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.

Effect of Metal-Cored Filler Wire on Surface Morphology and Micro-Hardness of Regulated Metal Deposition Welded ASTM A387-Gr.11-Cl.2 Steel Plates.

Environmental and human-friendly welding is the need of the hour. In this context, this study explores the application of the regulated metal deposition (RMD) technique for ASTM A387-Gr.11-Cl.2 steel plates. To examine the effect of metal-cored filler wire (MCFW), MEGAFIL 237 M was employed during regulated metal deposition (RMD) welding of 6 mm thick ASTM A387-Gr.11-Cl.2 steel plates. The welding was carried out at an optimized current (A) of 100 A, voltage (V) of 13 V, and gas flow rate (GFR) of 21 L/min. Thereafter, the as-welded plates were examined for morphological changes using optical microscopy. Additionally, the micro-hardness of the as-welded plates was measured to make corroboration with the obtained surface morphologies. In addition to this, the as-welded plates were subjected to heat treatment followed by surface morphology and micro-hardness examination. A comparison was made between the as-welded and heat-treated plates for their obtained surface morphologies and microhardness values. During this, it was observed that the weld zone of as-welded plates has a dendritic surface morphology which is very common in fusion-based welding. Similarly, the weld zone of heat-treated plates has a finer and erratic arrangement of martensite. Moreover, the obtained surface morphologies in the weld zone of as-welded and heat-treated plates have been justified by their respective hardness values of 1588.6 HV and 227.3 HV.

Effects of Self-Lubricant Coating and Motion on Reduction of Friction and Wear of Mild Steel and Data Analysis from Machine Learning Approach.

The applications of coated mild steels are gaining significant attention in versatile industrial areas because of their better mechanical properties, anticorrosive behavior, and reproducibility. The life period of this steel reduces significantly under relative motion in the presence of friction, which is associated with the loss of billion-dollar every year in industry. Productivity is hampered, and economic growth is declined. Several pieces of research have been conducted throughout the industries to seeking the processes of frictional reduction. This study is attributed to the tribological behavior of electroplated mild steel under various operating parameters. The efficiency of commercial lubricant and self-lubrication characteristics of coated layer plays a significant role in the reduction of friction. The reciprocating and simultaneous motion in relation to pin as well as disc are considered during experimentation. The lubricating effects in conjunction with motions are responsible for compensating the friction and wear at the desired level. During frictional tests, the sliding velocity and loads are changed differently. The changes in roughness after frictional tests are observed. The coated and rubbing surfaces are characterized using SEM (Scanning Electron Microscopy) analysis. The coating characteristics are analyzed by EDS (Energy Disperse Spectroscopy), FTIR (Fourier-transform Infrared Spectroscopy), and XRD (X-ray diffraction analysis) methods. The lubrication, reciprocating motion, and low velocity result in low friction and wear. The larger the imposed loads, the smaller the frictional force, and the larger the wear rate. The machine learning (ML) concept is incorporated in this study to identify the patterns of datasets spontaneously and generate a prediction model for forecasting the data, which are out of the experimental range. It can be desired that the outcomes of this research will contribute to the improvement in versatile engineering fields, such as automotive, robotics, and complex motion-based mechanisms where multidimensional motion cannot be ignored.

Hierarchical Microstructure Tailoring of Pure Titanium for Enhancing Cellular Response at Tissue-Implant Interface.

The main goal of this research is to scrutinize the effect of texture and grain size on the biological response of hierarchical structured pure titanium (Ti), examining the interrelation between grain refinement mechanisms with texture variation. The hierarchical structure was produced using two methods of severe plastic deformation (SPD). The Ti specimens were first processed up to six passes by equal channel angular pressing (ECAP) and subsequently treated at the top surface using surface mechanical attrition treatment (SMAT). Microstructure examination by Electron backscatter diffraction (EBSD) indicates that the SMAT-treated surface was categorized into three distinct microstructural regions based on the type of grain refinement process involved during SPD: twin induced dynamic recrystallization (TDRX) and geometric dynamic recrystallization (GDRX) in the topmost surface, and continuous (CDRX) and discontinuous dynamic recrystallization (DDRX) in the lower regions of the sample. The biological experiments showed meaningful improvement in the cellular response of SMATed and ECAPed samples. It was demonstrated that grain refinement could have the capability of improving the biological response of Ti surface. In this regard, SMATed + 2ECAPed sample showed the best result although it has not the smallest grain size and the highest texture intensity. It was observed that texture and grain orientation of planes have an important impact on the biological response of pure Ti and dominance of prismatic (1010) texture can improve the cell viability, adhesion and its differentiation. Therefore, microstructure and texture tailoring through combined SPD methods could be a promising strategy for the improvement of the next generation of medical implants.

