Qualification: 
Ph.D, BE
r_vairavignesh@cb.amrita.edu

Dr. R. Vaira Vignesh currently serves as Assistant Professor in the Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham (Coimbatore Campus). He received B.E. in Mechanical Engineering (Distinction) from Karpagam College of Engineering, an autonomous institution affiliated to Anna University, Chennai. He was conferred “Henry Ford Award” and “Best Academic Performer” for his distinct and meritorious academic performance in the senior year. Appreciating his excellence in the curricular and technical field, The Indian Society for Technical Education, New Delhi awarded him with “ISTE Chapter Best Student Award” in Tamil Nadu and Puducherry section.

He is the first and youngest scholar from Amrita Vishwa Vidyapeetham to hold a Ph. D. degree under the Faculty of Engineering directly after bachelor’s degree. With his academic and research credentials, he won Amrita Vishwa Vidyapeetham Ph. D. Scholarship consecutively for two years. His research work received “Best Technical Paper Award” in the International Conference on Emerging Trends in Materials and Manufacturing Engineering organized by National Institute of Technology, Tiruchirappalli. He has over 20+ publications in peer-reviewed international journals (SCI, SCIE, and Scopus indexed), 20+ conference publications (Scopus indexed), and 4 book chapters (Scopus indexed) to his credit. He is an active reviewer and editorial member in peer-reviewed journals.

Education

  • September 2019Ph. D. in Faculty of Engineering
    Amrita School of Engineering, Amrita Vishwa Vidyapeetham, India
  • March 2015B.E. in Mechanical Engineering with distinction (CGPA 9.5/10)
    Karpagam College of Engineering, Anna University, India

Research Experience

Ph. D. Work

Synthesis of Magnesium alloy Surface Composites by Friction Stir Processing 

Brief description: Magnesium alloys are preferred for biomedical applications attributable to its biocompatibility. However, magnesium alloys corrodes rapidly in physiological fluids. The proposed work aims to fabricate surface composites of magnesium alloy with controlled corrosion and degradation kinetics and improved mechanical properties by friction stir processing. 

Junior Research Fellow

Development of Laser Surface Texturing Technology for Automotive Application

  • Funded by Department of Science and Technology, Government of India. The project is a joint venture between the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI, Hyderabad) and Amrita Vishwa Vidyapeetham.
  • Duration: November 1, 2017 to August 31, 2018

Development, Field Trials, Pilot Production, and Technology Demonstration of Sintered Braked Pads with Improved Performance for Wind Turbine Applications Suitable to India Specific Wind Characteristics 

  • Funded by Department of Science and Technology, Government of India and Quantum Heat Treaters India Pvt. Ltd., Coimbatore.
  • Duration: November 1, 2018 to June 29, 2019

Relevant Research Work

Experimental Work

  • Friction stir processing of aluminum and magnesium alloys (AA2024, AA5083, AA5052, AZ31)
  • Surface composites fabrication by friction stir processing (AA5052, AA2024, AA7075)
  • Heat treatment of aluminum and magnesium alloys (AA5052, AZ31)
  • Laser welding (AZ91D @ ARCI, Hyderabad), friction stir welding (AA5052), friction welding 
  • Functionally gradient sintered brake pad material for wind turbines (Fe and Cu based)

Basic Computational Work using COMSOL Multiphysics

  • Numerical simulation of friction stir processing of aluminum and magnesium alloys 
  • Numerical modeling of corrosion phenomenon in magnesium alloy 

Professional Appointments

Year Affiliation
July 1, 2019  - Present Assistant Professor, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
Domain: Teaching and Research 
September 1, 2015 - October 31, 2017 Teaching Assistant, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
Domain: Assisted course instructors in lab and theory courses for evaluating assignments/tutorials, practical sessions, and evaluating answer sheets

Patents

Hybrid Black Toner 

  • Applicants & Inventors: R. Vaira Vignesh and G. Gnanakumar
  • Published in the Official Journal of the Patent Office, India, Issue: 26/2016, June 24, 2016
  • Status: Awaiting final approval

Virtual reality-based wireless rescue robot and a method to rescue child fallen into deep well

  • Applicants: S. Arivazhagan and G. Suganya Priyadharshini
  • Inventors: S. Arivazhagan, G. Suganya Priyadharshini, T. Velmurugan, R. Vaira Vignesh, M. Maheshkumar
  • Status: Submitted to The Patent Office, India by December 2019

Publications

Publication Type: Book Chapter

Year of Publication Title

2020

A. M. Siddharth, Dr. Padmanaban R., and Vaira Vignesh R., “Simulation of Friction Stir Welding of Aluminium Alloy AA5052 – Tailor Welded Blanks”, in Intelligent Systems Design and Applications, Advances in Intelligent Systems and Computing, vol. 940, A. Abraham, Cherukuri, A. Kumar, Melin, P., and Gandhi, N., Eds. Cham: Springer International Publishing, 2020, pp. 1-10.[Abstract]


Tailor welded blanks (TWBs) have been utilized by automotive industries to meet the light-weighting demands. Achieving defect free joints in the TWBs of aluminum alloys is a major challenge. Friction stir welding (FSW) has been successful in producing metallurgically sound joints in identical and diverse aluminum alloys. The present work aims at developing a Finite element method, which was used to explore the maximum temperature (Tp), contact status, plastic strain (PS) and energy input (EI) varied upon tool rotation speed (TRS), shoulder diameter (SD), tool traverse speed (TTS) and thickness ratio (TR). The study explored the influence of the FSW process parameters on the responses using a hybrid model integrating the linear function and radial basis function.

More »»

2019

A. Naidu, Dr. Padmanaban R., and Vaira Vignesh R., “Optimizing the Conveyor Belt Speed of a Bright Annealing Furnace”, in Lecture Notes in Mechanical Engineering (Accepted) , Springer, 2019.

2019

Vaira Vignesh R., Dr. Padmanaban R., and G. Priyadharshini, S., “Corrosion protection of Magnesium Alloys in Simulated Body Fluids using Nanophase Al2O3”, in Corrosion Protection at the Nanoscale, (Accepted), Micro and Nano Technologies, Elsevier, 2019.

2019

Vaira Vignesh R. and Dr. Padmanaban R., “Modelling Corrosion Phenomenon of Magnesium Alloy AZ91 in Simulated Body Fluids”, in Advances in Mathematical Methods and High Performance Computing, vol. 41, V. K. Singh, Gao, D., and Fischer, A., Eds. Cham: Springer International Publishing, 2019, pp. 471–486.[Abstract]


Magnesium alloy AZ91 is one of the best suited biodegradable biomaterials for bioimplants. Magnesium is a highly active metal with accelerated corrosion in physiological environments. AZ91 alloy has two distinct phases in the matrix, which form galvanic couple inducing micro galvanic corrosion (primary phase anodic with respect to the secondary phase) in the alloy. However, the corrosion rate could be controlled by tailoring the microstructure of the alloy. The distribution and dispersion of secondary phase particles greatly influence the corrosion rate of the material. A numerical model was developed using Comsol Multiphysics® to study the effect of distribution of secondary phase on the corrosion rate of the alloy. The average anodic current density was found to be higher for AZ91 with continuous network secondary phase microstructural configuration. The average anodic corrosion current and the corrosion rate were found to be lower for AZ91 with dispersed secondary phase microstructural configuration. The numerical modelling results were found to be consistent with the experimental results available in the literature.

More »»

2018

Dr. Ilangovan S., Vaira Vignesh R., Dr. Padmanaban R., and J. Gokulachandran, “Comparison of statistical and soft computing models for predicting hardness and wear rate of Cu-Ni-Sn alloy”, in Progress in Computing, Analytics and Networking, Advances in Intelligent Systems and Computing, vol. 710, , Ed. Springer Verlag, 2018, pp. 559-571.[Abstract]


Castings of Copper–Nickel–Tin alloy were produced by varying the composition of Ni and Sn. The cast specimens were subjected to homogenization and solution treatment. The specimens were characterized for microstructure, hardness and subjected to adhesive wear test. Statistical regression model, artificial neural network model and Sugeno fuzzy model were developed to predict the hardness and wear rate of the alloy based on %Ni, %Sn and ageing time of the specimens. As Sugeno Fuzzy logic model uses adaptive neuro-fuzzy inference system, an integration of neural networks and fuzzy logic principles, the prediction efficiency was higher than statistical regression and artificial neural network model. The interaction effect of %Ni, %Sn and ageing time on the hardness and wear rate of the specimens were analysed using the Sugeno Fuzzy model. © Springer Nature Singapore Pte Ltd. 2018.

