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Over the years the vehicle population has drastically grown which increases the number of road accidents. The accident severity caused fatality and disability being reduced by introducing energy absorption materials (Crash tube). Over the years, researchers have used aluminium, magnesium, and titanium crash tubes to enhance the energy absorption characteristics during different crash scenarios. However crash tube will possess sufficient rigidity to absorb the impact force during collision but it is still challenging to identify the right material. At the same time, this paper aims to examine the energy absorption characteristics of Aluminium-Magnesium hybrid material (Al-Mg 5456) crash tube designs. Three designs were considered square, cylindrical, and hexagonal designs along with different notch designs to minimize the weight percentage of tubes. The LSDYNA results the oval notches performed better in energy absorption when compared to other designs.

The present research investigates the corrosion behavior of aluminum metal matrix composites (AMMCs) in NaCl solution. The test was designed and performed based on Taguchi’s L8 orthogonal array. The stir casting technique fabricates the AMMCs, and silicon carbide (SiC) is individually reinforced in Al 6061 and Al 5052 matrix. The SiC particle are reinforced in a matrix with 5% and 10% separately in Al 6061 and Al 5052. The test variables used during corrosion studies were reinforced Al matrix, wt% of SiC, molar solution, and corrosion duration for stir-casted composite samples. The Al 6061 and Al 5052 composites were tested in 1M and 2M molar NaCl solutions for 15 and 30 days exposure duration. According to ASTM G31, the solution immersion tests were carried out. The corrosion surfaces are examined by optical microscope and field emission scanning electron microscopy (FESEM) equipment. Through microstructure, it is noted that the corrosion concentration is along the grain boundaries.

The increased use of electronic systems has become a severe concern for electromagnetic pollution, leading to the development of materials to reduce electromagnetic interference (EMI). The present study investigated the EMI-shielding effectiveness (EMI-SE) of flax fiber polymer composite (FFC) in the available free space method by varying the wt.% of Rice husk ash (RHA) and hematite. The flax fiber was coated with the dip coating technique, and the coated fibers were used for preparing FFC by hand layup. The EMI-SE was measured at 32-33.5 dB in the X-band frequency range (8-12 GHz). As the cost is low and can be mass-produced, results show that the developed FFC are suitable for electric vehicle applications specifically to shield Electronic control units (ECU), where the interference effect needs to be reduced.

The research aims to optimize the surface roughness, material removal rate (MRR), tool wear, and spark gap for input machining parameters such as Pulse on-off time and wire feed rate. The experiment results of WEDM of Duplex stainless steel are optimized by ANOVA and Response surface methodology (RSM) approach. Taguchi’s orthogonal array L9 (3*3) was used to design the test condition for the experiment. After the model validation, ANOVA was used to identify the most significant input factor on the output. Response surface methodology was used to find the ideal cutting conditions which produce the best-desired output in terms of less tool wear, lower surface roughness, lower spark gap, and higher material removal rate. The optimal MRR, Spark Gap, surface roughness, and tool wear parameters for Duplex Stainless Steel are obtained at Pulse on 110.23, Pulse off time of 56.0, and a wire feed rate of 1.0.

In the last decade, there was growing interest in the use of green composites because of their environment-friendly nature, improvement in mechanical & chemical properties, better processability, and low cost. In this work, short sisal fiber was reinforced in a polycaprolactone (PCL) matrix and four different degradable green composites were developed with different weight fractions. Experimental studies were conducted as per standard to find the mechanical properties of PCL based composites. The data obtained shows that there is a 22% increase in tensile strength, 18% increase in hardness and 100% increase in impact strength for the specimen with 10% sisal fiber compared to neat PCL specimen. The mechanical property reduces when the fiber content is increased to 15%. These PCL based composites shall find applications in the packaging industry and consumer goods that have less service temperature.

Aluminium metal matrix composite are broadly used in various field like aerospace, marine and automobile application. The application of composites necessitates joining process and its difficult due to different materials. To address the considering difficulties the present study is, Cr2O3 was reinforced in Al 6061 matrix in 2 % to 6 % in the incremental step of 2 %. The stir casting method was used to fabricate the composites with 300 rpm stirring speed and the stirring time duration was 3 min throughout the fabrication process. The H13 tool is used for prepared friction stir welded (FSW) joints and tool having 6.7 mm pin diameter and 6 mm pin height. The fabrication process is conducted by 500 rpm and 700 rpm tool rotational speed with 50 mm/min and 60 mm/min welding speed receptively. The atmospheric environmental condition was preferred to perform friction stir welding.

In industries, the usage of natural fibre composites (NFC) becomes one of the inevitable materials in the engineering field. The applications are owing to its characteristics like high strength to weight ratio, recyclability less density and inexpensive. In recent days the automotive parts like door trim panels, wheel arch, rear hatch, roof liner and bonnet insulation were replaced using NFC. Present-day huge usage of NFC people is working on the recyclability of composites. The present research aimed to recycle the NFC waste as reinforcement in the sisal/epoxy composite. The effect of composite waste reinforcement at various weight percentages (0, 5, 10 and 15%) were studied. The sisal/epoxy composite subjected to mechanical characterisations and drilling performance were studied by varying the process parameters such as feed and spindle speed using design of experiment (DOE).

