Experimental investigation on characterization of friction stir processed AZ31-based composite.

Present study has been conducted to characterize the Mg alloy namely AZ31-based composite joined by Friction stir processing (FSP) technique. This study deals with the effect of single and double passes in FSP of AZ31 Mg alloy. The single pass run in FSP is followed at tool rotation speed (N) of 1000 to 1400 rpm. Also, the double pass run in FSP was followed at these speeds without using reinforcements. The feedstock particles namely SiC, Al2O3, Cr, and Si powders were used in fabrication process. The hardness, impact strength, and tensile strength characteristics were assessed in the stir region zone, and the results indicated significant improvement in these properties. The highest values of mechanical strength were seen in the FSPed area with N = 1000 rpm at a constant transverse speed (r) of 40 mm/min. Also, the tensile strength of the two passes FSPed plates is much higher than that of the single section without any reinforcement, as revealed in previous study also. The Scanning electron microscopy (SEM) analysis is done at two different magnifications for the Silicon carbide, Alumina, Chromium, and Silicon powder reinforced composites fabricated at speed of 1000 rpm. The microstructure shows that reinforced particles were uniform dispersed into FSPed region and agglomerated with Mg matrix. Si powder produces finer microstructure as compare to SiC, Al2O3, Cr. FSP decreases the grain size of processed material. Optical Microscopy results revealed that the reinforcement particle produced a homogenous microstructure and, a refined grain and equally dispersed in matrix material without split to the particle.

An event triggered control scheme for enhanced production of Escherichia coli and biomass concentration during fed-batch cultivation.

Control of a bioprocess is a challenging task mainly due to the nonlinearity of the process, the complex nature of microorganisms, and variations in critical parameters such as temperature, pH, and agitator speed. Generally, the optimum values chosen for critical parameters during Escherichia coli (E.coli) K-12fed-batch fermentation are37 ᵒC for temperature, 7 for pH, and 35 % for Dissolved Oxygen (DO). The objective of this research is to enhance biomass concentration while minimizing energy consumption. To achieve this, an Event-Triggered Control (ETC) scheme based on feedback-feed forward control is proposed. The ETC system dynamically adjusts the substrate feed rate in response to variations in critical parameters. We compare the performance of classical Proportional Integral (PI) controllers and advanced Model Predictive Control (MPC) controllers in terms of bioprocess yield. Initially, the data are collected from a laboratory-scaled 3L bioreactor setup under fed-batch operating conditions, and data-driven models are developed using system identification techniques. Then, classical Proportional Integral (PI) and advanced Model Predictive Control (MPC) based feedback controllers are developed for controlling the yield of bioprocess by manipulating substrate flow rate, and their performances are compared. PI and MPC-based Event Triggered Feed Forward Controllers are designed to increase the yield and to suppress the effect of known disturbances due to critical parameters. Whenever there is a variation in the value of a critical parameter, it is considered an event, and ETC initiates a control action by manipulating the substrate feed rate. PI and MPC-based ETC controllers are developed in simulation, and their closed-loop performances are compared. It is observed that the Integral Square Error (ISE) is notably minimized to 4.668 for MPC with disturbance and 4.742 for MPC with Feed Forward Control. Similarly, the Integral Absolute Error (IAE) reduces to 2.453 for MPC with disturbance and 0.8124 for MPC with Feed Forward Control. The simulation results reveal that the MPC-based ETC control scheme enhances the biomass yield by 7 %, and this result is verified experimentally. This system dynamically adjusts the substrate feed rate in response to variations in critical parameters, which is a novel approach in the field of bioprocess control. Also, the proposed control schemes help reduce the frequency of communication between controller and actuator, which reduces power consumption.

Innovations in metal-organic frameworks (MOFs): Pioneering adsorption approaches for persistent organic pollutant (POP) removal.

