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This research investigates the feasibility of improving surface integrity of the Mg-2%Zn alloy via a novel combined process of multidirectional forging (MDF) with ball burnishing technique. Mg-2%Zn alloy was subjected to multidirectional forging up to 5 passes at 280 °C and same sample is ball burnished with depth of press of 0.3 mm, feed of 300 mm/min and force of 250 N for 1 pass. Microstructure (optical and transmission electron microscope), phases (X ray diffraction), roughness (atomic force microscope) and mechanical properties (microhardness and tensile) were analyzed for cast, MDF processed and MDF + ball burnished samples. The study also defines a new reliability simulation framework to predict the roughness and hardness of the MDF + ball burnished samples using Deep Neural Network (DNN) approach. For the analysis, depth of press, feed and number of passes served as inputs for the DNN model. After configuring and training procedure of the model, the predicted roughness and microhardness of the MDF + ball burnished were compared with the results of experimental data. A large increase of microhardness was observed for MDF-5 + BB-1 (5 pass MDF processed Mg-2%Zn alloy + Ball burnished sample), found to be 98 Hv and surface roughness of 306 nm was achieved. According to the results, the obtained R-squared value is very close to the 99.5 percentage from the model for predicting roughness and hardness which is a promising result. Corrosion behavior of the AS-1, MDF-5 and MDF-5 + BB-1 was evaluated in Hank's balanced salt solution. Corrosion rate of the MDF-5 + BB-1 samples were found to be 0.87 mm/y which is 7 times better than that of AS-1 samples (6.10 mm/y). Grain refinement and residual stresses were higher in the MDF-5 + BB-1 sample, which helped significantly to enhance corrosion resistance.

Aim of the present investigation is to study the microstructural and mechanical properties of Al-Zn-Mg-Cu alloy before and after multi-direction forging (MDF) at cryogenic condition up to 3 cycles. Microstructure evolution of specimen was examined using optical microscope and orientation imaging microscopy as well as X-ray diffraction. Mechanical properties were measured by tensile test and Vickers micro hardness. Microstructural investigation shows that after 3 cycle of MDF average grain size was reduced to 8 µm with low angle grain boundaries (LAGBs) and high dislocation density. Mechanical examination displays an improvement in hardness, yield strength and ultimate tensile strength is due to increases in grain boundaries and strain hardening effect. After 3 cycles of MDF process with cumulative strain ΣΔe = 3.64 led to the formation of fine grain structure, and microhardness were observed to be 168 HV.

In the present study, Mg-4Zn-1Si alloy was subjected to equal channel angular pressing (ECAP) up to 4 passes at 300 °C, followed by ball burnishing using 0.3 mm depth of press, 300 mm/min feed and 1 pass successfully. The effect of ECAP and ECAP + ball burnishing process on microstructure, mechanical properties (tensile and hardness) and corrosion behavior was systematically investigated. After 4 pass ECAP, initial coarse grains (210 μm) were refined and average grain size is 6 μm and after ball burnishing, the grain size is found to be 3.3 μm. Microstructure evolution is discussed using optical images, scanning electron microscope images and transmission electron microscope images. For ECAP samples, maximum strength and hardness was recorded at 3 pass. Both strength and hardness decreased for 4 pass ECAP processed samples, even though grain size decreased, this is because of texture modification in the material. ECAP 4 pass + ball burnished samples exhibited 48.5% enhancement of microhardness as compared to 4 pass ECAP samples. Corrosion resistance of the samples decreased with increase in the number of ECAP passes, this is due to strain-induced grain refinement with more crystalline defects in samples. Combined process of ECAP and ball burnishing effectively reduces the Icorr and this consequently reduces corrosion rate of the Mg–4Zn-1Si alloy.

Wear and corrosion properties of Cu-3%Ti alloy subjected to multiaxial forging (MAF) under cryogenic conditions are estimated at room temperature. Wear study was performed using pin-on-disk dry sliding wear setup at 10 and 20 N loads with varying sliding distances (500-3000 m) under different sliding velocities (1 and 2 m/s). Coefficient of friction and wear mass loss decreases with an increase in MAF cycles, due to increases in hardness of samples. Wear resistance decreases with an increase in load and sliding velocity. Worn surface shows the plastic deformation regions, wear track, micro-cracks, micro-plowing groove and scratches. Potentiodynamic polarization test clearly shows that current density (Icorr) increases with an increase in MAF passes, because of grain refinement. Reduction in corrosion rate was evident from electrochemical impedance spectroscopy results which show increased diameter of the capacitive arc. An enhancement of corrosion resistance was revealed at higher MAF passes.

