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It has been observed from the history of failed dies used in local extrusion industry that after certain press cycles, severe die damage occurs by using more number of in‐house recycled billets. The purpose of this paper is to focus on the effect of billet quality on the extrusion die service life, based on using microstructural and finite element analyses.

Numerical solution of stress distribution in extrusion die using microstructural and finite element analyses.

Simulation results demonstrate that extrusion die experiences high stresses and strains at critical locations by running secondary billets. Billet deformation behavior also shows that secondary billet has more resistance to flow during extrusion cycle, which results in such high stresses and strains in the die.

The study includes a particular die used to extrude the aluminum alloy billets. It may need to generalized including materials other than aluminum alloy.

The findings are original and believed to be useful for engineers working in the extrusion dies. Since it is shown that secondary billets (recycled billets) have more resistance to flow in the dye, a care should be taken when estimating the die life for the practical applications.

It is an original work. It deals with the comparison of new and recycled billets's performance in terms of stress formation in the die during the extrusion cycle.

Online spiral pipe manufacturing is one of the most common processes for producing water and gas transmission pipes. Weld quality and pipe circumstances are the most important qualitative characteristics of these pipes determining the overall cost of production. The purpose of this paper is describing how to implement Six Sigma on the production of spiral welded pipes with a real case study.

First, the capability of the pipe production process has been performed by using the defects per million opportunities to allow for comparison and analysis of the project effectiveness. Then, the variation pattern of this index, after an improvement project, has been investigated. Finally, Taguchi's loss functions are used to evaluate the effectiveness of these projects.

The results represent a significant improvement in the production process and a reduction in production costs regarding both weld quality and pipe circumstances. Due to the successful implementation of Six Sigma project in welding and pipe quality improvement, the Define, Measure, Analyze, Improve and Control (DMAIC) method can be used effectively in defining weld and pipe quality.

In this proposed work, for the first time, research on the implementation of Six Sigma in the pipeline and welding industries on two online spiral production machines has been investigated. The DMAIC method has been used for the first time to improve the dimensional quality and weld quality of spiral pipes.

The laser nitriding process is involved with high temperature heating and high cooling rates. This, in turn, results in high levels of thermal stresses in the heated region. Moreover, the residual stress in the heated region remains high after the completion of the heating process, which limits the application of the laser nitriding process. The purpose of this paper is to investigate thermal stresses development and residual stress levels in the nitrided region.

The microstructural changes and residual stress development in the laser gas‐assisted nitrided zone are examined. Finite element modeling is carried out to predict temperature and stress fields in the laser nitrided layer. The indentation tests and X‐ray diffraction (XRD) technique are used to determine the residual stress levels while previously derived analytical formula is used to predict the residual stress levels in the nitrided region.

The residual stress predicted attains values within 230 MPa, which remains almost uniform in the nitrided layer, except in the surface region. In this case, residual stress reduces slightly due to the low temperature gradient developed in this region and the unconstrained expansion of the free surface. When comparing the residual stress predicted with the measurement results as obtained from the XRD technique as well as the indentation tests, all the results are in reasonably good agreement. The small discrepancies between the experimental data and predictions are attributed to the assumptions made in the model study and the measurement errors.

The depth of nitrided layer is limited 60 μm. This limits the applicability of the coating for high wearing rates.

The nitrided surface improves the surface properties of steel, which can be used in industry more efficiently.

The paper describes an original model study on stress formation, an experiment for surface characterization and estimation of residual stress formation and contains new findings.

A numerical study on the reliability of soldered interconnects of c-Si solar photovoltaic cells has been conducted.

A three-year data (2012–2014) from outdoor weathering of PV modules was used to generate temperature cycle profiles to serve as thermal loads and boundary conditions for the investigation of the thermo-mechanical response of the soldered interconnects when subjected to real outdoor conditions using finite element analysis (FEA) Software (Ansys. 18.2). Two types of soldered interconnections, namely, Sn60Pb40 and Sn3.8Ag0.7Cu (Pb-free), were modelled in this study.

Life prediction results from accumulated creep energy density damage show that the solder interconnects will achieve maximum life under the 2014 thermal cycle loading. In particular, the Sn60Pb40 solder interconnection is expected to achieve 14,153 cycles (25.85 years) whilst the Pb-free solder interconnection is expected to achieve 9,249 cycles (16.89 years). Additionally, under the test region average (TRA) thermal cycle, the Pb-free and Pb-Sn solder interconnections are expected to achieve 7,944 cycles (13.69 years) and 12,814 cycles (23.4 years), respectively. The study shows that Sn60Pb40 solder interconnections are likely to exhibit superior reliability over the Pb-free solder interconnections at the test site.

This study would be useful to electronics manufacturing industry in the search for a suitable alternative to SnPb solders and also the thermo-mechanical reliability research community and manufacturers in the design of robust PV modules.

The study has provided TRA data/results which could be used to represent the test region instead of a particular year. The study also indicates that more than six thermal cycles are required before any meaningful conclusions can be drawn. Finally, the life of the two types of solders (SnPb and Pb-free) as interconnecting materials for c-Si PV have been predicted for the test region (Kumasi in sub-Saharan Africa).

Transient response of continuous composite material (CCM) fin made of high thermally conductive composite material is presented. The continuously varying effective properties of composite material such as thermal conductivity, heat capacity and density have been modelled using the Mori-Tanaka homogenization theory and rule of mixture. Additionally, temperature dependency of thermal conductivity, heat generation (composite materials) and convection coefficient (fluid properties) have also been incorporated. Different base boundary conditions are addressed such as oscillating heat flow, oscillating temperature, step-changing heat flow and step-changing temperature. At the other boundary, the fin is assumed to have a convective tip.

