Recent Trends in Industrial and Production Engineering: Select Proceedings of ICCEMME 2021 (Lecture Notes in Mechanical Engineering) 9811633290, 9789811633294

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Lecture Notes in Mechanical Engineering

Akshay Dvivedi Anish Sachdeva Rahul Sindhwani Rohit Sahu   Editors

Recent Trends in Industrial and Production Engineering Select Proceedings of ICCEMME 2021

Lecture Notes in Mechanical Engineering Series Editors Francisco Cavas-Martínez, Departamento de Estructuras, Universidad Politécnica de Cartagena, Cartagena, Murcia, Spain Fakher Chaari, National School of Engineers, University of Sfax, Sfax, Tunisia Francesco Gherardini, Dipartimento di Ingegneria, Università di Modena e Reggio Emilia, Modena, Italy Mohamed Haddar, National School of Engineers of Sfax (ENIS), Sfax, Tunisia Vitalii Ivanov, Department of Manufacturing Engineering Machine and Tools, Sumy State University, Sumy, Ukraine Young W. Kwon, Department of Manufacturing Engineering and Aerospace Engineering, Graduate School of Engineering and Applied Science, Monterey, CA, USA Justyna Trojanowska, Poznan University of Technology, Poznan, Poland Francesca di Mare, Institute of Energy Technology, Ruhr-Universität Bochum, Bochum, Nordrhein-Westfalen, Germany

Lecture Notes in Mechanical Engineering (LNME) publishes the latest developments in Mechanical Engineering—quickly, informally and with high quality. Original research reported in proceedings and post-proceedings represents the core of LNME. Volumes published in LNME embrace all aspects, subfields and new challenges of mechanical engineering. Topics in the series include: • • • • • • • • • • • • • • • • •

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Akshay Dvivedi · Anish Sachdeva · Rahul Sindhwani · Rohit Sahu Editors

Recent Trends in Industrial and Production Engineering Select Proceedings of ICCEMME 2021

Editors Akshay Dvivedi Department of Mechanical Engineering Indian Institute of Technology Roorkee Roorkee, India Rahul Sindhwani Department of Mechanical Engineering Amity University Noida, Uttar Pradesh, India

Anish Sachdeva Department of Industrial and Production Dr. B. R. Ambedkar National Institute of Technology Jalandhar, Punjab, India Rohit Sahu Department of Mechanical Engineering GL Bajaj Institute of Technology and Management Greater Noida, Uttar Pradesh, India

ISSN 2195-4356 ISSN 2195-4364 (electronic) Lecture Notes in Mechanical Engineering ISBN 978-981-16-3329-4 ISBN 978-981-16-3330-0 (eBook) https://doi.org/10.1007/978-981-16-3330-0 © The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 This work is subject to copyright. All rights are solely and exclusively licensed by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, expressed or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore

Preface

International Conference on Computational and Experimental Methods in Mechanical Engineering (ICCEMME 2021) has been the third conference of its series organized by the Department of Mechanical Engineering of GL Bajaj Institute of Technology and Management, Greater Noida, Uttar Pradesh, India. The institute is located in the vicinity of the industrial hub. Therefore, it was decided to provide a forum to bring together scientists, speakers from industries, university professors, graduate students, and mechanical engineers, presenting new research in science, technology, and engineering. This book includes research articles from various areas of industrial and production engineering such as sustainable manufacturing systems, rapid prototyping, manufacturing process optimization, machining, and machine tools, casting, welding, forming, machining, machine tools, computer-aided engineering, manufacturing, management, automation and metrology, industrial, management and marketing, etc. During the conference, about ten delegates were joined from various contraries and delivered keynote lectures on the theme of the conference. All papers were critically reviewed by two reviewers from national/international authors. Furthermore, we would like to extend our appreciation to all the authors for contributing their valuable research in the conference. The committee is also grateful to all reviewers who spared their time to carefully review all the assigned research articles and to all the committee members for their great effort for making the conference a grand success. We are thankful to all sponsored agencies who gave us their cooperation and funding support. We are thankful to our management and director of GL Bajaj Institute of Technology and Management, Greater Noida, Uttar Pradesh, India, for their continuous source of inspiration and valuable support. We are thankful to all the members of the organizing committee for their contribution in organizing the conference. Last but not least, we thank Springer for its professional assistance and

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particularly Ms. Priya Vyas and Ms. Sushmitha Shanmuga Sundaram who supported this publication. Roorkee, India Jalandhar, India Noida, India Noida, India

Akshay Dvivedi Anish Sachdeva Rahul Sindhwani Rohit Sahu

Contents

Effect of Process Parameter on Surface Composite Developed Through Friction Stir Processing: A Review . . . . . . . . . . . . . . . . . . . . . . . . . Ritesh Jaiswal, Anil Kumar, and Rajnish Singh

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Potential of Various Metal-Oxide Nanofluids for Sustainable Machining Application—A Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saurabh Mishra, Vineet Dubey, and Anuj Kumar Sharma

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Microstructural and X-ray Diffraction Analysis of Surface Composite AZ31b/MgO/B4 C Produced by Friction Stir Processing . . . . . Rakesh Kumar Singh, Ashish Kumar Srivastava, and Dheerendra Kumar Singh

