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Publication date: 11 January 2022

Tushar Sonar, Visvalingam Balasubramanian, Sudersanan Malarvizhi, Thiruvenkatam Venkateswaran and Dhenuvakonda Sivakumar

The primary objective of this investigation is to optimize the constricted arc tungsten inert gas (CA-TIG) welding parameters specifically welding current (WC), arc constriction…

144

Abstract

Purpose

The primary objective of this investigation is to optimize the constricted arc tungsten inert gas (CA-TIG) welding parameters specifically welding current (WC), arc constriction current (ACC), ACC frequency (ACCF) and CA traverse speed to maximize the tensile properties of thin Inconel 718 sheets (2 mm thick) using a statistical technique of response surface methodology and desirability function for gas turbine engine applications.

Design/methodology/approach

The four factor – five level central composite design (4 × 5 – CCD) matrix pertaining to the minimum number of experiments was chosen in this investigation for designing the experimental matrix. The techniques of numerical and graphical optimization were used to find the optimal conditions of CA-TIG welding parameters.

Findings

The thin sheets of Inconel 718 (2 mm thick) can be welded successfully using CA-TIG welding process without any defects. The joints welded using optimized conditions of CA-TIG welding parameters showed maximum of 99.20%, 94.45% and 73.5% of base metal tensile strength, yield strength and elongation.

Originality/value

The joints made using optimized CA-TIG welding parameters disclosed 99.20% joint efficiency which is comparatively 20%–30% superior than conventional TIG welding process and comparable to costly electron beam welding and laser beam welding processes. The parametric mathematical equations were designed to predict the tensile properties of Inconel 718 joints accurately with a confidence level of 95% and less than 4.5% error. The mathematical relationships were also developed to predict the tensile properties of joints from the grain size (secondary dendritic arm spacing-SDAS) of fusion zone microstructure.

Details

Aircraft Engineering and Aerospace Technology, vol. 94 no. 5
Type: Research Article
ISSN: 1748-8842

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Article
Publication date: 1 December 2022

Dhamothara kannan Thirumalaikkannan, Sivaraj Paramasivam, Balasubramanian Visvalingam, Tushar Sonar and Sathiya Sivaraj

Rotary friction welding (RFW) was used to solve the issues in fusion welding of rod to plate joints of low carbon steel (AISI 1020 steel/AISI 1018 steel) such solidification…

139

Abstract

Purpose

Rotary friction welding (RFW) was used to solve the issues in fusion welding of rod to plate joints of low carbon steel (AISI 1020 steel/AISI 1018 steel) such solidification cracking, wider heat affected zone (HAZ), lower HAZ hardness, high residual stresses and distortion. The main objective of this investigation is to develop parametric mathematic models (PMMs), 3D response surface analysis to predict tensile strength (TS) and weld interface hardness (WIH) of rod to plate joints and correlate microstructure with TS and WIH of rod to plate joints.

Design/methodology/approach

The three-factor x five-level central composite design (CCD) consisting fewer experiments was employed for designing experimental matrix. The tensile and microhardness tests were performed to evaluate mechanical performance of joints. The PMMs of TS and WIH of rod to plate joints were developed using polynomial regression equations incorporating the RFW parameters. The 3D response surfaces were developed using response surface methodology (RSM) to optimize RFW parameters for joining AISI 1020/AISI 1018 rod to plate.

Findings

The joints made using friction pressure/friction time (FRNP/FRNT) of 3.71 MPa/s, forging pressure/forging time (FRGP/FRGT) of 3.71 MPa/s and rotational speed (RTSP) of 19.99 rps exhibited higher TS and WIH of 452 MPa and 252 HV0.5. The PMMs accurately predicted TS and WIH of rod to plate joints at less than 1.5% error and 95% confidence. The RTSP revealed greater effect on TS and WIH of rod to plate joints followed by FRGP/FRGT and FRNP/FRNT. The superior TS and WIH of joints developed using optimized process parameters is correlated to the evolution of finer bainitic microstructure in weld interface due to the dynamic recrystallization of grains ensued by optimum frictional heating and plastic deformation.

Originality/value

The PMMs were developed for predicting TS and WIH of joints. The RFW parameters were optimized to enhance TS and WIH of joints. Low carbon steel rod to plates joints were developed using RFW for automotive applications without fusion welding defects. The microstructural features of low strength and high strength rod to plate joints were correlated to the TS and WIH of rod to plate joints.

Details

Multidiscipline Modeling in Materials and Structures, vol. 19 no. 1
Type: Research Article
ISSN: 1573-6105

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Article
Publication date: 10 February 2025

Laxmidhar Behera, Siddhartha Agarwal, Tushar Sandhan, Pratibha Sharma, Ashish Kumar, Ayush Ranjan, Sidhartha Watsa, Atul Singh and Jyothi Swaroop Kasina

The unmanned ground vehicle (UGV) described in this manuscript is a robot designed by the authors to map the underground mine environments. The UGV works to develop a…

78

Abstract

Purpose

The unmanned ground vehicle (UGV) described in this manuscript is a robot designed by the authors to map the underground mine environments. The UGV works to develop a computational intelligence-based cyber-physical system (CPS)-based analytical framework for mining operations. The UGV demonstrated excellent semi-autonomous navigation capabilities in the absence of GNSS signals. The UGV has a suite that works in unison to provide relevant information. These sensors are integrated to form a robust sensor fusion-based architecture, creating a CPS with a wide range of capabilities such as data acquisition and navigation in challenging underground environments. UGVs can be used to enhance the efficacy of safety inspections, rescue during underground emergencies and assist miners in hazardous conditions.

Design/methodology/approach

In this research, an UGV was constructed whose operations are enabled by sensors including a D415i Red Blue Green (RGB) depth camera, a LiDAR, a FLIR C5 infrared camera and smart air quality sensors. This sensor fusion-based architecture forms a CPS. Data obtained remotely are processed by deep learning algorithms to achieve overall capabilities such as real-time image analysis for miner identification, object detection, posture analysis and identifying threats of roof falls and overhangs. Simultaneous localization and mapping (SLAM) algorithms create a 3D map, facilitate autonomous navigation and build a decision support system for delivering mine rescue support.

Findings

The aim of this study is to include this capacity in training situations when it has been validated and authorized by the Directorate General of Mines Safety (DGMS) Indian government regulatory agency for safety in mines and oil fields. The longwall demo mine, at IIT (ISM) is being used as the site of the first operations. Once approved by the respective enforcement agencies, this technology and the accompanying rescue and training process can be used in underground operations.

Originality/value

In fact, this paper is the first attempt at remotely operated UGVs based on CPSs, the CPS–UGV in Indian mine conditions, so as to revolutionize Indian mines based on the idea of Industry 4.0.

Details

International Journal of Intelligent Unmanned Systems, vol. 13 no. 1
Type: Research Article
ISSN: 2049-6427

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