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MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES

Mahindra & Mahindra, Ltd.-Jayanthan Balasubramanian, Rahul Lalwani, Vinay Kumar
  • Technical Paper
  • 2019-28-2561
To be published on 2019-11-21 by SAE International in United States
TITLE: MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES. Keyword: Edge corrosion, Edge protection, Rust on edges, Corrosion mitigation. Objective: A major challenge to automotive industry is to protect the vehicle from corrosion in varying environment with respect to different service conditions. One of the main types of corrosion that affects aesthetic look is edge corrosion on sheet metal. Mostly edge is acting as starting point of corrosion due to unprotected metal exposed to environment. A special attention to be given to exposed edges to protect from rust formation. Methodology: To mitigate corrosion in visible area, various solution proposed in manufacturing process, material usage, sealer application, BIW design. Samples were prepared as per design of experiments with respect to manufacturing process condition and subjected for testing. Results: Proposed solutions were validated in manufacturing process line and reports are discussed. Improvements observed in controlled lab testing were furnished with observations and recommendations. Limitation of this study: On high volume passenger and commercial segment, corrosion mitigations are linked with high cost impact where high-end corrosion protection like…
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Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan
Published 2019-10-11 by SAE International in United States
Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that progress of flank wear associated with Waspaloy is faster that of Nimonic C-263 due to high cutting temperature for Waspaloy that…
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Mechanical and Corrosion Behaviour of Al 7075 Composite Reinforced with TiC and Al2O3 Particles

Vellore Institute of Technology-Subham Jaiswal, Govindasamy Rajamurugan, Prabu Krishnasamy, Yashwardhan Shaswat, Mishra Kaushik
Published 2019-10-11 by SAE International in United States
Various research regarding new types of fabrication and modifications of Aluminium alloy to improve the existing properties are going on. The wide range application of aluminium alloy is in aerospace and Automobile Industries. The demand for this material improved by mechanical properties with little to zero increment in weight. The current work is based on the fabrication of hybrid aluminium metal matrix composites with the addition of TiC (Titanium Carbide) and Al2O3 (Aluminium Oxide) reinforcement particle using stir casting technique. Three types of hybrid composite samples were prepared based on the weight percentage 5% Al2O3+0% TiC (sample-1), 8% Al2O3 + 12% TiC (sample-2), 20% Al2O3+15% TiC (sample-3). The objective of the study is to analyze the mechanical and corrosion properties of the hybrid composite with the influence of the reinforcement and varying the weight fraction of the particles. Overall, It is observed that a gradual increase in the hardness value in sample-1(83 BHN), Sample-2 (88 BHN) and sample-3 (96 BHN). This trend can be explained by the particulate strengthening of TiC over the soft ductile…
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Appraisal of Tribo Meter Study on 20MnCr5 Alloy Steel under Case Hardened and Shot Peened Condition

Shanthi Gears Limited-Vignesh Nataraj
Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Janarthanan Prakash, Dinu Mathew
Published 2019-10-11 by SAE International in United States
This research is limited to study the strength and wear resistance of 20MnCr5 (SAE 5120) alloy steel under monolithic, case hardened and case hardened with shot peening processing condition. Improve the hardness of the material by enhancing the core and surface strength of case hardened with the shot peened sample. The main objective of this proposed work is to conduct the tribometer test by varying the load of 10, 20, 30 and 40N and sliding speed of 193, 386 rpm respectively on wear rate and coefficient of friction be calculated and recorded for this study. Less wear rate and nominal coefficient of friction were observed for case hardened with the shot peened sample. Load increases wear rate increases and the coefficient of friction decreases when sliding distance increases wear rate decreases and the coefficient of friction increases for all the tested samples due to oxide layer formation. After reaching certain load and sliding speed the curve goes linear because of more contact between pin and disc, so that mechanical amalgamation layer will be formed. On…
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Parameter Optimization during Minimum Quantity Lubrication Turning of Inconel 625 Alloy with CUO, Al2O3 and CNT Nanoparticles Dispersed Vegetable-Oil-Based Cutting Fluid

Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan
Published 2019-10-11 by SAE International in United States
Inconel 625, nickel based alloy, is found in gas turbine blades, seals, rings, shafts, and turbine disks. On the other hand, the manufacturing of this alloy is challenging, mainly when machining processes are used due to excellent mechanical properties. Application of nanofluids in minimum quantity lubrication (MQL) shows gaining importance in the machining process, which is economical and eco-friendly. The principal objective of this investigational work is to study the influence of three types of nanofluids in the MQL turning of Inconel 625 nickel based alloys. The used nanofluids are multi-walled carbon nanotubes (CNT), alumina (Al2O3) and copper oxide (CUO) dispersed in vegetable oil. Taguchi-based L27 orthogonal array is used for the experimental design. The parameter optimization of design variables over response is carried out by the use of Taguchi-based derringer's desirability function. The design variables are machining parameters (speed, feed), nanofluids (Al2O3, CNT, CUO), and three different weight percentage (0.1, 0.25, and 0.5 wt. %). The results showed that minimum values of surface roughness could be achieved at 0.10 wt. % of nanoparticles, CNT…
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Tensile and Fatigue Behavior of Shallow Cryogenically Treated EN19 Alloy Steel