More »»

Publication Type: Patent

Year of Publication Title

2019

S. Arivazhagan, G. Priyadharshini, S., Velmurugan, T., Vaira Vignesh R., and Maheshkumar, M., “Virtual reality based wireless rescue robot and a method to rescue child fallen into deep well”, 2019.

2016

Vaira Vignesh R. and Gnanakumar, G., “Hybrid Black Toner”, U.S. Patent 5071/CHE/20132016.

Publication Type: Conference Proceedings

Year of Publication Title

2019

N. Udayan, Srinivasan, M. V., Govindaraju, M., and Vaira Vignesh R., “Reducing the porosity defect in castings of cold box core process”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

R. K. Kannan, Govindaraju, M., and Vaira Vignesh R., “Development of Fly Ash based Friction Material for Wind Turbines by Liquid Phase Sintering Technology”, (Accepted) IISc, Bengaluru. 2019.

2019

G. Ghongade, Kalyan, K. Pavan, Vaira Vignesh R., and Govindaraju, M., “Design, Fabrication, and Analysis of Cost Effective Steel Honeycomb Structures”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

J. B. Ravi Teja, Kalyan, K. Pavan, Vaira Vignesh R., and Govindaraju, M., “Vacuum Brazing of Mild Steel Using Eutectic CuSil Brazing Alloy”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

M. Muralimanokar, Vaira Vignesh R., Govindaraju, M., and Dr. Padmanaban R., “Characterization of AZ31-NbC Surface Composite Fabricated by Friction stir Processing”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

G. M. Keshav, Hemchandran, C. G., Pradhin, K., Dharsan, B., Vaira Vignesh R., and Govindaraju, M., “Investigations on the Tribological Characteristics of Continuous Fiber Reinforced Sintered Brake Pad Material”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

P. Kesava Sai Srujan, Kaka, H. Krishna, Vaira Vignesh R., Kalyan, K. Pavan, Dr. Padmanaban R., and Govindaraju, M., “Cost-effective manufacturing of piping components with consistent quality through continuous furnace brazing”, AIP Conference Proceedings, vol. 2128. AIP Publishing, p. 030006, 2019.[Abstract]


India is witnessing an incessant expansion in the establishment of manufacturing plants for the production of engineering components by local and foreign players. Adoption of innovative and advanced manufacturing methods improve components’ quality, meet international standards, increase export potential, and achieve “Make in India”. In the pressure vessel and compressor domain, development of suitable brazing technologies for joining piping components will result in properties (joint strength, fatigue strength, wear resistance, corrosion resistance) superior to conventionally welded piping components. For high-volume production, the most common equipment used for brazing is a continuous-type atmosphere-controlled furnace. The cost reduction realized is significant, as this technology is based on the continuous production line. Other advantages include consistency in quality and possibility of automation. This will secure a position for Indian Engineering Component Manufacturers at par with North American, European and Japanese counterparts. In this work, pipe components that are conventionally joined by welding process and amenable for brazing, are identified in terms of design and material (mainly steel based). Steel pipe components are joined by furnace brazing (continuous type) using copper alloy based filler material. The optimum brazing process parameters are established based on the obtained joint strength, corrosion resistance, and leak tightness.

More »»

2019

A. Ashwin, Lakshman, R. B. Hari, Swaroop, C. B. Chand, Vignesh, M., Vaira Vignesh R., and Dr. Padmanaban R., “Predicting the Wear Rate of Aluminum Alloy AA2024-T351 using Hybrid Linear function and Radial Basis Function”, IOP Conference Series: Materials Science and Engineering, vol. 561. IOP Publishing, p. 012046, 2019.[Abstract]


AA2024 is one of the heat treatable Al-Cu alloys with good strength to weight ratio and fracture resistance. It finds application mainly in aircraft and structural applications. In T351 tempered condition, AA2024 has improved hardness and strength. However, the softness of the matrix leads to high wear rate. In this study, tribological characteristics of AA2024-T351 is determined using a pin-on-disc tribometer by varying the sliding velocity, sliding distance and axial load as per face centered central composite design. A hybrid linear – radial basis function model is developed to explore the effect of normal load, sliding distance and sliding velocity on the wear rate of AA2024-T351 alloy. The predominant wear regimes in AA2024-T351 alloy is understood from the characterization study on the surface morphology of the worn specimens.

More »»

2019

R. K Kannan, Vaira Vignesh R., Kalyan, K. Pavan, Murugesan, J., Megalingam, A., Dr. Padmanaban R., and Govindaraju, M., “Tribological performance of heavy-duty functionally gradient friction material (Cu-Sn-Fe-Cg-SiC-Al2O3) synthesized by PM route”, AIP Conference Proceedings, vol. 2128. AIP Publishing, p. 020004, 2019.[Abstract]


Copper-based sintered materials with ceramic reinforcements and solid lubricants are identified as potential brake pad materials for heavy-duty applications (wind turbine), because of their prime thermal and tribological properties. However, the presence of ceramic reinforcement reduces the joint strength between the brake pad and the substrate material. The reduction in joint strength may lead to catastrophic failure of the braking system in the wind turbines when brakes are applied suddenly. This study attempts to synthesize functionally gradient material (FGM), which has a gradient composition of the ceramic particles along the traverse section. FGM was synthesized layer by layer deposition of Cu, Fe, Sn, Cg, SiC, Al2O3 powders with gradient composition. Microstructure, phases, and microhardness of the specimen were analyzed. Tribological studies were performed to assess the wear rate and friction coefficient of the FGM at various loads. The surface morphology of the worn surface was characterized using field emission scanning electron microscope. The study investigated the wear mechanism of the FGM at various loads.

More »»

2019

A. Joe Alex, Vaira Vignesh R., Dr. Padmanaban R., and Govindaraju, M., “Effect of heat treatment on the mechanical and wear behavior of friction stir processed AA5052 alloy”, Materials Today: Proceedings (Accepted). Elsevier, 2019.

2019

P. Kumar Chellu, Dr. Padmanaban R., Vaira Vignesh R., Menon, A. S., Shariff, S. M., and Padmanabham, G., “Experimental Study on Laser Welding of AISI 304 Steel with Design of Experiments Approach”, IOP Conference Series: Materials Science and Engineering, vol. 577. IOP Publishing, p. 012117, 2019.[Abstract]


Austenitic stainless steels find extensive applications in engineering and structural parts requiring inherent corrosion resistance. The main objective of this study is to achieve good quality butt joint in 2.5-mm thick 304 grade Stainless Steel. The joint quality is quantified in terms of weld-bead dimensions. The main issue that manufacturers face is controlling the input process parameters, to get a good quality joint, with required weld bead geometry under controlled thermal distortion. The objective of this work is to select proper input process parameters that would result in desirable weld-bead profiles with minimal heat input. The critical process parameters influencing laser-welding were found using response surface methodology technique. The results proved that the developed model could efficiently predict the responses. The criteria demonstrated a possible reduction in top width of weld bead with enhanced depth of penetration, which automatically envisaged an increase in aspect ratio. A two-factor five-level criteria design was used for predicting the optimized parameters by performing multi-response optimization. Among them, the third criterion has shown a significant decrease in heat input and it was chosen as the best-optimized parameter.

More »»

2019

K. B. Arjun, Harikeshava, R., Sreenath, C. R., Srihari, G., Vaira Vignesh R., Vaira Vignesh R., and Dr. Padmanaban R., “Effect of load, sliding distance and sliding velocity on the wear properties of aluminum alloy AA5052”, IOP Conference Series: Materials Science and Engineering, vol. 577. IOP Publishing, p. 012016, 2019.[Abstract]


Aluminum alloys are widely used in engineering applications. In motion established contact applications, wear is an inevitable phenomenon. In this study, the wear mechanism of AA5052was explored using pin-on-disc tribometer. The wear test parameters namely load (kg), sliding distance (m), and velocity (m/s) were varied according to central composite design. The wear tracks of the worn specimens were observed using high-resolution scanning electron microscope and the elemental composition was analysed using energy dispersive X-ray spectroscopy. A hybrid model integrating the linear function and radial basis function was developed to explore the effect of load, sliding distance, and sliding velocity on the wear rate of the AA5052 alloy. The results indicate that increase in axial load and sliding distance decreases the wear rate of the AA5052 alloy.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Influence of friction stir processing parameters on the wear resistance of aluminium alloy AA5083”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 7437-7446, 2018.[Abstract]


In this study, friction stir processing was applied on AA5083, with an objective to improve its wear resistance. FSP was conducted by varying tool rotation speed, tool traverse speed and tool shoulder diameter as per face centered central composite design. Adhesive wear test was performed using a pin-on-disc tribometer. The test results indicate that the wear resistance of most of the friction stir processed specimens was higher than the base material. A mathematical model was generated for predicting the wear resistance using linear-radial basis function and it was used to explore the influence of process parameters on the wear resistance. © 2017 Elsevier Ltd.

