Advanced Materials Research Vols. 264-265

Abstract: One of the most restricting aspects of the biaxial tensile test for sheet metal is the design of the cruciform specimen. Although specimens of the cruciform type have previoussly been investigated quite extensively, no standard geometry for the cruciform specimen exists. Using a specifically designed pantograph apparatus for operation in a standard tensile testing machine, various cruciform specimens were analysed experimentally. Finite element modelling of the specimens was also conducted to establish optimum specimen geometry. Through a process of optimisation, a standard cruciform specimen was designed which can be used to accurately predict the mechanical behaviour of cold rolled low-carbon steel when formed in multiple directions simultaneously.

Abstract: One substantial goal of modern vehicle construction is to reduce weight at a high level of crash safety. When steel is used in lightweight construction, the process of press hardening of boron-alloyed steels can be of great importance. The heat treatment during hot forming process increases the material’s tensile strength to a level of approximately 1500 MPa. The increased tensile strength needs to be considered in subsequent manufacturing processes, such as punching operations. At present, laser cutting is a common method to cut press hardened sheet metal, a process which is more cost-intensive and time-consuming as conventional tools and tool steels cannot be produced with a profitable output. One aim of the present project has been the investigation of tool steels as well as the different damage mechanisms occurring during the blanking of press-hardened sheet metal. A new tool concept has therefore been realized, which comprises the entire expertise of the Institute. Thus, the tool developed is a very good basis for assessing tool steels and their damage behaviour. Tool life and damage mechanisms have been analyzed.

Abstract: This paper investigates the performance of feedstock characteristics for micro metal injection molding (μMIM) by using optimum power loading variation and rheological characterization. The study has been emphasized on the powder and binder system in which stainless steel SS316L powder are mixed with composite binder, which consists of PEG (Polyethelena Glycol), PMMA (Polymethyl Methacrilate) and SA (Stearic Acid) by variation of powder loading concentration. The rheology properties are investigated using Shimadzu Flowtester CFT-500D capillary rheometer. As the geometry of water atomised stainless steel powder are irregular shape, therefore it is expected significant changes in the rheological results that can influence the microcomponent, surface quality, shape retention and resolution capabilities. The optimization of the μMIM rheological properties as a function of stainless steel powder loading concentration are evaluated by flow behavior exponent, activation energy and moldability index. From the results, it shows that 61.5%vol contributes a significant stability over a range of temperature and the best powder loading from a critical powder volume percentage (CPVP) and rheological point of view.

Abstract: Micro metal injection molding which is a new develop technology has attract most researcher where it becomes among the promising method in powder metallurgy research to produce small-scale intricate part at an effective process and competitive cost for mass production. Due to highly stringent characteristics of micro MIM feedstock,the study has been emphasized in investigating the optimization of highest green strength which plays an important characteristic in determining the successful of micro MIM. Stainless steel SS 316L with D50 = 5.96μm was used with composite binder, which consists of PEG, PMMA and Stearic Acid. From rheological characteristic and highly significant parameter through screening experiment, feedstock with 61.5% with several injection parameters were optimized such as injection pressure(A), injection temperature(B), mold temperature(C), injection time(D) and holding time(E). Besides that, interaction effects between injection pressure, injection temperature and mold temperature were also considered to optimize in the Taguchi’s orthogonal array. Analysis of variance (ANOVA) in terms of signal-to-noise ratio (S/N-larger is better) for green strength was also presented in this paper. Result shows that interaction between injection temperature and mold temperature(BxC) give highest significant factor followed by interaction between injection pressure and injection temperature(AxB). Single factor that also contributes to significant optimization are mold temperature(C), injection time(D) and injection pressure(A). This study shows that Taguchi method would be among the best method to solve the problem with minimum number of trials.