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Analyzing the Green Manufacturing and Organizational Performance of the Indian SMEs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manoj Kumar Singh, Pravin Kumar, and Saurabh Agrawal

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Two-Warehouse Inventory Model for Perishable Items with Variable Demand Under Inflationary Environment . . . . . . . . . . . . . . Sudesh Kumar Garg, Vineet Kumar, and Nirdosh Kumar Sisodia

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Modeling Technique—A Tool for Inventory Control in Supply Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tarun Kumar Gupta, Dharamvir Mangal, Vishal Shankar Srivastava, Rahul Kumar, Vijay Prakash Gupta, and Sandeep Kumar Singh Analyse the Critical Success Factor of Green Manufacturing for Achieving Sustainability in Automotive Sector . . . . . . . . . . . . . . . . . . . . Punj Lata Singh, Rahul Sindhwani, Bhupendra Prakash Sharma, Priyank Srivastava, Praveen Rajpoot, Lalit, Rahul, and Rajender Kumar Historical Analysis of Wheel and Diving into Future of Wheel Made with Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pratyush Kaushal, Divyansh Vatsa, Sandeep Gupta, Rishi Raj, and Amardeep

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Statistical Optimization of Process Parameters During the Friction Stir Processing of Al7075/Al2 O3 /waste Eggshell Surface Composite . . . . 107 Rishabh Dwivedi, Rakesh Kumar Singh, Ashish Kumar Srivastava, Anshu Anand, Sanjay Kumar, and Anurag Pal Improving the Resources Utility in Construction Sector for the Sustainable Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Nitin Kumar Garg, Rajat Negi, Sunita Bansal, and Rajender Kumar Barriers to Digital Marketing in Rural India . . . . . . . . . . . . . . . . . . . . . . . . . 127 Gautam Srivastava and Deepa Gupta Synthesis and Thermal Analysis of Chromium (III) Bakelite Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Brij Kishore Tiwari, Ashish Kumar, and Mamta Mishra The Role of Effective Inventory Management System on Customers’ Satisfaction; The Case Study of Ethiopia Electric Utility, Northeast Region Store Dessie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Sandeep Kumar Gupta, Sanjay Kumar Gupta, Renu Rana, Vinesh Kumar, Yimer Ayalew, and Tesfaye Nega Mekonen Study of Process Parameters and Performance Measure of Wire Electrical Discharge Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Utkarsh Mohan, Krishna Mohan Agarwal, Priyanka Singh, Chinmay Sharma, and Ashish Yadav A Study of Internal Factors Enabling Impulse Buying Behaviour—A Gap Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Bhavana Sharma, Nishant Kumar Singh, Shivi Mittal, and Shruti Yadav Influence of Incorporating Industrial Byproducts/Wastes on Mechanical Properties and Durability Characteristics of Self-Consolidating Concrete: A Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Rajat Saxena, Trilok Gupta, Rajesh Kumar Sharma, and Saurav Yadav A Frame Work for Ranking the Factors Affecting Customer Service Quality by MOORA Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Tarun Kumar Gupta, Dharamvir Mangal, Vishal Shankar Srivastava, Vijay Prakash Gupta, and Raj Vardhan Patel Nanotech Science as Well as Its Multifunctional Implementations . . . . . . 217 Rishabh Chaturvedi, Aman Sharma, Kamal Sharma, and Manish Saraswat A Study on Training of Workmen in a Manufacturing Organization—With Reference to Aluminium Foundry . . . . . . . . . . . . . . . 229 Deepa Gupta, Mukul Gupta, and Sonam Rani

Editors and Contributors

About the Editors Dr. Akshay Dvivedi is an Associate Professor in the Mechanical and Industrial Engineering Department of the Indian Institute of Technology Roorkee, Roorkee, Uttarakhand, India. Dr. Dvivedi has 20 years of experience in academics and industry. Dr. Akshay Dvivedi was a Visiting Associate Professor at AIT Bangkok. The Ministry of Human Resource Development, Government of India, seconded this assignment. Before joining IIT Roorkee, he has worked as Principal Scientist, Centre of Excellence in Manufacturing at Research Technology and Innovation Centre, Thermax, India. He has authored more than 120 research papers published in reputed international journals and conference proceedings. Based on his research work, he has authored 16 books/book chapters and filed seven patents. He is a member of several national and international advisory committees. He has handled several sponsored research projects with funding support from MHRD, DST, CSIR, etc. He has worked on several industrial consultancy projects. He has supervised 38 M.Tech. Dissertations and 10 Ph.D. theses. Currently, 12 research scholars are working in his research group. He is currently involved with research projects on microfabrication, development of hybrid manufacturing processes, rapid prototyping, product development, quality management, value stream management, and development of Lab-on-a-Chip Devices. Dr. Dvivedi is actively engaged in research work on the process as well as product development to fulfill the industrial viability. He has developed more than 30 research and experimentation facilities at IIT Roorkee. He is the recipient of several technical awards and social recognitions that includes Editor’s Choice Paper by Precision Engineering, Outstanding Teacher Award by IIT Roorkee, India, and multiple best paper awards. Dr. Anish Sachdeva is a Professor in Industrial and Production Engineering Department at Dr. B. R. Ambedkar National Institute of Technology Jalandhar, India. His areas of interest are reliability and maintenance engineering, supply chain management, optimization and simulation of production systems, and quality management. He obtained his B.Tech. from Dr B R Ambedkar National ix

