Mrityunjay Doddamani

Data characterizing tensile behavior of cenosphere/HDPE syntactic foam

The data set presented is related to the tensile behavior of cenosphere reinforced high density polyethylene syntactic foam composites “Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine” (Bharath et al., 2016) [1]. The focus of the work is on determining the feasibility of using an industrial scale polymer injection molding (PIM) machine for fabricating syntactic foams. The fabricated syntactic foams are investigated for microstructure and tensile properties. The data presented in this article is related to optimization of the PIM process for syntactic foam manufacture, equations and procedures to develop theoretical estimates for properties of cenospheres, and microstructure of syntactic foams before and after failure. Included dataset contains values obtained from the theoretical model.

Enhancing the Ignition, Hardness and Compressive Response of Magnesium by Reinforcing with Hollow Glass Microballoons

Magnesium (Mg)/glass microballoons (GMB) metal matrix syntactic foams (1.47–1.67 g/cc) were synthesized using a disintegrated melt deposition (DMD) processing route. Such syntactic foams are of great interest to the scientific community as potential candidate materials for the ever-changing demands in automotive, aerospace, and marine sectors. The synthesized composites were evaluated for their microstructural, thermal, and compressive properties. Results showed that microhardness and the dimensional stability of pure Mg increased with increasing GMB content. The ignition response of these foams was enhanced by ~22 °C with a 25 wt % GMB addition to the Mg matrix. The authors of this work propose a new parameter, ignition factor, to quantify the superior ignition performance that the developed Mg foams exhibit. The room temperature compressive strengths of pure Mg increased with the addition of GMB particles, with Mg-25 wt % GMB exhibiting the maximum compressive yield strength (CYS) of 161 MPa and an ultimate compressive strength (UCS) of 232 MPa for a GMB addition of 5 wt % in Mg. A maximum failure strain of 37.7% was realized in Mg-25 wt % GMB foam. The addition of GMB particles significantly enhanced the energy absorption by ~200% prior to compressive failure for highest filler loading, as compared to pure Mg. Finally, microstructural changes in Mg owing to the presence of hollow GMB particles were elaborately discussed.

Experimental Investigations on Drilling Characteristics of Cenosphere Reinforced Epoxy Composites

In the present paper, the experimental investigations on drilling characteristics of cenosphere reinforced epoxy composites with cemented carbide drill have been presented. The drilling aspects such as thrust and hole surface roughness have been performed as function of four process parameters, namely, spindle speed, feed rate, drill diameter and % weight of the filler. Composite specimens were prepared with 20%, 40% and 60% by weight of cenosphere filler in epoxy resin as the matrix. The full factorial design (FFD) has been employed for conducting drilling experiments and the proposed drilling characteristics were analysed using response surface methodology (RSM) based quadratic models. The response surface analysis reveals that the addition of cenosphere as filler in epoxy resin appreciably decreases with the thrust and hole surface roughness for the developed composites.

Influence of axial compressive loads on buckling and free vibration response of surface-modified fly ash cenosphere/epoxy syntactic foams:

This work deals with experimental buckling and free vibration behavior of silane-treated cenosphere/epoxy syntactic foams subjected to axial compression. Critical buckling loads are computed from compressive load–deflection plots deduced using universal testing machine. Further, compressive loads are applied in the fixed intervals until critical loading point on different set of samples having similar filler loadings to estimate natural frequency associated with the first three transverse bending modes. Increasing filler content increases critical buckling load and natural frequency of syntactic foam composites. Increasing axial compressive load reduce structural stiffness of all the samples under investigation. Syntactic foams registered higher stiffness compared to neat epoxy for all the test loads. Similar observations are noted in case of untreated cenosphere/epoxy foam composites. Silane-modified cenosphere embedded in epoxy matrix registered superior performance (rise in critical buckling load and natural frequencies to the tune of 23.75% and 11.46%, respectively) as compared to untreated ones. Experimental results are compared with the analytical solutions that are derived based on Euler–Bernoulli hypothesis and results are found to be in good agreement. Finally, property map of buckling load as a function of density is presented by extracting values from the available literature.