An aerospace structural material T300/914 has been studied to understand the Mode I interlaminar fracture toughness. For experimental analysis a Double Cantilever Beam (DCB) test is conducted on the laminate to estimate the Mode I interlaminar fracture toughness of the sample. A 48-layer laminate was prepared by hand layup process and an insert included at the mid plane to produce the artificial initial crack required for the test. All the tests are conducted in accordance to the ASTM standards. Pulse-Echo test results and C-Scan images of the laminate were analyzed to find the defects in the laminate. The data from DCB test were analyzed by Modified Beam theory, Compliance calibration method and modified compliance calibration methods to find the interlaminar fracture toughness. A crack length correction method is implemented for data reduction. Numerical analysis of the data derives results in accordance with the experimental analysis.

Multiaxial forging (MAF) was used to process Cu-4.5%Ti (wt.%) alloy at cryogenic temperature up to three cycles with a cumulative strain of 1.64. Microstructures, mechanical, and corrosion properties of as-received and deformed samples were analyzed. Microstructural analysis showed that average grain size decreased from 70 µm to 200 nm, and electron backscattered diffraction (EBSD) analysis revealed the transformation of high-angle grain boundaries (HAGBs) to low-angle grain boundaries (LAGBs). Variations in intensity of peaks were observed by x-ray diffraction (XRD) technique. Microstructural investigation showed elongated grains with shear bands having width ~ 200 nm for 3-cycle sample. Tensile testing and micro-hardness tests showed improvements in ultimate tensile strength (UTS), yield strength (YS), and micro-hardness, with the increase in MAF cycles. Ultimate tensile strength and hardness increased from 605 MPa and 252 HV (for as-received) to 1284 MPa and 428 HV for three cycles of MAF-processed sample, respectively. Improvement in strength and hardness was attributed to refined grain structure. Corrosion study was carried out for different cycles of MAF-processed samples using potentiodynamic polarization, and corroded surfaces were analyzed using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis.

Copper-Titanium alloy was subjected to multi axial forging (MAF) at cryogenic temperature. Microstructure evolution was observed using optical microscope (OM). After 9 pass of MAF, grain size reduced to 2 µm. As number of MAF pass increases, hardness of the sample increased, due to strain hardening effect. Dry sliding wear test was performed on as-received and MAF processed samples using pin on disc wear machine. Tests were performed at 30 N and 40 N loads at 3 m/s constant speed and at 1000 m and 2000 m, sliding distance. Scanning Electron Microscope (SEM) and EDS was used to analyze the worn-out surface of the specimen. Wear mass loss of MAF processed sample reduced, with increased number of MAF passes. Frictional Coefficient (COF) reduced with increase in MAF passes and improved with increase in load, because of increase in contact area between sample and disc.

AM80 magnesium alloy was processed with Equal Channel Angular Press (ECAP) for grain refinement. Laser shock peening without coating (LSPwC) were executed on ECAP processed sample at 8 GW cm−2 and further grain refinement were observed at surface. SEM image expose the grain refinement at different stage of processing, and fine grains of sub-micron size were observed at surface level after ECAP + LSPwC. Residual stress were measured using X-ray diffraction, sin2(Ψ) method and compressive residual stress was found after ECAP. LSPwC intensify the compressive residual stress at surface. Increases in magnitude of residual stresses were noticed with 200 and 300% of LSPwC. Increase in surface roughness were noticed from 0.6 to 6.8 μm by increasing the percentage of LSPwC coverage. Fatigue tests were acknowledged the effect of ECAP and ECAP + LSPwC on reliability of grain refinement technique. ECAP sample showed fatigue life of 7539 cycles against as received. Highest fatigue life of 85,268 life cycles was observed with ECAP + LSPwC by 100% of coverage. Further process of LSPwC for 200 and 300%, fatigue life was significantly decreases to 22,987 and 384 cycles respectively. SEM images of fractured surface exhibits effect of ECAP and LSPwC on crack initiation and propagation for failure.

