Papers by Author: K. Sreekumar

Abstract: Investment casting has emerged as the foremost casting process for manufacturing of intricate parts where better dimensional accuracy is required. Use of rapid prototyping polymer patterns is one of the major advancements in investment casting process. Elimination of die making step as required in the traditional wax process makes it quicker and a cost effective process. The direct conversion of 3D CAD data into rapid prototyping pattern decreases development time, chances of costly mistakes, minimizes sustaining engineering changes and extend product lifetime by adding necessary features and eliminating redundant features early in the design.

Abstract: In the present study, thermal treatments for homogenizing cast structures of Al-Cu-Li alloy AA2195 for improved workability are developed chiefly by empirical methods and detailed Differential Scanning Calorimetry (DSC) and microstructural characterization. DSC has been carried out on as-cast samples to establish the homogenization temperatures and avoid incipient melting. Homogenization time has been calculated empirically and microstructural characterization and DSC has been carriedout to after each cycle to validate the empirically established homogenization cycle. Homogenization cycle (435°C/8hrs+495°C/12hrs+525°C/32hrs) has been established for AA2195 alloy having an average grain size of 500μm based on calorimetric studies and microstructural examination.

Abstract: Al-Cu-Mg (Russian grade V65) alloys are used for riveting applications in aerospace industries due to relatively high shear strength of the order of 25 kg/mm² combined with a high plasticity. The main advantage of using V65 aluminum alloy for rivet application comes from its significantly slower natural aging response, which gives flexibility to carryout riveting operation even after 4 days after solution heat treatment and natural aging at room temperature. This very valuable feature is not found in its counterpart alloy AA2024 where due to rapid aging kinetics of this alloy, the riveting operation must be completed within 30 min of the solution treatment, which is many times impractical. This paper presents the processing of V65 aluminium alloy by Direct Chill (DC) casting followed by subsequent secondary processing through extrusion and forging to realize feedstock for caliber rolling. These ingots were caliber rolled to 12 mm diameter rods at different temperatures and mechanical properties were evaluated in T6 and T4 tempers. Detailed microstructural examination using optical microscopy and fractography of the tensile tested samples using scanning electron microscopy were carriedout to correlate microstructure and mechanical properties.

Abstract: Silver reinforced with carbon nanotubes, instead of graphite, would increase both the electrical conductivity, hardness and wear resistance of the electrical brush materials. The effective utilization of carbon nanotubes in the Ag/CNT composite depends strongly on its uniform distribution and strong interfacial adhesion to the silver matrix and thus demands for its surface modification. In order to carry out the surface modification of carbon nanotubes, electroless coating was given to them after liquid phase oxidation, sensitization and activation process. The room-temperature chemical treatment results in a nominally complete coating over the entire outer surface of multiwall carbon nanotube. The surface morphology of the carbon nanotubes after each step has been studied using TGA, DSC, XRD, FTIR and SEM.

Abstract: The objective of the present study was to melt and cast AA2195 alloy in Vacuum Induction Melting (VIM) under dynamic inert atmosphere. These billets were homogenized and subsequently hot forged and rolled to sheets. The products in the form of sheets were subjected to T8 (Solution Treatment +WQ+CW+Aging) temper condition. Mechanical properties were evaluated at room temperature and correlated with microstructure. Highest mechanical properties obtained in T87 temper have been reported.

Abstract: A novel technique of pure Lithium addition has been adopted for the processing of Al-Cu-Li alloy AA2195 cast ingots (7-8 kg each) in VIM under dynamic inert atmosphere, which gives more than 95% recovery of Lithium. The cast billets were homogenized, forged and converted into 12mm diameter rods by caliber rolling in the temperature range of 250°C, 300°C, 350°C and 400°C. The caliber rolled rods were treated to T8 (Solution Treatment+WQ+CW+Aging) condition. Mechanical properties were evaluated for T8 tempered bars at room temperature and correlated with microstructural observations. Highest mechanical properties in T87 temper have been obtained for rods caliber rolled at 350°C temperature.

Abstract: Missile and rocket motor cases are often fabricated by welding process. The replacement of welded hardware with the flow formed construction eliminates many problems associated with welded joints. Data on the cold workability of the material in different heat treatment conditions is essential for the flow forming of the material. The cold workability of a 0.3C-CrMoV grain refined steel processed by air melting and electroslag refining was studied in annealed and Q&T conditions through cold rolling process. The effect of heat treatment on the strength properties of the rolled materials was also studied. The observed behaviour is explained in the light of the results of the microstructural characterization.

Abstract: Aluminium alloys and austenitic stainless steels are often used for construction of cryogenic pressure vessels owing to their attractive properties at cryogenic temperatures. Indian space programme requires AA2219/ICSS1218-SS321 bimetallic components which are machined from explosive welded plates. Pure aluminium sheet is used as an interlayer between aluminium alloy and steel to achieve a satisfactory bond. Internal soundness of the joint is evaluated through ultrasonic testing (UT). The present paper discusses bonding trials carried out by varying the explosive parameters using facilities and expertise of Terminal Ballistic Research Laboratory (TBRL), Chandigarh and M/s Giridhari Explosives Private Limited (GEPL), Hyderabad. The welded joint is extensively characterised with respect to Lap Shear and Ultimate Tensile Strength at ambient temperature and for metallographic analysis.

Abstract: Ti15V3Al3Cr3Sn (Ti-15-3-3-3) alloy is a highly cold formable metastable beta alloy and attains very high strength by proper selection of cold working and heat treatment cycles. Due to the presence of softer BCC beta phase at ambient temperature in solution treated condition, this alloy is highly cold workable; to as much as 90% without need of any intermediate annealing. In the present work, cold working up to 83% was imparted to the sheet. Subsequently, cold worked sheet was solution annealed at various temperatures. Cold worked and solution annealed samples were provided with two types of aging cycles: 482°C/16hrs/AC (STA-1) and 538°C/8hrs/AC (STA-2). Hardness measurement, tensile property and microstructural evaluation in cold worked (CW), CW plus solution annealed (CWSA) and CWSA plus aged conditions were carriedout. Recrystallization temperature has been observed to be dependent on extent of cold working. Tensile properties are higher for STA-1 cycle as compared to STA-2 cycle. Hardness values in cold worked condition are higher than solution annealed samples whereas for cold worked and STA samples, an increase in hardness w.r.t. to annealed values has been observed. Corresponding volume fraction of alpha precipitates is found to be more with STA-1 cycle than STA-2 cycle. Also, distribution of the precipitates with STA-1 cycle is observed to be more uniform than STA-2 cycle. The present paper discusses the effect of cold working on recrystallization, mechanical properties and microstructure in Ti-15-3-3-3 beta alloy.

Abstract: nconel 718 is an age hardenable nickel base supper alloy with high strength at elevated temperatures, and excellent creep properties. It is used extensively in turbine discs, blades where components experience elevated temperatures for prolonged duration, leading to coarsening of the microstructure. To evaluate the life of such components after prolonged exposure to service conditions, LCF properties at such large grain sizes are essential. For this purpose, low cycle fatigue (LCF) behavior of forged Inconel 718 turbine rotor disc having large grain size was studied at room temperature. Total strain controlled fatigue tests were conducted in air at ambient temperature on this alloy in solution treated and aged condition. The results indicated that the material exhibits cyclic strain softening and the cyclic yield strength is lower by 40% compared to the monotonic yield strength. The deformation takes place by multiple planar slip.