Effect of Processing Route on Microstructure and Mechanical Properties of an Al-12Si Alloy.

Two different microstructures of an Al-12Si (wt. %) alloy were produced, respectively, via a powder laser bed fusion (P-LBF) additive manufacturing and casting. Compared to casting, additive manufacturing of Al-based alloy requires extra care to minimize oxidation tendency. The role of the microstructure on the mechanical properties of Al-12Si (wt. %) alloy was investigated by in situ compression of the micro-pillars. The microstructure of additively manufactured specimens exhibited a sub-cellular (~700 nm) nature in the presence of melt-pool arrangements and grain boundaries. On the other hand, the microstructure of the cast alloy contains typical needle-like eutectic structures. This striking difference in microstructure had obvious effects on the plastic flow of the materials under compression. The yield and ultimate compressive strength of the additively manufactured alloy were 23.69-27.94 MPa and 75.43-81.21 MPa, respectively. The cast alloy exhibited similar yield strength (31.46 MPa); however, its ultimate compressive strength (34.95 MPa) was only half that of the additively manufactured alloy. The deformation mechanism, as unrevealed by SEM investigation on the surface as well as on the cross-section of the distorted micro-pillars, confirms the presence of ductile and quasi-ductile facture of the matrix and the Si needle, respectively, in the case of the cast alloy. In contrast, the additively manufactured alloy exhibits predominantly ductile fractures.

Study of Respiratory Symptoms and Pulmonary Function among Neem Oil Industry Workers.

This study aims to investigate the pulmonary functions and respiratory symptoms of workers in the neem oil extraction industry in Tamil Nadu, India, who are exposed to neem oil dust and chemicalsin their occupational environment. Fifty male workers from the exposed group and 50 male workers from the non-exposed group to neem dust and chemicals were investigated for this study. A modified respiratory assessment questionnaire based on the American Thoracic Society (ATS) standard and portable hand-held spirometry were used to assess their respiratory symptoms and pulmonary function. Respiratory symptoms such as coughing, sneezing, wheezing, and, nasal irritation are found to be higher in the exposed groups than in the controlled groups. The pulmonary function of exposed workers had doubled respiratory problems than the controlled groups, which indicates the impacts of dust and chemicals generated during neem oil extraction on workers' health. Forced expiratory volume in one second (FEV1)/forced vital capacity FVC)% was noted regarding the duration of exposure to neem oil dust (P < 0.001). Also, there was a high difference between the heavily exposed and the lightly exposed (P < 0.001). Hence, to mitigate these problems, the oil mill workers should be cautious and wear personal protection equipment during working hours, and it is recommended to have an exhaust ventilation system.

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.

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.

Microstructure and tribological behaviour of CoCrCuFeTi high entropy alloy reinforced SS304 through friction stir processing.

Surface modification by suitable technique aids in improving the characteristics of material to resist severe wear in demanding environments and challenging applications. The present study aims to analyse the tribological performance of Stainless Steel (SS304) reinforced with CoCrCuFeTi High Entropy Alloy (HEA) through friction stir processing and compares the results with annealed specimens. The CoCrCuFeTi HEA was ball milled and revealed irregular fragment particles with Body Centred Cubic (BCC) phase. The processed samples exhibited excellent refinement in grains with uniform HEA reinforcement distribution. The grains were observed to be in nano level post-annealing promoting exceptional microhardness. The pin-on-disc wear test was conducted by varying load (10-40N), sliding velocity (0.5-3.5 m/s) and sliding distance (500-2000 m) and the respective worn surface was analysed. The processed sample with HEA after annealing offered 29.8%, 57.4% and 58.49% improved wear resistance at the minimum level of load, sliding velocity and sliding distance than the processed base samples. The worn morphology revealed delamination, abrasion, adhesion and oxide layer formation to be the predominant wear mechanisms.

Micro-Scale Deformation Aspects of Additively Fabricated Stainless Steel 316L under Compression.

