Ferit Ficici

Evaluation of the Taguchi method for wear behavior of Al/SiC/B4C composites

In this study, the wear behaviors of aluminum matrix composites with an A360 matrix reinforced with silicon carbide (SiC) and boron carbide (B4C) ceramic particles using Taguchi method were investigated. Wear tests of unreinforced aluminum alloy and Al17%SiC and Al17%B4C particles reinforced aluminum composites (Al/17%SiC and Al/17%B4C, respectively) versus AISI316L stainless steel disc were carried out for a dry sliding condition in a so-called a pin-on-disc arrangement. The wear tests were realized at the sliding speeds of 0.5, 1.0, and 1.5 m s−1 and under the loads of 10, 20, and 30 N. The obtained average specific wear rates for Al/17%B4C and Al/17%SiC composites are lower than unreinforced aluminum specific wear rate under the same test conditions. The experimental results are transformed into a signal-to-noise (S/N) ratio of using Taguchi method. Type of the material, applied load, and sliding speed exert a great effect on the specific wear rate, at 48.13%, 31.83%, and 8.77%, respectively. The estimated S/N ratio using the optimal testing parameters for specific wear rate were calculated and a good agreement was observed between the predicted and actual specific wear rate for a confidence level of 99.5%.

Production of functionally graded SiC/Al-Cu-Mg composite by centrifugal casting

Abstract This study is aimed at investigating the production and wear properties of a functionally graded (FG) silicon carbide (SiC)-reinforced composite material, which was produced by stir casting followed by centrifugal casting. SiC powder (5 wt.%) was added into liquid aluminum at 750°C via stir casting, at which temperature a centrifugal force was applied to the mixture to drive the SiC particles toward the outer region of the mold. The results showed that two distinct regions formed in the cast samples after the centrifugation process. The outer region showed approximately 25% SiC particles resulting in almost SiC particle-free area in the internal region of the FG SiC-reinforced composite material. The test results showed that higher hardness and higher wear resistance could be obtained at the SiC-rich periphery of the cast FG composite material.

Microstructural characterization and wear properties of in situ AlB2–reinforced Al–4Cu metal matrix composite

Aluminium matrix composites have been extensively studied for several decades due to the potential advantages over classical low-density materials. Low-density composites can offer high wear and corrosion resistance, high strength, and favorable thermal electrical properties that attract the attention of various industries such as aerospace and automotive. This study investigates the dry sliding wear behavior of AlB2–Al–4Cu composites with 5, 10, 20, and 30% weight reinforcement. In situ developed AlB2 flakes were incorporated as the reinforcing compound in the Al–4Cu matrix. The composite samples were tested against a steel disk using a pin-on-disk wear rig. The effect of reinforcement ratio, applied load, sliding velocity on the wear rate and friction coefficient of the composite samples was investigated. In addition, the worn surfaces have been characterized in terms of wear patterns. Compared to the matrix alloy, composite samples exhibited better wear resistance and lower friction coefficient to varying degrees of magnitudes.

Determination of optimum particle size of Al2O3/SiCp reinforced hybrid composites materials in wear testing

Purpose – The purpose of this study is to optimize input parameters of particle size and applied load to determine minimum weight loss and friction coefficient for Al2O3/SiC particles-reinforced hybrid composites by using Taguchi’s design methodology. Design/methodology/approach – The experimental results demonstrate that the applied size is the major parameter influencing the weight loss for all samples, followed by particle size. The applied load, however, was found to have a negligible effect on the friction coefficient. Moreover, the optimal combination of the testing parameters was predicted. The predicted weight loss and friction coefficient for all the test samples were found to lie close to those of the experimentally observed ones. Findings – The optimum levels of the control factors to obtain better weight loss and friction coefficient were A8 (particle size, 60 μm) and B1 (applied load, 20 N), respectively. Taguchi’s orthogonal design was developed to predict the quality characteristics (weight...

Experimental optimization in turning of in-situ AlB2 reinforced AlMg3 matrix composites produced by centrifugal casting method

Ceramic particle-reinforced aluminum matrix composites are gaining attention especially from the automotive and aerospace industry requiring light-weight and high-strength materials for various applications. Since the AlB2 reinforced composites are relatively new materials, there is no investigation into the machinability of such materials in the literature. Therefore, the aim of this paper is to study machinability of AlB2/Al-Mg3 composite materials to optimize cutting force and surface roughness during turning operation. Taguchi’s statistical approach has also been utilized for the optimization of the process parameters. The optimum conditions providing the lowest cutting force and surface roughness were estimated. For the experimental planning, L8 (27) orthogonal array and the smaller-the-better response criterion were selected to obtain optimum conditions. Analysis of variance was used to determine the most significant parameters affecting the cutting force and surface roughness generated. The optimum condition was predicted from the combination of following factors and their respective levels; the second level of material type (AlB2/Al-Mg3), first level of cutting tool (TiN coating), first level of feed rate (0.08 mm/rev) and first level of cutting speed (350 m/min). Confirmation tests were performed to determine the effectiveness of Taguchi’s optimization method using the optimal levels of test parameters. A good agreement with a confidence level of 99.5% has been observed between the predicted and tests results for both cutting force and surface roughness.