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Institute of Technology (erstwhile REC Jalandhar), M.Tech. from Guru Nanak Dev Engineering College Ludhiana and Ph.D. from Indian Institute of Technology Roorkee (India). He has over 23 years of industry and teaching experience. He has guided 65 M.Tech. and 12 Ph.D. students, presently supervising 02 M.Tech. and 06 Ph.D. scholars. He has over 140 publications in international and national journals and proceedings of international conferences to his credit. He has organized five international conferences at NIT Jalandhar as Organizing Secretary. He has organised around 20 short term courses in his area of expertise. He has also conducted several workshops and training programs for academic institutes and companies. He has published three special issues of International Journal of Manufacturing Technology Management (Emerald Publications) as guest editors and has also edited three volumes of books published by Springer. Dr. Rahul Sindhwani received his Ph.D. degree in Mechanical Engineering (Industrial Engineering & Management) in 2017; M.Tech. degree in Mechanical Engineering (Industrial Engineering & Management) with distinction and Gold Medal in 2010; and B.Tech. degree in Mechanical Engineering in 2008, from Kurukshetra University, India. Currently, he is an Assistant Professor-III in the Mechanical Engineering Department, Amity School of Engineering and Technology, Amity University, Noida, India. He is an active lifetime member of the Indian Society of Technical Education and a fellow member of Institution of Engineering and Technology. He is having teaching, research, and administrative experience of more than 10 years. He has published 26 papers in reputed international journals and books in the area of industrial engineering and management. His area of expertise is industrial engineering and management, supply chain management, lean, green and agile manufacturing system along with analysis of problems using structural equation modelling, statistical analysis, interpretive structural modelling and multi-criteria decision modelling, etc. Mr. Rohit Sahu is an Assistant Professor at the Department of Mechanical Engineering, G. L Bajaj Institute of Technology and Management, Greater Noida, U.P. He obtained his B.Tech. (Mechanical) from Uttar Pradesh Technical University (Presently Known as AKTU), M.Tech. (Manufacturing Science and Technology) from Bundelkhand Institute of Engineering and Technology, Jhansi and Pursuing Ph.d from Delhi Technological University, Delhi. His major areas of research interests include composite materials, unconventional machining, and manufacturing process optimization etc. He has published more than 15 papers in national & international journals and conferences. He is Guest Editor of SCI Journal Process in Mechanical Engineering, Materials Today: Proceedings and IOP Conference Series Material Science and Engineering.

Editors and Contributors

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Contributors Krishna Mohan Agarwal Mechanical Engineering Department, Amity University Uttar Pradesh, Noida, India Saurabh Agrawal Delhi School of Management, Delhi Technological University, Delhi, India Amardeep Department of Mechanical Engineering, GL Bajaj Institute of Technology and Management, Greater Noida, India Anshu Anand Noida Institute of Engineering & Technology, Greater Noida, U.P, India Yimer Ayalew Wollo University, Dessie, Ethiopia Sunita Bansal Civil Engineering Department, FET, MRIIRS, Faridabad, India Rishabh Chaturvedi Department of Mechanical Engineering, GLA University, Mathura, India Vineet Dubey Centre for Advanced Studies, Dr. A.P.J Abdul Kalam Technical University, Lucknow, India Rishabh Dwivedi M.Tech Student, Noida Institute of Engineering & Technology, Greater Noida, U.P, India Nitin Kumar Garg Civil Engineering Department, FET, MRIIRS, Faridabad, India Sudesh Kumar Garg G. L. Bajaj Institute of Technology and Management, Greater Noida, India Deepa Gupta Department of Management Studies, GL Bajaj Institute of Management and Research, Greater Noida, India Mukul Gupta GL Bajaj Institute of Management, Greater Noida, India Sandeep Gupta Department of Mechanical Engineering, GL Bajaj Institute of Technology and Management, Greater Noida, India Sandeep Kumar Gupta IIMT College of Engineering (Dr A P J Abdul Kalam Technical University), Greater Noida, India Sanjay Kumar Gupta Department of Civil Engineering, Indian Institute of Technology (BHU), Varanasi, India Tarun Kumar Gupta Department of Mechanical Engineering, GLBITM, Greater Noida, U.P., India Trilok Gupta Department of Civil Engineering, College of Technology and Engineering, MPUAT, Udaipur, India Vijay Prakash Gupta Institute of Technology & Science, Ghaziabad, U.P., India