The deformation aspects associated with the micro-mechanical properties of the powder laser bed fusion (P-LBF) additively manufactured stainless steel 316L were investigated in the present work. Toward that, micro-pillars were fabricated on different planes of the stainless steel 316L specimen with respect to build direction, and an in situ compression was carried out inside the chamber of the scanning electron microscope (SEM). The results were compared against the compositionally similar stainless steel 316L, which was fabricated by a conventional method, that is, casting. The post-deformed micro-pillars on the both materials were examined by electron microscopy. The P-LBF processed steel exhibits equiaxed as well as elongated grains of different orientation with the characteristics of the melt-pool type arrangements. In contrast, the cast alloy shows typical circular-type grains in the presence of micro-twins. The yield stress and ultimate compressive stress of P-LBF fabricated steel were about 431.02 ± 15.51 - 474.44 ± 23.49 MPa and 547.78 ± 29.58 - 682.59 ± 21.59 MPa, respectively. Whereas for the cast alloy, it was about 322.38 ± 19.78 MPa and 477.11 ± 25.31 MPa, respectively. Thus, the outcome of this study signifies that the AM-processed samples possess higher mechanical properties than conventionally processed alloy of similar composition. Irrespective of the processing method, both specimens exhibit ductile-type deformation, which is typical for metallic alloys.

Microstructural and Nanoindentation Investigation on the Laser Powder Bed Fusion Stainless Steel 316L.

Additive manufacturing (AM) of stainless steel is more difficult than other metallic materials, as the major alloying elements of the stainless steel are prone to oxidation during the fabrication process. In the current work, specimens of the stainless steel 316L were made by the powder laser bed fusion (P-LBF) additive manufacturing process. These specimens were investigated by electron microscopy and micro-/nano-indentation techniques to investigate the microstructural aspects and the mechanical properties, respectively. Compositionally, a similar wrought stainless steel was subjected to identical investigation, and used as a benchmark material. The microstructure of the P-LBF-processed alloy shows both equiaxed and elongated grains, which are marginally smaller (3.2-3.4 µm) than that of the wrought counterpart (3.6 µm). Withstanding such marginal gain size refinement, the increase in shear stress and hardness of the L-PBF alloy was striking. The L-PBF-processed alloy possess about 1.92-2.12 GPa of hardness, which was about 1.5 times higher than that of wrought alloy (1.30 GPa), and about 1.15 times more resistant against plastic flow of material. Similarly, L-PBF-processed alloy possess higher maximum shear stress (274.5-294.4 MPa) than that of the wrought alloy (175.9 MPa).

Investigation into the Microstructure and Hardness of Additively Manufactured (3D-Printed) Inconel 718 Alloy.

Additive manufacturing (AM) of Ni-based super alloys is more challenging, compared to the production other metallic alloys. This is due to their high melting point and excellent high temperature resistance. In the present work, an Inconel 718 alloy was fabricated by a powder laser bed fusion (P-LBF) process and investigated to assess its microstructural evolution, together with mechanical properties. Additionally, the alloy was compared against the cast (and forged) alloy of similar composition. The microstructure of the P-LBF-processed alloy shows hierarchy microstructure that consists of cellular sub-structure (~100-600 nm), together with melt pool and grain boundaries, in contrast of the twin infested larger grain microstructure of the cast alloy. However, the effect of such unique microstructure on mechanical properties of the L-PBF alloy was overwritten, due to the absence of precipitates. The hardness of the L-PBF-processed alloy (330-349 MPa) was lower than that of cast alloy (408 MPa). The similar trend was also observed in other mechanical properties, such as Young's modulus, resistance to plasticity and shear stress.

Formation and Characterization of the Recast Layer Formed on Inconel 718 during Wire Electro Discharge Machining.

The present work investigates the formation and microstructural and micro-mechanical characterization of the recast layer that formed on Inconel 718 alloy in the course of the wire electro-discharge machining (WEDM). The as-machined surface contains globules, shallow cracks, and re-deposition of molten materials, together with the elements from the decomposition of wire electrode and electrolyte, which does not exceed beyond the surface of the recast layer. Under presently investigated machining parameters, the recast layer was about 6.2 ± 2.1 µm thick. There was no presence of a heat-affected zone (HAZ), as otherwise indicated for other hard-to-cut materials. The transmission electron microscopy (TEM) and electron back-scattered diffraction (EBSD) investigations show that the microstructure of the recast layer is similar to that of bulk alloy. Micro-mechanical characterizations of the recast layer were investigated via in-situ micro-pillar compression on the micro-pillars fabricated on the recast layer. The strength of the superficial layer (1151.6 ± 51.1 MPa) was about 2.2 times higher than that of the base material (523.2 ± 22.1 MPa), as revealed by the in-situ micro-pillar compression.