More »»

2018

Dr. Padmanaban R., Vaira Vignesh R., Povendhan, A. P., and Balakumharen, A. P., “Optimizing the tensile strength of friction stir welded dissimilar aluminium alloy joints using particle swarm optimization”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 24820-24826, 2018.[Abstract]


Aluminium alloys AA2024 and AA7075 plates were friction stir welded by varying the tool rotation speed and welding speed and corresponding tensile strength of the joints were measured. A mathematical model was developed using response surface methodology to predict the tensile strength of the joints. The FSW process parameters were optimized for maximizing the tensile strength using particle swarm optimization algorithm. The optimum FSW process parameters for dissimilar welding of AA2024 and AA7075 plates were deduced as welding speed of 15 mm/min and tool rotation speed of 1087 rpm. © 2018 Elsevier Ltd.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Intergranular corrosion susceptibility of friction stir processed aluminium alloy 5083”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 16443-16452, 2018.[Abstract]


The amalgamation of high strength and low density of aluminium alloys makes it suitable for light weight structural applications. Aluminium alloy AA5083 is prone to intergranular corrosion, when exposed to aggressive chloride containing marine environments. When aluminium alloy 5083 is exposed to marine environments, the continuous network of secondary phase particles present in the matrix reacts with the chloride ions and dissolves into the solution, creating new cites for corrosion. In addition to this phenomenon, secondary phase particles form galvanic couple with primary phase of the matrix, accelerating the corrosion. With an objective to improve the intergranular corrosion resistance, AA5083 was subjected to friction stir processing (FSP). FSP trials were conducted by varying the tool rotation speed, tool traverse speed and tool shoulder diameter, as per face centered central composite design. The intergranular corrosion susceptibility of friction stir processed AA5083 was studied by nitric acid mass loss test according to the ASTM G67-04 standard. Mathematical model was generated using linear - radial basis function and the model was used to study the effect of process parameters on the intergranular corrosion susceptibility of friction stir processed AA5083. The results indicate that FSP results in refinement of grain structure, dispersion and partial dissolution of secondary phase particles in the matrix, thereby reducing the intergranular corrosion susceptibility of AA5083. © 2017 Elsevier Ltd.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Artificial neural network model for predicting the tensile strength of friction stir welded aluminium alloy AA1100”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 16716-16723, 2018.[Abstract]


Friction stir welding (FSW) is a solid state welding technique, in which high strength weldswith minimal defects, can be obtained even with materialsthat are hardly weldable by conventional techniques. FSW is influenced by a number of process parameters. Some of the highly influential process parameters that determine the quality of the welds in FSW are tool rotation speed, welding speed, shoulder diameter and pin diameter of tool. In this study, FSW trials were conducted on AA1100 as per central composite design, with four parameters varied at five levels. The tensile strength of the joints were measured using a computerized tensile testing machine and these results were used to develop an artificial neural network model. The input parameters to the model were tool rotation speed, welding speed, shoulder diameter and pin diameter and the output was tensile strength of the joints. Levenberg Marquardt algorithm was used to establish the relationship between the process parameters and the output. The feed forward model was trained using 80% of the experimental data and the remaining 20% of the data was used for validation and testing of the model. The R2 valuesfor validation data and testing datawere found to be 0.80and0.99respectively, displaying the closeness between the experimental and predicted data. The results indicate that the generated model has high efficacy in predicting the tensile strength of friction stir welded aluminium alloy AA1100 joints. © 2017 Elsevier Ltd.

More »»

2018

C. B. Kiruthi Murugan, Balusamy, V., Dr. Padmanaban R., and Vaira Vignesh R., “Friction surfacing mild-steel with Monel and predicting the coating parameters using fuzzy logic”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 16402-16410, 2018.[Abstract]


Engineering components made of AISI 1012 are susceptible to stress corrosion cracking in marine environments, where more free chloride ions are present. The cladding of Monel over the surface of the AISI 1012 components improves the corrosion resistance. Friction surfacing is an emerging solid-state technique for coating consumables (mostly metallic materials) in the form of the rod over the solid substrate. In this study, FS trials were conducted as per central composite design with five levels of variation for each FS process parameters. Width and thickness of the coating were measured for all the friction surfaced specimens. Soft computing model relating the FS process parameters to the coating thickness and width was generated using the fuzzy logic technique. It is observed that the spindle speed and surfacing speed have an inverse relationship with coating parameters. Increasing the axial load increased the coating thickness and width. © 2017 Elsevier Ltd.

More »»

2018

B. K. Murugan, Balusamy, V., Dr. Padmanaban R., and Vaira Vignesh R., “Study of the effect of parameters in friction surfacing of Monel over Mild Steel using linear - Radial basis function model”, Materials Today: Proceedings, vol. 5. Elsevier Ltd, pp. 8604-8611, 2018.[Abstract]


This paper investigates suitability of friction surfacing (FS) for cladding AISI 1012 with Monel K500. FS trials were conducted by varying the spindle speed, axial pressure and the horizontal feed rate. The thickness and width of the coating were measured and the data were used to develop radial basis function network model relating the FS process parameters with the coating thickness and width. The model was used to analyze the variation of coating thickness and width. The coating thickness and width decreased with increase in spindle speed and horizontal feed rate, while they increased with increase in axial load. © 2017 Elsevier Ltd.

More »»

2018

C. Jayakarthick, Povendhan, A. P., Vaira Vignesh R., and Dr. Padmanaban R., “Analysing the influence of FSP process parameters on IGC susceptibility of AA5083 using Sugeno - Fuzzy model”, IOP Conference Series: Materials Science and Engineering, vol. 310. Institute of Physics Publishing, p. 012043, 2018.[Abstract]


Aluminium alloy AA5083 was friction stir processed to improve the intergranular corrosion (IGC) resistance. FSP trials were performed by varying the process parameters as per Taguchi's L18 orthogonal array. IGC resistance of the friction stir processed specimens were found by immersing them in concentrated nitric acid and measuring the mass loss per unit area. Results indicate that dispersion and partial dissolution of secondary phase increased IGC resistance of the friction stir processed specimens. A Sugeno fuzzy model was developed to study the effect of FSP process parameters on the IGC susceptibility of friction stir processed specimens. Tool Rotation Speed, Tool Traverse Speed and Shoulder Diameter have a significant effect on the IGC susceptibility of the friction stir processed specimens. © Published under licence by IOP Publishing Ltd.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Modelling of peak temperature during friction stir processing of magnesium alloy AZ91”, IOP Conference Series: Materials Science and Engineering , vol. 310. Institute of Physics Publishing, p. 012019, 2018.[Abstract]


Friction stir processing (FSP) is a solid state processing technique with potential to modify the properties of the material through microstructural modification. The study of heat transfer in FSP aids in the identification of defects like flash, inadequate heat input, poor material flow and mixing etc. In this paper, transient temperature distribution during FSP of magnesium alloy AZ91 was simulated using finite element modelling. The numerical model results were validated using the experimental results from the published literature. The model was used to predict the peak temperature obtained during FSP for various process parameter combinations. The simulated peak temperature results were used to develop a statistical model. The effect of process parameters namely tool rotation speed, tool traverse speed and shoulder diameter of the tool on the peak temperature was investigated using the developed statistical model. It was found that peak temperature was directly proportional to tool rotation speed and shoulder diameter and inversely proportional to tool traverse speed. © Published under licence by IOP Publishing Ltd.

More »»

2018

V. R. Barath, Vaira Vignesh R., and Dr. Padmanaban R., “Analysing the strength of friction stir welded dissimilar aluminium alloys using Sugeno Fuzzy model”, IOP Conference Series: Materials Science and Engineering, vol. 310. Institute of Physics Publishing, p. 012043, 2018.[Abstract]


Friction stir welding (FSW) is a promising solid state joining technique for aluminium alloys. In this study, FSW trials were conducted on two dissimilar plates of aluminium alloy AA2024 and AA7075 by varying the tool rotation speed (TRS) and welding speed (WS). Tensile strength (TS) of the joints were measured and a Sugeno - Fuzzy model was developed to interconnect the FSW process parameters with the tensile strength. From the developed model, it was observed that the optimum heat generation at WS of 15 mm.min-1 and TRS of 1050 rpm resulted in dynamic recovery and dynamic recrystallization of the material. This refined the grains in the FSW zone and resulted in peak tensile strength among the tested specimens. Crest parabolic trend was observed in tensile strength with variation of TRS from 900 rpm to 1200 rpm and TTS from 10 mm.min-1 to 20 mm.min-1. © Published under licence by IOP Publishing Ltd.