Adsorption is a promising way to remove persistent organic pollutants (POPs), a major environmental issue. With their high porosity and vast surface areas, MOFs are suited for POP removal due to their excellent adsorption capabilities. This review addresses the intricate principles of MOF-mediated adsorption and helps to future attempts to mitigate organic water pollution. This review examines the complicated concepts of MOF-mediated adsorption, including MOF synthesis methodologies, adsorption mechanisms, and material tunability and adaptability. MOFs' ability to adsorb POPs via electrostatic forces, acid-base interactions, hydrogen bonds, and pi-pi interactions is elaborated. This review demonstrates its versatility in eliminating many types of contaminants. Functionalizing, adding metal nanoparticles, or changing MOFs after they are created can improve their performance and remove contaminants. This paper also discusses MOF-based pollutant removal issues and future prospects, including adsorption capacity, selectivity, scale-up for practical application, stability, and recovery. These obstacles can be overcome by rationally designing MOFs, developing composite materials, and improving material production and characterization. Overall, MOF technology research and innovation hold considerable promise for environmental pollution solutions and sustainable remediation. Desorption and regeneration in MOFs are also included in the review, along with methods for improving pollutant removal efficiency and sustainability. Case studies of effective MOF regeneration and scaling up for practical deployment are discussed, along with future ideas for addressing these hurdles.

Effect of Elevated Acetabular Cup on Contact and Failure Analysis in Hip Implants for Different Microseparations and Cup Inclinations Under Routine Gait Activities Using In Silico Approach.

Objectives: The acetabular cup design plays a critical role in reducing contact stress between femur head acetabular cup. Many studies used ellipsoidal and spheroidal geometry in acetabular cup design to effectively reduce contact stress. The present study focuses on elevated acetabular cup rim with round corner design to reduce contact stress with round corner geometry. Methods: The cobalt chromium femur head and cup are considered for finite element (FE) model of hip resurfacing. The gait loads of routine activities of humans like normal walking, stair ascending and descending and sitting down and getting up gait activities are applied to the developed 3D FE model. Five microseparations of 0.5, 1, 1.5, 2 and 2.5 mm are considered in the present study. The acetabular cup inclination angle considered for this study are 35°, 45°, 55°, 65° and 75°. The contact stress and von Mises stress plot for each gait activities under these microseparations are analyzed for betterment of longevity of implants. Results: Overall elevated cup rim design helped in reducing contact stress to a greater extent than conventional cup with different geometries. Also, the predicted von Mises stress for all the parameters considered in the current study are well within the yield strength of CoCr material. Therefore, elevated cup rim could be used as a better alternative to spline and, ellipsoidal and circular geometries of cup.

Nano-Sized Al2O3-Gr Reinforced Al7075 Hybrid Composite: Impact of Cooling Agents on Mechanical, Wear, and Fracture Behavior.

Aluminum metal cast composites (AMCCs) are frequently used in high-tech sectors such as automobiles, aerospace, biomedical, electronics, and others to fabricate precise and especially responsible parts. The mechanical and wear behavior of the metal matrix composites (MMCs) is anticipated to be influenced by the cooling agent's action and the cooling temperature. This research paper presents the findings of a series of tests to investigate the mechanical, wear, and fracture behavior of hybrid MMCs made of Al7075 reinforced by varying wt % of nano-sized Al2O3 and Gr and quenched with water and ice cubes. The heat-treated Al7075 alloy hybrid composites were evaluated for their hardness, tensile, and wear behavior, showcasing a significant process innovation. The heat treatment process greatly improved the hybrid composites' mechanical and wear performance. The samples quenched in ice attained the highest hardness of 119 VHN. There is a 45.37% improvement in the hardness of base alloy with the addition of 3% of Al2O3 and 1% of graphite particles. Further, the highest tensile and compression strengths were found in the ice-quenched 3% Al2O3 and 1% graphite hybrid composites with improvements of 34.2 and 48.83%, respectively, compared to the water-quenched base alloy. Under the samples quenched in ice, the mechanical and wear behavior improved. The tensile fractured surface showed voids, particle pullouts, and dimples. The worn-out surface of wear test samples of the created hybrid composite had micro pits, delamination layers, and microcracks.

