemical treatments. The present research focuses on extending the frontiers of use of bamboo leaves from being an unutilized biowaste to its conversion into a value added product, which can be compassed in terms of sustainable applications.

Graphene and carbon nanotubes (CNTs) have tremendous interest as reinforcing fillers due to their excellent physical properties. However, their reinforcing effect in polymer matrix is limited due to agglomeration of graphene and CNTs within the polymer matrix. Mechanical properties by the admixture of reduced graphene oxide (rGO) and CNTs in Poly (methyl methacrylate) (PMMA) prepared by solution mixing method has been investigated. The prepared samples are characterized using X-ray diffraction (XRD), scanning electron microscope (SEM), transmission electron microscope (TEM) and Raman spectroscopy. The hybrid composite shows improvement in the mechanical properties compared to rGO/PMMA and MWCNTs/PMMA composites due to better interaction between rGO-MWCNTs and polymer matrix.

The newer technological developments are exerting immense pressure on domain of production. These fabrication industries are busy finding solutions to reduce the costs of cutting materials, enhance the machined parts quality and testing different materials, which can be made versatile for cutting materials, which are difficult for machining. High-speed machining has been the domain of paramount importance for mechanical engineering. In this study, the variation of surface integrity parameters of hardened AISI 4340 alloy steel was analyzed. The surface integrity parameters like surface roughness, micro hardness, machined surface morphology and white layer of hardened AISI 4340 alloy steel were compared using coated and uncoated cermet inserts under dry cutting condition. From the results, it was deduced that coated insert outperformed uncoated one in terms of different surface integrity characteristics.

Fiber reinforced polymeric (FRP) composite materials are exposed to diverse changing environmental temperatures during their in-service period. Current investigation is aimed to investigate the influence of thermal-shock exposure on the mechanical behavior of multiwalled carbon nanotube (MWCNT) enhanced glass fiber reinforced polymeric (GFRP) composites. The samples were exposed to +70°C for 36 hrs followed by further exposure to − 60°C for the similar interval of time. Tensile tests were conducted in order to evaluate the results of thermal-shock on the mechanical behavior of the neat and conditioned samples at 1 mm/min loading rate. The polymer phase i.e. epoxy was modified with various MWCNT content. The ultimate tensile strength (UTS) was raised by 15.11 % with increase in the 0.1 % MWCNT content GFRP as related to the thermal-shocked neat GFRP conditioned samples. The possible reason may be attributed to the variation in the coefficients of thermal expansion at the time of conditioning. Also, upto some extent the pre-existing residual stresses allows uniform distribution of stress and hence the reason in enhanced mechanical properties of GFRP and MWCNT filled composites. In order to access the modifications in the glass transition temperature (T_g) due to the addition of MWCNT in GFRP composite and also due to the thermal shock temperature modulated differential scanning calorimeter (TMDSC) measurements are carried out. Scanning electron microscopy(SEM) was carried out to identify different modes of failures and strengthening morphology in the composites.

TÍO2 thin films have been synthesized by dip coating process on the p-type silicon wafer for different withdrawal speeds varied from 1 cm/min to 4 cm/min. The films were annealed at 500°C for 1 hour in air atmosphere. The film thickness was found to be increased with the increase in withdrawal speed. The evolution of the anatase phase of TiOs₂ has been confirmed by structural studies. Optical characteristics of the dip coated TiO₂ films were investigated by Raman spectroscopy. For electrical measurement Al/TiO₂/Si MOS structures were fabricated. The current-voltage characteristics have shown the rapid rise in leakage current for initial bias voltage and afterwards, it became quasi saturated. The film, deposited at the withdrawal speed of 1 cm/min, has shown higher leakage current.

In the field of composite research, use of industrial wastes such as slag and sludge particles as filler in wear resistant polymer composites has not been very common. Owing to the very high cost of conventional filler materials in polymer composites, exploring the possibility of using low cost minerals and industrial wastes for this purpose has become the need of the hour. In this context this work explores the possibility of such polymer composites filled with low cost industrial wastes and presents a comparison of mechanical characteristics among three types of epoxy based composites filled with Linz - Donawitz sludge (LD sludge), blast furnace slag (BF slag) and Linz - Donawitz slag (LD slag) respectively. A comparative study in regard to their solid particle erosion wear characteristics under similar test conditions is also included. Composites with different weight proportions (0, 5, 10, 15 and 20 wt. %) of LD sludge are fabricated by solution casting technique. Mechanical properties such as micro- hardness, tensile strength and flexural strength of three types of composites have been evaluated as per ASTM test standards and solid particle erosion wear test is performed following a design of experiment approach based on Taguchi's orthogonal array. Five control factors (impact velocity, erodent size, filler content, impingement angle and erodent temperature) each at five levels are considered to conduct erosion wear tests. The test results for epoxy-LD sludge composites are compared with those of epoxy-BF slag and epoxy-LD slag composites reported by previous investigators. The comparison reveals that epoxy filled with LD sludge exhibits superior mechanical and erosion wear characteristics among the three types of composites considered in this study. This work also opens up a new avenue for value added utilization of an abundant industrial waste in the making of epoxy based functional composites.

