Browsing by Author "Shukla, Amarish Kumar"

Now showing 1 - 11 of 11

Development of wire arc additive manufactured Cu-Si alloy: study of microstructure and wear behavior
(Springer Nature, 2023-02-21) Kazmi, Kashif Hasan; Sharma, Sumit K.; Das, Alok Kumar; Mandal, Amitava; Shukla, Amarish Kumar
Wire arc additive manufacturing (WAAM) is an approach to develop unique and sophisticated design products in comparison to other traditional techniques. In the present study, the components of Cu-Si alloy have been developed using WAAM with a robotic gas metal arc welding technique. In this process, the current and voltage varied from 70 to 110 A and 17 to 19 V, respectively. The effect of process parameters on the microstructure, hardness, and wear behavior of components have been studied in details. The results show that the surface roughness of the components reduced with the increase in current and voltage. The microstructure of the uppermost surface of WAAM components shows columnar followed by dendritic with equiaxed morphology. The process parameter also affects the mechanical and wear resistance properties of WAAM components. The results show that the microhardness (from 100.03 to 160.03 HV) and wear resistance of the Cu-Si alloy component increase with the increases in current and voltage.
Microstructural, mechanical, and thermal analysis of SS316L weldment for marine engineering application
(2023-07) Kumar, Aswin S.; Shukla, Amarish Kumar
A SS316L steel is known as a marine-grade material, which is frequently used in a shipbuilding structure and marine industries. In the present study, a shielded metal arc welding (SMAW) process was used for similar welding of SS316L steel plate with dimension of 60 mm x 60 mm x 2 mm. A two different electrode E316L-16 and E308L-16, welding currents of 70 A, 80 A and 90 A and constant voltages of 24 V has been used for weldment. The impact of electrodes and current on the microstructure and mechanical properties of welded specimens was thoroughly investigated. To evaluate the flaw in the fusion zone (FZ), a surface macrograph and microstructure were analysed using scanning electron microscopy (SEM). In order to study the surface characteristics and ascertain the elemental composition of the samples, energy dispersive spectroscopy (EDS) was used. The hardness tests have been carried out in the base, heat-affected zone, and fusion zone of the welded joint. Tensile tests were carried out to study the effect of heat input on the yield strength (Y.S), Ultimate tensile strength (UTS) and elongation of a welded sample. According to the microstructure results, as the heat input increases, the grain structure of the welded zone gets finer in comparison to the base material. A hardness and tensile result shows that the properties of electrode and applied current has an effect on the mechanical properties of the SMAW welded sample. The hardness of the fusion zone increases compared to base material. The hardness result shows that as the current increases from70 A to 80 A by using the electrode of E316L-16 the hardness increases from 214 HV to 223 HV while the hardness further decreases to 208 HV for 90 A. Similarly, for E308L-16 electrode the hardness increases from 190 HV to 218 HV, and further it decreases to 168 HV for the applying current of 70A, 80A and 90 A respectively. A tensile result shows that the UTS of the SMAW welded sample varies from 190 to 262 N/mm2 compared to base material, i.e., 565 N/mm2Furthermore, thermal analysis was performed using ANSYS software to look at the impact of heat input at various welding arc times and identify the temperature distribution on the plate across various regions. In addition, the effect of heat input on the microstructure behaviour were studied in detail. The current thesis has been broken into six chapters. The first chapter presents an overview of steel welding and its applications in numerous fields. It also emphasises the distinguishing feature of the SMAW welded 316L stainless steel. Chapter 2 discusses the literature on various stainless steel processing processes, as well as the reported literature on the properties of 316L ix stainless steel, such as microstructural, mechanical, and thermal analysis of steel using the ANSYS software tool, and their applications. This is followed by identifying gaps in the literature and developing targets for addressing the issues related with SMAW welded 316L stainless steel. The materials and procedures employed in the current study are described in Chapter 3. Furthermore, this chapter discusses the various characterization strategies used in the current work. SMAW welded 316L stainless steel results and discussion in Chapter 4. A detailed investigation on the influence of changing current and electrodes on the microstructure and mechanical properties of SMAW welded 316L stainless steel was also conducted. Furthermore, the ANSYS software tool was used to study the temperature distribution during the SMAW welded 316L stainless steel. The study's summary and results are detailed in Chapter 5. Finally, in Chapter 6, the future scope and additional possibilities of current research work on SMAW welded 316L stainless steel were thoroughly examined.