Assessment of pulmonary function and respiratory symptoms among INDIAN textile sizing mill workers.

BACKGROUND: Textile-sizing mill workers are exposed to various hazards in the sizing units during their working hours and are at risk of acquiring lung impairments due to the usage of sizing chemicals in the sizing process. OBJECTIVE: The main aim of this study is to assess the influence of cotton dust and sizing agents on lung function and breathing difficulties among Indian textile sizing mill workers. METHODS: This cross-sectional study was carried out at a textile-sizing mill from August 2022 to September 2022. A modified questionnaire based American Thoracic Society's standard was used to assess respiratory symptoms among sizing mill workers and the pulmonary function test was conducted Spirometry. The chi-square test was used to find the difference between respiratory symptoms and the t-test was used to find the difference between spirometric parameters. RESULTS: Textile sizing mill workers showed significant (P <  0.0001) decline in peak expiratory flow rate, forced vital capacity (FVC), ratio of FEV1 and forced vital capacity, and forced expiratory volume in 1 s (FEV1). There was an association between symptoms and duration of exposure to pulmonary abnormality. Sizing mill workers showed a significant decline in lung functions and an increase in pulmonary symptoms. As the service duration of exposure in terms of years increased, respiratory symptoms increased and spirometric abnormality also increased. CONCLUSION: This study confirms that sizing agents such as polyvinyl alcohol (PVA), emulsifier, wax, carboxymethyl cellulose (CMC), and starch used in sizing mills are also responsible for respiratory illness and lung impairment among textile workers.

Approaches for Memristive Structures Using Scratching Probe Nanolithography: Towards Neuromorphic Applications.

This paper proposes two different approaches to studying resistive switching of oxide thin films using scratching probe nanolithography of atomic force microscopy (AFM). These approaches allow us to assess the effects of memristor size and top-contact thickness on resistive switching. For that purpose, we investigated scratching probe nanolithography regimes using the Taguchi method, which is known as a reliable method for improving the reliability of the result. The AFM parameters, including normal load, scratch distance, probe speed, and probe direction, are optimized on the photoresist thin film by the Taguchi method. As a result, the pinholes with diameter ranged from 25.4 ± 2.2 nm to 85.1 ± 6.3 nm, and the groove array with a depth of 40.5 ± 3.7 nm and a roughness at the bottom of less than a few nanometers was formed. Then, based on the Si/TiN/ZnO/photoresist structures, we fabricated and investigated memristors with different spot sizes and TiN top contact thickness. As a result, the HRS/LRS ratio, USET, and ILRS are well controlled for a memristor size from 27 nm to 83 nm and ranged from ~8 to ~128, from 1.4 ± 0.1 V to 1.8 ± 0.2 V, and from (1.7 ± 0.2) × 10-10 A to (4.2 ± 0.6) × 10-9 A, respectively. Furthermore, the HRS/LRS ratio and USET are well controlled at a TiN top contact thickness from 8.3 ± 1.1 nm to 32.4 ± 4.2 nm and ranged from ~22 to ~188 and from 1.15 ± 0.05 V to 1.62 ± 0.06 V, respectively. The results can be used in the engineering and manufacturing of memristive structures for neuromorphic applications of brain-inspired artificial intelligence systems.

Synergy of silica sand and waste plastics as thermoplastic composites on abrasive wear characteristics under conditions of different loads and sliding speeds.

