Industrial applications of aluminium and its alloys are restricted because of their poor tribological properties. Thermal spraying, laser surfacing, electron beam welding are the most widely used techniques to alter t...Industrial applications of aluminium and its alloys are restricted because of their poor tribological properties. Thermal spraying, laser surfacing, electron beam welding are the most widely used techniques to alter the surface morphology of base metal. Preliminary studies reveal that the coating and layering of aluminium alloys with ceramic particles enhance the ballistic resistance. Furthermore, among aluminium alloys,7075 aluminium alloy exhibits high strength which can be compared to that of steels and has profound applications in the designing of lightweight fortification structures and integrated protection systems. Having limitations such as poor bond integrity, formation of detrimental phases and interfacial reaction between reinforcement and substrate using fusion route to deposit hard particles paves the way to adopt friction stir processing for fabricating surface composites using different sizes of boron carbide particles as reinforcement on armour grade 7075 aluminium alloy as matrix in the present investigation. Wear and ballistic tests were carried out to assess the performance of friction stir processed AA7075 alloy. Significant improvement in wear resistance of friction stir processed surface composites is attributed to the change in wear mechanism from abrasion to adhesion. It has also been observed that the surface metal matrix composites have shown better ballistic resistance compared to the substrate AA7075 alloy. Addition of solid lubricant Mo S2 has reduced the depth of penetration of the projectile to half that of base metal AA7075 alloy. For the first time, the friction stir processing technique was successfully used to improve the wear and ballistic resistances of armour grade high strength AA7075 alloy.展开更多
The contact resistance between the armature and rails is an important indicator of the contact characteristics in electromagnetic launches.As the contact resistance depends not only on the contact state but also on th...The contact resistance between the armature and rails is an important indicator of the contact characteristics in electromagnetic launches.As the contact resistance depends not only on the contact state but also on the contact stress and temperature,there are some limitations in analyzing the contact characteristics using only the contact resistance.In this paper,the contact characteristics of the augmented railgun are analyzed by the combination of contact resistance and sliding friction coefficient.Firstly,the theoretical calculation model of the contact resistance and friction coefficient of the augmented electromagnetic railgun is established.Then the contact resistance and friction coefficient are calculated by the measured values of the muzzle voltage,rail current and armature displacement.Finally,the contact characteristics are analyzed according to the features of the waveforms of the contact resistance and the friction coefficient,and the analysis conclusions are verified by experimental rail images.The results showed that:the aluminum melt film gradually formed on the contact surface reduces the contact resistance and the friction coefficient;the wear and erosion of the armature cause deterioration of the contact state;after the transition,the reliability of the sliding contact between the armature and rails decreases,resulting in an increase in contact resistance.展开更多
The aluminium alloy AA2219(Al—Cu—Mg alloy) is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance.Welding is main fabrication method of AA2219 al...The aluminium alloy AA2219(Al—Cu—Mg alloy) is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance.Welding is main fabrication method of AA2219 alloy for manufacturing various engineering components.Friction stir welding(FSW) is a recently developed solid state welding process to overcome the problems encountered in fusion welding.This process uses a non-consumable tool to generate frictional heat on the abutting surfaces.The welding parameters,such as tool pin profile,rotational speed,welding speed and axial force,play major role in determining the microstructure and corrosion resistance of welded joint.The main objective of this work is to develop a mathematical model to predict the corrosion resistance of friction stir welded AA2219 aluminium alloy by incorporating FSW process parameters.In this work a central composite design with four factors and five levels has been used to minimize the experimental conditions.Dynamic polarization testing was carried out to determine critical pitting potential in millivolt,which is a criteria for measuring corrosion resistance and the data was used in model.Further the response surface method(RSM) was used to develop the model.The developed mathematical model was optimized using the simulated annealing algorithm optimizing technique to maximize the corrosion resistance of the friction stir welded AA2219 aluminium alloy joints.展开更多
Surface modification is essential for improving the service properties of components. Cladding is one of the most widely employed methods of surface modification. Friction surfacing is a candidate process for depositi...Surface modification is essential for improving the service properties of components. Cladding is one of the most widely employed methods of surface modification. Friction surfacing is a candidate process for depositing the corrosion resistant coatings. Being a solid state process, it offers several advantages over conventional fusion based surfacing process. The aim of this work is to identify the relationship between the input variables and the process response and develop the predictive models that can be used in the design of new friction surfacing applications. In the current work, austenitic stainless steel AISI 304 was friction surfaced on high strength low alloy steel substrate. Friction surfacing parameters,such as mechtrode rotational speed, feed rate of substrate and axial force on mechtrode, play a major role in determining the pitting corrosion resistance and bond strength of friction surfaced coatings. Friction surfaced coating and base metal were tested for pitting corrosion by potentiodynamic polarization technique. Coating microstructure was characterized using optical microscopy, scanning electron microscopy and X-ray diffraction. Coatings in the as deposited condition exhibited strain-induced martensite in austenitic matrix. Pitting resistance of surfaced coatings was found to be much lower than that of mechtrode material and superior to that of substrate. A central composite design with three factors(mechtrode rotational speed, substrate traverse speed, axial load on mechtrode) and five levels was chosen to minimize the number of experimental conditions. Response surface methodology was used to develop the model. In the present work, an attempt has been made to develop a mathematical model to predict the pitting corrosion resistance and bond strength by incorporating the friction surfacing process parameters.展开更多