More »»

2016

Vaira Vignesh R., Dr. Padmanaban R., Arivarasu, M., Karthick, K. P., Sundar, A. A., and Dr. Gokulachandran J., “Analysing the strength of friction stir spot welded joints of aluminium alloy by fuzzy logic”, IOP Conference Series: Materials Science and Engineering, vol. 149. Institute of Physics Publishing, p. 012136, 2016.[Abstract]


Friction stir spot welding (FSSW) is a recent joining technique developed for spot welding of thin metal sheets. This process currently finds application in automotive, aerospace, marine and sheet metal industry. In this work, the effect of FSSW process parameters namely tool rotation speed, shoulder diameter and dwell time on Tensile shear failure load (TSFL) is investigated. Box-Behnken design is selected for conducting experiments. Fuzzy based soft computing is used to develop a model for TSFL of AA6061 joints fabricated by FSSW. The interaction of the process parameters on TSFL is also presented. © Published under licence by IOP Publishing Ltd.

More »»

2016

Vaira Vignesh R., Dr. Padmanaban R., Arivarasu, M., Dr. Thirumalini S., Dr. Gokulachandran J., and Ram, M. Sesha Saty, “Numerical modelling of thermal phenomenon in friction stir welding of aluminum plates”, IOP Conference Series: Materials Science and Engineering, vol. 149. p. 012208, 2016.[Abstract]


Friction stir welding (FSW) is a solid state welding process with potential to join materials that are non weldable by conventional fusion welding techniques. The study of heat transfer in FSW aids in the identification of defects like flash, inadequate heat input, poor material flow and mixing etc. In this paper, transient temperature distribution during FSW of aluminum alloy AA6061-T6 was simulated using finite element modelling. The model was used to predict the peak temperature and analyse the thermal history during FSW. The effect of process parameters namely tool rotation speed, tool traverse speed (welding speed), shoulder diameter and pin diameter of tool on the temperature distribution was investigated using two level factorial design. The model results were validated using the experimental results from the published literature. It was found that peak temperature was directly proportional to tool rotation speed and shoulder diameter and inversely proportional to tool traverse speed. The effect of pin diameter on peak temperature was found to be trivial.

More »»

2015

Vaira Vignesh R. and Dr. Padmanaban R., “Corrosion of Aluminium and Magnesium Alloys: A Review”, International Conference on Modelling, Simulation and Control, vol. 1. pp. 377-383, 2015.[Abstract]


The materials that has been proven as a light weight, durable and affordable is Aluminium and Magnesium. The amalgamation of high strength and low density property suits the wide range of engineering applications such as naval ships to go faster speeds and cargo ships carrying bigger payloads. Emerging technologies and advancements make Aluminium alloys as the best choice for military ships and automotives and Magnesium alloys as the best choice for automotive applications. These applications subject to an array of different types of varying loads in the marine and / or corrosive environment. Their environmental exposure and loading creates corrosion features such as pitting that produces crack initiation morphologies. Nucleation of these cracks followed by their growth under the influence of mechanical stress and corrosion leads to structural failure. This review paper deals with the corrosion and corrosion mechanisms of Aluminium and Magnesium alloys exposed to marine and corrosive environment, corrosion of welded structures and measures for enhancing the corrosion resistance. The development of new cast or wrought alloys, metal matrix composites and chemical agents (corrosion inhibitors) for enhancing the corrosion resistance are also discussed.

More »»

2015

Vaira Vignesh R., Dr. Padmanaban R., and Thirumalini, S., “Reducing the environmental hazards by devising reduce recycle reuse system with hybrid black toner”, International Conference on Advances in Chemical Engineering, vol. 1. p. 4, 2015.[Abstract]


Photocopiers make use of Toner (powder) to form the latent electrical image on the electrostatically charged drum. The paper has to slide over the drum during Xerography process and hence it picks up the toner. Vague issues cause the non-picking of toner particles (approximately 10%) and they are left over the drum. This non-picked toner is termed as Waste Toner (WT). As it adversely affects the quality of proceeding copies, this has to be removed from the drum. A cleaning blade made of synthetic material removes WT formed over the surface of the drum and it gets deposited in the cleaner sump. This WT cannot be further reused as the quality of the copier and copy will also be reduced. Non biodegradable metal-plastic materials are used in the synthesis of toner. So dumping WT in open or in landfills leads to environmental hazards. The WT is mixed in proportion with Nano phase Carbon and original toner to get Hybrid Black Toner which can be used in photo copiers as an alternative toner. This research work deals with characterising the WT with respect to Original toner and Carbon Black Nano Powder to get an optimised copier quality with the usage of WT. This practice reduces the risk of environmental hazards of the WT if it is dumped in the landfills.

More »»

2015

Vaira Vignesh R., “Optimization of Hybrid Black Toner Synthesis from Waste Toner”, National Conference on Safety Environment and Industrial Applied Science and Technology, Book of Abstracts – SEIAST 2015, Part: Materials. p. 42, 2015.

2015

Vaira Vignesh R., Krishnaraj, C., Sridharan, A., and Pradeep, M., “Effect of Carbon Nano Tube Reinforcement on Physical, Chemical and Mechanical Properties of AISI 1330”, National Conference on Safety Environment and Industrial Applied Science and Technology, Book of Abstracts – SEIAST 2015, Part: Nano Technology. p. 34, 2015.

2015

Vaira Vignesh R., Krishnaraj, C., Sridharan, A., and Pradeep, M., “Effect of Carbon Nano Tube Reinforcement on Physical, Chemical and Mechanical Properties of Alloy Steel AISI 1330”, International Conference on Advances in Materials, Manufacturing, and Applications, vol. 1. pp. 1017-1024, 2015.[Abstract]


Nano composite metal is produced by introducing the nano phase material in the metal matrix of metal or an alloy. The unique property of the nano phase materials is their high surface area. The high surface area and surface dominant characteristics tend to be more reactive with the metal matrix. The method of mixing the nano reinforcements in the metal in liquid state followed by solidification process is convenient method of production of metal matrix nano composite. The Carbon Nano Tube reinforcement and Nano phase Carbon introduction to the molten metal matrix of AISI 1330 steel may result in enhanced physical, chemical and mechanical properties. The paper deals with a comparative analysis in the properties of MMNC – AISI 1330.

More »»

2015

Vaira Vignesh R., “Single Variable Algorithm Optimized Hybrid Black Toner Synthesis from Waste Toner and Nano Phase Carbon”, International Conference on Intelligent Systems & Control, vol. 3. pp. 847- 851, 2015.

2014

Vaira Vignesh R. and Gnanakumar, G., “Synthesis of Hybrid Black Toner from Waste Toner using Nano Technology – Optimization Technique”, International Conference on Intelligent Systems & Control, vol. 1. pp. 1-9, 2014.

2012

Vaira Vignesh R., “Impurity Analysis in Molten Copper Using Tungsten Nano Sensor”, National level Technical Symposium – MAGMA’12. 2012.

Publication Type: Journal Article

Year of Publication Title

2019

A. Aravind, Vaira Vignesh R., Dr. Padmanaban R., and Govindaraju, M., “Study on the Mechanical and Corrosion behavior of AA 5052 Tailor Welded Blanks Fabricated using Friction Stir Welding”, Journal of Materials and Environmental Sciences, vol. 10, no. 7, pp. 624-636, 2019.[Abstract]


Friction stir welding is a unique and promising technique to produce joints with desirable mechanical strength and properties. Tailor welded blanks are processed by joining two plates of dissimilar thickness with relatively less mass. As tailor welded blanks offer higher strength at a minimal weight, the material consumption decreases making it more economically viable. In this study, the influence of the critical friction stir welding process parameters namely tool traverse speed, tool rotation speed and thickness mismatch ratio on the microhardness, corrosion rate, tensile strength (before and after corrosion) of AA5052 tailor welded blanks are investigated. The friction stir welding trials were conducted based on Box Behnken design at three levels of process parameters. Hybrid-Radial Basis Function based models were developed to explore the effect of process parameters on the properties. The optimum process parameters to obtain high tensile strength in AA5052 tailor welded blanks was found to be tool traverse speed of 60mm/min, the tool rotation speed of 850rpm and thickness mismatch ratio of 0.9.