Al–Si alloy-based composite is one of the most promising MMC materials owing to its outstanding mechanical properties, wear and corrosion resistance, low cost and ability to be synthesized via conventional casting routes. Challenges in achieving clean interface between reinforced particles and matrix alloy have been overcome by means of in-situ techniques of fabrication. Present investigation is concerned with synthesizing Al-Si-TiB₂ in-situ composites through stir casting route using K₂TiF₆ and KBF₄ halide salts for exothermic salt metal reaction. X-Ray diffraction analysis revealed the existence of TiB₂ in the prepared samples. Effect of TiB₂in-situ particles in the Al-Si base alloy has been investigated from the results obtained from optical microscopy as well as SEM study and wear analysis with a pin on disc wear testing apparatus. Improved hardness and wear properties were observed with addition of TiB₂.

The Antimicrobial and anti-inflammatory nature of the castor oil is used for the treatment of constipation and also used to clean the intestine before a surgical treatment. The growing demand castor oil due to its cheaper price and have much demand to grow hairs faster which give proteins to hair and increases the life span of hair and increases the hair capacity and provide hair smoothness because it has high ricinoleic ratio which is beneficial for skin and hair. The main objective of this paper is by observing its usefulness and the current aim for the research work is to produce bio-char/carbon compounds and extraction of higher carbon content. The castor leaves are collected and dried in the sun light to get it moisture free and proximate analysis is studied that reveals 14% of fixed amount of carbon. The dried leaves of castor plant are pyrolized at different temperature ranges 250°C, 350 °C, 450°C, 600°C and 900°C. The pyrolised specimens were studied by Fourier-transform infrared spectroscopy analysis which shows the transformation and formation of several bonds including carbon bonds which are affected during carbonization. Scanning electron microscope and energy dispersive x-ray spectroscopy have been studied on pyrolised specimen to get microstructures elements in the bio-char. The parameter called carbon/oxygen ration gives the advantage of char in the agricultural land for fertility motive and discrepancy of carbon and oxygen contents have been analysed. It has been found that carbon/oxygen ration increased along increment in Pyrolysis tempt. Up to 500°C and therefore along moreover increment in tempt. Beyond 500°C there is a decrement trend has been found.

Cu₂ZnSnS₄ (CZTS) has emerged as a potential absorber towards inorganic photovoltaic device application for its outstanding properties like non toxicity, earth abundancy nature, optimal band gap matched with solar spectrum (1.45- 1.65eV), high absorption coefficient (10⁴cm⁻¹). Here, a low cost, environment friendly facile hydrothermal route to synthesize phase pure CZTS nanoparticles using Cu (II), Zn (II), Sn (II) inorganic metal salts and thiourea as Sulphur source in distilled water solution as precursor is reported. The as synthesized samples characterized by X-Ray diffraction (XRD) and RAMAN confirmed structure and phase of CZTS nanocrystals. The morphology of the prepared CZTS have been characterized by scanning electron microscopy (SEM). The particle size is found in the range 4-5 nm with crystalline nature have been characterized by transmission electron microscope (TEM). The optical band gap of the as prepared samples is calculated to be 1.65eV from UV-Visible analysis which proves it can be used towards photovoltaic applications.

Graphene with two dimensional structures is a very exceptional material, since it has advantage of being excellent conducting material. Few layer of graphene sheets (FLGS) have been successfully prepared by an electrochemical method directly from graphite using oxalic acid as electrolyte. The prepared few layer FLGS have been characterized by X-ray diffraction(XRD), UV-Vis spectroscopy, field emission scanning electron microscope(FESEM), transmission electron microscope(TEM). The characterization reveals that the prepared FLGS is very good in quality. The measured current (I) vs voltage (v) shows that FLGS are highly conducting in nature. The hydrophobicity/Hydrophilicity of the prepared FLGS have been investigated for various applications.