Multidirectional forging (MDF) was applied to Mg-6%Zn alloy up to 5 passes successfully at 280 °C. MDF-processed materials were characterized using optical microscope, scanning electron microscope, electron backscatter diffraction, transmission electron microscope, and x-ray diffraction. Obtained results showed a significant reduction in grain size (up to 3.8 μm) having a large fraction of high-angle grain boundaries after 5 passes of MDF process. Maximum tensile strength of 230 MPa was achieved for 5-pass MDF-processed Mg-6%Zn alloy which is about ~ 2.0 times higher in comparison with that of homogenized alloy (117 MPa) and was attributed to higher dislocations density and grain refinement. Corrosion behavior of the alloy was investigated in 0.1 M NaCl solution using potentiodynamic polarization test, electrochemical impedance spectra analysis, and immersion tests. It was found that the corrosion rate of 5-pass MDF sample improved (0.34 mm/year) ~2.5 times in comparison with that of homogenized Mg-6%Zn alloy (0.86 mm/year) due to fine grain structure, which creates more grain boundaries that act as a corrosion barrier.

This paper presents a novel approach for the optimization of machining parameters of end milling process with multiple responses, based on Taguchi’s orthogonal array (OA) and gray relational analysis (GRA). Experiments were conducted on BS L168-T6511 aluminum alloy test specimens with uncoated carbide solid end mills under dry condition. The cutting process parameters considered: cutting speed (S), feed rate (F) and depth of cut (D) are optimized for betterment of the multiple responses such as: surface roughness (Ra), cutting tool tip temperature rise (T) and material removal rate (MRR). A grey relational grade (GRG) is determined from the grey relational analysis (GRA). Optimum levels of process parameters have been identified based on the values of grey relational grade and influence of each cutting process parameter is determined by ANOVA. To validate the test results, confirmation tests are performed. Experimental outcomes have proved that the output responses in end milling process can be enhanced efficiently through this approach.

Equal channel angular pressing (ECAP) was used to process Mg-4Zn-1Mn alloy at 300 °C using route Bc up to 4 pass with a cumulative strain of 3.2. Optical microscope (OM), microstructures results shows homogenized sample grain size was 260 µm, after 4 pass ECAP grain size was decreased to 6 µm. Electron back-scattered diffraction (EBSD) shows the misorientation angle converted from low-angle grain boundaries (LAGB) to high-angle grain boundaries (HAGB). Dislocation density and fine grains were observed from transmission electron microscope (TEM) images. Strength has been increased from 156 to 218 MPa and hardness increased to 68 Hv after 4 pass of ECAP. Fractography analysis revealed that dimple size decreases as ECAP passes increased. XRD analysis shows the peak broadening and intensity variation, because of grain refinement. The corrosion behavior of the homogenized and ECAP-processed samples were investigated by electrochemical tests using simulated body fluids (SBF) at 37 ± 1 °C. The lower corrosion resistance of ECAP-processed Mg-4Zn-1Mn alloy attributed to the strain-induced crystalline defects, subgrain boundaries and high-density dislocations. Enhanced strength and ductility combined with lower corrosion resistance of ECAP-processed Mg-4Zn-1Mn has greater potentials for biomedical implants.

This paper presents the numerical simulation of inducing residual stresses on equal channel angular pressed (ECAP) magnesium alloy by shot peening process. Mg-Al-Mn (AM) series magnesium alloy was ECAP processed up to 4 passes using route BC. Microstructures were analysed and grain size reduced from 100 µm for the as-received sample to 3 µm for ECAP 4 pass sample. Tensile test was carried out and maximum tensile strength was found in ECAP 2 pass sample and decreased with higher ECAP passes. Grain refinement was characterized by optical microscopy, electron backscatter diffraction analysis (EBSD) and X-ray diffraction (XRD). Material (tensile) behaviour of 2 pass sample was implemented for finite element modelling. A finite element method was used to estimate the intensity of residual stresses developed due to shot peening in ECAP processed AM80 alloy. Simulation was done with different boundary condition such as impact velocity, geometry of shot-peen media, angle of impact and multiple impacts. The results are presented and the relationship between process parameters and the intensity of residual stresses are discussed. Increase in velocity of shot peening media showed an increase in the magnitude of residual stresses. Change in geometry of shot media altered the contact area between target and shot media during impact which influenced the magnitude of residual stresses and coverage area. The magnitude of residual stresses varied with the angle of impact and the multiple repeated impacts showed that the effective depth of residual stresses increased with the number of impacts.