More »»

2019

Vaira Vignesh R., Dr. Padmanaban R., Govindaraju, M., and G. Priyadharshini, S., “Investigations on the corrosion behaviour and biocompatibility of magnesium alloy surface composites AZ91D-ZrO2 fabricated by friction stir processing”, Transactions of the Institute of Metal Finishing (The International Journal of Surface Engineering and Coatings), vol. 97, no. 5, pp. 261-270, 2019.[Abstract]


In the current study, friction stir processing was applied as a methodology to produce surface composites of AZ91D magnesium alloy with ZrO2 particles. Microstructural evolution, microhardness profile and corrosion behaviour of the developed surface composite were analysed. The results indicate that the combined effect of friction stir processing and reinforcement of ZrO2 reduced the grain size, and fragmented and dispersed the secondary phases. The fine dispersion of ZrO2 particles contributed to the enhancement of cumulative surface potential, and hence the corrosion resistance of the developed surface composite. The analysis of post-corrosion test specimens revealed the formation of corrosion products that had similar composition to that of hydroxyapatite. The formation of such corrosion products is beneficial, as it contributes to corrosion resistance (stable and adherent layer) and biocompatibility. © 2019, © 2019 Institute of Materials Finishing Published by Taylor & Francis on behalf of the Institute.

More »»

2019

Vaira Vignesh R., Dr. Padmanaban R., and Govindaraju, M., “Study on the Corrosion and Wear Characteristics of Magnesium Alloy AZ91D in Simulated Body Fluids”, Bulletin of Materials Science (Article in Press) , 2019.

2019

Dr. Padmanaban R., Balusamy, V., and Vaira Vignesh R., “Effect of FSW process parameters on the tensile strength of dissimilar aluminum alloy AA2024-T3 and AA7075-T6 joints”, Materialwissenschaft und Werkstofftechnik (Article in Press) , 2019.

2019

Dr. Ilangovan S., Vaira Vignesh R., Dr. Padmanaban R., and Dr. Gokulachandran J., “Effect of composition and aging time on hardness and wear behavior of Cu-Ni-Sn spinodal alloy”, Journal of Central South University, vol. 26, no. 10, pp. 2634-2642, 2019.[Abstract]


Copper alloyed with various compositions of nickel and tin were cast into molds under argon atmosphere. The cast rods were homogenized, solution heat treated, followed by aging for different time duration. The specimens were characterized for microstructure and tested for microhardness and wear rate. A hybrid model with a linear function and radial basis function was developed to analyze the influence of nickel, tin, and aging time on the microhardness and tribological behavior of copper-nickel-sin alloy system. The results indicate that increase in the composition of nickel and tin increases the microhardness and decreases the wear rate of the alloy. The increase in the concentration of nickel and tin decreases the peak aging time of the alloy system. © 2019, Central South University Press and Springer-Verlag GmbH Germany, part of Springer Nature.

More »»

2019

Dr. Govindaraj M., Vaira Vignesh R., and Padmanaban, R., “Effect of Heat Treatment on the Microstructure and Mechanical Properties of the Friction Stir Processed AZ91D Magnesium Alloy”, Metal Science and Heat Treatment, vol. 61, no. 5-6, pp. 311-317, 2019.[Abstract]


We study the microstructure and mechanical properties of friction stir processed AZ91D cast magnesium alloy under various conditions of heat treatment. It is shown that, in the initial as-cast state, the structure of the alloy contained a continuously networked β-phase with an average grain size of 150 μm. The friction stir processed (FSP) specimens had an average grain size of 12 μm and smooth grain boundaries. The subsequent heat treatment of the FSP specimens at various temperatures between 150°C and 250°C led to the appearance of numerous particles of the β-phase. The FSP specimens heat-treated at 200°C had finer grains, a larger number of fine particles of the β-phase, and better mechanical properties than any other specimens. © 2019, Springer Science+Business Media, LLC, part of Springer Nature.

More »»

2019

Vaira Vignesh R., Dr. Padmanaban R., Govindaraju, M., and G. Priyadharshini, S., “Mechanical properties and corrosion behaviour of AZ91D-HAP surface composites fabricated by friction stir processing”, Materials Research Express, vol. 6, no. 8, 2019.[Abstract]


The biomedical applications of magnesium alloy AZ91D are limited because of the dendritic β-Mg17Al12 phase, which degrades the mechanical properties and corrosion resistance. To overcome this, friction stir processing is implemented to fabricate surface composite of AZ91D with hydroxyapatite as reinforcement. This results in refinement of grains and fragmentation of the β phase with homogeneous dispersion of hydroxyapatite in the composite. The combined effect of reinforcement of hydroxyapatite and fragmentation of the β phase resulted in simultaneous improvement in mechanical and corrosion properties. The various phases, surface morphology, and composition of the developed composite are analyzed using a transmission electron microscope and a scanning electron microscope before and after corrosion studies. The mechanism behind the improvement in the property of the developed composite is correlated with the characterization results. © 2019 IOP Publishing Ltd.

More »»

2019

Vaira Vignesh R., Dr. Padmanaban R., and Govindaraju, M., “Investigations on the surface topography, corrosion behavior, and biocompatibility of friction stir processed magnesium alloy AZ91D”, Surface Topography: Metrology and Properties, vol. 7, no. 2, 2019.[Abstract]


Magnesium and its alloys have been identified as potential biodegradable implant materials for orthopaedic applications considering their bone equivalent density, biocompatibility, and biodegradability. However, the rapid corrosion rate of magnesium alloys in the physiological environment is a severe problem. This study attempts to simultaneously improve the microhardness and reduce the corrosion rate of AZ91D alloy by friction stir processing. Magnesium alloy AZ91D is friction stir processed by varying the process parameters namely tool rotation speed and tool traverse speed. The effects of friction stir processing parameters on the microstructural evolution, surface topography, microhardness, and corrosion rate of AZ91D alloy are investigated using the hybrid models, which are developed by integrating the quadratic function and radial basis function. The results indicate that the optimum process parameters for friction stir processing of AZ91D alloy is 750 rpm and 45 mm min-1. Cytotoxicity test revealed that the biocompatibility of friction stir processed AZ91D alloy is in good agreement with the biocompatibility of the AZ91D alloy. © 2019 IOP Publishing Ltd.

More »»

2019

Vaira Vignesh R., Ramasamy, P., Kovukkal, M. D., and Myilsamy, G., “Research and Development in Magnesium Alloys for Industrial and Biomedical Applications: A Review”, Metals and Materials International, 2019.[Abstract]


Abstract: The work reviews the research and development status of magnesium alloy, with more attention to the methodologies and technologies adopted to improve the properties of AZ91 alloy. The drive force of utilizing magnesium alloys for automotive and biomedical application is light weightiness and biocompatibility respectively. However, the softness and high activity of magnesium alloys result in high wear and high corrosion rate respectively. One of the essential factors influencing the properties of magnesium alloy is its microstructure. Consequently, the grain size, morphology and distribution of phase constituents influence the properties of magnesium alloys. The modification of microstructure through processing route (hot working and cold working), heat treatment, and alloying elements improves the mechanical, corrosion, biocompatible, and tribological properties of magnesium alloys. Besides microstructural modification processes, addition of reinforcements, and coatings improves the properties of magnesium alloys. This article emphasis on the recent research on the technologies to improve the microstructure, hardness, tensile strength, ductility, yield strength, wear resistance, and corrosion resistance of magnesium alloy AZ91. Moreover, this review addresses the key issues hindering the applications of magnesium alloys for structural and biomedical applications. Graphic Abstract: [Figure not available: see fulltext.]. © 2019, The Korean Institute of Metals and Materials.