In-situ SEM micropillar compression of porous and dense zirconia materials.

The reduction of failure rates of small-sized zirconia devices depends on the understanding of their micromechanical properties. This paper reports the micromechanical behaviors of porous and dense zirconia materials using in-situ micropillar compression with a flat diamond indenter in a scanning electron microscope (SEM). Porous and dense zirconia micropillars were made using focused ion beam (FIB) milling technique in the SEM. They were then subject to in-situ SEM compression to identify their Young's moduli, yield stresses, plastic deformation, compressive and fracture strengths, damage accumulations, and failure mechanisms. We found that while both porous and dense zirconia microstructures exhibited plastic behaviors, the former had much lower Young's moduli, strengths (yield, compression and fracture), resilience and toughness but higher ductility, resulting in significant buckling than the latter. In plastic regions, alternative strain softening and hardening may have caused stress variations in porous zirconia while dislocation movement contributed to strain hardening in dense zirconia. Although both zirconia materials had quasi-brittle failures, there were different damage mechanisms. The quasi-brittle failure for porous state was due to mushrooming buckling damage driven by breaking of weak interconnected pore networks, resulting in severe compaction and pulverization, microcracks and material piling. The quasi-brittle failure for dense state was identified as plastic crushing damage, involving microcrack initiation and propagation, cleavage and intergranular fractures, and delamination. The mechanical properties of porous and dense zirconia micropillars investigated contributed to the knowledge on deformation and damage mechanisms of zirconia materials at the small scale.

Vacancy-Induced Temperature-Dependent Thermal and Magnetic Properties of Holmium-Substituted Bismuth Ferrite Nanoparticle Compacts.

Multiferroics have gained widespread acceptance for room-temperature applications such as in spintronics, ferroelectric random access memory, and transistors because of their intrinsic magnetic and ferroelectric coupling. However, a comprehensive study, establishing a correlation between the magnetic and thermal transport properties of multiferroics, is still missing from the literature. To fill the void, this work reports the temperature-dependent thermal and magnetic properties of holmium-substituted bismuth ferrite (BiFeO3) and their dependencies on oxygen vacancies and structural modifications. Two distinct magnetic transitions on temperature-dependent magnetic and heat capacity responses are identified. Experimental analysis suggests that the excess of oxygen vacancies shifts the magnetic transition temperature by ∼64 K. The holmium substitution-induced structural modification increases BiFeO3 heat capacity by 30% up to the antiferromagnetic phase transition temperature. Furthermore, an unsaturated heat capacity even at temperatures as high as 850 K is observed and is ascribed to anharmonicity and partial densification of the nanoparticles used during heat capacity measurements. The room-temperature thermal conductivity of BiFeO3 is ∼0.33 ± 0.11 W m-1 K-1 and remains unchanged at high temperatures due to defect scattering from porosities.

In-situ SEM cyclic nanoindentation of pre-sintered and sintered zirconia materials.

Efficient diamond machining of zirconia requires a comprehensive understanding of repetitive diamond indentation mechanics. This paper reports on in-situ cyclic nanoindentations of pre-sintered and sintered zirconia materials performed inside a scanning electron microscope (SEM). In-situ SEM imaging of cyclic indentation processes and high-magnification SEM mapping of indentation imprints were conducted. The elastic and plastic behaviors of pre-sintered and sintered zirconia materials were investigated as a function of the cyclic nanoindentation number using the Sakai and Sakai-Nowak models. For pre-sintered zirconia, cyclic nanoindentation induced quasi-plastic deformation, causing localized agglomeration of zirconia crystals with microcracks and large cracking along the indentation edge. Severely compressed, fragmented, and pulverized zirconia crystals and smeared surfaces were also observed. For sintered zirconia, shear bands dominated quasi-plastic deformation with the formation of edge pile-ups and localized microfractures occurred at indentation apex and diagonals. All elastic and plastic behaviors for pre-sintered and sintered zirconia materials revealed significantly microstructure-dependent. Pre-sintered zirconia yielded significantly lower contact hardness, Young's moduli, resistance to plasticity, elastic deformation components, and resistance to machining-induced cracking, and higher elastic and plastic displacements than sintered state. Meanwhile, all the behaviors for the two materials were independent from the cyclic nanoindentation number. A model was proposed for cyclic nanoindentation mechanics, revealing their cyclic indentation-induced microstructural changes in the two zirconia materials. This study advances the fundamental understanding of nanoindentation mechanics of zirconia materials.

