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GMAW Process Parameter Optimization to Reduce Porosity Defect in a Longitudinal Seam Welding of Pressure Vessels

SAE International Journal of Materials and Manufacturing

Amrita Vishwa Vidyapeetham, India-A. Kuppusamy, K. Rameshkumar, A. Sumesh
ELGI Equipment Limited, India-S. Premkumar
  • Journal Article
  • 05-13-01-0005
Published 2019-12-02 by SAE International in United States
Pressure vessels are critical equipment used in industries for storing liquids or gases at a pressure significantly different from ambient conditions. Porosity is one of the major weld defects in pressure vessels that leads to failure during inspection and as well as during its service. Gas Metal Arc Welding (GMAW) process is widely used in industries to fabricate pressure vessels using carbon steel “IS 2062 E250BR” material for storing compressed air. The main objective of this article is to reduce the porosity defect in the longitudinal seam (LS) welding of the pressure vessels. Detailed analysis is carried out to identify the parameters which are influencing the porosity defect. Central Composite Design (CCD) and Response Surface Methodology (RSM) approaches are used to find the optimum value of the weld parameters which produce weld without porosity or any major defects in the pressure vessel. An experimental setup has been established and welding experiments have been conducted under a controlled environment. Experiments were conducted without any external disturbances ensuring clean weld surface and filler wire without any moisture,…
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Forgings, Steel, For Aircraft/Aerospace Equipment

AMS E Carbon and Low Alloy Steels Committee
  • Aerospace Material Specification
  • AMS6400A
  • Current
Published 2019-12-02 by SAE International in United States

This specification establishes requirements for steel forgings of any shape or form from which finished parts are to be made (See 8.2, 8.3, & 8.4). This specification covers steel forgings suitable for use in the construction of aircraft/aerospace equipment.

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An alternate cost effective material for rocker arm used in heavy commercial vehicles

VE Commercial Vehicles, Ltd.-Sonu Paroche, Kaarthic Kaundabalaraman, Suresh Kumar Kandreegula, Hemantkumar Rathi
  • Technical Paper
  • 2019-28-2550
Published 2019-11-21 by SAE International in United States
Rocker arm in internal combustion engine is very important part which transfer the cam motion and force to the valve. In heavy commercial vehicles, the engine components are design for an infinite life (considerable higher than other components). Recently industries are working for light weight and optimized cost material. Hence it is required to have an optimized cost effective design of rocker arm without affecting its performance. A rocker arm should meet the stiffness and strength requirement. The objective of this study is to find out the alternate material for rocker arm which can provide the similar strength & stiffness as conventional rocker arm material. To achieve the performance and cost target, alternate material cast iron has been evaluated for rocker arm. Cast iron is lighter than the forged steel rocker arm, also it has a good frictional characteristic. Further bush is eliminated from the rocker arm assembly due to self-lubricant property of the cast iron rocker arm. This is significant reduce in cost of material and assembly procedure. A 2-d simulation and finite element…
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Optimization of the critical parameters affecting the fuel lid performance

Maruti Suzuki India, Ltd.-Piyush Kumar Pareek
  • Technical Paper
  • 2019-28-2413
Published 2019-11-21 by SAE International in United States
Fuel lid is one of the parts which are mostly operated mechanically by the end user while filling the fuel. Therefore part design should be done in such a manner that it can be operated smoothly without any hassles. The conventional steel fuel filler doors are of two types: Three-piece type fuel filler doors also known as the dog-leg type and two-piece type fuel filler doors also known as the butterfly type. Both types of fuel filler doors have a pin that acts as a rotational hinge axis about which the fuel filler door opens and closes. Depending on the styling and shape of the side body outer, fuel lid type is decided. In the current study, dog-leg type fuel lid is considered. The factors that primarily affect the opening-closing performance are the weight of fuel lid, hinge axis, and the friction at the hinge area. The orientation of the hinge axis is derived from the profile of the side body outer panel. The fuel lid weight and hinge axis are decided in the initial…
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Fabrication and Wear Characteristics Basalt Fiber Reinforced Polypropylene Matrix Composites

Dhanalakshmi Srinivasan Institute of Technology-Krishnaraj M, Thirugnana Sambandha T, Arun R
Trichy Engineering College-Vaitheeswaran T
  • Technical Paper
  • 2019-28-2570
Published 2019-11-21 by SAE International in United States
Generally brake pads are manufacturing by use of asbestos materials, that materials are chemically harmful and toxic nature to affect the human health. The present investigation is to fabricates polypropylene composites with mixing constant volume [5 vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt Fiber by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition. The test was carried out pin on disc apparatus, configured with hardened steel counter-face at elevated temperature. The load was applied 10 N to 30 N with the interval of 10 N and varying of sliding speed 300 rpm to 900 rpm with the interval of 300 rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and the frictional force was increases due to basalt Fiber content present in the composites. The co-efficient of friction was increases 0.1 to 0.66 under normal loading condition.
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STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

General Motors Global Technical Center-Abolhassan Khosrovaneh
General Motors Technical Center India-Karthigan Ganesan, Biswajit Tripathy
  • Technical Paper
  • 2019-28-2576
Published 2019-11-21 by SAE International in United States
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed. Possible material variation in fatigue life prediction is included as B5, B10 and B20 fatigue material properties. Methodology: Fatigue strength coefficient (σf') and fatigue strength exponent (b) are obtained by performing a linear regression on true stress amplitude (∆σ/2) versus reversals to failure (2Nf) in log-log scale. Fatigue ductility coefficient (εf')…
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High Rigidity and Light Weight Bumper Material Development in India

Honda Cars India Limited-Manu Sharma
  • Technical Paper
  • 2019-28-2553
Published 2019-11-21 by SAE International in United States
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries.With this background, High tensile and Super high tensile steel application has become increasing.Similarly, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face.In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are contradictory property. It is necessary to develop new material to achieve this technical concern.Moreover, we verified part shape and thickness optimization to achieve part requirement.Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.In this report, we report the analysis and verification result example of high rigidity and light weight bumper material development in India.
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Precipitation Hardenable Steel Alloy, Corrosion and Heat-Resistant Powder for Additive Manufacturing 16.0Cr - 4.0Ni - 4.0Cu - 0.30Nb

AMS AM Additive Manufacturing Metals
  • Aerospace Material Specification
  • AMS7012
  • Current
Published 2019-11-14 by SAE International in United States

This specification covers a corrosion and heat-resistant steel alloy in the form of pre-alloyed powder.

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Steel, Corrosion and Heat-Resistant, Welding Wire 15Cr - 25.5Ni - 1.3Mo - 2.2Ti - 0.006B - 0.30V

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS5804H
  • Current
Published 2019-11-12 by SAE International in United States
This specification covers a corrosion and heat-resistant steel in the form of welding wire.
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Steel, Corrosion and Heat Resistant, Welding Wire 9.0Mn - 20Cr - 6.2Ni - 0.20N

AMS F Corrosion Heat Resistant Alloys Committee
  • Aerospace Material Specification
  • AMS5818C
  • Current
Published 2019-11-12 by SAE International in United States
This specification covers a corrosion and heat resistant steel in the form of welding wire.
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