More »»

2019

Vaira Vignesh R., Ramasamy, P., and Datta, M., “Microstructure, hardness and corrosion behaviour of friction-stir processed AA5083”, Anti-Corrosion Methods and Materials, vol. 66, no. 6, pp. 791-801, 2019.[Abstract]


Purpose: The purpose of this study is to refine the microstructure and improve the corrosion behaviour of aluminium alloy AA5083 by subjecting it to friction stir processing (FSP). Design/methodology/approach: FSP trials are conducted as per central composite design, by varying tool rotation speed, tool traverse speed and shoulder diameter at three levels. The microstructure is examined and the hardness is measured for both the base material and the processed workpieces. The corrosion behaviour of the base material and processed workpieces is studied using potentiodynamic polarization technique for three different testing temperatures, and the corrosion current and corrosion rate are calculated. Findings: The results reveal that FSP refined the grains, dispersed secondary phases, increased the hardness and improved the corrosion resistance of most of the friction stir processed specimens than the base material at all the three testing temperatures. Grain refinement and fine dispersion of ß phase improves the hardness and corrosion resistance of most of the FSPed specimens. However partial dissolution of ß phase decreases the hardness in some of the specimens. Most of the FSPed specimens displayed more positive potential than the base material at all the testing temperatures representing a higher nobility than the base material, as a result of fine dispersion of secondary phase particles in the matrix. Large pits formed on the surface of the base specimen indicating a higher corrosion rate at all three testing temperatures. The SEM image of FSPed specimens reveals the occurrence of very few pits and minimal corrosion products on the surface, which indicates lower corrosion rate. Originality/value: The corrosion mechanism of the friction stir-processed AA5083 specimens is found to be a combination of activation and concentration polarization. © 2019, Emerald Publishing Limited.

More »»

2019

Vaira Vignesh R., Dr. Padmanaban R., and Govindaraju, M., “Synthesis and Characterization of Magnesium Alloy Surface Composite (AZ91D - SiO2) by Friction Stir Processing for Bioimplants”, Silicon, 2019.[Abstract]


Magnesium shows potential for bioimplant applications because of its high biocompatibility and equivalent bone strength. However, the high corrosion rate of magnesium and magnesium alloys in the physiological environment results in the rapid evolution of H2 gas, which is lethal to the neighboring tissues. With an intention to reduce the corrosion rate, magnesium alloy AZ91D is reinforced with nanophase SiO2 to fabricate surface composite by friction stir processing. The metallurgical characterization reveals the refinement of grains, fine dispersion of β phase and nanophase SiO2 in the composite matrix. The surface characterization of the corrosion products depicts the formation of an adherent layer of corrosion products that are rich in calcium hydroxyapatite and calcium-magnesium phosphate. The combined consequence of metallurgical and corrosion phenomenon reduces the corrosion rate, aids bone growth, and augments implant-bone integration. The results demonstrate that AZ91D-SiO2 composite is an effective material for bioimplant applications. [Figure not available: see fulltext.]. © 2019, Springer Nature B.V.

More »»

2019

A. R. Kumar, K. Sai, P., Vaira Vignesh R., and Dr. Radhika N, “Investigations on the Tribological Properties of Heat-Treated Copper Composite Using Hybrid Quadratic–Radial Basis Function Model”, Transactions of the Indian Institute of Metals, vol. 72, no. 12, pp. 3117-3128, 2019.[Abstract]


This research investigates the effect of heat treatment on mechanical and tribological properties of Cu–11Ni–4Si—10 wt% B4C functionally gradient composite, which is fabricated by the centrifugal casting method. The cast specimens are solutionized at 700 °C for 90 min, followed by air quenching/water quenching. The specimens are artificially aged at different temperatures (500 °C, 550 °C, and 600 °C) and time (1 h, 2 h, and 3 h). The optimum heat treatment condition is established based on the microstructure, microhardness, and tensile strength. The specimens that are heat-treated at optimum condition are subjected to tribological tests by varying the load between 15.8 and 44.44 N and sliding velocity between 0.8 to 2.2 m/s for a sliding distance of 1000 m and 1500 m. The surface morphology and topography of the worn surface are analyzed using FESEM and AFM, respectively. The influence of load and sliding velocity on the wear rate of the specimens is explored using the mathematical models, which are developed using a hybrid polynomial–radial basis function. The results indicate that the load has a direct influence on the wear rate, while the wear rate follows crest parabolic pattern with an increase in the sliding velocity. © 2019, The Indian Institute of Metals - IIM.

More »»

2018

M. N. Abijith, Nair, A. R., Aadharsh, M., Vaira Vignesh R., Dr. Padmanaban R., and Arivarasu, M., “Investigations on the mechanical, wear and corrosion properties of cold metal transfer welded and friction stir welded aluminium alloy AA2219”, Jordan Journal of Mechanical and Industrial Engineering, vol. 12, no. 4, pp. 281-292, 2018.[Abstract]


Aluminium - Copper alloy AA2219 finds application in aerospace and automotive components because of its high strength to weight ratio and corrosion resistance. However, joining of the alloy by conventional welding techniques results in poor property profile. In this study, AA2219 rolled plates of thickness 5.5 mm are joined by cold metal transfer welding process and friction stir welding process. The microstructure, mechanical, corrosion and wear properties of the welded plates are analyzed. The results indicate that cold metal transfer welded specimens have high hardness and tensile strength than the friction stir welded specimens. However, the corrosion resistance and wear resistance of friction stir welded specimens are higher than the base material and cold metal transfer welded specimens. © 2018 Jordan Journal of Mechanical and Industrial Engineering.

More »»

2018

Vaira Vignesh R., Dr. Padmanaban R., and Chinnaraj, K., “Soft computing model for analysing the effect of friction stir processing parameters on the intergranular corrosion susceptibility of aluminium alloy AA5083”, Koroze a Ochrana Materialu, vol. 62, no. 3, pp. 97-107, 2018.[Abstract]


Aluminium alloy AA5083 is prone to intergranular corrosion in marine environments. In an attempt to reduce the intergranular corrosion, AA5083 was subjected to friction stir processing (FSP). The FSP experimental trials were conducted as per face-centered central composite design with three levels of variation in FSP process parameters viz. tool rotation speed (TRS), tool traverse speed (TTS) and tool shoulder diameter (SD). Intergranular corrosion susceptibility of the processed specimens was assessed by performing nitric acid mass loss test. The mass loss of the specimens was correlated with the intergranular corrosion susceptibility as per the standard ASTM G67-13. The experimental results indicate that FSP had significantly reduced the intergranular corrosion susceptibility of the AA5083 alloy. Soft computing techniques namely Artificial Neural Network, Mamdani Fuzzy system, and Sugeno Fuzzy system were used to predict the intergranular corrosion (IGC) susceptibility (mass loss) of the friction stir processed specimens. Among the developed models, Sugeno fuzzy system displayed minimum percentage error in prediction. So Sugeno fuzzy system was used to analyze the effect of friction stir processing process parameters on the IGC of the processed specimens. The results suggest that stir processing of AA5083 at a TRS of 1300 rpm, TTS of 60 mm/min and SD of 21 mm would make the alloy least susceptible to intergranular corrosion. © 2018 Vaira Vignesh R. et al., published by Sciendo 2018.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Comparison of ANN training algorithms for predicting the tensile strength of friction stir welded aluminium alloy AA1100”, International Journal of Vehicle Structures and Systems, vol. 10, no. 2, pp. 98-102, 2018.[Abstract]


Aluminium alloy AA1100 finds application in light weight structures due to its high strength to weight ratio. Friction stir welding is a solid state welding process, in which the materials are joined in the plasticized state. The quality of the friction stir welded joints depends on the process parameters used and tool parameters. In this study, four process parameters were varied at five levels and experimental trials were performed as per face centered central composite design. Artificial neural network model was developed with cascade forward propagation network architecture and trained with LM algorithm and BFGS QN algorithm. The models were used to predict the tensile strength of the joints and the error in prediction was used to judge the accuracy of the developed models. It is observed that BFGS QN algorithm trains the ANN efficiently and results in accurate predictions. © 2018.

More »»

2018

Vaira Vignesh R. and Dr. Padmanaban R., “Forecasting Tribological Properties of Wrought AZ91D Magnesium Alloy Using Soft Computing Model”, Russian Journal of Non-Ferrous Metals, vol. 59, no. 2, pp. 135-141, 2018.[Abstract]


The wear characteristics of wrought magnesium alloy AZ91D is assessed by varying the wear test parameters namely sliding velocity, sliding distance and normal load in the pin-on-disc tribometer. The experimental results are used to develop a statistical model, and soft computing models based on artificial neural network and Sugeno–Fuzzy logic to predict the wear rate of AZ91D alloy. Sugeno–Fuzzy model had the highest accuracy in prediction and hence used to study the effect of wear test parameters on the wear rate of AZ91D alloy. It is observed that the wear rate increases with decrease in load, increase in sliding velocity, and increase in sliding distance. © 2018, Allerton Press, Inc.

