i-manager's Journal on Material Science (JMS)


Volume 10 Issue 3 October - December 2022

Research Paper

Optimization of Adsorption Parameters for Lead (II) Removal from Wastewater using Box-Behnken Design

D. Krishna* , D. V. Padma**, D. R. Prasada Raju***
*-*** Department of Chemical Engineering, Maharaj Vijayaram Gajapathi Raj College of Engineering, Vizianagaram, Andhra Pradesh, India.
Krishna, D., Padma, D. V., and Raju, D. R. P. (2022). Optimization of Adsorption Parameters for Lead (II) Removal from Wastewater using Box-Behnken Design. i-manager’s Journal on Material Science, 10(3), 1-7. https://doi.org/10.26634/jms.10.3.19069

Abstract

The effective use of ragi husk powder for the removal of lead from waste water has been investigated. Influences of parameters like initial lead concentration (VI) (20-100 mg/L), pH (8-10), and adsorbent dosage (3-5 g/L) on lead adsorption were examined using Box Behnken Design (BBD) in response surface methodology. The BBD design in response surface methodology was used for designing the experiments as well as for full response surface estimation and 15 trials as per the model were run. The optimum conditions for optimum removal of lead from waste water of 20 mg/L were as follows: adsorbent dosage (4.1639 g/L), pH (9.0354) and initial lead concentration (21.7848 mg/L). The high correlation coefficient (R2 =0.996) between the model and the experimental data showed that the model was able to predict the removal of lead (VI) from waste water using ragi husk powder efficiently.

Research Paper

Optimization of Al 6063 Button Head Rivet FEM Analysis Subjected to CRYO ECAP and RT ECAP

Gorsa Jayaram* , Srinivasulu Arnuri**, Gurugubelli Swaminaidu***, Varri Vinay Kumar****
*-**** Department of Metallurgy, Jawaharlal Nehru Technological University, Gurajada Vizianagaram, College of Engineering Vizianagaram, Andhra Pradesh, India.
Jayaram, G., Arnuri, S., Swaminaidu, G., and Kumar, V. V. (2022). Optimization of Al 6063 Button Head Rivet FEM Analysis Subjected to CRYO ECAP and RT ECAP. i-manager’s Journal on Material Science, 10(3), 8-18. https://doi.org/10.26634/jms.10.3.19102

Abstract

The severe plastic deformation technique that has attracted much attention from the material community in recent years is Equal Channel Angular Pressing (ECAP). By using this technique, ultrafine-grained microstructures can be produced without a significant change in the geometry of the material. In the present research, an aluminum 6063 sample was tensile tested after the ECAP process to know the properties of the material. ECAP is performed for two sets of specimens in which the channel angle is 108. One set of samples is at room temperature, and the other set is at -197oC, i.e., dipped in liquid nitrogen for 20 minutes. Tensile properties of the obtained samples are tested once more. The tensile test properties of samples, i.e., before processing and after Room Temperature (RT) and CRYO ECAP, are tabulated and saved for simulation. A rivet with American Society for Testing and Materials (ASTM) dimensions is designed using a design modeller in Analysis of Systems (ANSYS), and the properties obtained from the tensile tests are assigned to the rivet. One end of the rivet is constrained with a fixed support, and the other end is loaded with 35 kN in the downward direction. The process is repeated for three different sets of samples. The developed stresses in the three rivets are tabulated and correlated, and the results are drawn in the present investigation, which showed good correlation.

Research Paper

Effect of (SiC+Gr) Addition on the Corrosion Behavior of Powder Metallurgy Copper MMC

Gowtham Satya Swaroop Akkarapu* , Srinivasulu Arnuri**, Swami Naidu Gurugubelli***, Rama Krishna Varmalanke****
*-**** Jawaharlal Nehru Technological University-Gurajada, Vizianagaram, Andhra Pradesh, India.
Akkarapu, G. S. S., Arnuri, S., Gurugubelli, S. N., and Varmalanke, R. K. (2022). Effect of (SiC+Gr) Addition on the Corrosion Behavior of Powder Metallurgy Copper MMC. i-manager’s Journal on Material Science, 10(3), 19-29. https://doi.org/10.26634/jms.10.3.19096

Abstract

Copper metal matrix composites are seeing tremendous growth due to their properties, which are suitable for a wide range of applications. The potential for combining reinforcements uniformly in the matrix via powder metallurgy is stimulating new research. In the present study, copper powder is used as the matrix and SiC and graphite are used as reinforcements for the fabrication of a hybrid metal matrix composite using the powder metallurgy route. Silicon Carbide (SiC) and graphite are used as reinforcements in copper Metal Matrix Composite (MMC). SiC is a ceramic material that increases the hardness of the composite by adding it as reinforcement, and graphite is a material that helps increase corrosion resistance when used as reinforcement. In each sample, SiC and graphite mixture reinforcement is in equal proportion, varying this composition from 0 to 10% of the weight percentage. These samples are investigated for Vickers hardness, densities, and electrochemical corrosion properties after being prepared by powder metallurgy with dimensions of 16 mm x 16 mm x 25 mm. The sample with 8% reinforcement showed good corrosion resistance and poor corrosion resistance for the 4% reinforcement sample. These composition samples were subjected to X-ray diffraction (XRD) analysis and Scanning Electron Microscopy (SEM) characterizations, which showed good correlation for the hardness and corrosion test values.