Magnesium AM90 alloy was subjected to equal-channel angular pressing (ECAP) using route $$\hbox {B}_{\mathrm{C}}$$ . Microstructural characterization revealed refined grains having average grain size $$\sim \,3\,\upmu \hbox {m}$$ after ECAP 4 passes. Samples were subjected to electrochemical measurements to study the corrosion behavior. Potentiodynamic polarization test showed reduced corrosion current density $$(I_{\mathrm{corr}})$$ for processed samples up to ECAP 3 pass due to grain refinement. Electrochemical impedance spectroscopy showed an increase in the diameter of the capacitive arcs and charge-transfer resistance $$(R_{\mathrm{t}})$$ for ECAP-processed 3 pass sample indicating the reduction in corrosion rate. Increase in corrosion resistance is due to refined microstructure and uniform distribution of secondary particles forming a protective passivation layer $$(\hbox {Mg}(\hbox {OH})_{2})$$ on the sample’s surface. Immersion test indicated lower hydrogen evolution from ECAP-processed samples compared to the unprocessed condition indicating decreased corrosion rate.

Spring steel (EN47) samples are machined (turning) using Sandvik make coated tungsten carbide tool insert with different nose radii (0.4 and 0.8mm) in dry condition and the results are compared with each other. Spring steel is widely used in the manufacturing of vehicle components such as crankshaft, knuckle and leaf spring. EN47 spring steel material is relatively low cost compare to other alloy steels. Experiments are conducted based on taguchi L9 technique. Input parameters are cutting speed, feed rate and depth of cut. The corresponding output parameters are cutting force, surface roughness and tool tip temperature have been analyzed. Experimental result reveals that better surface roughness obtained with higher nose radius. ANOVA results confirm that cutting force is influenced by depth of cut (ap), surface roughness is influenced by feed rate (f) and tooltip temperature is influenced by cutting speed (Vc). Chip morphology and machined surface samples are analyzed using scanning electron microscope (SEM).

Multilayered composite of Mg-2%Zn/anodized Al-7075 was developed by accumulative roll bonding (ARB) of wrought Mg-2%Zn and anodized aluminium 7075 alloy. The Mg-2%Zn/anodized Al-7075 composite exhibited density of 2298 kg/m3 which is about 1.2 times lighter weight as compared to Al-7075 alloy. The electron backscatter diffraction (EBSD), transmission electron microscopy (TEM) showed an average grain size of 1 μm and 0.73 μm in Mg-2%Zn and anodized Al-7075 layers respectively, and with high angle grain boundaries (HAGBs). Mechanical properties were evaluated by microhardness and tensile tests and found significant improvement in strength and hardness values as compared with Mg-2%Zn alloy after four pass ARB process. The multilayered composite shows better corrosion resistance as compared to rolled Mg-2%Zn alloy evaluated using using potentiodynamic polarization test.

Multi axial forging (MAF) is one among the severe plastic deformation (SPD) processes, where large strains are imposed into the component. In the present work, as-received Cu-1.5%Ti alloy was subjected to MAF for 2 and 4 cycles at room temperature. Microstructure showed grain refinement after 2 and 4 cycles. Average grain size obtained for MAF processed samples after 2 and 4 cycles are 120 µm and 40 µm, respectively compared to initial grain size of 800 µm. The Mechanical properties were analyzed for as-received and MAF processed samples. Tensile test showed increased ultimate tensile strength (493 MPa) for MAF 4-cycle sample compared to as-received (191 MPa) condition with accumulated strain of 2.18 for 4 cycles. Increase in hardness was observed for MAF processed sample of 143 Hv for 4-cycle compared to as-received sample of 67 Hv