Microstructural, Mechanical, and Thermal Analysis of SS316L Weldment for Marine Engineering Application
(Springer Nature, 2023-11-16) Kumar, A. S.; Sharma, S. K.; Shukla, Amarish Kumar
SS316L steel is known as a marine-grade material, which is frequently used in shipbuilding structures and marine industries. In the present study, a shielded metal arc welding (SMAW) process was used for welding of SS316L steel plate by using electrode E316L-16 and E308L-16, welding currents of 70, 80 and 90 A and constant voltages of 24 V. The effect of process parameters on the microstructure and mechanical properties of the welded specimens in the fusion zone (FZ), heat-affected zone (HAZ) and at base has been analysed using scanning electron microscopy (SEM) and microhardness test. The results show that the mechanical properties of the SMAW welded sample are influenced by both electrode properties and applied current. The fusion zone hardness increases compared to the base material. The welded sample processed by using electrode E316L-16 and 80 A current exhibits the higher hardness i.e., 223 HV due to a combination of lower heat input, higher welding speed, and the presence of a fine grain structure compared to other welded sample. A tensile result shows that the Ultimate tensile strength (UTS) of the SMAW welded sample varies from 190 to 262 N/mm2 compared to a base material, i.e., 565 N/mm2. This drop in tensile strength in the welded joints is attributed to HAZ softening stemming from the formation of coarse-grained microstructures. Furthermore, thermal analysis utilizing ANSYS software was employed to assess the influence of heat input at different welding arc times and to map temperature distribution across various plate regions. The results indicate that reducing welding time leads to lower temperatures in the electrode samples, consistent with simulation outcomes. Additionally, variations in microstructure were evident across distinct plate regions. The impact of heat input on microstructural behaviour was further comprehensively examined.
Microstructural, mechanical, and thermal analysis of SS316L weldment for marine engineering application /
(Springer Nature, 2023-11-16) Kumar, Aswin S.; Shukla, Amarish Kumar
SS316L steel is known as a marine-grade material, which is frequently used in shipbuilding structures and marine industries. In the present study, a shielded metal arc welding (SMAW) process was used for welding of SS316L steel plate by using electrode E316L-16 and E308L-16, welding currents of 70, 80 and 90 A and constant voltages of 24 V. The effect of process parameters on the microstructure and mechanical properties of the welded specimens in the fusion zone (FZ), heat-affected zone (HAZ) and at base has been analysed using scanning electron microscopy (SEM) and microhardness test. The results show that the mechanical properties of the SMAW welded sample are influenced by both electrode properties and applied current. The fusion zone hardness increases compared to the base material. The welded sample processed by using electrode E316L-16 and 80 A current exhibits the higher hardness i.e., 223 HV due to a combination of lower heat input, higher welding speed, and the presence of a fine grain structure compared to other welded sample. A tensile result shows that the Ultimate tensile strength (UTS) of the SMAW welded sample varies from 190 to 262 N/mm2 compared to a base material, i.e., 565 N/mm2. This drop in tensile strength in the welded joints is attributed to HAZ softening stemming from the formation of coarse-grained microstructures. Furthermore, thermal analysis utilizing ANSYS software was employed to assess the influence of heat input at different welding arc times and to map temperature distribution across various plate regions. The results indicate that reducing welding time leads to lower temperatures in the electrode samples, consistent with simulation outcomes. Additionally, variations in microstructure were evident across distinct plate regions. The impact of heat input on microstructural behaviour was further comprehensively examined.