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Ritesh Jaiswal Mechanical Engineering Department, Kamla Nehru Institute of Technology, Sultanpur, Uttar Pradesh, India Pratyush Kaushal Department of Mechanical Engineering, GL Bajaj Institute of Technology and Management, Greater Noida, India Anil Kumar Mechanical Engineering Department, Kamla Nehru Institute of Technology, Sultanpur, Uttar Pradesh, India Ashish Kumar Department of Applied Science and Humanities, G. L. Bajaj Institute of Technology and Management, Greater Noida, UP, India Pravin Kumar Department of Mechanical Engineering, Delhi Technological University, Delhi, India Rahul Kumar Research Scholar, Gautam Buddha University, Greater Noida, U.P., India Rajender Kumar Department of Mechanical Engineering, FET, MRIIRS, Faridabad, India Sanjay Kumar Noida Institute of Engineering & Technology, Greater Noida, U.P, India Vineet Kumar Inderprastha Engineering College, Ghaziabad, India Vinesh Kumar Higher College of Technology, University of Technology and Applied Sciences, Muscat, Sultanate of Oman Lalit Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Dharamvir Mangal Mechanical Engineering Department, Gautam Buddha University, Greater Noida, U.P., India Tesfaye Nega Mekonen Wollo University, Dessie, Ethiopia Mamta Mishra Department of Applied Science and Humanities, G. L. Bajaj Institute of Technology and Management, Greater Noida, UP, India Saurabh Mishra Centre for Advanced Studies, Dr. A.P.J Abdul Kalam Technical University, Lucknow, India Shivi Mittal GL Bajaj Institute of Technology and Management, Greater Noida, India Utkarsh Mohan Mechanical Engineering Department, Amity University Uttar Pradesh, Noida, India Rajat Negi Civil Engineering Department, FET, MRIIRS, Faridabad, India Anurag Pal Noida Institute of Engineering & Technology, Greater Noida, U.P, India

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Raj Vardhan Patel Department of Mechanical Engineering, Sherwood College of Engineering Research and Technology, Barabanki, India Rahul Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Rishi Raj Department of Mechanical Engineering, GL Bajaj Institute of Technology and Management, Greater Noida, India Praveen Rajpoot Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Renu Rana AIBS, Amity University, Noida, India; IIMT Group of College, Greater Noida, India Sonam Rani GL Bajaj Institute of Management, Greater Noida, India Manish Saraswat Department of Mechanical Engineering, ABES Engineering College, Ghaziabad, UP, India Rajat Saxena Department of Civil Engineering, College of Technology and Engineering, MPUAT, Udaipur, India Aman Sharma Department of Mechanical Engineering, GLA University, Mathura, India Anuj Kumar Sharma Centre for Advanced Studies, Dr. A.P.J Abdul Kalam Technical University, Lucknow, India Bhavana Sharma G.L Bajaj Institute of Management and Research, Greater Noida, India Bhupendra Prakash Sharma Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Chinmay Sharma Mechanical Engineering Department, Amity University Uttar Pradesh, Noida, India Kamal Sharma Department of Mechanical Engineering, ABES Engineering College, Ghaziabad, UP, India Rajesh Kumar Sharma Department of Civil Engineering, G.L. Bajaj Institute of Technology and Management, Greater Noida, India Rahul Sindhwani Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Dheerendra Kumar Singh Madan Mohan Malviya University of Technoogy, Gorakhpur, India Manoj Kumar Singh Department of Mechanical Engineering, Pusa Institute of Technology, New Delhi, India

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Nishant Kumar Singh G.L Bajaj Institute of Management and Research, Greater Noida, India Priyanka Singh Civil Engineering Department, Amity University Uttar Pradesh, Noida, India Punj Lata Singh Department of Civil Engineering, Amity University Uttar Pradesh, Noida, India Rajnish Singh Mechanical Engineering Department, Kamla Nehru Institute of Technology, Sultanpur, Uttar Pradesh, India Rakesh Kumar Singh IFTM University, Moradabad, India; Noida Institute of Engineering & Technology, Greater Noida, U.P, India Sandeep Kumar Singh Centre for Energy Studies, IIT Delhi, Delhi, India Nirdosh Kumar Sisodia Shambhu Dayal Inter College, Ghaziabad, India Ashish Kumar Srivastava G.L. Bajaj Institute of Technology and Management, Greater Noida, U.P, India Gautam Srivastava Department of Management Studies, GL Bajaj Institute of Management and Research, Greater Noida, India Priyank Srivastava Department of Mechanical Engineering, Amity University Uttar Pradesh, Noida, India Vishal Shankar Srivastava Department of Mechanical Engineering, GLBITM, Greater Noida, U.P., India Brij Kishore Tiwari Department of Applied Science and Humanities, G. L. Bajaj Institute of Technology and Management, Greater Noida, UP, India Divyansh Vatsa Department of Mechanical Engineering, GL Bajaj Institute of Technology and Management, Greater Noida, India Ashish Yadav Mechanical Engineering Department, Amity University Uttar Pradesh, Noida, India Saurav Yadav Department of Civil Engineering, G.L. Bajaj Institute of Technology and Management, Greater Noida, India Shruti Yadav G.L Bajaj Institute of Management and Research, Greater Noida, India

Effect of Process Parameter on Surface Composite Developed Through Friction Stir Processing: A Review Ritesh Jaiswal, Anil Kumar, and Rajnish Singh

