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      • KCI등재

        Genetic algorithm based optimization of the process parameters for gas metal arc welding of AISI 904 L stainless steel

        P. Sathiya,P. M. Ajith,R. Soundararajan 대한기계학회 2013 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.27 No.8

        The present study is focused on welding of super austenitic stainless steel sheet using gas metal arc welding process with AISI 904 L super austenitic stainless steel with solid wire of 1.2 mm diameter. Based on the Box - Behnken design technique, the experiments are carried out. The input parameters (gas flow rate, voltage, travel speed and wire feed rate) ranges are selected based on the filler wire thickness and base material thickness and the corresponding output variables such as bead width (BW), bead height (BH) and depth of penetration (DP) are measured using optical microscopy. Based on the experimental data, the mathematical models are developed as per regression analysis using Design Expert 7.1 software. An attempt is made to minimize the bead width and bead height and maximize the depth of penetration using genetic algorithm.

      • KCI등재

        Dissimilar Cladding of Ni–Cr–Mo Superalloy over 316L Austenitic Stainless Steel: Morphologies and Mechanical Properties

        A. Evangeline,P. Sathiya 대한금속·재료학회 2021 METALS AND MATERIALS International Vol.27 No.5

        The solid solution strengthened Inconel 625, a Ni-based alloy is known for its excellent strength and good corrosion resistanceat extreme environments used in thermal plants, boiler tubes, petrochemical industry and power plant. The presence ofCr content (~ 20 wt%) along with Mo-rich, Nb and Fe makes Ni–Cr–Mo–Nb austenitic alloy called as Inconel 625 to achieveexcellent corrosion resistance property. Using cold metal arc transfer (CMT) cladding, the metallurgical, mechanical andcorrosion properties of Inconel 625 on 316L is evaluated. The process parameters selected includes welding current, torchangle and travel speed with a constant voltage. From the results of microstructural and EDS inferences, the formation of cellulardendritic structure with secondary phases like Laves phase, complex nitrides along with the interdendritic segregationof Mo and Nb as well as microsegregation of Cr, Ni and Fe. In case of Ni–Cr–Mo alloy, Ni and Cr contribute to resistance tocorrosion in NaCl environments. The formation of Cr2O3and the passivation action of the clad zone is due to the presence ofCr. The solid solution effect in Ni–Cr matrix is contributed by the presence of Nb and Mo. Apart from that the strengtheningaction happens due to the precipitation of Ni3(Al, Ti, Nb) commonly known as γ′, γ″ and MC carbides confirmed throughXRD. Uni-axial tensile tests and Vickers-micro hardness indentation tests were performed on Inconel 625 cladded over316L. Based on the fractographic results fatigue striations, tear rigdes with river markings, dimples with fibrous structureand cleavages are observed. Unlike other studies, unique type of cuboidal precipitates are seen, which is due to the presenceof Ti, which form carbonitrides containing Ti, which are further characterised as NbC. The potentiodynamic polarisationtests is performed on 3.5% NaCl solution. The results suggest that Ni–Cr–Mo alloy protects the substrate from corrosion.

      • KCI등재

        Corrosion and Creep Properties of Weld Beads Produced on AA5083-H111 Alloy Sheets Using SpinArc GMAW Process

        V. Poonguzhali,M. Umar,P. Sathiya 대한금속·재료학회 2020 METALS AND MATERIALS International Vol.26 No.1

        In this work, the corrosion and creep properties of weld beads produced on AA5083-H111 alloy using SpinArc gas metalarc welding process were analyzed. For that, bead on plate welding was carried out considering welding current, filler spindiameter and filler rotation speed as input parameters. It is evident from the microstructures that change in filler spin diameterand filler rotation speed altered the shape of weld bead irrespective of welding current. Also, porosities were formed atboth side walls where the columnar dendrites grow upward while the equiaxed dendrites zone contains comparatively fewerporosities. On comparing the left and a right side wall, a higher density of porosities are observed at the right side wall andthe direction of rotation was expected to be responsible for this occurrence. The pitting morphology of both side walls wasnot similar due to the variance in concentration of Mg and a higher amount of Mg exists on the right side wall led to theprecipitation of Mg-rich rich particles result in severe corrosion. A welding current of 130 Amps, the filler rotation speed of1050 rpm and filler spin diameter of 2 mm produced a high density of dislocations and a higher number of Fe and Mn-richintermetallics at grain interiors as well as grain boundaries, thereby, results in improved corrosion and creep properties ofweld. The weld contains larger porosities results in poor corrosion and creep properties.

      • KCI등재

        Comparison of thermal fatigue behaviour of ASTM A 213 grade T-92 base and weld tubes

        G. R. Jinu,P. Sathiya,G. Ravichandran,A. Rathinam 대한기계학회 2010 JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY Vol.24 No.5

        Super-heater tubes are subjected to alternate heating and cooling in power plants causing them to crack and eventually fail. This phenomenon is referred to as “thermal fatigue.” In this paper, a laboratory simulation for reproducing the thermal fatigue phenomenon is developed to determine the number of cycles necessary before failure occurs in super-heater tubes. The temperature and strain distributions along the specimen were computed theoretically using ANSYS software for the applied temperature condition. The thermal fatigue test was conducted for both base and shielded metal arc (SMA) welded tubes separately and both passed in the non-destructive tests. These tubes were subjected to thermal cycles from 800ºC (accelerated temperature) to room temperature. Oxy-acetylene heating setup was utilized as a heating source, and a water bath was utilized for quenching purposes. The tests were carried out until open cracks were identified. Surface cracks were identified in the base and weld tubes after 90 and 60 cycles respectively. This study reveals that heating and cooling cause thermal fatigue, initiate cracks in the tubes.

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