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Multicriteria Optimization, Sensitivity Analysis, and Prediction of Bond Characteristics of Vacuum Diffusion Bonded Aero Engine Ti6Al4V Alloy Joints

SAE International Journal of Aerospace

Annamalai University, India-T. Pragatheswaran, S. Rajakumar, V. Balasubramanian, S. Kavitha
Materials Group, Gas Turbine Research Establishment (GTRE), India-Vijay Petley, Shweta Verma
  • Journal Article
  • 01-12-02-0008
Published 2019-12-13 by SAE International in United States
Joining titanium (Ti) alloys with conventional processes is difficult due to their complex structural properties and ability of phase transformation. Concerning all the difficulties, diffusion bonding is considered as an appropriate process for joining Ti alloys. Ti6Al4V, which is an α+β alloy widely used for aero engine component manufacturing, is diffusion bonded in this investigation. The diffusion bonding process parameters such as bonding temperature, bonding pressure, and holding time were optimized to achieve desired bonding characteristics such as shear strength, bonding strength, bonding ratio, and thickness ratio using response surface methodology (RSM). Empirical relationships were developed for the prediction of the bond characteristics, and sensitivity analysis was performed to determine the increment and decrement tendency of the shear strength with respect to the bonding parameters. Various criteria were applied to achieve the desired bond characteristics and their effects; optimum values and limits were evaluated through graphical and numerical optimization. The predicted and experimented results are validated and found that they are in good agreement with each other. The microstructural examination and X-ray diffraction (XRD) analysis…
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Effect of Shielding Gas on Weldmetal Properties in Flux Cored Arc Welding

Anna University Tiruchirappalli-B. Kumaragurubaran, T. Senthilkuma, M. Vivekanandan
Annamalai University, Chidambaram-V. Balasubramanian
Published 2008-09-16 by SAE International in United States
The E71T-5 basic type flux cored wire is designed for 100% CO2 shielding gas. But this wire gives harsh arc, spatter and poor slag removal with 100% CO2 shielding gas. The arc running characteristics of the E71T-5 flux cored wire is very poor with 100% CO2 shielding. However, the same E71T-5 basic type flux cored wire when used with 80% Ar +20%CO2 mixed gas shielding the process had stable arc, free from spatter and excellent slag detachability. The effect of shielding gas on weld metal properties (mechanical, chemical and metallurgical properties) was investigated in this paper.
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Flow Field Analysis of a Carburettor Using CFD

Indian Institute of Technology Madras, Chennai, India-V. Ganesan
UCAL Fuel Systems Ltd., Chennai, india-M. Sivakumar, V. Balasubramanian
Published 2005-01-19 by The Automotive Research Association of India in India
The objective of present study is to predict and analyze the flow through the Carburettor for two different throttle opening conditions. The studies have been carried out by Computational Fluid Dynamics (CFD) software and the prediction has been validated with experimental data. Three dimensional geometrical models of two different throttle positions namely 50% opening and wide open throttle (100% throttle opening) were created using the commercially available software. The mesh was generated using the Tet-hybrid scheme which includes primarily of tetrahedral mesh elements but may also include hexahedral, pyramidal and wedge elements. The pressure boundary conditions are used to define the fluid pressure at the inlet and outlet of the carburettor. The steady state flow field analysis inside a carburettor has been simulated using the Multiphase mixture model and Langrangian Discrete phase model.The CFD plots give informative pictures of the flow field, which will help the designer to understand the effect of various components of carburettor. The predicted air and fuel flow rate shows good agreement with the experimental results. The result obtained from the…
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FLOW FIELD ANALYSIS OF A MULTI CYLINDER S.I. ENGINE AIR INTAKE SYSTEM USING COMPUTATIONAL FLUID DYNAMICS

Internal Combustion Engines Laboratory Department of Mechanical Engineering Indian Institute of Technology Madras Chennai 600 036, INDIA-V Ganesan, J. Suresh Kumar, V. Balasubramanian
Published 2004-01-16 by The Automotive Research Association of India in India
The objective of present study is to predict and analyze the flow through the Air Intake System (AIS) of a multicylinder S.I. engine by Computational Fluid Dynamics (CFD). The predicted results are validated by experimental data. Three-dimensional model of air intake system was created by using the commercially available software and the mesh was generated using the Tet-hybrid scheme. The pressure boundary conditions are used to define the fluid pressure at the inlet and outlet of the flow domain. Three different throttle conditions namely idling, 50% throttle opening and wide open throttling (WOT) are considered. Flow through the domain is analyzed for all the three cylinders. The CFD plots give informative pictures of the flow field, which will help the designer to understand the effect of various components of air intake system. The predicted airflow rate shows good agreement with the experimental results. The result obtained from the present study indicate that the method employed in the prediction can be used as a tool to understand the effect of various parts of Air Intake System…
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Performance Evaluation of a Small Agricultural Engine Operated on Dual Fuel (Diesel + Natural Gas) System

Brakes India Ltd.-V. Balasubramanian, K. Sridhara
Indian Institute of Technology-V. Ganesan
Published 1995-09-01 by SAE International in United States
Diesel has been used extensively as fuel for small agricultural engines in India. As natural gas is available in abundance, lot of interest is shown to substitute gas for diesel in these engines either partially or fully.Natural gas has a high Octane rating and hence to replace diesel fully, major irreversible changes in the diesel engine is required. However, in the dual fuel (diesel + gas) system a large percentage of diesel substitution is possible by the addition of the components of the conversion system. A simple dual fuel system has been developed indigenously for this study.Engine tests with dual fuel gas system have been conducted on a single cylinder diesel engine. These results show that the performance of the engine with dual fuel system can almost match that of standard diesel engine.
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