Processing techniques, microstructural and mechanical properties of additive manufactured 316L stainless steel: Review
(Springer Nature, 2023-06-07) Sharma, Sumit K.; Singh, Abhinav Kumar; Mishra, Rohit Kumar; Shukla, Amarish Kumar; Sharma, Chaitanya
The 316L stainless steel owing to its good combination of mechanical properties, corrosion resistance, fabricability, and weldability finds applications in pharmaceutical, food, and other industries where high corrosion resistance is of prime importance. Nowadays, this alloy is finding increasing favor to produce orthopedic implants using modern techniques like additive manufacturing. In the past, several manufacturing methods have been widely used in the field of aerospace, naval, automobile, biomedical, and other industrial sectors. Traditional methods of manufacturing are the most adaptable and cost-effective of all the processes that have been developed; however, these techniques have limitations to manufacturing complicated design and waste management. In recent years, the additive manufacturing technique is widely used in handling complicated geometrical structures. Additive manufacturing technology has seen a major transformation in the manufacturing world as a result of recent technological advancements. In additive manufacturing, the development process began with polymers, progressed to composites, and finally to nanocomposites. Additive manufacturing offers a small waste production management solution with improved procedures. Additive manufacturing outperforms conventional methods to fabricate high-quality and intricate stainless steel, difficult-to-develop machine components. This paper aims to discuss the principal of various traditional and additive manufacturing techniques used for creating many grades of stainless steel. Consequently, the microstructural and mechanical properties of steels have been examined and compared for various applications, like orthopedic implants, and other engineering applications.
Processing Techniques, Microstructural and Mechanical Properties of Additive Manufactured 316L Stainless Steel: Review
(Springer Nature, 2023-06-07) Shukla, Amarish Kumar
The 316L stainless steel owing to its good combination of mechanical properties, corrosion resistance, fabricability, and weldability finds applications in pharmaceutical, food, and other industries where high corrosion resistance is of prime importance. Nowadays, this alloy is finding increasing favor to produce orthopedic implants using modern techniques like additive manufacturing. In the past, several manufacturing methods have been widely used in the field of aerospace, naval, automobile, biomedical, and other industrial sectors. Traditional methods of manufacturing are the most adaptable and cost-effective of all the processes that have been developed; however, these techniques have limitations to manufacturing complicated design and waste management. In recent years, the additive manufacturing technique is widely used in handling complicated geometrical structures. Additive manufacturing technology has seen a major transformation in the manufacturing world as a result of recent technological advancements. In additive manufacturing, the development process began with polymers, progressed to composites, and finally to nanocomposites. Additive manufacturing offers a small waste production management solution with improved procedures. Additive manufacturing outperforms conventional methods to fabricate high-quality and intricate stainless steel, difficult-to-develop machine components. This paper aims to discuss the principal of various traditional and additive manufacturing techniques used for creating many grades of stainless steel. Consequently, the microstructural and mechanical properties of steels have been examined and compared for various applications, like orthopedic implants, and other engineering applications.
Surface Characteristics, Microstructural, and Tribological Behavior of Wire Arc Additive Manufactured Aluminum-5356 Alloy
(Springer Nature, 2024-03-18) Shukla, Amarish Kumar
In the present work, aluminum-5356 alloy was deposited using wire arc additive manufacturing (WAAM) equipped with a robotic gas metal arc welding setup (GMAW). The morphology, microhardness, microstructure, and tribological features of the WAAM-deposited specimen were studied in detail. The results show that the microhardness of the WAAM-deposited Al-5356 alloy increased from 57 to 81 HV from the top to the bottom portion. The wear resistance of the deposited component also increased from the top to the bottom portion. Moreover, the microstructure and mechanical properties of the deposited wall were investigated on deposited specimens with selected parameters from the top to bottom area of specimens, respectively. The detailed study shows the understanding of the effect of variation in current on the surface morphology, microstructure, hardness, and wear behavior of different areas from top to bottom of the deposited multilayer components.
Wire arc additive manufacturing of ER-4043 aluminum alloy: effect of tool speed on microstructure, mechanical properties and parameter optimization
(Springer Nature, 2023-05-23) Kazmi, Kashif Hasan; Sharma, Sumit K.; Das, Alok Kumar; Mandal, Amitava; Shukla, Amarish Kumar; Mandal, Ranjan
Recent technological breakthroughs have had a significant impact on wire arc additive manufacturing (WAAM) technology in the metal manufacturing industry. Current and tool speed are the essential factors influencing the bead quality in WAAM, and experiments were conducted to optimize these parameters. Central composite design was applied for the deposition of beads, and their responses (bead width, height, depth of penetration and surface roughness) were measured using the coordinate measuring machine and 3D profilometer. Analysis of variance was applied to check the validity of the actual and predicted models. In this research, the morphology, microstructure, microhardness and wear behavior of the aluminum alloy ER-4043 were examined. Specimens were deposited using robotic gas metal arc welding (GMAW), using a 1.2 mm wire diameter, a constant current of 250 A and varying tool speed from 7 to 11 mm/s.