3D Printing Technologies in Metallic Implants: A Thematic Review on the Techniques and Procedures.

Additive manufacturing (AM) is among the most attractive methods to produce implants, the processes are very swift and it can be precisely controlled to meet patient's requirement since they can be produced in exact shape, dimension, and even texture of different living tissues. Until now, lots of methods have emerged and used in this field with diverse characteristics. This review aims to comprehensively discuss 3D printing (3DP) technologies to manufacture metallic implants, especially on techniques and procedures. Various technologies based on their main properties are categorized, the effecting parameters are introduced, and the history of AM technology is briefly analyzed. Subsequently, the utilization of these AM-manufactured components in medicine along with their effectual variables is discussed, and special attention is paid on to the production of porous scaffolds, taking pore size, density, etc., into consideration. Finally, 3DP of the popular metallic systems in medical applications such as titanium, Ti6Al4V, cobalt-chromium alloys, and shape memory alloys are studied. In general, AM manufactured implants need to comply with important requirements such as biocompatibility, suitable mechanical properties (strength and elastic modulus), surface conditions, custom-built designs, fast production, etc. This review aims to introduce the AM technologies in implant applications and find new ways to design more sophisticated methods and compatible implants that mimic the desired tissue functions.

Functionally graded titanium implants: Characteristic enhancement induced by combined severe plastic deformation.

Commercially pure titanium was processed by equal channel angular pressing (ECAP) and surface mechanical attrition treatment (SMAT) for the purpose of developing functionally graded titanium used for implants and a gradient structure including nanostructured, deformed and undeformed zones were produced on the samples. In particular, it was aimed to design the gradient-structure in the titanium with enhanced properties by applying 4 ECAP passes to form bulk structure of ultrafine-grains and subsequently subjecting SMAT to the surface of ECAPed samples to produce nanostructured surface region. Microstructural examination was made by electron back scatter diffraction (EBSD). Also, microhardness, nanoindentation, topography, roughness and wettability were evaluated. To examine the biological response, human osteosarcoma cells were cultured in contact with the samples in various time periods and morphology change, cell viability and alkaline phosphate activity were conducted also cell morphology was monitored. EBSD showed development of ultrafine-grained structure after 4 passes of ECAP with an average grain size of 500 nm. Applying SMAT resulted in additional refinement in the ECAP samples, particularly in the subsurface regions to a depth of 112 µm. Furthermore, the SMATed samples showed an enhancement in roughness, wettability and hardness magnitudes. Viability enhanced up to 7% in SMATed + ECAPed sample, although the acceptable cell adhesion, improved cell differentiation and mineralization were seen. The combined use of ECAP and SMAT has shown a good potential for optimizing the design of modern functionally graded medical devices and implants.

Investigating the Microstructure and Mechanical Properties of Aluminum-Matrix Reinforced-Graphene Nanosheet Composites Fabricated by Mechanical Milling and Equal-Channel Angular Pressing.

Layered-graphene reinforced-metal matrix nanocomposites with excellent mechanical properties and low density are a new class of advanced materials for a broad range of applications. A facile three-step approach based on ultra-sonication for dispersion of graphene nanosheets (GNSs), ball milling for Al-powder mixing with different weight percentages of GNSs, and equal-channel angular pressing for powders' consolidation at 200 °C was applied for nanocomposite fabrication. The Raman analysis revealed that the GNSs in the sample with 0.25 wt.% GNSs were exfoliated by the creation of some defects and disordering. X-ray diffraction and microstructural analysis confirmed that the interaction of the GNSs and the matrix was almost mechanical, interfacial bonding. The density test demonstrated that all samples except the 1 wt.% GNSs were fully densified due to the formation of microvoids, which were observed in the scanning electron microscope analysis. Investigation of the mechanical properties showed that by using Al powders with commercial purity, the 0.25 wt.% GNS sample possessed the maximum hardness, ultimate shear strength, and uniform normal displacement in comparison with the other samples. The highest mechanical properties were observed in the 0.25 wt.% GNSs composite, resulting from the embedding of exfoliated GNSs between Al powders, excellent mechanical bonding, and grain refinement. In contrast, agglomerated GNSs and the existence of microvoids caused deterioration of the mechanical properties in the 1 wt.% GNSs sample.

The Correlation of Microstructure and Mechanical Properties of In-Situ Al-Mg2Si Cast Composite Processed by Equal Channel Angular Pressing.