The diverse nature of polymers with attractive properties has replaced the conventional materials with polymeric composites. The present study was sought to evaluate the wear performance of thermoplastic-based composites under the conditions of different loads and sliding speeds. In the present study, nine different composites were developed by using low-density polyethylene (LDPE), high-density polyethylene (HDPE) and polyethylene terephthalate (PET) with partial sand replacements i.e., 0, 30, 40, and 50 wt%. The abrasive wear was evaluated as per the ASTM G65 standard test for abrasive wear through a dry-sand rubber wheel apparatus under the applied loads of 34.335, 56.898, 68.719, 79.461 and 90.742 (N) and sliding speeds of 0.5388, 0.7184, 0.8980, 1.0776 and 1.4369 (m/s). The optimum density and compressive strength were obtained to be 2.0555 g/cm3 and 46.20 N/mm2, respectively for the composites HDPE60 and HDPE50 respectively. The minimum value of abrasive wear were found to 0.02498, 0.03430, 0.03095, 0.09020 and 0.03267 (cm3) under the considered loads of 34.335, 56.898, 68.719, 79.461 and 90.742 (N), respectively. Moreover, the composites LDPE50, LDPE100, LDPE100, LDPE50PET20 and LDPE60 showed a minimum abrasive wear of 0.03267, 0.05949, 0.05949, 0.03095 and 0.10292 at the sliding speeds of 0.5388, 0.7184, 0.8980, 1.0776 and 1.4369 (m/s), respectively. The wear response varied non-linearly with the conditions of loads and sliding speeds. Micro-cutting, plastic deformations, fiber peelings, etc. were included as the possible wear mechanism. The possible correlations between wear and mechanical properties, and throughout discussions for wear behaviors through the morphological analyses of the worn-out surfaces were provided.

A rare case report of pleomorphic adenoma of the upper lip: An unusual clinical presentation.

Pleomorphic adenoma is the most common salivary gland tumor which accounts for about 60% of all salivary neoplasms. It is also known as "mixed tumor because of its wide cytomorphologic diversity". Pleomorphic adenoma salivary glands mostly occurs on the palate, but the involvement of the upper lip is rare. The present report describes a case of a 62-year-old male with asymptomatic firm nodular swelling attached with upper lip which was later diagnosed as pleomorphic adenoma in the excisional biopsy.

Optimization of Selective Laser Melting Parameter for Invar Material by Using JAYA Algorithm: Comparison with TLBO, GA and JAYA.

In this study, the hardness and surface roughness of selective laser-melted parts have been evaluated by considering a wide variety of input parameters. The Invar-36 has been considered a workpiece material that is mainly used in the aerospace industry for making parts as well as widely used in bimetallic thermostats. It is the mechanical properties and metallurgical properties of parts that drive the final product's quality in today's competitive marketplace. The study aims to examine how laser power, scanning speed, and orientation influence fabricated specimens. Using ANOVA, the established models were tested and the parameters were evaluated for their significance in predicting response. In the next step, the fuzzy-based JAYA algorithm has been implemented to determine which parameter is optimal in the proposed study. In addition, the optimal parametric combination obtained by the JAYA algorithm was compared with the optimal parametric combination obtained by TLBO and genetic algorithm (GA) to establish the effectiveness of the JAYA algorithm. Based on the results, an orientation of 90°, 136 KW of laser power, and 650 mm/s scanning speed were found to be the best combination of process parameters for generating the desired hardness and roughness for the Invar-36 material.

Advancements in the Additive Manufacturing of Magnesium and Aluminum Alloys through Laser-Based Approach.

Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role processing parameters of laser-based additive manufacturing is critical to maximize the usage of material in forming the product geometry. LPBF (Laser powder-based fusion) method is regarded as a potent and effective additive manufacturing technique for creating intricate 3D forms/parts with high levels of precision and reproducibility together with acceptable metallurgical characteristics. While dealing with LBPF, some degree of porosity is acceptable because it is unavoidable; hot ripping and cracking must be avoided, though. The necessary manufacturing of pre-alloyed powder and ductility remains to be the primary concern while dealing with a laser-based additive manufacturing approach. The presence of the Al-Si eutectic phase in AlSi10Mg and AlSi12 alloy attributing to excellent castability and low shrinkage, attaining the most attention in the laser-based approach. Related studies with these alloys along with precipitation hardening and heat treatment processing were discussed. The Pure Mg, Mg-Al alloy, Mg-RE alloy, and Mg-Zn alloy along with the mechanical characteristics, electrochemical durability, and biocompatibility of Mg-based material have been elaborated in the work-study. The review article also summarizes the processing parameters of the additive manufacturing powder-based approach relating to different Mg-based alloys. For future aspects, the optimization of processing parameters, composition of the alloy, and quality of powder material used will significantly improve the ductility of additively manufactured Mg alloy by the LPBF approach. Other than that, the recycling of Mg-alloy powder hasn't been investigated yet. Meanwhile, the post-processing approach, including a homogeneous coating on the porous scaffolds, will mark the suitability in terms of future advancements in Mg and Al-based alloys.

Elastic Properties of Jute Fiber Reinforced Polymer Composites with Different Hierarchical Structures.

A two-stage micromechanics technique is used to predict the elastic modulus, as well as the major and minor Poisson's ratio of unidirectional natural fiber (NF) reinforced composites. The actual NF microstructure consists of cellulose, hemicellulose, lignin, lumen, etc., and these constituents and their contributions are neglected in classical models while quantifying their mechanical properties. The present paper addresses the effect of the real microstructure of the natural jute fiber (JF) by applying a micromechanics approach with the Finite Element Method. Six different hierarchically micro-structured JFs are considered to quantify the JF elastic properties in the first level of homogenization. Later, the JF reinforced polypropylene matrix properties are investigated in the second stage by adopting a homogenization approach. Taking into account the different hierarchical structures (HS), the fiber direction modulus (E1), transverse modulus (E2 and E3), in-plane and out-of-plane shear modulus (G12 and G23), and major (ν12, ν13) and minor (ν23, ν21) Poisson's ratios are estimated for JF and JF reinforced polypropylene composites. The predicted elastic modulus from micromechanics models is validated against the analytical results and experimental predictions. From the present work, it is observed that the HS of NF needs to be considered while addressing the elastic properties of the NF-reinforced composite for their effective design, particularly at a higher volume fraction of NF.

Strength Evaluation of Functionalized MWCNT-Reinforced Polymer Nanocomposites Synthesized Using a 3D Mixing Approach.

The incorporation of carboxyl functionalized multi-walled carbon nanotube (MWCNT- COOH) into a polymethyl methacrylate (PMMA) has been investigated. The resultant tensile and flexural mechanical properties have been determined. In this paper, a novel synthesis process for a MWCNT-reinforced polymer nanocomposite is proposed. The proposed method significantly eliminates the most challenging issues of the nano-dispersed phase, including agglomeration and non-homogeneous mixing within a given matrix material, and also resolves the issues occurring in conventional mixing processes. The results of scanning electron microscopy support these claims. This 3D-mixing process is followed by an extrusion process, using a twin-screw extruder for pristine MWCNT, and a compression molding process for COOH-MWCNT, to prepare test specimens for experimentally determining the mechanical properties. The test specimens are fabricated using 0.1, 0.5, and 1.0 wt.% MWCNT, with a remaining PMMA phase. The testing is conducted according to ASTM D3039 and ASTM D7264 standards. Significant improvements of 25.41%, 35.85%, and 31.75% in tensile properties and 18.27%, 48%, and 33.33% in flexural properties for 0.1, 0.5, and 1.0 wt.% COOH-MWCNT in PMMA, respectively, compared to non-functionalized MWCNTs, were demonstrated. The highest strength was recorded for the nanocomposite with 0.5 wt.% f-MWCNT content, indicating the best doping effect at a lower concentration of f-MWCNT. The proposed CNT-PMMA nanocomposite may be found suitable for use as a scaffold material in the domain of bone tissue engineering research. This type of research possesses a high strength requirement, which may be fulfilled using MWCNT. Furthermore, this analysis also shows a significant amount of enhancement in flexural strength, which is clinically required for fabricating denture bases.