Today’s growing demand for steels and spring steels are widely used in industries as they possess high yield strength and their property resistance to deform easily. Spring steels have huge demand in many large scale industries, because of their applications in nuclear power plant, jet engine parts, forming tools and extrusion dies. EN47 is one of such spring steels with relatively low cost. Machinability study of EN47 material was analysed using a L27 orthogonal array (OA) for dry turning condition using TiCN/Al2O3/TiN CVD coated tungsten carbide insert with nose radius of 0.4mm. Depth of cut (d), Speed (v), feed (f) and are varied to the level-3. During machining, cutting forces and cutting temperatures was measured using Kistler based dynamometer and heat gun respectively. Surface roughness was measured by using Mitutoyo SJ201 after machining. Machined surface and chip were analysed using scanning electron microscope (SEM). Tool tip temperature, surface finish and cutting forces are optimized using Design of Experiments technique and proof trails are conducted with satisfactory results.

Accumulative roll bonding (ARB) process have been used develop Mg-2%Zn/Ce/Al hybrid composite and microstructure, mechanical and corrosion properties were investigated. The electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) revealed that the grains are significantly reduced and reaches up to 1 μm in Mg-2%Zn layer and 1.8 μm in Al layer having high angle misorientation of grain boundaries after subjected to 5-passes of the ARB process. The Al17Mg12, AlMg4Zn11 and Al11Ce3 intermetallic phases were observed through the XRD analysis. Mechanical properties of the hybrid composite improved with increase in the number of ARB passes which is attributed to work hardening, grain refinement and uniform distribution of Ce particles. Presence of Ce in the hybrid composite restricts the phenomenon of dynamic recrystallization and prevents the grain growth during ARB process. The corrosion rate of Mg-Zn/Ce/Al hybrid composite (0.72 mm/y) improved about 3.3 times as compared to that of Mg-2%Zn alloy (2.37 mm/y).

AM80 magnesium alloy was subjected to equal-channel angular pressing (ECAP), and microstructural evolution was studied using scanning electron microscope (SEM). Grain size was found to decrease up to 3 µm after four passes. An increase in number of ECAP passes led to a corresponding increase in hardness of the processed samples. Unprocessed and ECAP-processed samples were subjected to wear test using pin-on-disk wear test machine to study the wear behavior. Effects of varying loads (30 and 40 N) with sliding distances (2500 and 5000 m) were studied. The results showed reduction in wear mass loss for the ECAP-processed samples in comparison with unprocessed condition. Coefficient of friction (COF) was studied for different loads, and improvement in COF values was observed for ECAP-processed samples compared to unprocessed condition. Worn surfaces were studied using SEM and energy-dispersive x-ray spectrometer, and they exhibited plastic deformation, delamination, plowing, wear debris and oxidation in the sliding direction. X-ray diffraction analysis was conducted on the worn surfaces to identify the phases. It revealed the presence of magnesium oxide and magnesium aluminum oxide which led to oxidation wear in the sliding direction. Wear mechanism was found to be abrasive and oxidation wear.

Equal-channel angular pressing (ECAP) was applied on AM90 magnesium alloy using processing route \(\hbox {B}_{\mathrm {C}}\) at \(275\,^\circ \)C up to four passes. Microstructural evolution and the corresponding modification in mechanical properties (strength, elongation and hardness) corresponding to the number of ECAP passes were evaluated using X-ray diffraction (XRD), electron backscatter diffraction, scanning electron microscopy, transmission electron microscopy, tensile test and microhardness test. Shear deformation was found to refine the microstructure by breaking it into smaller grains formed by dislocation reconstruction. Tensile strength and hardness were found to increase by \(\sim \)128 and 23%, respectively, for ECAP-processed 2-pass sample in comparison with that of the homogenized condition. After two passes, tensile strength and hardness started decreasing even though the grain size was still decreasing, which was found to be associated with texture modification during ECAP processing as observed by XRD analysis.