In this paper, the effect of equal channel angular pressing (ECAP) on microstructure and mechanical properties of hypereutectic Al-20%Mg2Si and Al-15%Mg2Si, as well as hypoeutectic Al-10%Mg2Si composites has been investigated. After fabricating the composites by in-situ casting, the composites were processed using the ECAP process up to two passes at room temperature. Microstructural studies have been carried out using a field emission scanning electron microscopy equipped with an energy dispersive X-ray spectrometer. Mechanical properties were also documented using Vickers microhardness and shear punch tests. In the hypereutectic composites, a decrease in the average size of pro-eutectic Mg2Si (Mg2Sip) particles, breakages in eutectic networks, and lengthening of the Al (α) phase in direction of shear bands were observed after the ECAP process. For instance, the average size of Mg2Sip Particles in Al-20%Mg2Si composite reduced from 40 to 17 µm after 2 passes of ECAP. Furthermore, a uniform distribution of Mg2Sip particles was developed in the matrix. In hypoeutectic composite, the ECAP process caused a uniform distribution of eutectic Mg2Si (Mg2SiE) in the matrix that considered a favorable microstructure. Microhardness measurements and shear punch results showed an ascending trend after each pass of ECAP for all specimens. For example, microhardness and shear strength of Al-20%Mg2Si increased from 88 HV and 109 MPa to 119 HV and 249 MPa after two passes indicating 35% and 34% increments, respectively. Density and porosity calculations by Archimedes principle revealed that the density of the composites increased after two passes of ECAP due to the reduction of porosity.

Tribological and mechanical investigation of multi-directional forged nickel.

Tailoring material properties to specific application requirements is one of the major challenges in materials engineering. Grain size is a key factor affecting physical and mechanical properties of polycrystals materials, the presented work enables insight into how the pure nickel properties are affected by application of multi-directional forging (MDF) as a well-known severe plastic deformation method. It is demonstrated that the hardness and wear rate are improved by imposing MDF process. The rate of enhancement is reduced at the higher pass numbers. It is also shown that the application of MDF process changed the mechanism of wear. Non-MDF sample's surface shows spalling and delamination, while the dominated wear mechanism of final pass sample is peeling with a slight of adhesion. The change of wear mechanism can be associated with the reduction of friction coefficient of the deformed sample. By considering the linear correlation between the hardness and wear rate, a simple and fast procedure is proposed to estimate the wear rate of sample after the different MDF pass numbers using the corresponding hardness magnitude. Additionally, the attained microstructure of the final pass sample shows a combination of ultrafine grains and micro shear bands.

Effect of Graphene Nanosheets Content on Microstructure and Mechanical Properties of Titanium Matrix Composite Produced by Cold Pressing and Sintering.

The effect of graphene nanosheet (GNS) reinforcement on the microstructure and mechanical properties of the titanium matrix composite has been discussed. For this purpose, composites with various GNS contents were prepared by cold pressing and sintering at various time periods. Density calculation by Archimedes' principle revealed that Ti/GNSs composites with reasonable high density (more than 99.5% of theoretical density) were produced after sintering for 5 h. Microstructural analysis by X-ray diffraction (XRD) and a field emission scanning electron microscope (FESEM) showed that TiC particles were formed in the matrix during the sintering process as a result of a titanium reaction with carbon. Higher GNS content as well as sintering time resulted in an increase in TiC particle size and volume fraction. Microhardness and shear punch tests demonstrated considerable improvement of the specimens' mechanical properties with the increment of sintering time and GNS content up to 1 wt. %. The microhardness and shear strength of 1 wt. % GNS composites were enhanced from 316 HV and 610 MPa to 613 HV and 754 MPa, respectively, when composites sintered for 5 h. It is worth mentioning that the formation of the agglomerates of unreacted GNSs in 1.5 wt. % GNS composites resulted in a dramatic decrease in mechanical properties.

Microstructure, Texture, Electrical and Mechanical Properties of AA-6063 Processed by Multi Directional Forging.

In current research, the effect of the multi-directional forging (MDF) process on the microstructure, texture, mechanical and electrical properties of AA-6063 under different heat treatment conditions at various MDF temperatures was studied. The annealed AA-6063 alloy was processed up to three passes of MDF at ambient temperature. Three passes of this process were also applied to the solution-treated AA-6063 at ambient temperature and 177 °C. Microstructural investigations demonstrated that the MDF process led to a significant reduction in the average grain size as well as a considerable increase in the fraction of low angle grain boundaries. Texture analysis revealed that copper and Goss textures were mainly developed within the annealed and solution-treated samples of AA-6063, respectively. The hardness and shear strength values of all processed samples also showed a sizeable improvement compared to the initial heat-treated samples. For example, the hardness and shear yield strength value of the solution-treated sample MDFed for three passes showed more than 100 and 70% increase, respectively. The effect of the MDF process on the electrical conductivity of AA-6063 under different heat treatment conditions at various temperatures was negligible. So, it can be concluded that the MDF process increased the mechanical properties without an appreciable decrease in electrical conductivity.