Feasibility Analysis of Machining Cobalt-Chromium Alloy (Stellite-6) Using TiN Coated Binary Inserts.

The objective of the study was to check the feasibility of machining Stellite 6, a cobalt-chromium superalloy, using TiN-coated carbide inserts in an end milling operation. The inserts were coated using the magnetron sputtering process. The sputtering power and gas flow rate were considered as the variables during the coating process. The performance of the coated binary carbide insert was checked during the end milling of Stellite 6 (~45 HRC) through an experiment with a Taguchi design. Experimental runs based on an orthogonal array were executed for each insert type to check the feasibility of machining this cobalt-based alloy. Adequate precision and the optimum parametric conditions were determined and are reported in this study. Analysis of variance (ANOVA) with a two-factor interaction model was also undertaken to forecast the key elements influencing surface roughness. Based on the ANOVA model, the depth of the cut, combined with the insert type, was the factor that had the greatest influence on surface roughness, followed by the cutting feed, whereas the cutting velocity had the least significance based on the tests. Moreover, the regression analysis demonstrated that the created model can be used to accurately forecast surface roughness in end milling of Stellite 6 with confidence intervals of 95%.

Advanced Characterization of Adhesive Joints and Adhesives.

Structural adhesives have shown significant improvements in their behavior over the past few decades [...].

Effect of Mass on the Dynamic Characteristics of Single- and Double-Layered Graphene-Based Nano Resonators.

Graphene has been widely and extensively used in mass sensing applications. The present study focused on exploring the use of single-layer graphene (SLG) and double-layer graphene (DLG) as sensing devices. The dynamic analysis of SLG and DLG with different boundary conditions (BDs) and length was executed using the atomistic finite element method (AFEM). SLG and DLG sheets were modelled and considered as a space-frame structure similar to a 3D beam. Spring elements (Combin14) were used to identify the interlayer interactions between two graphene layers in the DLG sheet due to the van der Waals forces. Simulations were carried out to visualize the behavior of the SLG and DLG subjected to different BDs and when used as mass sensing devices. The variation in frequency was noted by changing the length and applied mass of the SLGs and DLGs. The quantity of the frequency was found to be highest in the armchair SLG (6, 6) for a 50 nm sheet length and lowest in the chiral SLG (16, 4) for a 20 nm sheet length in the bridged condition. When the mass was 0.1 Zg, the frequency for the zigzag SLG (20, 0) was higher in both cases. The results show that the length of the sheet and the various mass values have a significant impact on the dynamic properties. The present research will contribute to the ultra-high frequency nano-resonance applications.

Influence of Fiber Angle on Steady-State Response of Laminated Composite Rectangular Plates.

Significant advances in the field of composite structures continue to be made on a variety of fronts, including theoretical studies based on advances in structural theory kinematics and computer models of structural elements employing advanced theories and unique formulations. Plate vibration is a persistently interesting subject owing to its wider usage as a structural component in the industry. The current study was carried out using the Co continuous eight-noded quadrilateral shear-flexible element having five nodal degrees of freedom, which is ground on first-order shear deformation theory (FSDT). For small strain and sufficiently large deformation, the geometric nonlinearity is integrated using the Von Kármán assumption. The governing equations in the time domain are solved employing the modified shooting technique along with an arc-length and pseudo-arc-length continuation strategy. This work explored the effect of fiber angle on the steady-state nonlinear forced vibration response. To explain hardening nonlinearity, the strain and stress fluctuation throughout the thickness for a rectangular laminated composite plate is determined. The cyclic fluctuation of the steady-state nonlinear normal stress during a time period at the centre of the top/bottom surfaces is also provided at the forcing frequency ratio of peak amplitude in a nonlinear response. Because of the variation in restoring forces, the frequency spectra for all fiber angle orientations show significantly enhanced harmonic participation in addition to the fundamental harmonic.