Multilayered composite of Mg-2%Zn/Al-7075 was developed by accumulative roll bonding (ARB) of wrought Mg-2%Zn and aluminum 7075 alloy. The Mg-2%Zn/Al-7075 multilayered composite exhibited density of 2295 kg/m3 and an average grain size of 1 and 1.3 μm in Mg-2%Zn and Al-7075 layers, respectively. A thorough microstructural characterization was performed on the composites by scanning electron microscope, electron backscatter diffraction (EBSD), transmission electron microscope and phase analysis by x-ray diffraction. In addition, mechanical properties were evaluated by microhardness and tensile tests. Corrosion behavior of the multilayered composite was examined using electrochemical polarization test. EBSD analysis showed the presence of ultrafine grains with high-angle grain boundaries. The composite exhibited a significant improvement in ultimate tensile strength (~1.82 times) and elongation (~1.5 times) as compared with Mg-2%Zn alloy, after four-pass ARB process.

Equal Channel Angular Pressing (ECAP) with different passes was carried out for Mg-Al-Mn (AM) series magnesium alloy to investigate the microstructure and mechanical properties. ECAP process was carried up to 4 passes using route B C , where the samples are rotated by 90° in the same direction between consecutive passes. Microstructures were studied using optical microscope (OM) and scanning electron microscope (SEM) and it was observed that the grain size was reduced from 100 µm to 1 µm after 4 passes. Tensile test was conducted and the ultimate tensile strength (UTS) increased up to 2 passes but decreased with higher passes, even though grain size became finer with increase in ECAP passes. Microhardness was carried out and it was observed that the hardness was increased up to 2 passes of ECAP and decreased with higher passes.

Magnesium alloy Mg-Al-Mn (AM70) was processed by equal channel angular pressing (ECAP) at 275 °C for up to 4 passes in order to produce ultrafine-grained microstructure and improve its mechanical properties. ECAP-processed samples were characterized for microstructural analysis using optical microscopy, scanning electron microscopy, and transmission electron microscopy. Microstructural analysis showed that, with an increase in the number of ECAP passes, grains refined and grain size reduced from an average of 45 to 1 µm. Electron backscatter diffraction analysis showed the transition from low angle grain boundaries to high angle grain boundaries in ECAP 4 pass sample as compared to as-cast sample. The strength and hardness values an showed increasing trend for the initial 2 passes of ECAP processing and then started decreasing with further increase in the number of ECAP passes, even though the grain size continued to decrease in all the successive ECAP passes. However, the strength and hardness values still remained quite high when compared to the initial condition. This behavior was found to be correlated with texture modification in the material as a result of ECAP processing.

AM80 magnesium alloy was processed by Equal Channel Angular Pressing up to 2 passes under route BC and C, to study the effect of change in microstructure. Microstructures were examined under optical microscope. Samples processed by route BC showed heterogeneous grain structure with good tensile strength compared to that processed by route C. Tensile tests of 2-pass equal channel angular pressed samples showed high tensile strength under route BC. Laser shock peening without coating was carried out on route BC sample for further grain refinement on the surface. Laser pulses with power density of 8 GW cm−2, under different percentages of cover, were used to peen the surface at high strain rate. Microstructures were analysed through scanning and transmission electron microscope, and fine grains of less than 100 nm were observed. Tensile tests indicated that the laser shock peened samples had increased strength and ductility. Fracture details from tensile tested specimens, were examined under SEM. Mixed mode of brittle and ductile fractures was observed in ECAP processed samples. Fracture surface of Laser shock peening without coating treated on equal channel angular pressed samples showed small dimples near the peened surface and intensity of dimples increased with increase in percentage of cover. Wear test was carried out on before and after Laser shock peening without coating processed samples, on pin-on-disc wear test machine. Increase in friction coefficients and wear rate was observed due to roughness induced by peening effect and it decreased after increase in sliding distance due to increase in hardness. Nano indentation experiments were carried out to examine the mechanical characterization at nano level, and it expose the effect of LSPwC in terms of increase in hardness at peened region.

Equal channel angular pressing (ECAP) is a technique for inducing high strain into the material to achieve ultrafine grain refinement. AM80 magnesium was processed by ECAP with processing route BC. ECAP-processed samples were tested for microstructural studies and electrochemical measurements. Potentiodynamic polarization test revealed decrease in corrosion current density due to uniform refined microstructure of the processed samples. Increment in charge transfer resistance (Rt) was observed for ECAPed samples with increase in capacitive arc diameters in Nyquist plots showing increased corrosion resistance in comparison with as-cast condition. The increment in corrosion resistance is because of grain refinement and uniform dispersal of intermetallic particles, which improved development of protective layer and bonding due to increased grain boundary density by ECAP process.

