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Pure aluminium alloy (AA) components are not extending their cyclic life due to soft nature of the surfaces for most of the automotive structural parts, exposed to various loading and stress exposed areas through various surface property enhancement techniques. Among all the technique friction stir processing (FSP) followed by shot peening (SP) technique is the most viable and cost-effective process for enhancement of component performance and SP removing residual stresses on the samples thereby improving surface strength. The main objective of the proposed work was cast A356 alloy reinforced with nano form of 6wt% silicon carbide (SiC) harder particles and 3wt% self-lubricant graphene (Gr) was used to fabricated a surface nano hybrid composite through FSP technique. SP route was performed on the FSP-ed samples with optimal parametric conditions for obtaining improved mechanical performances.

Fused deposition Modeling (FDM) is one of the 3D techniques which are mainly used to fabricate the three-dimensional object directly and it is more economical method. The objective of this investigation is to primarily fabricate as-build and annealed polymer associated composites of carbon fiber Polyethylene Terephthalate Glycol (CF-PETG) material by FDM with the effect of different raster angle and layer thickness were consider as the prime parameters. The test specimen was prepared by FDM process with different raster angle (00/900, -450, +450, -450/+450) and layer thickness (100, 400 microns) with other parameters were kept constant. The study of the mechanical properties such as hardness, tensile and impact test of the as-built and annealed CF-PETG were investigated. The best results obtained for annealed specimens printed with raster angle of 00/900 and layer thickness of 100 microns produced more influence in all the mechanical properties.

Among all metal matrix composites, A356 is the most applicable matrix due to its low density and exhibits nominal strength with soft nature. This proposed study is concerned with the examination of mechanical and tribological behavior of virgin A356 alloy and A356 reinforced with 10wt.% power plant waste flyash particles composites were processed by liquid metallurgy stir cum squeeze casting technique. The fabricated composites expose enhanced higher hardness when compared to the virgin A356 alloy due to the presence of flyash particles in the matrix. The wear and friction behavior of casted samples were evaluated with a pin on disk tribometer apparatus under dry and wet sliding environment at the presence of lubricant (SAE 80W-90) by varying sliding load of 10N-40N and sliding velocity of 1-3 m/s respectively. Wear rate increase with the increasing load and sliding velocity.

Friction stir processing (FSP) is a typical process for refinement changes of microstructure, enhance material's mechanical properties, and fabricating surface layer composites. The cast A356 surface composites were fabricated via Friction Stir Processing (FSP) and the enhancement of it’s metallurgical and mechanical properties are studied and conveyed in this research study. The three combinations of test samples of FSP'ed cast A356 alloy, FSP'ed cast A356 FSP with tungsten nanoparticle addition (5 and 10 vol%) were considered to fabrication under fixed parametric conditions like tool rotational speed of 1000 rpm, a load acting 9 kN,./ tool travel speed of 20 mm min−1 through four number of tool travel passes respectively. Obtained FSP'ed samples were exposed to microstructural, tensile strength tests and fracture surface morphology analysis were carried out to record the responses.

AA2014 Aluminum alloys are most widely used for automobile and aerospace structures where specific strength is important. Hot cracking is a major problem while welding these alloys. In the present investigation, the metallurgical studies, viz, hot cracking sensitivity, microstructure and the mechanical properties, viz, hardness and tensile strength of the 4 mm thickness AA2014 aluminum alloy were studied using two different methods. The first method involves TIG (Tungsten Inert Gas) welding with continuous current process and the second method involves TIG welding with pulsed current process. In both the process commercial argon pure gas was used as a shielding gas. The results showed that hot cracking sensitivity was decreased when the specimen was welded using pulsed current process compared to continuous current process.