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Friction stir welding (FSW) is a method of welding that creates a weld trail by pressing a non-consumable rotating tool with a profiled pin on the adjacent surfaces while moving transversely along the welding direction. The method was initially used with metals and alloys, but more recently, thermoplastic polymers have also been included in its application. Investigations on FSW of thermoplastic polymers made of nylon and High-density polythene (HDPE) are presented here. Weld characteristics that are like those of the base materials are attempted to be achieved. Because of their unique nature and thermal conductivity, thermoplastics FSW differs from that of metals. The use of thermoplastic materials with conventional FSW procedures presents numerous difficulties and is currently ineffective. On the weld characteristics of nylon and HDPE, statistical methods were utilized to study the impact of temperature, rotational speed, and transverse speed.

Additive manufacturing (AM) is currently the most sought-after production process for any complex shaped geometries commonly encountered in Aerospace Industries. Although, several technologies of AM do exits, the most popular one is the Direct Metal Laser Sintering (DMLS) owing to its high versatility in terms of precision of geometries of components and guarantee of highest levels of reduction in production time. Further, metallic component of any complex shape such as Gas Turbine Blades can also be developed by this technique. In the light of the above, the present work focuses on development of iron silicon carbide (Fe-SiC) complex part for ball screw assembly using DMLS technique. The optimized process parameters, hardness and wear resistance of the developed iron-SiC composite will be reported. Further, since the material chosen is a metallic composite one, the effect of SiC on the thermal stresses generated during the DMLS processing of Fe-SiC composite will also be discussed.

The aerospace industry's unceasing quest for lightweight materials with exceptional mechanical properties has led to groundbreaking advancements in material technology. Historically, aluminum alloys and their composites have held the throne in aerospace applications owing to their remarkable strength-to-weight ratio. However, recent developments have catapulted magnesium and its alloys into the spotlight. Magnesium possesses two-thirds of aluminum's density, making it a tantalizing option for applications with regard to weight-sensitive aerospace components. To further enhance magnesium's mechanical properties, researchers have delved into the realm of metal matrix composites (MMCs), using reinforcements such as Alumina, Silicon carbide, Boron carbide and Titanium carbide.

In recent decades, silicon nitride (Si3N4) and carbon fibres (Cf) have been the most popular candidate materials as reinforcements in the production of metal matrix composites (MMCs) due to their superior wear and corrosion resistance. Al6061 is the most sought after matrix alloy owing to its excellent formability among all class of aluminium alloys. Several researchers have reported on dry sliding wear and corrosion properties of cast composite with carbon fibres and silicon nitride as reinforcements but limited information is available related to the slurry erosive wear behaviour of hot extruded hybrid MMCs with carbon fibre as one of the reinforcement. In the light of the above, the current experimental work is aimed at investigating the slurry erosive wear behaviour of Al6061 dispersed with Si3N4 (6 wt %) and Cf (1 wt %) hybrid MMC after hot extrusion.

Several conventional methods on preparation of exfoliated graphite are in practice. However, their major limitations are poor quality of exfoliated graphite, lower yield, more expensive with higher processing time. To address these issues, a unique method for development of exfoliation of graphite using tri-solvents namely Water, Ethanol and Acetic acid is attempted in the present work. Ethanol acts as a supporting group for the long term stable dispersions of ex-graphite nanosheets. Glacial acetic acid, which readily dissolves in water, penetrates through the layers of graphite sheets and breaks the -C=C bond force between layers with the help of stirring and sonication resulting in exfoliation of graphite layers. Exfoliated graphite nanosheets were produced by using optimized mixtures of water, acetic acid and ethanol. XRD, SEM and FTIR studies have been carried out on the developed exfoliated graphite.

Acrylonitrile Butadiene Styrene (ABS) is a highly sought-after engineering plastic for industrial applications, particularly in modern aircrafts. It offers better balance of impact strength, tensile strength, thermal resistance, dimensional stability, processing ability and affordability, the aircraft interior parts are made up of ABS plastic. However, ABS plastic is not a good choice for heavy-duty industrial applications that require corrosion resistance, abrasion resistance and durability. Several studies have been published on surface metallization of ABS plastic using conventional electroplating and electroless methods, but there is little information is available on the use of thermal spray technique. This opens up a huge opportunity for research in this area to be conducted using most commonly used materials like zinc and low carbon steel. In the light of the above, the current work employs an electric arc spray technique to coat zinc and low carbon steel on ABS plastic.