Carbon epoxy composite T300/914 which has wide applications in aerospace industries, as a structural material, has been analyzed, to determine the interlaminar fracture toughness. Laminates with a thickness of 4.6 mm, consisting of 48 layers of T300/914, are considered for estimating the inter-laminar fracture toughness. These specimens have been fabricated by hand layup method followed by controlled curing in an autoclave. Tests have been conducted in accordance with ASTM standards, for Mode I by Double Cantilever Beam (DCB) test and End Notch Flexure (ENF) test for Mode II. Pulse-Echo test results and C-Scan images of the specimens were also analyzed to locate the exact position of delamination. During the preliminary tests, it was found that the interlaminar fracture toughness varied, because of bonding of release film with the sides of the laminate. By Modified Beam Theory, Mode I and Mode II fracture toughness values of the prepared specimens were found to be 0.090 kJ/m2and 0.542 kJ/m2, respectively. It was also noted that the fracture toughness of the specimens from the same laminate varied with the degree of compaction.

Cu-3%Ti alloy is cold rolled with different reduction ratios and the microstructures and mechanical properties are compared with that of as-cast Cu-3%Ti alloy. Microstructure was analyzed using optical microscope and scanning electron microscope. Optical microscopy revealed significant grain refinement that occurred during the rolling process. Tensile test results indicate that the UTS is increased by a significant amount up to 80% rolling reduction. A significant amount of tensile strength increased up to 812 MPa is about 1.69 times that of the cast Cu-3%Ti alloy. Hardness of the rolled Cu-3%Ti increased as % reduction increased. Dimples were revealed on the fracture surface of the rolled Cu-3%Ti specimens indicating a ductile nature of the fracture.

In the present study, homogenized Mg−4%Zn (wt%) alloy was exposed to multi-direction forging (MDF) at 280 °C up to 5 passes successfully. Microstructural evolution, mechanical properties and corrosion behavior of the MDF-processed Mg−4%Zn alloy was investigated using different characterization techniques. Five passes of MDF (cumulative strain, ΣΔe = 3.45) led to the formation of ultrafine grain structure (grain size ~2.3 μm) with high angle grain boundaries (HAGBs) and high dislocation density. Corresponding ultimate tensile strength (UTS) and microhardness were observed to be 228 MPa and 88 Hv. Potentiodynamic polarization test results exhibited higher corrosion resistance (0.38 mm/y) in comparison with that of homogenized condition (1.33 mm/y).

The effects of cold rolling on the microstructure evolution and mechanical properties of Cu-1.5%Ti alloy were investigated. The results showed that the tensile strength of the Cu-1.5%Ti alloy increased with an increase of rolling deformation at room temperature. Significant grain refinement took place during rolling process revealed in optical microstructure and transmission electron microscope analysis. XRD patterns revealed peaks indexed to Cu, Cu3-Ti2 and Cu4-Ti3 after 8-pass rolling process. Microhardness of the rolled Cu-1.5%Ti alloy layers increased incessantly with increase in the number of rolling passes. Tensile strength increased up to 294 MPa which was about 1.54 times higher than that of the cast Cu-1.5%Ti alloy. Fracture surfaces of the rolled Cu-1.5%Ti alloy revealed the dimples in the structure, which is an indication of ductile fracture.

AZ31 wrought magnesium alloys are light weight materials which play an important role in order to reduces the environmental burdens in modern society because of its high strength to weight ratio, corrosion resistance, and stiffness and machinability. Applications of this material are mainly in structural component i.e., in constructions, automobile, aerospace, electronics and marine industries. In the present work, the microstructure characterization of the AZ31 alloys up to four ECAP passes at temperature of 573 K was observed for route Bc. Average grain size of the material was reduced from 31.8 μm to 8 μm after four ECAP passes. Mechanical properties of the alloy improved with increase in number of ECAP passes. Moreover, X-ray diffraction analysis was carried out for as received and ECAP processed material.