Recently,computational fluid dynamics(CFD)approaches have been effectively used by researchers to calculate the resistance characteristics of ships that have rough outer surfaces.These approaches are mainly based on m...Recently,computational fluid dynamics(CFD)approaches have been effectively used by researchers to calculate the resistance characteristics of ships that have rough outer surfaces.These approaches are mainly based on modifying wall functions using experimentally pre-determined roughness functions.Although several recent studies have shown that CFD can be an effective tool to calculate resistance components of ships for different roughness conditions,most of these studies were performed using the same ship geometry(KRISO Container Ship).Thus,the effect of ship geometry on the resistance characteristics of rough hull surfaces is worth investigating.In this study,viscous resistance components of four different ships are calculated for different roughness conditions.First,flat plate simulations are performed using a previous experimental study for comparison purposes.Then,the viscous resistance components of three-dimensional hulls are calculated.All simulations are performed using two different turbulence models to investigate the effect of the turbulence model on the results.An examination of the distributions of the local skin friction coefficients of the DTMB 5415 and Series 60 showed that the plumpness of the bow form has a significant effect on the increase in frictional resistance with increasing roughness.Another significant finding of the study is that viscous pressure resistance is directly affected by the surface roughness.For all geometries,viscous pressure resistances showed a significant increase for highly rough surfaces.展开更多
Considering the special resistance characteristics of fluids flowing through ducts with small gaps, experiments are performed to investigate the resistance characteristics of single-phase water, which is forced to flo...Considering the special resistance characteristics of fluids flowing through ducts with small gaps, experiments are performed to investigate the resistance characteristics of single-phase water, which is forced to flow through ver tical annuli. The gap sizes are 0.9, 1.4 and 2.4mm, respectively. The experiments are conducted under condition of 1atm. The water in the annuli is heated by high temperature water reversely flowing through the inner tube and the outer annulus. The results show that the flow pattern begin to change from laminar to turbulent before Reynolds number approaches 2000, the flow resistance in annulus has little relations with the temperature difference and ways of being heated, but mainly depends on the ratio of mass flux to the width of annulus.展开更多
基金Financial assistance from Armament Research Board, New Delhi, India
文摘Industrial applications of aluminium and its alloys are restricted because of their poor tribological properties. Thermal spraying, laser surfacing, electron beam welding are the most widely used techniques to alter the surface morphology of base metal. Preliminary studies reveal that the coating and layering of aluminium alloys with ceramic particles enhance the ballistic resistance. Furthermore, among aluminium alloys,7075 aluminium alloy exhibits high strength which can be compared to that of steels and has profound applications in the designing of lightweight fortification structures and integrated protection systems. Having limitations such as poor bond integrity, formation of detrimental phases and interfacial reaction between reinforcement and substrate using fusion route to deposit hard particles paves the way to adopt friction stir processing for fabricating surface composites using different sizes of boron carbide particles as reinforcement on armour grade 7075 aluminium alloy as matrix in the present investigation. Wear and ballistic tests were carried out to assess the performance of friction stir processed AA7075 alloy. Significant improvement in wear resistance of friction stir processed surface composites is attributed to the change in wear mechanism from abrasion to adhesion. It has also been observed that the surface metal matrix composites have shown better ballistic resistance compared to the substrate AA7075 alloy. Addition of solid lubricant Mo S2 has reduced the depth of penetration of the projectile to half that of base metal AA7075 alloy. For the first time, the friction stir processing technique was successfully used to improve the wear and ballistic resistances of armour grade high strength AA7075 alloy.
文摘The contact resistance between the armature and rails is an important indicator of the contact characteristics in electromagnetic launches.As the contact resistance depends not only on the contact state but also on the contact stress and temperature,there are some limitations in analyzing the contact characteristics using only the contact resistance.In this paper,the contact characteristics of the augmented railgun are analyzed by the combination of contact resistance and sliding friction coefficient.Firstly,the theoretical calculation model of the contact resistance and friction coefficient of the augmented electromagnetic railgun is established.Then the contact resistance and friction coefficient are calculated by the measured values of the muzzle voltage,rail current and armature displacement.Finally,the contact characteristics are analyzed according to the features of the waveforms of the contact resistance and the friction coefficient,and the analysis conclusions are verified by experimental rail images.The results showed that:the aluminum melt film gradually formed on the contact surface reduces the contact resistance and the friction coefficient;the wear and erosion of the armature cause deterioration of the contact state;after the transition,the reliability of the sliding contact between the armature and rails decreases,resulting in an increase in contact resistance.