Wire Arc Additive Manufacturing of ER-4043 Aluminum Alloy: Effect of Tool Speed on Microstructure, Mechanical Properties and Parameter Optimization
(Springer Nature, 2023-05-23) Shukla, Amarish Kumar
Recent technological breakthroughs have had a significant impact on wire arc additive manufacturing (WAAM) technology in the metal manufacturing industry. Current and tool speed are the essential factors influencing the bead quality in WAAM, and experiments were conducted to optimize these parameters. Central composite design was applied for the deposition of beads, and their responses (bead width, height, depth of penetration and surface roughness) were measured using the coordinate measuring machine and 3D profilometer. Analysis of variance was applied to check the validity of the actual and predicted models. In this research, the morphology, microstructure, microhardness and wear behavior of the aluminum alloy ER-4043 were examined. Specimens were deposited using robotic gas metal arc welding (GMAW), using a 1.2 mm wire diameter, a constant current of 250 A and varying tool speed from 7 to 11 mm/s.
Wire arc additive manufacturing of ER-4043 aluminum alloy: evaluation of bead profile, microstructure, and wear behavior /
(Springer Nature, 2023-07-13) Shukla, Amarish Kumar
Wire arc additive manufacturing technique has a major transformation in metal manufacturing as a result of recent technological advancements. The present study is aimed at the deposition of the defects-free bead of ER-4043 aluminum alloy (aluminum–silicon alloy) by using wire arc additive manufacturing (WAAM) with robotic gas metal arc welding (GMAW) with varying current and tool speeds. The arc served as the heat source, and a 1.2-mm diameter of ER-4043 aluminum alloy wire was used as the raw material during bead deposition. The cross-section profile of the single bead in WAAM is essential for determining surface quality and dimensional accuracy. The cross-section profile of each bead was measured using a coordinate measuring machine (CMM) by taking multiple points on the surface of each bead. Points taken from each bead are fitted with Gaussian, logistic, parabola, and sine functions using the least square regression analysis to determine the geometry of the single bead. Moreover, the microstructure and mechanical properties of the deposited bead were investigated on selected parameters with a constant tool speed of 10 mm/s, varying heat input in terms of current from 153 A, 202 A, and 246 A of specimens A, B, and C, respectively. The detailed study shows the understanding of the effect of variation of current on the surface morphology, microstructure, hardness, and wear behavior of deposited beads.
Wire arc additive manufacturing of ER-4043 aluminum alloy: evaluation of bead profile, microstructure, and wear behaviour
(Springer Nature, 2023-07-13) Kazmi, Kashif Hasan; Das, Alok Kumar; Sharma, Sumit K.; Mandal, Amitava; Shukla, Amarish Kumar
Wire arc additive manufacturing technique has a major transformation in metal manufacturing as a result of recent technological advancements. The present study is aimed at the deposition of the defects-free bead of ER-4043 aluminum alloy (aluminum–silicon alloy) by using wire arc additive manufacturing (WAAM) with robotic gas metal arc welding (GMAW) with varying current and tool speeds. The arc served as the heat source, and a 1.2-mm diameter of ER-4043 aluminum alloy wire was used as the raw material during bead deposition. The cross-section profile of the single bead in WAAM is essential for determining surface quality and dimensional accuracy. The cross-section profile of each bead was measured using a coordinate measuring machine (CMM) by taking multiple points on the surface of each bead. Points taken from each bead are fitted with Gaussian, logistic, parabola, and sine functions using the least square regression analysis to determine the geometry of the single bead. Moreover, the microstructure and mechanical properties of the deposited bead were investigated on selected parameters with a constant tool speed of 10 mm/s, varying heat input in terms of current from 153 A, 202 A, and 246 A of specimens A, B, and C, respectively. The detailed study shows the understanding of the effect of variation of current on the surface morphology, microstructure, hardness, and wear behavior of deposited beads.