Wear Response of Walnut-Shell-Reinforced Epoxy Composites

Present work utilizes agricultural by-product, walnut shell, as reinforcing filler in epoxy matrix for investigating dry sliding wear behavior using a pin-on disc wear-testing machine. Effects of sliding velocity (0.5–1.5 m/s), normal load (10–50 N), sliding distance (1000–3000 m) and filler content (10–30 wt. %) on wear rate (Wt), specific wear rate (Ws) and coefficient of friction (μ) are investigated. The experiments were planned as per design of the experiments scheme and the wear characteristics were analyzed through response surface modeling (RSM) method. The lowest Wt of 1.1 mm3/km was noted for 1.5 m/s sliding velocity with 30-wt. % filler content. Sliding distance did not have a significant influence on Ws above a critical load of 40 N. The minimum μ was observed at 1-m/s sliding velocity, 40-N load, 1000-m sliding distance, and 30-wt. % filler. Lower values of Wt and μ at higher walnut-shell loadings support feasibility of using such composites in wear-prone applications. The wear mechanism was determined in the composites using extensive scanning electron microscopic observations.

Multi-objective optimization of stacked radial passive magnetic bearing

Modeling, design, and optimization for performances of passive magnetic bearings (PMBs) are indispensable, as they deliver lubrication free, friction less, zero wear, and maintenance-free operations. However, single-layer PMBs has lower load-carrying capacity and stiffness necessitating development of stacked structure PMBs for maximum load and stiffness. Present work is focused on multi-objective optimization of radial PMBs to achieve maximum load-carrying capacity and stiffness in a given volume. Three-dimensional Coulombian equations are utilized for estimating load and stiffness of stacked radial PMBs. Constraints, constants, and bounds for the optimization are extracted from the available literature. Optimization is performed for force and stiffness maximization in the obtained bounds with three PMB configurations, namely (i) mono-layer, (ii) conventional (back to back), and (iii) rotational magnetized direction. The optimum dimensions required for achieving maximum load without compromising stiffness for all three configurations is investigated. For designers ease, equations to estimate the optimized values of load, stiffness, and stacked PMB variables in terms of single-layer PMB are proposed. Finally, the effectiveness of the proposed method is demonstrated by considering the PMB dimensions from the available literature.

Generalized optimization procedure for rotational magnetized direction permanent magnet thrust bearing configuration

Optimization of rotational magnetized direction permanent magnet thrust bearing configuration is carried out using generalized three-dimensional mathematical model. The bearing features namely axial force and stiffness are maximized using in-house developed mathematical expressions solved using MATLAB. The design variables selected for the optimization are axial offset, number of ring pairs, air gap and inner radius of inner and outer rings. The maximized axial force values of the optimized configuration are validated with the finite element analysis results. To overcome the high computational cost associated with three-dimensional equations, generalized method of optimization is sucessfully demonstrated using plots representing variation of optimal design variables as a function of air gap with respect to bearing’s outer diameter. Simple and useful method of using the generalized plots for the process of optimization is presented by dimension optimization of representative bearing configuration with a particular aspect ratio. The proposed optimization using mathematical model and generalized approach assists designer in selecting optimized geometrical parameters of rotational magnetized direction thrust bearing configurations easily for variety of high-speed applications.

Cyclic oxidation behavior of plasma sprayed NiCrAlY/WC-Co/cenosphere coating

Components working at elevated temperature like boiler tubes of coal and gas fired power generation plants, blades of gas and steam turbines etc. experience degradation owing to oxidation. Oxidation resistance of such components can be increased by developing protective coatings. In the present investigation NiCrAlY-WC-Co/Cenosphere coating is deposited on MDN 321 steel substrate using plasma spray coating. Thermo cyclic oxidation behavior of coating and substrate is studied in static air at 600 °C for 20 cycles. The thermo gravimetric technique is used to approximate the kinetics of oxidation. X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM), Energy Dispersive Spectroscopy (EDS) and X-ray mapping techniques are used to characterize the oxidized samples. NiCrAlY-WC-Co/Cenosphere coating exhibited lower oxidation rate in comparison to MDN 321 steel substrate. The lower oxidation rate of coating is attributed to formation of Al2O3, Cr2O3, NiO and CoWO4 oxides on the outermost surface.