1 Introduction Ductile materials such as aluminum, and magnesium find a huge application in aerospace, automobile, and marine industry. These materials exhibit excellent mechanical, electrical, and thermal properties. But their applications are reduced to a greater extent due to its weak surface property. This drawback can be reduced by modifying the surface of the materials. For this purpose, the reinforcement material is selected, which strengthens the matrix of the material. The reinforcement material is mixed on the surface for improving the hardness and wear resistance of the surface. The metal-matrix reinforced composite exhibits high elastic modulus, high strength, excellent fatigue and creep resistance, improved resistance to wear, resistance to corrosion, etc. [1]. To improve the surface properties of materials, various techniques are known such as plasma spraying [2], high-velocity oxy-fuel spraying [3, 4], casting, cast-sinter [5], high energy electron processing [6], laser beam processing [7], powder metallurgy [8], mechanical alloying [9], etc. Among the entire techniques, laser beam processing is mostly used. The laser processing technology is based on liquid-phase processing by achieving a high temperature. At high temperature, dendrites are formed due to internal reaction between metal matrix and reinforcement [10]. Since this process is happening above the melting point temperature of material, so various processing parameters are needed to control the solidification to get the solidified microstructure, on the surface layer, and this problem can be avoided if the processing is done below melting point (MP) of material. So, a new technique called FSP is used. The composite made by other processes may have

R. Jaiswal (B) · A. Kumar · R. Singh Mechanical Engineering Department, Kamla Nehru Institute of Technology, Sultanpur, Uttar Pradesh 228118, India e-mail: [email protected] © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 A. Dvivedi et al. (eds.), Recent Trends in Industrial and Production Engineering, Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-16-3330-0_1

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Fig. 1 Schematic of friction stir processing [16]

porosity, surface cracks, irregular grain arrangement, and some other defects at interface which may lead to premature failure of the component [11]. FSP can be used to form the uniform microstructure and repairing the defects. The concept of FSP was developed from friction stir welding (FSW) developed at ‘The Welding Institute,’ the UK in 1991 by Wayne Thomas [12]. FSP is a surface treatment process that is used to enhance the microstructure of metal surface by deforming the material plastically to improve the grains of the surface. The basic principle of FSP and FSW is similar, the only difference between them is that FSP is used to modify surface properties of the material, while FSW is used to fabricate two plates for joining purpose [13, 14]. Reinforcement materials are mixed with the base material to increase its wear and hardness resistance. In FSP, a rotating tool having shoulder and pin is inserted for the mixing of reinforcement material into the base material. The tool is moved along the desired region for modification of microstructure and to form the metal-matrix composites (MMCs). As the tool is made in contact with the workpiece, frictional heat develops between the tool and base metal. This heat makes the material soft, and due to stirring action of the tool, the reinforcement material is mixed into base material to obtain metal-matrix composite. During the process, the grain of the material is refined as it undergoes plastic deformation [15]. The schematic of friction stir processing is shown in Fig. 1.

2 Process Variables in FSP During the friction stir processing, processing parameters need to be controlled for desired grain refinement. The process parameters in FSP are tool material, tool rotational speed, transverse speed, tool profile, reinforcement materials, etc., which are shown in Fig. 2. Tool transverse speed and rotational speed determine the heat produced in the material [17]. The heat produced determines the formation of stir zone

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Tool rotational speed Tool transverse speed Machine variable

Tool tilt angle Tool plunge depth Diameter Shoulder

FSP process variable Tool Design variable

Probe

Profile Diameter Profile

Material properties

Mechanical

Height

Thermal

Fig. 2 FSP process variable [19]

and grain refinement. The maximum temperature achieved in stir zone is reported below melting point of material and ranged in (0.6–0.9) Tm. To achieve the defectfree stir zone, sufficient amount of heat is necessary [18]. Tool profile and tool tilt angle on the workpiece affect the development of the stir zone. Hardness and wear resistance of the surface composite mainly depend on the types of reinforcement selected.

2.1 Tool for FSP/W In FSP, a non-consumable tool is used on workpiece material to improve the grain refinement, wear resistance, and the hardness of the material in a specific area. The tool plays a very crucial role in FSP for creation of final product. The primary function of the tool in FSP is (i) Localized heating: This phenomenon occurs as the tool comes in contact with workpiece. Rotating tool develops heat due to friction and softens the workpiece. (ii) Material flow: The tool helps in flow of soft material in the direction of tool movement. The tool used in FSP can be fixed, adjustable, or self-reacting [20]. Fixed tool contains both shoulder and probe of a single piece of material. This tool is used for processing of the uniform thickness of the material [21]. An adjustable tool consists of an independent part of the shoulder and probe which are allowed to adjust during the friction stir processing. This type of tool has a benefit of replacement of either part of the shoulder and probe when they are damaged [22]. This kind of tool can be used for the processing of material of variable thickness. The self-reacting FSP tool, also called the Bobbin tool, consists of the top and bottom shoulder, and in the