More »»

2018

Vaira Vignesh R., Dr. Padmanaban R., and Datta, M., “Influence of FSP on the microstructure, microhardness, intergranular corrosion susceptibility and wear resistance of AA5083 alloy”, Tribology - Materials, Surfaces and Interfaces, vol. 12, no. 3, pp. 157-169, 2018.[Abstract]


This article investigates the role of friction stir processing (FSP) process parameters on the evolution of microstructure, hardness, intergranular corrosion resistance and wear resistance of aluminium alloy AA5083. The FSP trials are performed by changing the process parameters as per face-centered central composite design. The friction stir processed (FSPed) specimens subjected to intergranular corrosion test and wear test are characterized using field emission scanning electron microscope, energy dispersive x-ray spectroscopy and X-ray diffraction. Outcomes suggest that grain refinement, dispersion and partial dissolution of secondary phase has simultaneously increased the hardness, intergranular corrosion resistance and wear resistance of the FSPed specimens. The study found that tool rotation speed of 700 rpm, tool traverse speed of 60 mm min−1 and shoulder diameter of 15 mm results in maximum hardness, wear resistance and intergranular corrosion resistance. © 2018 Institute of Materials, Minerals and Mining and Informa UK Limited, trading as Taylor & Francis Group

More »»

2017

Vaira Vignesh R. and Dr. Padmanaban R., “Modelling Corrosion Behavior of Friction Stir Processed Aluminium Alloy 5083 Using Polynomial: Radial Basis Function”, Transactions of the Indian Institute of Metals, vol. 70, no. 10, pp. 2575–2589, 2017.[Abstract]


Aluminium alloy 5083, widely used in marine applications, undergoes accelerated corrosion in sea water due to the aggressive reaction of chloride ions with the secondary phase particles and other intermetallics present in the alloy matrix. The corrosion rate of the alloy is also influenced by the temperature difference between the alloy and its environment. Friction stir processing (FSP) is a recent solid state processing technique for improving the surface properties of metals and alloys. In this study, an attempt has been made to explore the possibility of improving the corrosion resistance of AA5083 by FSP. FSP trials were performed by varying the tool rotation speed, tool traverse speed and shoulder diameter of the tool, as per face centered central composite design. The corrosion potential and the corrosion rate of friction stir processed AA5083 was studied using potentiodynamic polarization studies, at three different temperatures. Mathematical models based on polynomial–-radial basis function were developed and used to study the effect of process parameters on the corrosion potential and the corrosion rate of friction stir processed AA5083. FSP resulted in refinement of the grain structure, dispersion and partial dissolution of secondary phase particles in the matrix, which increased the corrosion resistance of the alloy.

More »»

2016

Dr. Padmanaban R., Vaira Vignesh R., Arivarasu, M., Karthick, K. P., and A. Sundar, A., “Process parameters effect on the strength of Friction Stir Spot Welded AA6061”, ARPN Journal of Engineering and Applied Sciences, vol. 11, no. 9, pp. 6030-6035, 2016.[Abstract]


Friction Stir Spot Welding (FSSW) is a recent welding technique used for spot welding of thin sheets. Response surface methodology (RSM) is used to develop a model for the tensile shear failure load of AA6061joined by FSSW. The experiments are conducted for different combinations of three parameters viz. tool rotational speed, dwell time and shoulder diameter as per Box -Behnken design and mathematical model is developed. The developed equation is used to find the optimum parameter combinations for obtaining joints with higher TSFL. © 2006-2016 Asian Research Publishing Network (ARPN). All rights reserved.

More »»

2015

Vaira Vignesh R., “Single Variable Algorithm Optimized Hybrid Black Toner Synthesis from Waste Toner and Nano Phase Carbon”, Karpagam Journal of Engineering Research, vol. 2, no. Special Issue on IEEE sponsored International Conference on Intelligent Systems and Control – ISCO’15, pp. 286-294, 2015.[Abstract]


The toner is used in photocopiers to form the latent electrical image on the drum. The paper picks up the toner particles (image), when it slides over the drum. Specific factors cause 10% of toner particles (approximately) to be left over the drum. This left out toner is cleaned by the unit to ensure the copy quality of the proceeding copies. This left out toner is called as waste toner and is collected in cleaner sump. If this waste toner is used in the photocopiers, the quality of the copier is reduced. The waste toner is mixed in proportion with Nano phase Carbon and original toner to get Hybrid Black Toner. The original toner is the toner prescribed for the photocopier by the manufacturer. By implementation of this technique, the cost of photocopy can be reduced and the quality of the photocopy can be increased. The Hybrid Black Toner is synthesis is optimized by Single Variable Optimization Algorithm.

More »»

2015

Vaira Vignesh R., “Optimization of Hybrid Black Toner Synthesis from Waste Toner”, International Journal of Innovative Research in Science, Engineering and Technology, vol. 4, no. Special Issue – 2, pp. 222–227, 2015.[Abstract]


The toner is used in photocopiers to form the latent electrical image on the drum. The paper picks up the toner particles (image), when it slides over the drum. Specific factors cause 10% of toner particles (approximately) to be left over the drum. This left out toner is cleaned by the unit to ensure the copy quality of the proceeding copies. This left out toner is called as waste toner and is collected in cleaner sump. If this waste toner is used in the photocopiers, the quality of the copier is reduced. The waste toner is mixed in proportion with Nano phase Carbon and original toner to get Hybrid Black Toner. The original toner is the toner prescribed for the photocopier by the manufacturer. By implementation of this technique, the cost of photocopy can be reduced and the quality of the photocopy can be increased.The Hybrid Black Toner is synthesis is optimized by Single Variable Optimization Algorithm

More »»

2015

C. Krishnaraj and Vaira Vignesh R., “Characterization of hybrid black toner using the parameters waste toner and Nano phase carbon”, ARPN Journal of Engineering and Applied Sciences, vol. 10, no. 14, pp. 6135-6139, 2015.[Abstract]


Toner is used in photocopiers to form the latent electrical image on the electrostatically charged drum. The paper picks up the toner particles, when it slides over the drum. Specific factors cause 10% of toner particles (approximately) to be left over the drum. This left out toner is cleaned by the unit to ensure the quality of the proceeding copies. This left out toner is called as waste toner and is collected in cleaner sump. If this waste toner is used in the photocopiers, the quality of the copier is reduced. The waste toner is mixed in proportion with Nano phase Carbon and original toner to get Hybrid Black Toner. The original toner is the toner prescribed for the photocopier by the manufacturer. The hybrid black toner is characterized by the two parameters say waste toner and nano phase carbon in this article. © 2006-2015 Asian Research Publishing Network (ARPN).

More »»

2014

Vaira Vignesh R. and Gnanakumar, G., “Synthesis of Hybrid Black Toner from Waste Toner Using Nano Technology–Optimization Technique”, International Journal of Engineering and Technology, vol. 3, no. 3, pp. 204 - 213, 2014.[Abstract]


The toner is used in photocopiers to form the latent electrical image on the drum. The paper picks up the toner particles (image), when it slides over the drum. Approximately 10% of toner particles are left over the drum due to specific factors. This left out toner is cleaned by the unit to ensure the copy quality of the proceeding copies. This left out toner is called as waste toner and is collected in cleaner sump. If this waste toner is used in the photocopiers, the quality of the copier is reduced. The waste toner is mixed in proportion with Carbon Black Nano powder and original toner to get Hybrid Carbon Black Toner. The original toner is the toner prescribed for the photocopier by the manufacturer. By implementation of this technique, the cost of photocopy can be reduced and the quality of the photocopy can be increased.

More »»

2013

Vaira Vignesh R., “Synthesis of Hybrid Black Toner from Waste Toner using Nano Technology – Optimization Technique – Phase 2”, Journal of Material Science Engineering in association with the 2nd International Conference and Exhibition on Materials Science and Engineering, vol. 2, no. 4, p. 261, 2013.

Publication Type: Conference Paper

Year of Publication Title

2018

T. Abinaya, Vaira Vignesh R., and Vijayan, T. M., “Solar based grid tie integration system for efficient power management”, in 2017 International Conference on Energy, Communication, Data Analytics and Soft Computing, 2018, pp. 3405-3410.[Abstract]


Solar power is currently been used in many commercial applications such as solar water heaters, solar pumps, stand-alone solar powered houses etc. The extensive power of the Sun can be used for power generation with the help of solar cells. The power demand in our country is at its peak level and will tend to increase in the upcoming days. This project mainly focuses on the conversion of excessive solar energy into useful power to eliminate the power scarcity, where the solar power can be converted into electricity and can be synchronized with the grid. The solar power is trapped with the help of solar cells, which will produce a DC voltage. This DC voltage will be converted into AC using IGBT based three phase six pulse inverter. Filters are used to remove the higher order harmonics present in the signal inverter output signal. This filtered AC voltage can be synchronized with the grid through Phase Locked Loop (PLL) base control system. © 2017 IEEE.