Lattice Boltzmann method is implemented using an in-house source code for obtaining the numerical solution of typical non-linear heat balance equation of the aforementioned problem under various transient base boundary conditions.

The effects of various thermal parameters such as material diffusivity ratio and conductivity ratio, area ratio and Biot number on transient response of fin and temperature distribution of fins are studied and interpreted. The heat transfer rate and time for attainment of steady state temperature of metal matrix composite (MMC) fin are found to be proportionally dependent on their diffusivity ratio. Additionally for higher values of area ratio and biot number, MMC fins are reported to dissipate the heat more efficiently in comparision to homogeneous fins in terms of time required to attain the steady state and surface temperature.

Response of transient fin associated with advanced class of material can facilitates the practicing engineers for designing high-performance and/or miniaturized thermal management devices as used in electronic packaging industries.

Studies of composite fin consisting of laminating second layer of material over the first layer have been reported previously, however transient response of CCM fin fabricated by continuously varying the volume fraction of two materials along the fin length has not been reported till date. Such material finds its application in thermal management and electronic packaging industries. Results are plotted in form of a graph for different application-wise material combinations that have not been reported earlier, and it can be treated as design data.

A local company producing aluminum profile encounters frequent failures to bridge dies. In total, 22 dies failed within a year, entailing production disruptions and extensive downtimes. Bridges usually exhibit cracks on the ribs. The failure analysis of the failed parts has been performed in order to propose solution for correct and economical process. The paper aims to discuss these issues.

Recorded history was collected regarding tool’s material selection, manufacturing conditions, usage and service. A representative failed bridge was in depth analyzed. The piece was optically inspected. Rockwell hardness measurements and chemical analysis were performed. The paper is focussed on the microscopic examination of the failed parts. Specimens were cut from bridge’s ribs. Areas including cracks were analyzed on the cross section of the samples by optical and scanning electron microscopy. Local chemical analysis was made by X-ray microanalysis.

Design, deficiency and improper maintenance are considered to be responsible for the systematic die damage. Prolonged preheating duration and poor quality surfaces before nitriding render dies premature unusable. The preheating duration should be controlled and protective atmosphere should be used. Furthermore, it is suggested to protect the ribs during nitriding as a preventive measure against crack initiation. The bridge’s geometry can be improved by fabricating ribs with larger radii. A finer polishing is recommended.

The present analysis resolved a serious deficiency in extrusion production. Extended research has been conducted in the field of aluminum extrusion dies, nevertheless, the present work presents new metallographic aspects as well as some interesting notes regarding the repetitive nitriding of bridge dies.

The purpose of this paper is to investigate the corrosion resistance of high velocity oxy-fuel (HVOF)-sprayed Diamalloy 2002 coating on carbon steel. The coating microstructure is examined in line with the corrosion resistance.

HVOF spraying of coating is achieved, and the coating response to electrolytic solution is measured experimentally in terms of corrosion resistance.

HVOF coating improves the corrosion resistance of the substrate such that the corrosion rate of the substrate is 7.1 mpy and the coating results in 4.5 mpy. However, presence of deep pit sites at the surface suggests the occurrence of preferential corrosion around the splat boundaries. In addition, closely spaced surface texture peaks act as crevice corrosion centers at the surface while initiating the formation of deep pit sites.

This study is limited by experimental investigations. In future, it may be extended to include model studies.

The findings of this study are very useful for those working in the coating industry. However, HVOF coating is limited to high temperature protection in harsh environments.

It is useful for the power industry, particularly for gas turbines.

It is an original work and describes the corrosion resistance of the coating surface. It is found that the coating improved the corrosion resistance of the steel surface.

A mixed approach to large strain elastoplastic problems is presented in a somewhat different way to that usually used within the context of the additive split of the rate of deformation tensor into an elastic and plastic part. A non‐linear extended mixed variational equation, in which the Jacobian of the deformation gradient and the pressure part of the stress tensor appear as additional independent variables, is introduced. This equation is then linearized in the accordance with the Newton‐Raphson method to obtain the system of linear equations which represent the basis of the mixed finite element procedure. For the case of a bilinear isoparametric interpolation of the displacement field, and for piece‐wise constant pressure and Jacobian, simplified expressions, differing from similar expressions corresponding to mixed finite element implementations, are obtained. The effectiveness of the proposed mixed approach is demonstrated by means of two examples.

This study aims to examine the cutting performance of a coated carbide tool during the boring of 1Cr17Ni2 martensitic stainless steel, with a focus on how the tool’s structural parameters, particularly the nose radius, affect the wear patterns, wear volume and lifetime of the cutting tool, and related mechanisms.

A full factorial boring experiment with three factors at two levels was conducted to analyze systematically the impact of cutting parameters on the tool wear behavior. The evolution of tool wear over the machining time was recorded, and the influences of the cutting parameters and nose radius on wear behavior of the tool were examined.

The results show that higher cutting parameters lead to significant wear or plastic deformation at the tool nose. When the cutting depth is less than the nose radius, the tool wear tends to be minimized. Larger nose radius tools have weaker chip-breaking but greater strength and wear resistance. Higher cutting parameters reduce wear for the tools with larger nose radius, maintaining their integrity. Wear mechanisms are primarily abrasive, adhesive and diffusion wear. Furthermore, the full-factorial analysis of variance revealed that for the tool with r_ε = 0.4 mm and 0.8 mm, the factors contributing the most to tool wear were cutting speed (38.76%) and cutting depth (86.43%), respectively.

This study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.