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Fig. 3 Tool geometry of FSP/W tool

middle of these shoulders, the tool probe is designed. During the processing with the bobbin tool, no backing plate is required, which makes easy fixturing. Bobbin tool has many advantages over fixed and adjustable tools such as the absence of tool plunge reduces tool wear, lower normal force, greater homogeneity, lower distortion, lack of penetration defect eliminated, and uniform mechanical property across the thickness of the workpiece material [23]. In FSP, the parts of the tool (shoulder and pin) have a different function. So, for good tool design, the shoulder and pin are desired to be made of different materials. A schematic of tool geometry is shown in Fig. 3. The shoulder and pin design are to be considered based on workpiece and tool materials, tool parameters (rotational and transverse speed), user’s own experience, etc. A good design helps inadequate material flow during processing in the advancing direction and an adequate amount of heat generation on contact of tool and workpiece. Generally, shoulder with cylindrical shape is used, but in some cases, it may be conically tapered [24]. The bottom face of the tool shoulder is designed in a concave shape, which helps in maintaining the material reservoir beneath the tool during the processing. The flat end surface shoulder tool is ineffective in trapping the flowing material beneath the shoulder. This process leads to an FSP defect called material flash. Shoulder end surface can also contain different shapes including concentric circles, ridges, knurling, scrolls, etc., for improvement of material friction and deformation rate for proper mixing of the material. Scrolled feature on the concave shoulder helps to reduce the lifting of the tool during friction stir processing. The tool has tilt angle (1–3) degrees normal to the workpiece to facilitate the shoulders trailing edge to produce sufficient forging force. Yigezu et al. studied the effect of different shoulder diameter (18, 20, and 22 mm) on FSW of Al-12% Si/TiC plates. It was reported that the tensile strength of the joint varies from 124 to 172 MPa. The

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tool with a shoulder diameter of 20 mm is preferable for joining the workpiece for the maximum value of ultimate tensile strength (UTS). Different tool pin-shaped such as a conical, triangular probe, square probe, columnar probe, and threaded columnar probe are used. Tool probe with a flat bottom is the most commonly used tool due to its ease of manufacturing [25]. Flat bottom-shaped tool pin has disadvantages of high plunging force during the process. Now, a flat probe is being replaced by a round or domed shaped tool probe to reduce the tool wear. In the fabrication of the Al2 O3 /AZ31 surface composite, threaded tool probe reduced the defects as compared to a tool probe without thread [26]. More uniform particle distribution was found in the stir zone when a square-shaped pin is used as compared to the triangular and circular pin profile in the fabrication of Al/SiC composite via friction stir processing. Threaded pin helps in uniform powder distribution as compared to the plain shape or with flutes in the case of a columnar pin.

2.2 Tool Material and Wear Proper selection of tool material is very critical in friction stir processing. The tool material selection depends on the type of workpiece material which means the strength of tool material should be more than the workpiece material. During FSP, the tool selected should have high strength, dimensional stability, and good creep resistance. Tool material should have higher compressive strength at an elevated temperature. Good thermal and fatigue strength and repeated heating and cooling resistance are desirable for the FSP tool [20]. A FSP tool should not damage during plunging and contain good fracture toughness. Low thermal expansion of tools is necessary to reduce thermal stress developed during processing. The tool selected should not produce any harmful gas during the processing of the workpiece. Manufacturing of tools should be easy in such a way that complex shapes can be machined on the shoulder and pin. Tool material should be easily available at an affordable cost. Various tool materials like die steel, HCHCr steel, H13 double-tempered steel, cermets tool, etc., were used during the processing of composite materials. For light workpiece, hard steel materials are chosen as tool material. For hard workpiece, poly cubic boron nitride (PCBN), cermets (WC–Co), and tungsten (W)-based alloys are used. Other materials such as cobalt (Co) alloy, tungsten carbide (WC), iridiumrhenium (Ir–Re) are used [16]. Dinaharan et al. used double-tempered steel as a tool material for the processing of the composite. Xue et al. performed friction stir processing of Ni by selecting the tool steel as tool material. The fabricated composite exhibited no tool abrasion and defect-free processing surface [27]. Lie et al. reported that at a location of 30 vol% of SiC, more tool wear occurred by a threaded tool of WC–Co hard alloy. The tool material used for processing of different composite is mentioned in Table 1. Tool wear in manufacturing of surface composite is caused by tool rotation and transverse movement and friction during the processing. Excessive tool wear leads to change the tool shape which increases the chance of defect generation and poor

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R. Jaiswal et al.

processing zone. Inside the tool, material flow is parallel to the cylindrical axis, and material flow is circulated around the pin in case of threaded tool. The wear is more in threaded tool at the initial stage and after it the thread filled with base material and pin become smoothened, so less tool wear occurs from this stage. In the case of the PCBN tool, tool wear happens at low speed due to adhesive wear, while at high-speed tool wear is due to abrasive nature of the tool [28]. Faridas et al. explained that the tool wear causes poor surface quality and tool material inclusion inside the workpiece [29]. Buffa et al. used the WC (4.2%) based tool for FSP which had high strength, but the tool failed due to fracture at its initial operation [30]. Prado et al. reported that at high tool rotational speed less tool wear occurs. In non-ferrous metal alloys, tool wear is not a problem of concern, but in ferrous material, severe tool wear takes place. Generally, for the processing of soft material, steel tools are used, but this is ineffective for processing of high melting point materials like carbide, titanium, nickel-based alloy, etc. For the FSP of high M.P. materials, tools are generally made of high strength alloy such as tungsten carbide, PCBN is used [31]. Molybdenum, tungsten, and iridium are suitable options for the selection of tool material due to the high wear resistance and hardness‚ low reactivity with oxygen, and good strength at high temperatures. The tool wear at different tool rotation speed is shown in Fig. 4. Hasan et al. studied the tool wear on friction stir welding. They suggested that for accurate result of wear measurement, it is necessary to clean the tool with nitric acid (68% wet HNO3 ). For the measurement of tool wear, the weight-loss and area-reduction method is used, which is given by the formula [32]: h = K · σn ·

Vr ·t H

(1)

where h—Tool wear depth, K —Wear coefficient, σn —Normal stress, Vr—Relative velocity, H —The hardness of worn material, t—Time (in s).