文摘The aluminium alloy AA2219(Al—Cu—Mg alloy) is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance.Welding is main fabrication method of AA2219 alloy for manufacturing various engineering components.Friction stir welding(FSW) is a recently developed solid state welding process to overcome the problems encountered in fusion welding.This process uses a non-consumable tool to generate frictional heat on the abutting surfaces.The welding parameters,such as tool pin profile,rotational speed,welding speed and axial force,play major role in determining the microstructure and corrosion resistance of welded joint.The main objective of this work is to develop a mathematical model to predict the corrosion resistance of friction stir welded AA2219 aluminium alloy by incorporating FSW process parameters.In this work a central composite design with four factors and five levels has been used to minimize the experimental conditions.Dynamic polarization testing was carried out to determine critical pitting potential in millivolt,which is a criteria for measuring corrosion resistance and the data was used in model.Further the response surface method(RSM) was used to develop the model.The developed mathematical model was optimized using the simulated annealing algorithm optimizing technique to maximize the corrosion resistance of the friction stir welded AA2219 aluminium alloy joints.
基金Financial assistance from Defence Research Development Organization
文摘Surface modification is essential for improving the service properties of components. Cladding is one of the most widely employed methods of surface modification. Friction surfacing is a candidate process for depositing the corrosion resistant coatings. Being a solid state process, it offers several advantages over conventional fusion based surfacing process. The aim of this work is to identify the relationship between the input variables and the process response and develop the predictive models that can be used in the design of new friction surfacing applications. In the current work, austenitic stainless steel AISI 304 was friction surfaced on high strength low alloy steel substrate. Friction surfacing parameters,such as mechtrode rotational speed, feed rate of substrate and axial force on mechtrode, play a major role in determining the pitting corrosion resistance and bond strength of friction surfaced coatings. Friction surfaced coating and base metal were tested for pitting corrosion by potentiodynamic polarization technique. Coating microstructure was characterized using optical microscopy, scanning electron microscopy and X-ray diffraction. Coatings in the as deposited condition exhibited strain-induced martensite in austenitic matrix. Pitting resistance of surfaced coatings was found to be much lower than that of mechtrode material and superior to that of substrate. A central composite design with three factors(mechtrode rotational speed, substrate traverse speed, axial load on mechtrode) and five levels was chosen to minimize the number of experimental conditions. Response surface methodology was used to develop the model. In the present work, an attempt has been made to develop a mathematical model to predict the pitting corrosion resistance and bond strength by incorporating the friction surfacing process parameters.
文摘Recently,computational fluid dynamics(CFD)approaches have been effectively used by researchers to calculate the resistance characteristics of ships that have rough outer surfaces.These approaches are mainly based on modifying wall functions using experimentally pre-determined roughness functions.Although several recent studies have shown that CFD can be an effective tool to calculate resistance components of ships for different roughness conditions,most of these studies were performed using the same ship geometry(KRISO Container Ship).Thus,the effect of ship geometry on the resistance characteristics of rough hull surfaces is worth investigating.In this study,viscous resistance components of four different ships are calculated for different roughness conditions.First,flat plate simulations are performed using a previous experimental study for comparison purposes.Then,the viscous resistance components of three-dimensional hulls are calculated.All simulations are performed using two different turbulence models to investigate the effect of the turbulence model on the results.An examination of the distributions of the local skin friction coefficients of the DTMB 5415 and Series 60 showed that the plumpness of the bow form has a significant effect on the increase in frictional resistance with increasing roughness.Another significant finding of the study is that viscous pressure resistance is directly affected by the surface roughness.For all geometries,viscous pressure resistances showed a significant increase for highly rough surfaces.
文摘Considering the special resistance characteristics of fluids flowing through ducts with small gaps, experiments are performed to investigate the resistance characteristics of single-phase water, which is forced to flow through ver tical annuli. The gap sizes are 0.9, 1.4 and 2.4mm, respectively. The experiments are conducted under condition of 1atm. The water in the annuli is heated by high temperature water reversely flowing through the inner tube and the outer annulus. The results show that the flow pattern begin to change from laminar to turbulent before Reynolds number approaches 2000, the flow resistance in annulus has little relations with the temperature difference and ways of being heated, but mainly depends on the ratio of mass flux to the width of annulus.
