r. jaiswal

This research aims to study the effect of different tool pin shapes on the mechanical properties of friction stir processed (FSP) surface composites. The focus is on fabricating 6061-T6 Al/SiC composites using cylindrical, triangular, tapered cylinder, square, and hexagonal tool pin geometries. The experiments were conducted on a vertical milling machine with H13 tool steel at a transverse speed of 20 mm/min and a rotational speed of 1000 rpm, with three passes. Dye penetrant tests confirmed the absence of surface defects. Microhardness testing using the Vickers method showed that the square pin geometry achieved the maximum hardness value (120 HV). Surface topography analysis using optical and scanning electron microscopy revealed significant grain refinement and fragmentation of silicon carbide particles. Wear tests using a pin-on-disk tribometer indicated that 6061-T6 aluminum alloy without reinforcement exhibited the highest wear rate, while the square tool pin geometry resulted in the least wear rate due to increased microhardness. The processed Al/SiC composites demonstrated a lower average friction coefficient compared to the base metal.

Electron beam welding has shown a remarkable job in the space industry for welding of components. It is performed under a vacuum environment that eliminates foreign matter such as hydrogen, oxygen, and other gases. Joining of similar and dissimilar materials is the main advantage of electron beam welding with high depth to width ratio as well as sharp focus at the point where parts are to be welded. EBW reduces the HAZ (heat affected zone), making it one of the most acceptable welding processes. In this study, evaluation of the effect of joining parameters on the mechanical strength and hardness is conducted using Minitab software. The strength of the electron beam weld varies with welding parameters. Therefore, correct and optimized parameter selection imparted the highest welding strength. Some welding parameters directly affect weld strength; those were judiciously selected for our experiments. Therefore, 3x3 arrays were selected for investigation on the microhardness and ultimate tensile strength of Fe49Co2V. Three levels and four factors are chosen for analysis. The input parameters are selected as Accelerating Voltage (KV), Welding Speed (mm/min), Beam Current (mA), and Focus Current (mA). This study reveals the maximum welding strength obtained at High Voltage (55 KV), High Beam current (7 mA), Moderate Speed (20 mm/min), and moderate focus current (2365 mA). Similarly, the microhardness obtained at a High Voltage (55 KV), High beam current (7 mA), high welding speed (30 mm/min) and minimum focus current (2210 mA). This study reveals the maximum welding strength obtained at High Voltage (55KV), High beam current (7mA), moderate speed (20 mm/min) & moderate focus current (2365mA). Similarly, the micro-hardness obtained at a High Voltage (55KV), High beam current (7mA), and the high welding speed (30 mm/min) & minimum focus current (2210mA).