2.3 Tool Rotation and Transverse Speed In FSP, rotational tool speed is a significant process parameter as it directly affects the transverse tool speed. Rotational speed and transverse tool speed determine the amount of heat developed during the processing. Higher tool rotation results in a

Effect of Process Parameter on Surface Composite Developed …

7

Fig. 4 Tool pin wear at a constant tool rotation of 1000 rpm at different transverse speed (mm/s) a 1, b 3, c 6, d 9 at a different location (meters), e wear rate versus weld length, f wear rate versus weld speed [33]

higher temperature rise which softens the material in the contact region due to which mixing of base material and reinforcement becomes easy. Tool rotation speed directly affects the grain refinement of the stir zone due to the numerous amount of heat developed [26]. The area of processed zone decreases with fall in rotational speed, and it affects the temperature distribution in the friction processed zone. Since rotational speed and transverse speed of the tool directly influence the grain refinement and fabrication of composite, it is necessary to optimize the tool to get a defect-free and uniform size of the grain. Kurt et al. reported that SiC particle distribution is highly uniform in AA1050 alloy when it was processed at increasing tool rotation and transverse speed. Zhang et al. reported that in the fabrication of Al-TiO2 surface composite, the tool transverse speed effect was higher than the rotational speed [20]. K. Elangoven found that during the processing of AA2219 aluminum alloy, better tensile strength was achieved at a rotational tool speed of 1600 rpm irrespective of the tool pin profile. The defect in the processing zone was found at 1500 rpm when it was fabricated by a cylindrical-threaded tool pin and a triangular pin profiled tool [45]. M. Salehi et al. developed an L16 Taguchi orthogonal model to optimize the process parameters during FSP. It was seen from the Taguchi experimental method that rotational speed of the tool (43.70%) and transverse tool speed (33.79%) were the most influencing parameters [46]. Tunnel defects were found absent during FSP of materials with a truncated tool profile at a rotational tool speed of 2000 rpm. But excessive flash was seen when the transverse tool speed was set at 50 mm/min [47]. L. Karthikeyan reported that both rotational speeds of tool and transverse speed

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R. Jaiswal et al.

Table 1 Tool material and its specification used in FSP of composites Composite

Tool material

Shoulder specification

Probe specification

Cu/RHA (rice husk ash) [34]

H13 double-tempered tool steel

Diameter-24 mm

Diameter-6 mm, length-4.5 mm, cylindrical profile

Al3 Ni/TiC [35]

Hardened high carbon steel

Diameter-18 mm

Diameter-6 mm, length-5 mm, cylindrical pin

AA6061/RHA [36]

HCHCr steel

Diameter-18 mm

Diameter-6 mm, length-5.8 mm

AIN/Cu [37]

Double-tempered H13 steel

Diameter-0 mm

Diameter-6 mm, length-5 mm

Cu/SiC [38]

2344 hot work steel

Diameter-20 mm

Diameter-5 mm, length-2 mm, square pin

Cu/zircon [39]

H13 tool steel

Diameter-18 mm

Diameter-6 mm, length-4 mm, threaded pin

MWCNTs/AZ31 [40]

SKD61

Diameter-12 mm

Diameter-4 mm, length-1.8 mm, columnar shape

Al6056 [41]

Die steel

Diameter-20 mm

Length-5 mm, triflat pin

Al alloy A319 [14]

H13 steel

Diameter-13 mm

Diameter-6 mm, length-5.7 mm, hemispherical pin

AA6061/Cu [42]

HCHCr steel

Diameter-18 mm

Diameter-6 mm, length-5.7 mm, hexagonal pin profile

AA6082/TiB2 [43]

HCHCr steel

Diameter-18 mm

Diameter-6 mm, length-5.8 mm, cylindrical threaded profile

Al/TiO2 [44]

Cermet tool

Diameter-20 mm

Diameter-6 mm, length-5 mm, threaded cylindrical

influence the microstructure and mechanical properties of the FSPed cast A319 grade aluminum alloy. At tool rotational speed of 1200 rpm, mechanical properties are best of processed composite [48]. The particle size at the low tool transverse speed and high tool rotational speed were found to be uniform. The diffusion of material takes place at a high rotational speed in a very short period. Yousef Mazaheri et al. optimized the parameters on an experiment carried on Mg AZ31 alloy during fabrication of the composite, and the optimum value of rotational speed and transverse speed was found to be 1000 rpm and 56 mm/min. At the transverse speed of 112 mm/min, some defects were found on the microstructure of the sample. At the optimum value of the

