Abstract
The tensile strength, hardness and toughness of any materials are the most important mechanical properties in the selection of materials for varied industrial applications. In the development of aluminum based composite material, tensile strength and hardness were significantly improved by adding various ceramic reinforcement particles. However, toughness was reduced. In this research work, an attempt was made to enhance tensile strength, hardness and toughness simultaneously by using carbonized eggshell as reinforcement material developed via electromagnetic stir casting. The process parameters used in this study are the matrix pouring temperature, wt.-% of the reinforcement; preheat temperature, stirring current and stirring time. Response surface methodology (RSM) is used for conducting the experiment. The multi-objective optimization technique utility theory is employed to optimize the combined mechanical properties viz. tensile strength, hardness and toughness. Microstructure results show that at the optimum level of process parameters, eggshells are uniformly distributed. Confirmation tests are conducted to validate the experimental results. Experimental results revealed that at optimum process parameters, hardness and tensile strength are significantly improved without affecting the toughness property of the composite. The optimum level of process parameters to enhance all mechanical properties (tensile strength, hardness and toughness) were found to be a reinforced preheating temperature of about 448.32 °C, a stirring current of about 11.64 A, a stirring time of about 63.64 s, a maximum pouring temperature of about 800.24 °C and a percentage of eggshells of about 9.16 %. The novelty of this work lies in the fact that no attempt was made to optimize these electromagnetic process parameters. Corrosion loss, thermal expansion behavior and a wear test were investigated to observe the effect of adding eggshell at optimum electromagnetic stir casting parameters.
About the authors
Dr. Shashi Prakash Dwivedi is currently Associate Professor in the Mechanical Engineering Department of the G. L. Bajaj Institute of Technology and Management, Greater Noida. He has developed the electromagnetic stir casting set-up in the advance research lab of Noida institute of Engineering and Technology, Greater Noida
Mr. Nagendra Kumar Maurya, born in 1987, studied Mechanical Engineering at UPTU, India and received his Master’s degree at the MotiLal Nehru Institute of Technology, Allahabad in 2010. He is pursuing his Doctorate degree at the Delhi Technical University (DTU), India. Since 2010, he has been Assistant Professor at the G. L. Bajaj Institute of Technology and Management, Greater Noida. His research mainly focuses on metal machining, metal casting and rapid prototyping.
Mr. Manish Maurya, born in 1984, studied Mechanical Engineering at the UPTU, India. Since 2008, he has been in academics. He received his M. Tech in Mechanical Engineering in 2012. He is pursuing his Doctorate degree at the National Institute of Technology, Patna (NITP), India. From 2012 to present, he has been working as an Assistant Professor in the Mechanical Engineering Department of the Accurate Institute of Management & Technology, Greater Noida, India. His research area mainly includes material fabrication and characterization, casting etc.
Dr. Ambuj Saxena is currently an Associate Professor in Mechanical Engineering in the Department at the G L Bajaj Institute of Technology and Management, Greater Noida. He received his PhD at the Defence Institute of Advance Technology, Pune.
Dr. Ashish Kumar Srivastava is currently Associate Professor in Mechanical Engineering Department at the G L Bajaj Institute of Technology and Management, Greater Noida. He received his PhD at ISM, Dhanbad.
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