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Considerable weight of an automobile is constituted by the engine and there is scope for improvement in fuel efficiency and emission control through optimization of weight in the engine. In this work, AlSi10Mg alloy produced by the direct metal laser sintering (DMLS) is suggested for engine application which is a lightweight aluminum alloy. Mechanical properties like tensile strength, compressive strength, and hardness of both cast and DMLS manufactured alloy are compared followed by analysis of SEM images of tensile test fractured surfaces. Reciprocating wear test is carried out for one lakh cycles at 125°C temperature with SAE 40 grade oil as lubricant. Co-efficient of friction (COF), wear rate of the cast and DMLS manufactured samples are compared. Wear patterns are analyzed using SEM images of the wear tracks.

The main purpose of this study is to investigate additive manufactured Inconel super alloy subjected to cryogenic treatment (CT). Cryogenic treatment is mainly used in aerospace, defense and automobile application. Direct metal laser sintering is an additive manufacturing technique used for manufacturing of complex and complicated functional components. Inconel is an austenitic chromium nickel based super alloy often used in the applications which require high strength & temperature resistant. In this work, a study is carried out on microstructure and mechanical properties of additive manufactured Inconel 718 when subjected to cryogenic treatment at three different time intervals. The micro-structural evolution of IN718 super-alloy before and after CT was investigated by both optic microscope and scanning electron microscope. Surface roughness and hardness at different CT time intervals has also analyzed. Additionally, XRD technique was used to analyze the surface residual stress.

The utilization of Additive Manufacturing (AM) technology in the current manufacturing sector is growing day - by - day. This is made possible by the constant development of new materials and techniques to overcome the difficulties that are encountered while fabricating a part. In AM, parts are fabricated by laying successive layers on one another till the complete part is build. This gives AM an edge over conventional manufacturing. Even intricate or hollow parts can be fabricated with the same ease as fabricating a solid part. The key objective of this project is to evaluate and compare mechanical properties of Polyethylene Terephthalate - Glycol modified (PETG) and Carbon fiber reinforced Polyethylene Terephthalate - Glycol modified (CF - PETG), which are fabricated using Fused Deposition Modelling (FDM) process of AM. The ASTM standards D638 and D790 were followed for fabricating tensile test and Flexural test specimens respectively.

Today manufacturing industries have become more competitive and to survive, industries should be capable of accommodating the sudden market change. The conventional manufacturing systems like Dedicated Manufacturing Lines (DMLs) can produce high volume of product but difficult to cater to varying product types. On the other hand, Flexible Manufacturing System (FMS) is capable of handling product variety but not suited for mass production, The Reconfigurable Manufacturing System (RMS) gives the advantage of both the system, as it has the capability to adjust to both high volume requirement and product variety, and it able to upgrade to new process technology with minimal effort. In this work the reconfiguration is carried out in machine and system level. At machine level, a new inspection machine is proposed which can be used for multiple products with minimal adjustments and a special drilling and bore tool is suggested to reduce the cycle time and ramp up time when product changes.

Experimental investigations were carried out on the machinable wax filament using the fused deposition modelling (FDM) rapid prototyping process. The printer used for conducting the experiments was Flash Forge guider 2. The filament material used for this study was machinable wax filament of 1.75 mm diameter. Experimental trials were carried out as per Taguchi L9 orthogonal array to determine the optimum process parameter combination. The dimensional analysis of test samples were carried out in terms of change in volume of samples which is result of combine effect of deviations in all the dimensions of test sample. Four factors each at three levels was used to obtain the optimum printing parameters for better dimensional accuracy and proper printing. The four important printing parameters were taken as factor and set to analyse the significant factor affecting on printing. The complexity in printing of wax filament is taken in to consideration during the experimental study.

The use of thermoplastics in various fields like aerospace, automotive, medical and packaging industries is growing day by day, due to their light weight and compactness. In some instances, the plastic components are required to be welded. In this research study, process parameters used for the ultrasonic welding of thermoplastics which produces highest weld strength for complex use in the above said applications is carried out. Also, the possibilities of welding dissimilar plastics are also tested. Tensile testing of above welded samples fabricated through injection moulding was carried out for all possible welds and the ultimate tensile strength was calculated in each case. Of all the welded specimens, at given parameters like weld time, weld pressure and energy director, it is observed that ultimate tensile strength of ABS (8.89 N/mm2) is highest.

Fiber-reinforced polymer composites propose exceptional directional mechanical properties, and combining their advantages with the potential of 3D printing has resulted in many novel research fronts. Industries have started using 3D printed components which are rapidly replacing conventional material components in most of the industries. Carbon fiber reinforced Polylactic Acid (PLA) often finds its application in reasonably high loading conditions working at lesser speed like lightweight gears, spanners, nuts, and bolts. Wear reduction is an important factor that plays an important role in prolonging the component's life. Hence, it is crucial to optimize 3D printing parameters to get desired strength according to the application. The aim of this paper is to conduct the wear rate test on the Fused Deposition Modelled (FDM) printed carbon fiber reinforced PLA parts, to identify the optimum printing parameters which are crucial for wear reduction.

In additive manufacturing, lasercusing is the selective laser melting technique. Finely pulverized metal is melted using a high-energy fibre laser, by Island principle strategy produces mechanically and thermally stable metallic components with reduced thermal gradients, stresses & at high precision. Maraging steel 300 (18Ni-300) is an iron-nickel steel alloy often used in applications requires high fracture toughness and strength. It maintains dimensional changes at a minimal level, e.g. aircraft and aerospace industries for rocket motor castings and landing gear or tooling applications. Current research attempts to analyze the effect of laser shock peening on lasercused material. Surface roughness of the material was found to be increased by 8%, due to effect of laser shock pulse & ablative nature. Also 8% increase in macro hardness on the surface.

In Additive manufacturing, Direct Metal Laser Sintering (DMLS) is a rapid manufacturing technique used for manufacturing of functional component. Finely powered metal is melted by using high-energy fiber laser, by Island principle strategy that produces mechanically and thermally stable metallic component with reduced stresses, thermal gradients and at high precision. Inconel is an austenitic chromium nickel-based superalloy often used in the applications which require high strength and temperature resistant. It can retain its properties at high temperature. An attempt is made to examine the effect of laser shot peening (LSP) on DMLS Inconel 718 sample. Microstructure shows elliptical shaped structure and formation of new grain boundaries. The surface roughness of the material has been increased due to the effect of laser shock pulse and ablative nature. Macro hardness increased to 13% on the surface.

Additive manufacturing of aluminium alloy has paved way for the recent advancement in the automobile and aerospace industry due to its light weightlessness and good physical and mechanical features.Even though the additive process has an upper hand in terms of complexity and monotonous nature of the process its sustainability of it over traditional manufacturing is still a question when the whole cycle of the process is considered.This study mainly focuses on the quantitative life cycle analysis conducted on AlSi10Mg with cast AlSi10Mg as a baseline. Life cycle assessment measures environmental impacts, to determine where most impacts arise: machine and supporting hardware; aluminium powder material used, or electricity used to print