Effect of Process Parameter on Surface Composite Developed …

9

rotational and transverse speed, the surface-modified had no defects like a tunnel, pinhole, piping, and warm hole. L. Pan et al. suggested that the penetration depth and width of the stirred zone increased as translation speed of tool decreased. The penetration depth of surface increased to 2 mm on the reduction of translation speed to 150 mm/min. The difference in microstructure was seen between advancing and retreating side due to high tool translational speed (300 mm/min) which leads to an insufficient amount of heat input [49]. Namrata Gangil et al. suggested that a proper ratio of tool rotational and transverse speed is necessary. Since higher value of ratio of tool rotation speed and transverse speed generates more amount of heat which causes the melting of the material, it leads to large cavities and coarse microstructure of base material in the stir zone [50]. The successful combination of tool rotation and transverse speed, number of pass, tilt angle is mentioned in Table 2. Table 2 Successful combination of tool rotational speed, transverse speed, number of the pass, and tilt angle for FSPed composites FSPed composite Al/Cu [51]

Rotational speed (rpm)

Transverse speed (mm/min)

No. of pass

Tilt angle (degree)

700

45

2

3

1400

45

2,4

3

Al/Mo (4 μm) [53] 1400

30–45

4

–

Al 1060/Ni μm [54]

1500

23.5

3

3

Al/TiO2 [55]

1000

25

4

–

AA5052-H32 (Al–Mg) [55]

1200

100

4

2.5

630

100

6

3

Al 6061/SiC

1500

52

–

3

A356/SiC (4 μm) [57]

1800

127

6

–

A356/Al2 O3 [58]

1600

200

4

2

Al 5083/Cu [59]

1900

25

4

3

AA 6061/ZrB2 [60]

1150

50

–

–

AA 6061/SiC [61] 1100

45

–

–

TiC/Al [62]

1000

60

1,2

–

950

30

5

2

SiO2 /AZ91 [64]

1250

63

3

3

Al2 O3 /AA2024 [3]

1250

50

5

3

SiC/MoS2 [65]

1600

50

–

–

Al/Fe(10%) [52]

AA 6061/Cr2 O3 [56]

MWCNT/AA 1016 [63]

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R. Jaiswal et al.

2.4 Number of Passes In FSP, reinforcement particle distribution in stir zone mainly depends upon the number of passes performed. It was seen that coarse microstructure changes into fine microstructure on increasing the number of passes which leads to more uniform reinforcement particle distribution and hence improves the hardness value and wear resistance of surface. During the mixing of reinforcement particles into the base, material clusters are formed. It was found that clusters of Al2 O3 /AA5052 surface nanocomposite were reduced at 70 nm after four passes which were earlier 650 nm in size at a single pass. Jian Wang et al. studied that the bonding strength between the reinforcement and base material increases at higher pass number, which improves shear strength. The maximum shear strength was found at three number of passes which was 33.35 MPa. Yousef Mazhari et al. found that the average grain size was reduced of composite formed via FSP. The grain size of AZ31/ZrO2 nanocomposite decreased by 40% at a single pass while 80% at four passes. They also suggested the proper mixing of reinforcement by increasing the number of passes during FSP. It was also found that by increasing the number of the pass at four passes, the microhardness of nanocomposite fabricated improves by 90%, wear rate reduced by 50%, and the average coefficient of friction reduced from 0.5 to 0.22 [58]. Fine reinforcement particles leading to good mechanical characteristics were also seen at high number of pass. Hardik Vyas et al. reported that multi-pass FSP gives visually better surface finish than the single-pass FSP because two-time stirring effects were experienced by the surface material flow. It was seen that between single and double pass FSP, increased hardness and tensile strength were reported in case of two pass due to intense refinement of grain. Figure 5 shows the backscattered images of FSPed pure titanium at different passes. The average grain size of the specimen decreases from 4.5 to 3.1 μm with an increasing FSP pass number from 1 to 3, higher microhardness value achieved at three passes.

3 Reinforcement Particles The reinforcement particle plays a key role in fabrication of composite via FSP as mechanical and thermal properties of composite directly depend on the particle. Different kinds of reinforcement particle used in the fabrication of metal-matrix composite (MMCs) via FSP such as SiC, ZrO2 , TiC, Al2 O3 , carbon nanotubes, and fly ash. Silicon carbide is used widely as reinforcement particle due to its availability, low cost, and low density (3.20 g/cm3 ). Some reinforcement used for composite fabrication is mentioned in Table 3. The MMCs fabricated using SiC found wide application in transportation, aerospace, and marine industry. The mechanical and the thermal properties of the FSPed composite are related to the refinement of the grains in stir zone. The selection of appropriate reinforcement particle is very necessary to achieve the desired grain shape and size. The size of the grain (dz) of the surface

Effect of Process Parameter on Surface Composite Developed …

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Fig. 5 BS micrographs of a unprocessed and, b 1 pass FS processed, c 2 pass FS processed and, d 3 pass FS processed pure titanium [66]

Table 3 Typical reinforcement used in metal-matrix composites [67] Type

Aspect ratio

Diameter

Examples

Particle

1–4

(1–25) μm

BN, Al2 O3 , WC, SiC

Short fiber

10–10,000

(1–5) μm

C, Al2 O3, SiO2 + Al2 O3, SiC

Continuous fiber

>1000

(3–150) μm

Nb + Ti, B, SiC, Nb3 Sn, C, Al2 O3 , W

Nanoparticle

1–4

1000