Optimization of the Preheater Cyclone Separators Used in the Cement Industry

In this work, Taguchi methods have been utilized to optimize the pressure drop and particle collection efficiencies. These key parameters play an important role in process parameters of preheater cyclone separators used in the cement industry. The process parameters have been analyzed under varying vortex finder diameters (80, 120, and 160 mm), lengths of vortex finder (90, 130, and 170 mm), inlet velocities (9.51, 9.81, and 10.18 m/s), and inlet farin concentrations (0.24, 0.39, and 0.52 kg/m3). The settings of the test parameters were determined by using Taguchis experimental design method. Orthogonal arrays of Taguchi, the signal-to-noise ratio, and the analysis of variance have been employed to find the optimal levels and to analyze the effects of the experiment parameters on pressure drop and collection efficiency accuracy values. Confirmation tests with the optimal levels of test parameters have been performed in order to check the effectiveness of the Taguchi optimization method. Results show that developed approach yields worthy results when comparing with observed values with confidence level of 99.5%, error rate in 3.85% for pressure drop, and 4.01% for collection efficiency.

The experimental optimization of abrasive wear resistance model for an in-situ AlB2/Al-4Cu metal matrix composite

Purpose The paper aims to describe the Taguchi design method-based abrasive wear modeling of in situ AlB2 flake reinforced Al-4Cu matrix alloy composites. Design/methodology/approach The abrasive wear behaviors of the composite samples were investigated using pin-on-disk method where the samples slid against different sizes of SiC abrasive grits under various testing conditions. The orthogonal array, signal-to-noise (S/N) ratio and analysis of variance were used to study the optimal testing parameters on composite samples. Findings The weight loss of composites decreased with increasing grit size and percentage reinforcement and increased with increasing sliding speed. The optimum test condition, at which the minimum weight loss is obtained, has been determined to be A3B3C1 levels of the control factors. Deviations between the actual and the predicted S/N ratios for abrasive weight losses are negligibly small with 99.5 per cent confidence level. Originality/value This paper fulfils an identification of Taguchi method-based abrasive wear behavior of AlB2/Al-4Cu metal matrix composites produced by squeeze casting under various testing conditions.

Investigation of the Delamination Factor of Glass Sphere and Silicon Particle Reinforced (GS-SCR) Hybrid Composite Material

Reinforced polymer composite materials have opened a new era because they can substitute the conventional metallic materials. These materials have found numerous usage areas, especially in aviation, military and space applications due to such advantages as the high tensile strength, high modulus, high corrosion resistance and low density. However, during the assembly of parts from these materials, a huge amount of holes is required. There are problems during machining of reinforced polymer composite materials. Main reason behind these problems is the inhomogeneous microstructure. Some of these problems are burr, pullout, swelling, microcrack, rapid tool wear and delamination. Among the most important of these defects is the delamination damage. Delamination is a severe drilling failure. In this work, three different cutting speeds (15, 20, 25 m/min), three different feed rates (0.05, 0.10, 0.15 mm/rev) and three different cutting tool materials (Carbide, TiN Coated HSS and HSS) have been used. Effect of different feed rates, cutting speeds and tool materials on delamination is studied by drilling of %10 glass sphereand %10 silicon particle-reinforced polypropylene hybrid composite material.

Önısıtıcılı Siklonlarda Dalma Borusu Çap Değişiminin Toz Toplama Verimliliğine Etkisinin Deneysel Olarak İncelenmesi

Siklonlar, icinde kati bulunan bir gaz akiminin sinirlari belli bir girdaba donusturulmesi sonucu meydana gelen merkezkac kuvveti ile katinin gazdan ayrilmasi isleminde kullanilan sabit parcali cihazlardir. Basit yapili olmalari, yuksek sicaklik ve basinc sartlarinda calismalari gibi onemli avantajlari vardir. Siklonlar muhendislik acisindan degerlendirilirken iki onemli parametre goz onunde bulundurulur. Bunlar, toz toplama verimliligi ve basinc kaybidir. Bu calismada onisitici siklonlarda toz toplama verimliligini etkileyen dalma borusu capinda degisiklikler yapilarak deneysel olarak incelenmistir. Deneyler, endustride kullanilan gercek onisiticili siklonun prototipi imal edilerek gercek calisma sartlarinda yapilmistir