In-vitro tribological study and submodeling finite element technique in analyzing wear of zirconia toughened alumina against alumina with bio-lubricants for hip implants.

Tribological study of zirconia toughened alumina against alumina is investigated using ball-on-disk tribometer with different bio-lubricants. Friction and wear coefficients are estimated for these bio-lubricants under four different loading conditions which are equivalent to regular and risky human gait activities. Experiments are carried out for a total sliding distance of 10 km with each bio-lubricant to estimate its friction and wear coefficients. Using submodeling finite element approach, cumulative linear and volumetric wear is estimated with the help of contact pressure. The sesame oil bio-lubricant showed better wear coefficient for risky gait activities and Ringer's solution exhibited minimum wear coefficient for normal walking gait activity. Overall minimum cumulative linear and volumetric wear for 2 million cycles was obtained for Ringer's solution.

Investigating the Efficacy of Adhesive Tape for Drilling Carbon Fibre Reinforced Polymers.

In the present research work, an effort has been made to explore the potential of using the adhesive tapes while drilling CFRPs. The input parameters, such as drill bit diameter, point angle, Scotch tape layers, spindle speed, and feed rate have been studied in response to thrust force, torque, circularity, diameter error, surface roughness, and delamination occurring during drilling. It has been found that the increase in point angle increased the delamination, while increase in Scotch tape layers reduced delamination. The surface roughness decreased with the increase in drill diameter and point angle, while it increased with the speed, feed rate, and tape layer. The best low roughness was obtained at 6 mm diameter, 130° point angle, 0.11 mm/rev feed rate, and 2250 rpm speed at three layers of Scotch tape. The circularity error initially increased with drill bit diameter and point angle, but then decreased sharply with further increase in the drill bit diameter. Further, the circularity error has non-linear behavior with the speed, feed rate, and tape layer. Low circularity error has been obtained at 4 mm diameter, 118° point angle, 0.1 mm/rev feed rate, and 2500 RPM speed at three layers of Scotch tape. The low diameter error has been obtained at 6 mm diameter, 130° point angle, 0.12 mm/rev feed rate, and 2500 rpm speed at three layer Scotch tape. From the optical micro-graphs of drilled holes, it has been found that the point angle is one of the most effective process parameters that significantly affects the delamination mechanism, followed by Scotch tape layers as compared to other parameters such as drill bit diameter, spindle speed, and feed rate.

Microstructural responses of Zirconia materials to in-situ SEM nanoindentation.

Development of optimal shaping processes for pre-sintered and sintered zirconia materials requires a fundamental understanding of damage and deformation mechanisms at small-scale contacts with diamond tools. This paper reports on responses of zirconia materials with distinct microstructures to nanoindentation associated with diamond machining using a Berkovich diamond indenter. In-situ nanoindentation was performed in a scanning electron microscope (SEM) and in-process filmed to record small contact events. Indentation morphology was SEM-mapped at high-magnifications. Although both pre-sintered porous and sintered dense zirconia materials mechanically revealed the quasi-plastic behavior in indentation, there were distinct responses of the two materials to quasi-plasticity at the microstructural level. For pre-sintered porous zirconia, the quasi-plasticity was attributed to shear faults resulting from breaking pore networks as microstructurally discrete interfaces, to lead to compression, fragmentation, pulverization and microcracking of zirconia crystals in indentation imprints. In contrast, sintered dense zirconia had shear band-induced quasi-plastic deformation, accompanied with localized tensile microfracture. A material index associated with the mechanical properties ranked the lower quasi-plasticity for pre-sintered porous zirconia than its sintered dense state, predicting more machining-induced damage in the former than the latter. Significantly higher indentation imprint volumes induced in indented pre-sintered porous zirconia than sintered dense state previses higher machining efficiency for the former than the latter. The microstructure-dependent indentation mechanisms provide the fundamental knowledge into micromechanics of abrasive machining of zirconia materials and may lead to a new microstructural design for zirconia materials to achieve a balanced machining efficiency and damage control.

Magneto-Rheological Fluid Assisted Abrasive Nanofinishing of ß-Phase Ti-Nb-Ta-Zr Alloy: Parametric Appraisal and Corrosion Analysis.