Combined multiaxial forging (MAF) and rolling was performed on Cu-3% Ti (wt%) alloy at room temperature with emphasis on microstructural evolution, improvement in mechanical properties, and corrosion resistance. Microstructural changes were confirmed from various characterization techniques, and co-related with mechanical properties. TEM analysis revealed high shear band density in the 3 pass MAF + 90% rolled sample appearing due to high strain. EBSD analysis revealed transformation to low angle grain boundaries from high angle grain boundaries. Maximum microhardness and UTS reached to 340 HV and 960 MPa, respectively in the processed samples. Significant grain refinement was observed in MAF processed Cu-3%Ti alloy, and after combined MAF + rolling, higher dislocation density and refinement of shear bands were observed. In addition, potentio-dynamic polarization test was used to study the corrosion behavior of the alloy. Scanning electron microscope (SEM) was used to analyze the corroded surface morphology.

Cu-Ti alloy, processed by multiaxial forging (MAF) at cryogenic temperature with a cumulative strain up to 1.64, was investigated for microstructure and mechanical properties. The deformed microstructures were analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The average grain size of 2 μm was achieved in the deformed sample after 3 cycles of MAF. TEM studies indicated that the shear bands width of the deformed sample after 3 cycles reduced to 1 μm. Tests for mechanical properties indicated an increase in tensile strength and hardness and it was found to be correlated with an increase in dislocation density and grain boundary strengthening mechanism. Ultimate tensile strength (UTS) of 390 MPa, 480 MPa, and 590 MPa was observed in MAF processed samples after 1, 2, and 3 cycles, respectively. Hardness increased from 65 Hv (as-received) to 240 Hv after 3 cycles of MAF. Fractography analysis showed that, with an increase in number of MAF cycles, dimple size reduced up to 1 cycle and percentage elongation increased after 2 cycles of MAF.

In this experimental work dry turning process carried out on EN47 spring steel with coated tungsten carbide tool insert with 0.8 mm nose radius are optimized by using statistical technique. Experiments were conducted at three different cutting speeds (625, 796 and 1250 rpm) with three different feed rates (0.046, 0.062 and 0.093 mm/rev) and depth of cuts (0.2, 0.3 and 0.4 mm). Experiments are conducted based on full factorial design (FFD) 33 three factors and three levels. Analysis of variance is used to identify significant factor for each output response. The result reveals that feed rate is the most significant factor influencing on cutting force followed by depth of cut and cutting speed having less significance. Optimum machining condition for cutting force obtained from the statistical technique. Tool wear measurements are performed with optimum condition of Vc = 796 rpm, ap = 0.2 mm, f = 0.046 mm/rev. The minimum tool wear observed as 0.086 mm with 5 min machining. Analysis of tool wear was done by confocal microscope it was observed that tool wear increases with increasing cutting time.

Equal Channel Angular Pressing (ECAP) is one of the promising techniques in Severe Plastic Deformation (SPD) used to refine the grain size of the metals and its alloys. The main aim of the present study is to give an in depth knowledge of effect of processing routes on AZ31 alloy in ECAP process. In this, processing route A, route C, and route Bc are used to refine the grain size of AZ31 alloy up to two ECAP passes at a temperature of 498K. Initial average grain size of the as received material was found to be 31.8 μm. Further, it was reduced to 14.0 μm, 15.9 μm and 13.3 μm for processing route A, route C, and route Bc respectively. Mechanical properties of the AZ31 alloy are experimentally evaluated for three processing routes. The percentage elongation of the material was found to be increased with increasing number of passes. Maximum microhardness of the material was observed in route Bc when compared to route A and route C.

Summary The present study aims at development of light weight, high strength Mg–2%Zn/Al and Mg–2%Zn/anodized Al based multilayered composite by the accumulative roll bonding (ARB) process. The ultrafine grained multilayer composite was successfully roll bonded by using binary Mg–2%Zn alloy, pure aluminium and anodized aluminium at 300 °C with 50% reduction up to 5 passes. Multilayered composites are characterized with respect to microstructure, mechanical properties. Density of the ARB processed Mg–Zn/Al multilayered composites have been found to be 21% reduction of weight as compare to pure Al. The composite with anodized Al showed better tensile strength and microhardness as compare to Mg–Zn/Al multilayered composites.