Research Paper

Assessment of Reuse Potential of Low-Grade Iron Ore Fines through Beneficiation Routes

Nirlipta P. Nayak*
Department of Petroleum Engineering & Earth Sciences, UPES, Dehradun, Uttrakhand, India.
Nayak, N. P. (2022). Assessment of Reuse Potential of Low-Grade Iron Ore Fines through Beneficiation Routes. i-manager’s Journal on Material Science, 10(3), 30-37. https://doi.org/10.26634/jms.10.3.19192

Abstract

The iron ore deposits are sedimentary in nature. In 2021, approximately 1.95 billion metric tons of crude steel were produced globally, compared to 2.6 billion metric tons of usable iron ore. Iron ore is the primary source of the iron and steel industries, which in turn are essential to maintaining a strong industrial and economic base. Globally, 86% of the total iron produced is used in steelmaking. The most important iron ore minerals include hematite, magnetite, and taconite. The other iron ore minerals include goethite, laterite, etc. Hematite and magnetite are most commonly exploited for their iron values. Considering the non-renewable nature of iron ore, there is a paradigm shift towards the upgrading and beneficiation of low-grade iron ore. The widely accepted techniques for beneficiation include jigging, magnetic separation, enhanced gravity separation, froth flotation, etc. Owing to density contrast, iron can be separated from the gangue in simple jigging cycles. The electromagnetic laboratory-scale Wet High Intensity Magnetic Separator (WHIMS) removes fine magnetics and para-magnetics from mineral slurries. The physical and chemical properties of the ore mineral, as well as their mutual relationship, have a large impact on the beneficiation efficiency. In most of the processing units, the small, dense particles report to the tailing fraction, causing a significant loss in ore values. In such challenging cases, the enhanced gravity technique is useful. It is a combination of centrifugal force and gravitational force that facilitates the separation of low-density ore minerals and gangue. The paper focuses on the importance of a characterization study for the success of beneficiation.

Research Paper

Characterization of Copper MMC Reinforced with SiC and Graphite in Equal Proportion Made by the Powder Metallurgy Route

Rama Krishna Varma Lanke* , Srinivasulu Arnuri**, Swami Naidu Gurugubelli***, Gowtham Satya Swaroop Akkarrapu****
*-**** Department of Metallurgical Engineering, JNTU-GV, Vizianagaram, Andhra Pradesh, India.
Lanke, R. K. V., Arnuri, S., Gurugubelli, S. N., and Akkarrapu, G. S. S. (2022). Characterization of Copper MMC Reinforced with SiC and Graphite in Equal Proportion Made by the Powder Metallurgy Route. i-manager’s Journal on Material Science, 10(3), 38-52. https://doi.org/10.26634/jms.10.3.19079

Abstract

Powder metallurgy is playing a very important role in the manufacturing industry. In this research, an attempt is made with copper Metal Matrix Composites (MMC) reinforced with an equal proportion of Silicon Carbide (SiC) and graphite powders. The powders are taken in such a way that the reinforcement weight percentage varies from 0 to 10%. The materials are fabricated through the powder metallurgy route. The powder mixtures are blended and then compacted with a uniaxial pressure of 500 MPa to make the green compacted composites with different compositions. The dimensions of all samples are 25 mm x 16 mm x 16 mm, with an average weight of 40 g. Compacted green samples are sintered by the inert gas sintering process. Sintering is performed at 8000C in an inert argon gas furnace for 120 minutes for all the samples. The obtained samples are made suitable for different tests like porosity, the Vickers hardness test, the wear test, Raman spectroscopy, Scanning Electron Microscopy (SEM), and Energy Dispersive X-Ray (EDX) Analysis. From the values obtained from the hardness test, it is observed that for all MMCs, the minimum value is obtained at Cu-4% (SiC+Gr) and the maximum value at Cu-8% (SiC+Gr), and in between these percentages of composition, there is a little bit of an increase and decrease in values. Wear test results give the maximum wear rate at Cu-4% (SiC+Gr) and the minimum wear rate at Cu-8% (SiC+Gr). Raman spectroscopy test results are given the calculations of Full Width at Half Maximum (FWHM), depth of incident, absorbance, and Id/Ig values, and they are better at 8% of SiC+Gr, which gives the indication of good bonding between molecules of the powder particles. Image analysis is performed using optical microscopy, SEM, and EDX. The microstructures were revealed in such a way that there was good correlation between the properties at different compositions.

Research Paper

Evaluation and Comparison of Turning Process Performance during Machining of D2 Steel Material under Two Sustainable Machining Techniques

V. Chengal Reddy * , Marupudi Mouneesh Kumar**, T. Nishkala***, S. M. Jameel Basha****
*-**** Department of Mechanical Engineering, Chadalawada Ramanamma Engineering College, Tirupati, Andhra Pradesh, India.
Reddy, V. C., Kumar, M. M., Nishkala, T., and Basha, S. M. J. (2022). Evaluation and Comparison of Turning Process Performance during Machining of D2 Steel Material under Two Sustainable Machining Techniques. i-manager’s Journal on Material Science, 10(3), 53-59. https://doi.org/10.26634/jms.10.3.19185

Abstract

In the present work, two sustainable machining techniques namely Minimum Quantity Lubrication (MQL) and dry machining were investigated during turning of AISI D2 steel material using tungsten carbide tools. Cutting velocity, feed rate and depth of cut were considered as turning process variables whereas cutting temperature, tool rake wear, tool flank wear and surface roughness were taken as turning process performance characteristics for investigation purpose. Based on the obtained results it was found that MQL machining technique significantly controlled the cutting temperature, tool rake wear, tool flank wear and surface roughness values to a maximum of 46%, 22%, 23% and 35% when compared to dry machining condition. It was noticed that MQL cooling technique uses tiny quantity of coolant and contributes for sustainable requirements in present industry. Further, it was observed that more chip entanglement marks as major surface defectives and edge chipping as major tool wear mechanism in dry machining.