BSACIST-Loganathan Sekar, Tamil Arasan
SRM Institute of Science and Technology-Rajendran Raj
Published 2019-10-11 by SAE International in United States
Tensile and axial fatigue tests were conducted on shallow cryogenically treated EN19 medium carbon alloy steel to investigate its mechanical behavior. The test samples were conventionally heat treated then oil quenched at room temperature. Followed by the samples were kept for shallow cryogenic treatment to -80°C for 8 hours using liquid nitrogen. Then the samples were tempered in a muffle furnace to relieve the induced residual stresses. Tensile and axial fatigue test were carried out on both treated and non-treated samples to measure its tensile strength and fatigue behavior respectively. Microscopic examination also had done to compare the effect of shallow cryogenic treatment on its microstructure. The results exposed that there is an increase in the tensile strength and reduction in fatigue life of shallow cryogenically treated samples over base metal and improved wear resistance.
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Corrosion Characteristics on Friction Stir Welding of Dissimilar AA2014/AA6061 Alloy for Automobile Application

Bannari Amman Institute of Technology-Sadhasivam Deepankumar, Anbalagan Ramakrishnan, Dinesh Dhanabalan
Vellore Institute of Technology-Govindasamy Rajamurugan, Prabu Krishnasamy
Published 2019-10-11 by SAE International in United States
Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to the below recrystallization temperature due to frictional force. FSW mostly avoids welding defects like hot cracking and porosity which are mainly occur in conventional welding techniques. In this process the combination of frictional force and the mechanical work provide heating the base metal to get defect free weld joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of automobile applications like Engine valves and tie rod, shipbuilding, and aerospace due to their high corrosion resistance, lightweight, and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The tool rotational speed, travel speed, and tool profile are the important parameters in FSW process. High Speed Steel (HSS) tool with Hexagonal profile is used for this joining. The tool rotational speed is varied form 700, 1000 and 1400 rpm and the travel speed is varied from 25, 30 and 50 mm/min. From the…
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Mechanical and Metallurgical Analysis of HSLA Steel for Gas Tungsten Arc Welding with Different Shielding Gases

CSI College of Engineering-Dhanraj Gurusamy, Prashanth Murthy, Senthilkumar Ramakrishnan, Sivakumar Nanjappan
Sri Krishna College of Engineering and Technology-Soundararajan Ranganathan
Published 2019-10-11 by SAE International in United States
The special designed HSLA (High Speed Low Alloy) Steel is most commonly used in Naval Steel Structures and aircraft structures due to its indigenous properties. The aim of this paper is used to investigate the effect of shielding gases in the Gas Tungsten Arc Welding process. DMR 249A [HSLA] plates were welded by GTAW by using helium and argon as shielding gas with a flow rate of 16 L/min, the interpass temperature is 140 degree Celsius and the heat input is less than 1.2KJ/min where the impact toughness, Tensile and micro hardness was studied with different shielding gas and the metallurgical properties were analysed in the base metal, heat affected zones and weld zones. A detailed study has been carried out to analyze the elements using Scanning Electron Microscopy and Energy Dispersive Spectroscopy (EDS) analysis. The properties of the high speed low alloy steel carried out reveals a better mechanical properties suitable in naval applications.
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Experimental Study on Verification of Alloy ASTM A510 High-Speed Micro Turning by Parameters Validation through Ranking Algorithm

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Durai Kumaran, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
Published 2019-10-11 by SAE International in United States
In the details and assembly, in the range of less than 1 mm, the number of functions increases, and the demand for industrial products in which the size and characteristics of components are decreasing is increasing. Micromachining is the most basic technology for producing these small parts and components. In this study, a series of turning operations, micromachining parameters, were performed under microscopic conditions to obtain the best response for the benefit of the industry. The needle is very high. Speed (3000, 3500, 4000 rpm), pre- (20, 40, 80 μm / sec), depth of cut (0.2.0.4.0.8 μm), tool radius (0.4.08, 1, 2 mm). Surface quality, material removal rates, energy consumption, and tool wear differences for various input process variables were investigated. Once the experiment is complete, we will develop an optimization strategy for this set of input parameters to improve responsiveness using the Grey Relational Analysis (GRA) and ANOVA. Therefore, the model can create micro-process parameters to achieve the highest product accuracy and improved performance.
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Corrosion and Corrosive Wear of Steel for Automotive Exhaust Application

Crescent Institute of Science and Technology-Tiruvannamalai Rajendra Prasad Tamilarasan
SRM Institute of Science and Technology-Raj Rajendran
Published 2019-10-11 by SAE International in United States
In the current scenario, durable exhaust system design, development and manufacturing are mandatory for the vehicle to be competitive and challenging in the automotive market. Material selection for the exhaust system plays a major role due to the increased warranty requirements and regulatory compliances. The materials used in the automotive exhaust application are cast iron, stainless steel, mild steel. The materials of the exhaust systems should be heat resistant, wear and corrosion resistant. Stainless steel is the most commonly used material in the automotive exhaust system. Due to increasing cost of nickel and some other alloying elements, there is a need to replace the stainless steel with EN 8 steel. Recent trends are towards light weight concepts, cost reduction and better performance. In order to reduce the cost and to achieve better wear and corrosion resistance, the surface of the EN 8 steel is modified with coatings. This work focuses on the evaluation of corrosion and corrosive wear resistance of hard chrome plating (HCP), hot dip aluminized coatings (HDA), spray aluminized coatings (SA), electroless nickel…
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