More »»

2017

R. Harikeshava, Srinivasan, M. S., Vaira Vignesh R., and Dr. Padmanaban R., “ANN model for predicting the intergranular corrosion susceptibility of friction stir processed aluminium alloy AA5083”, in Proceedings of the 2nd International Conference on Communication and Electronics Systems, ICCES 2017, 2017, vol. 2018-January, pp. 716-720.[Abstract]


Aluminium alloy AA5083 was subjected to friction stir processing with an objective to increase the intergranular corrosion resistance of the alloy. Experimental trials were performed by varying the friction stir process parameters namely Tool Rotation Speed, Tool Traverse Speed and Shoulder Diameters as per Taguchi's L18 orthogonal array. The base specimen and friction stir processed specimens were subjected to intergranular corrosion susceptibility test according to the standard ASTM G67-04. Artificial Neural Network model was developed with cascade forward propagation network architecture to predict the intergranular corrosion susceptibility of the friction stir processed specimens. The network was trained with 80% experimental data using Levenberg Marquardt algorithm and the remaining data was used for testing and validation. Least root mean squared error value and prediction error indicated high accuracy of the developed model. © 2017 IEEE.

More »»

2017

Vaira Vignesh R. and Dr. Padmanaban R., “Modelling tensile strength of friction stir welded aluminium alloy 1100 using fuzzy logic”, in Proceedings of 2017 11th International Conference on Intelligent Systems and Control, ISCO 2017, 2017, pp. 449-456.[Abstract]


Friction stir welding (FSW) is a promising technique in which joints with high strength and minimal defects can be realized by adopting optimum process parameters. The prominent parameters are tool rotation speed, welding speed, shoulder diameter and pin diameter of the tool. In this study Mamdani fuzzy system was used to generate the model for predicting and exploring the influence of FSW process parameters on tensile strength of AA1100 joints. The FSW trials are conducted at various levels of process parameters according to central composite design. The study proved that the process parameters had significant effect on the tensile strength of friction stir welded joints. Crest parabolic variation trend was observed in tensile strength of the joints, with respect to the interaction effects of TRS, WS and SD. Increase in pin diameter had positive effect in increasing the tensile strength of the joints, for any change in TRS, WS and SD. Maximum tensile strength of 72.4 MPa was obtained at tool rotation speed of 1050 rpm, welding speed of 60 mm/min, shoulder diameter of 18 mm and pin diameter of 6 mm. The methodology given in this paper delivers a useful tool to assess the tensile strength of friction stir welded AA1100. © 2017 IEEE.

More »»

2016

Vaira Vignesh R. and Dr. Padmanaban R., “Investigations on the mechanical properties of MWCNT reinforced ASTM A48 by testing & mathematical modelling”, in Proceedings of the 10th International Conference on Intelligent Systems and Control, ISCO 2016, 2016.[Abstract]


Nano Technology, being the most hopeful technology of this century, plays a dynamic role in the development of Metal Matrix Nano Composites (MMNC). The high reactivity of Nano Phase Materials (NPH) can be outlined to their surface prominent characteristics. Enhancement mechanical or corrosion properties would be imperative for engineered materials to bear the forces from machines and environment. The scope of this research work is to increase the tensile strength of Grey Cast Iron ASTM A48 by reinforcing Multi Walled Carbon Nano Tube (MWCNT) in the matrix. © 2016 IEEE.

More »»

2013

Vaira Vignesh R., “Chromium oxide nano powder-An Alternative to fuser oil in photo copiers”, in 7th International Conference on Intelligent Systems and Control, ISCO 2013, Coimbatore, Tamilnadu, 2013.[Abstract]


During the developmental period of photo copiers, toner is used to make a copy of the document on the paper. The toner was simply a carbon powder, for the past two decades. Then, to improve the quality of the photocopy, carbon was melt-mixed with a polymer. Photo copiers use fuser oil (primarily, Di-methyoxy siloxane), which melts the toner particles and then bind on the paper. This gives a glossy effect and the best quality in fusion of toner particles. But it reduces the life span of drum roller, heat roller unit etc. To mitigate these problems and not compromising the glossy effect in the photocopy, nano phased Chromium Oxide may be mixed with the toner. © 2013 IEEE.

More »»

Professional Recognition

Member of Board of Studies

  • Department of Mechanical Engineering, Karpagam College of Engineering (Autonomous), Affiliated to Anna University, India
  • Department of Automobile Engineering, Karpagam College of Engineering (Autonomous), Affiliated to Anna University, India

Active Reviewer

  • Materials Research Express, IOP Publishing, United Kingdom
  • Engineers Australia Technical Journals, Taylor and Francis, United Kingdom
  • ESN International Journal of Engineering and Technology, ESN Publications, India.

Editorial Board Member

  • ESN International Journal of Engineering and Technology, ESN Publications, India.

Workshops / Training Programs Attended

  1. Robokriti – NXT, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 2011.
  2. Ecological Awareness and Development of Renewable Energy Applications, Karpagam College of Engineering, Coimbatore, 2012.
  3. Non Destructive Testing, Coimbatore Institute of Technology, Coimbatore, 2013
  4. Automobile Designing and Styling using Reverse Engineering, National Technology Awareness Campaign, Anna University, Chennai, 2013.
  5. Manufacturing solutions using Autodesk products, Shri Eshwar College of Engineering, Coimbatore, 2013.
  6. Auto Factory, National Technology Awareness Campaign, Indian Institute of Science, Bengaluru, 2013.
  7. Renewable Energy and it's Rural Reach, Karpagam Institute of Technology, Coimbatore, 2013.
  8. Advanced Materials, GRD Centre for Materials Research, PSG College of Technology, Coimbatore, 2014.
  9. Advanced Materials and their Applications, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 2014.
  10. Stress Assisted Environmental Damage in Structural Materials, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras (IITM), Chennai, 2015.
  11. Advanced Nano Composite Materials: Characterization and Applications, Anna University Regional Office, Coimbatore, 2015.
  12. Advanced Materials and Joining Processes, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 2016.
  13. Introduction to MATLAB, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 2016.
  14. COMSOL Multiphysics 5.2, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 2016.
  15. Computational Research Techniques using Matlab, National Institute of Technology, Warangal, 2016.
  16. Advanced Material Characterization Techniques, The Indian Institute of Metals, Trivandrum Chapter, Trivandrum, 2016.
  17. Author Workshop on Scholarly Writing and Publishing, Springer Nature and Central Library, Amrita Vishwa Vidyapeetham, Coimbatore, 2018.
  18. Research Workshop on Additive Manufacturing and Weldability of Nickel-Based Super Alloys, Centre of Excellence in Welding Engineering and Technology (A Centre sponsored by Department of Heavy Industry, Government of India), PSG College of Technology, Coimbatore, 2018.
  19. Challenges in Welding of Advanced Materials, Centre of Excellence in Welding Engineering and Technology (A Centre sponsored by Department of Heavy Industry, Government of India), PSG College of Technology, Coimbatore, Indian Institute of Metals, Coimbatore Chapter, and Indian Welding Society Coimbatore Chapter, 2019.

Additional Qualifications

  1. Advanced Diploma in Java Programming (Grade: A), CSC Computer Education, 2011.
  2. Bachelor of Arts (Hindi), Dakshina Bharath Hindi Prachar Sabha, Chennai, 2011.
  3. Business English Certificate Preliminary (Level B1, 72%) Cambridge English Language Assessment, Part of University of Cambridge, 2013.
  4. Integrated Program in Nanotechnology (86.7%), Nano Science and Technology Consortium, Noida, 2014.
  5. Online course AuthorAID Course in Research Writing (Pass), AuthorAID INASP, 2016.
  6. Advanced Casting and Solidification of Light Alloys for Transportation (Grade: B), Global Initiative of Academic Networks (GIAN), Indian Institute of Technology Madras, Chennai, 2016.
  7. Experimentation for improvement (89.5%), McMaster University, Canada, 2016
  8. Tribology: Fundamentals to the Cutting Edge, Global Initiative of Academic Networks (GIAN), National Institute of Technology Calicut, Kozhikode, 2018.

Technical Society

  • Life Member - The Indian Institute of Metals, India
  • Life Member - Indian Welding Society, India

Research Field: Solid-state processing, Solid-state welding, Surface engineering, Powder Metallurgy, Corrosion science & engineering, Tribology.