Abstract: The effect of hot extrusion process on the microstructure, mechanical properties and fracture behavior of metal-matrix composites (MMCs) of AA6061 alloy reinforced with 10 volume percent particulate SiC with the average size of 46 µm was studied. The MMC ingots were fabricated by the stir casting method and were extruded at 450°C at a ram speed of 1mm/s and at the extrusion ratios of 6:1, 12:1 and 18:1. Various techniques including metallography, density measurement, tensile testing, and SEM fractography were utilized to characterize the mechanical behavior of the MMCs. Results demonstrated that extruded composites possessed considerably lower porosity contents, higher strength, and enhanced ductility in comparison with the as-cast samples. In addition, further improvement in the mechanical properties of the extruded composites was noticed by increasing the extrusion ratio. Fractographic observations revealed that the brittle fracture behavior of the as-cast specimens was promoted by cracking of the large SiC particle clusters. Whereas, the fracture surfaces of extruded composites showed extensive tear ridge formation by initiation and growth of shallow dimples, around the cracked particles, which is characteristic of a ductile fracture process. This change in the fracture behavior and improvement in mechanical properties is attributed to the break up of particle clusters and diminishment of pores during the extrusion process.

Abstract: At present many researches are about low density and high strength material, Metal Matrix Composite (MMC) is one kind of high performance material which is very popular and can fit that condition very well. In this study, matrix material is Al alloy and Al2O3 short fiber is reinforcement, volume fractions of Al2O3 short fiber is 10, 15 and 20 %. Manufacture by a low-pressure infiltration method. And the performance is evaluated by microstructure observation, porosity ratio and relative density. It is found that the porosity ratio can be effectively adjusted by the infiltration temperatures and the loads of Al2O3 short-fibres, exhibiting a minimum of 2 for 10% loading at 700°C. Meanwhile, the relative density of composites reached to be a maximum of 98% for 15% loading at 700°C. The low porosity ratio and high density of composites are reasonably attributed to the proper processing techniques.

Abstract: Dynamic modeling of compaction process ,and evaluation of hardening parameters of powder compacts undergoing uni-axial/multi compaction is a tedious process and requires many elaborate tests .However ,assuming a two-parameter failure surface ( such as Mohr–Coulomb),evolution of failure surface may be monitored by two points on the failure surface. Results of uni-axial compression and direct or indirect tensile tests may readily provide the two required points. In order to assess this hypothesis ,a laboratory investigation was carried out using atomized iron powder(WPL-200) and aluminum powder(+160Mm) . Green compacts of the said drop-hammer , specifically designed for this purpose. Specimens with various relative compactions were produced and tested in uni-axial compression test and Brazilian split test .Variations of compressive/tensile strength with compaction energy(hammer speed) and relative density were studied and hardening law for green compacts were developed.

Abstract: The paper describes results of investigation on sputtered NiFe Films to determine the sputter deposition condition that could produce magnetic field sensors with the desired magnetic and magnetoresistive properties. The magnetic thin films materials used in such devices should have a low coercive force, a low anisotropy field and low magnetization dispersion, α50 with high magnetoresistance ratio. From the results presented, it is shown that that the most useful films for 82%Ni-Fe composition are produced at 200 °C-250 °C moderate substrate temperatures. It is also possible to specify the substrate bias potential and sputter gas pressure sputter deposition conditions under which the 82%Ni-Fe thin films may be employed for the production of magnetoresistine sensors with near optimum magnetic and magnetoresistive properties. The work also provide understanding of the effects on the magnetic properties of sputtered magnetic films that is very limited as current literature is almost entirely limited to evaporated magnetic films.

Abstract: This study aims to clarify the process conditions of the radial compression of aluminum tube. It provides a model that predicts not only the correct punch load for compression, but also the precise final shape of products after unloading, based on the compression properties of the material and the geometry of the tools used. An elasto-plastic incremental finite-element computer code, based on an updated Lagrangian formulation, was developed to simulate the radial compression of aluminum tube. In particular, selective reduced integration was adopted to formulate the stiffness matrix. The extended r-minimum technique was used to deal with the elasto-plastic state and contact problems at the tool-metal interface. A series of simulations were performed to validate the formulation in the theory, leading to the development of the computer codes. The whole deformation history and the distribution of stress and strain during the forming process were obtained by carefully considering the moving boundary condition in the finite-element method. Results in this study clearly demonstrated that the computer code for simulating the radial compression of aluminum tube was efficient.

Abstract: Lateral extrusion of gear- like components with radial tooth profile, has been studied in this paper. To analyze the process, the two types of theoretical approaches, i.e. the upper bound technique and the slab method of analysis have been applied and extrusion load values have been estimated. The theoretical results of load values estimated from the above approaches have been compared with theoretical and experimental results that given by a reference. Good agreement has been found among the predicted load values and those obtained from the experimental results.