The use of natural fibers composite matrix is tremendously increasing day to day and acting as a replacement product to many conventional materials in the automobile and aviation sectors. It was preferred due to its bio-degradability, weight to strength ratio, easy availability, and lightweight. The crisscrossed woven jute and raw-sisal fibers had drawn the superior properties in the advanced developing field of the composite. The main purpose of this project is to evaluate the mechanical properties and the influence of raw sisal fiber with woven Jute/Epoxy composite by varying the size of raw sisal in three variable lengths such as 10mm, 20mm, and 30mm respectively. The composite laminates were fabricated by the conventional hand-layer technique. The mechanical characterization like the tensile test, flexural test, and hardness, was estimated on the fabricated jute/sisal hybrid composite material.

In this developing world, the need for lightweight and high strength materials is increasing in various industries. As a result of the above, the importance of natural fiber is also increasing to satisfy the industrial need. In manufacturing industries in order to assembly the engineering components the drilling is one of the important operations. The main objective of this research is to determine the mechanical properties and drilling efficiency of natural fiber composite. Sisal/flax as a natural fiber, the copper foil of thickness 0.025mm as structural reinforcement and epoxy resin as a matrix was used for making composite. The hand layup technique was used for the fabrication of the composite. Two different types of the composite were fabricated such as C1 (Sisal and flax fiber, embedded with punched copper foil (Ø5mm), 20mm apart and 90° to each other) and C2 (Sisal and flax fiber embedded with a punched copper foil of (Ø4mm), 20mm apart and 45° to each other).

The economic growth of the company depends on the quality and delivery time of the components. The pursuit of new techniques is mandatory to maintain quick delivery time without compromising quality. Ergonomics is one such technique that helps to improve workstation productivity by reorganizing the workspace, changing the sequence in operations, up-gradation of machine tools, reducing operator fatigue, etc. The ergonomic study was performed in a tractor steering gearbox manufacturing unit. In the present work, an ergonomic assessment of the workstation is done. Ergonomics assessment includes RULA assessment and Work-place assessment helped to find out the factors influencing the work station to be in the alert zone. During the observation of base milling operation, the operator needs to clamp and de-clamp the steering box manually by using mechanical tools. Due to which operator feel more fatigue in the wrist and lower-arm position which reduces productivity.

Various research regarding new types of fabrication and modifications of Aluminium alloy to improve the existing properties are going on. The wide range application of aluminium alloy is in aerospace and Automobile Industries. The demand for this material improved by mechanical properties with little to zero increment in weight. The current work is based on the fabrication of hybrid aluminium metal matrix composites with the addition of TiC (Titanium Carbide) and Al2O3 (Aluminium Oxide) reinforcement particle using stir casting technique. Three types of hybrid composite samples were prepared based on the weight percentage 5% Al2O3+0% TiC (sample-1), 8% Al2O3 + 12% TiC (sample-2), 20% Al2O3+15% TiC (sample-3). The objective of the study is to analyze the mechanical and corrosion properties of the hybrid composite with the influence of the reinforcement and varying the weight fraction of the particles.

In lieu of the drastic growth of the vehicle population, there is a huge consumption of fossil fuels and mineral oils for mobility. This leads to depletion in fossil fuels and mineral oils which are the by-products of petroleum. These fossil fuels can’t sustain for a long period of time because of its toxicity. In order to reduce the usage of existing mineral oil for lubrication, a source of non-edible oil from Jatropha curcus is processed as jatropha methyl ester (JME). It is holding high viscosity, density and easy blend with base oil. In this current work, the wear resistance of the lubricating oil is enhanced by the addition of nano-copper oxide particle blend with the base oil. The emission performance and tribological behavior have been experimentally tested in 98.2CC two-stroke air cooled engine. The 20% of JME blend with CuO nano particle provides better emission performance and wear characteristics than the other combination of blends.

The surface properties have a vital role in the overall performance of the parts like brake shoe pad and other frame system. The mechanical and residual stress measurements of aluminium alloy 5083 were investigated on friction stir processed plates using the reinforcements of chromium oxide (Cr2O3) and titanium dioxide (TiO2) separately as well as combination of these powders. A comparative study was made to analyze the effects of reinforcements, tool type (cylindrical and threaded), parameters and the volume fraction of the reinforcements. The mechanical properties such as surface hardness and residual stress of the friction stir processed specimens were investigated. The experimental results shows that there was a significant increase in surface hardness (118 HRC) as well as a decrease in residual stress compare to the base metal. This study also reveals that the threaded tool with a reinforcement of Cr2O3 and TiO2 reflected better mechanical properties than the cylindrical tool.

Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to the below recrystallization temperature due to frictional force. FSW mostly avoids welding defects like hot cracking and porosity which are mainly occur in conventional welding techniques. In this process the combination of frictional force and the mechanical work provide heating the base metal to get defect free weld joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of automobile applications like Engine valves and tie rod, shipbuilding, and aerospace due to their high corrosion resistance, lightweight, and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The tool rotational speed, travel speed, and tool profile are the important parameters in FSW process. High Speed Steel (HSS) tool with Hexagonal profile is used for this joining.