The present work explores the potential of magneto-rheological fluid assisted abrasive finishing (MRF-AF) for obtaining precise surface topography of an in-house developed ß-phase Ti-Nb-Ta-Zr (TNTZ) alloy for orthopedic applications. Investigations have been made to study the influence of the concentration of carbonyl iron particles (CIP), rotational speed (Nt), and working gap (Gp) in response to material removal (MR) and surface roughness (Ra) of the finished sample using a design of experimental technique. Further, the corrosion performance of the finished samples has also been analyzed through simulated body fluid (SBF) testing. It has been found that the selected input process parameters significantly influenced the observed MR and Ra values at 95% confidence level. Apart from this, it has been found that Gp and Nt exhibited the maximum contribution in the optimized values of the MR and Ra, respectively. Further, the corrosion analysis of the finished samples specified that the resistance against corrosion is a direct function of the surface finish. The morphological analysis of the corroded morphologies indicated that the rough sites of the implant surface have provided the nuclei for corrosion mechanics that ultimately resulted in the shredding of the appetite layer. Overall results highlighted that the MRF-AF is a potential technique for obtaining nano-scale finishing of the high-strength ß-phase Ti-Nb-Ta-Zr alloy.

Tribological Properties of Chromium Nitride on the Cylinder Liner under the Influence of High Temperature.

The chromium nitride coating is a hard coating used to improve the sliding friction and wear behavior and is applied to engine components in various operating conditions even at an elevated temperature. In this study, chromium nitride was deposited by a physical vapor deposition process onto the cast iron substrate. All tribological tests were performed on linear reciprocating tribometer with a stroke length of 5 mm in a dry condition at variable temperature levels of 28 °C, 100 °C, 200 °C, and of 300 °C corresponding to loads of 10 N, 20 N, 30 N, and 40 N against the cylinder liner material. The worn surfaces of chromium nitride(CrN) coatings after friction tests were analyzed by scanning electron microscope (SEM) and energy-dispersive spectroscopy (EDS). The results showed that friction coefficients (COF) ranged from 0.93 to 0.34 from room temperature to 300 °C against the cylinder liner material as a counter-body of 6 mm in diameter; higher temperature results in the positive tribological performance of CrN, with at least 0.34 COF at 300 °C. The wear mechanisms of CrN and counter-body surfaces are abrasive wear accompanied by the slight oxidation. This study guides the wear behavior of cylinder liner coatings in an environment similar to the engine.

Evaluating Hole Quality in Drilling of Al 6061 Alloys.

Hole quality in drilling is considered a precursor for reliable and secure component assembly, ensuring product integrity and functioning service life. This paper aims to evaluate the influence of the key process parameters on drilling performance. A series of drilling tests with new TiN-coated high speed steel (HSS) bits are performed, while thrust force and torque are measured with the aid of an in-house built force dynamometer. The effect of process mechanics on hole quality, e.g., dimensional accuracy, burr formation, surface finish, is evaluated in relation to drill-bit wear and chip formation mechanism. Experimental results indicate that the feedrate which dictates the uncut chip thickness and material removal rate is the most dominant factor, significantly impacting force and hole quality. For a given spindle speed range, maximum increase of axial force and torque is 44.94% and 47.65%, respectively, when feedrate increases from 0.04 mm/rev to 0.08 mm/rev. Stable, jerk-free cutting at feedrate of as low as 0.04 mm/rev is shown to result in hole dimensional error of less than 2%. A low feedrate along with high spindle speed may be preferred. The underlying tool wear mechanism and progression needs to be taken into account when drilling a large number of holes. The findings of the paper clearly signify the importance and choice of drilling parameters and provide guidelines for manufacturing industries to enhance a part's dimensional integrity and productivity.

Pediatric thymoma with a difference: report of a case and review of literature.

Thymoma represents <1% of all mediastinal tumors in children. Less than 50 cases of pediatric thymoma are reported in the literature. Thymomas are considered to be highly aggressive in pediatric patients, especially when age is <10 years. Paraneoplastic syndromes, of which around 70% are myasthenia gravis, correlate with poor prognosis. In this article, we report a case of a thymoma in an 8-year-old boy, who had favorable histopathology (Masaoka stage I, WHO type B2), despite the presence of young age and necrosis along with absence of myasthenia gravis. We have also reviewed the available literature on pediatric thymoma.