Determination of Optimum Machining Parameters for Face Milling Process of Ti6A14V Metal Matrix Composite.

This paper shows the novel approach of Taguchi-Based Grey Relational Analysis of Ti6Al4V Machining parameter. Ti6Al4V metal matrix composite has been fabricated using the powder metallurgy route. Here, all the components of TI6Al4V machining forces, including longitudinal force (Fx), radial force (Fy), tangential force (Fz), surface roughness and material removal rate (MRR) are measured during the facing operation. The effect of three process parameters, cutting speed, tool feed and cutting depth, is being studied on the matching responses. Orthogonal design of experiment (Taguchi L9) has been adopted to execute the process parameters in each level. To validate the process output parameters, the Grey Relational Analysis (GRA) optimization approach was applied. The percentage contribution of machining parameters to the parameter of response performance was interpreted through variance analysis (ANOVA). Through the GRA process, the emphasis was on the fact that for TI6Al4V metal matrix composite among all machining parameters, tool feed serves as the highest contribution to the output responses accompanied by the cutting depth with the cutting speed in addition. From optimal testing, it is found that for minimization of machining forces, maximization of MRR and minimization of Ra, the best combinations of input parameters are the 2nd stage of cutting speed (175 m/min), the 3rd stage of feed (0.25 mm/edge) as well as the 2nd stage of cutting depth (1.2 mm). It is also found that hardness of Ti6Al4V MMC is 59.4 HRA and composition of that material remain the same after milling operation.

Microstructure and Mechanical Properties Analysis of Al/Cu Dissimilar Alloys Joining by Using Conventional and Bobbin Tool Friction Stir Welding.

The feasibility of producing welding joints between 6061-T6 aluminum and pure copper sheets of 6 mm thickness by conventional friction stir welding (CFSW) and bobbin tool friction stir welding (BTFSW) by using a slot-groove configuration at the joining surface was investigated. The microstructure of the welded samples was examined by using an optical microscope and X-ray diffraction. Furthermore, the mechanical properties of the weld samples are compared based on the results of the tensile test, hardness measurement, and fractography test. The slot-groove configuration resulted in the presence of a bulk-sized Al block on the Cu side. The microscopic observations revealed the dispersion of fine Cu particles in the stir zone. The presence of intermetallic compounds (IMCs) CuAl2, which are hard and brittle, lowered the strength of the weld joints. The strength of the weld joints produced with BTFSW was superior to that of the C-FSW. The maximum hardness values of 214 HV and 211 HV are reported at the stir zone for BTFSW and CFSW, respectively. The fracture location of all the joints was at the intersection of the stir zone and the thermomechanically affected zone was on the Cu side.

Corrosion Behavior of Friction Stir Welded AA8090-T87 Aluminum Alloy.

Aerospace alloys with reduced wall thickness but possessing higher hardness, good tensile strength and reasonable corrosion resistance are essential in manufacturing of structures such as fuselage. In this work, friction stir welding has been carried out on such an aerospace aluminum alloy AA8090 T87 which contains 2.3% lithium. Tool rotational speed of 900 rpm and traverse speeds of 90 mm/min., 110 mm/min. are the welding parameters. Hardness analysis, surface roughness analysis and corrosion analysis are conducted to analyze the suitability of the joint for the intended application. The samples were corrosion tested in acid alkali solution and they resulted in the formation of pits of varying levels which indicate the extent of surface degradation. Hardness of the samples was measured after corrosion analysis to observe the changes. The analysis suggests that the change in tool traverse speed transformed the corrosion behavior of the joint and affected both the hardness and surface roughness which mitigated the quality of the joint.