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 Ph.D. degree under 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.

Research Field: Solid-state Processing, Solid-state Welding, Surface Engineering, Powder Metallurgy, Corrosion Science & Engineering, Tribology

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

Experience (Teaching & Research)

Year Affiliation
July 1, 2019- Present Assistant Professor, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
November 1, 2018 - June 30, 2019 Junior Research Fellow, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
Topic: 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
Investigators: Dr. M. Govindaraju, Dr. Ramesh Kumar, Dr. Venkata Ravi Kumar Darbha
November 1, 2017 - October 31, 2018 Junior Research Fellow, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
Topic: Development of Laser Surface Texturing Technology for Automotive Application
Investigators: Dr. G. Padmanabham, Dr. Ravi Nathuram Bathe, and Dr. S. Thirumalini
September 1, 2015 - October 31, 2017 Teaching Assistant, Department of Mechanical Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India

Thrust Area of Research: Materials and processing - Composites

Awards

  • ISTE Chapter Best Student Award
    Indian Society for Technical Education, New Delhi for excellence in academic, extra-curricular activities in 14th ISTE Tamil Nadu and Puducherry Section Annual Convention of for Engineering Students on September 12, 2014.
     
  • Henry Ford Award
    Karpagam College of Engineering for the meritorious in the Mechanical Engineering discipline during the period of 2011 – 2015.
     
  • Best Technical Paper Award
    International Conference on Emerging Trends in Materials and Manufacturing Engineering, 2017 (National Institute of Technology Tiruchirappalli) for the research work titled “Modelling Corrosion Behavior of the Friction Stir Processed Aluminium Alloy 5083 using Linear – Radial Basis Function Model”
     
  • Certified Publons Academy Peer Reviewer 

Teaching/Research Interests

Major Subjects Taught

  • Advanced Welding Technology
  • Manufacturing Process II
  • Metallurgy and Materials Science
  • Composite Materials and Processing
  • Introduction to Biocompatible Materials

Publications

Publication Type: Journal Article

Year of Publication Title

2021

S. K Kumar, Vaira Vignesh R., G Kumar, A., Abiram, A., and Padmanaban, R., “Soft computing model for predicting the wear resistance of friction stir processed aluminum alloy AA5083”, Materials Today: Proceedings, 2021.

2021

R. Jagadeep, Vaira Vignesh R., Sumanth, P., Sarathi, V., and M Govindaraju, “Fabrication of fly-ash based tiles using liquid phase sintering technology”, Materials Today: Proceedings, 2021.[Abstract]


Flyash, a residue of coal combustion, is an industrial waste. Flyash is a mixture of toxic chemicals and heavy metals like arsenic, lead, and selenium that is carcinogenic agents. However, more than 65% of flyash produced from coal-powered thermal power plants is disposed of in landfills and ash ponds. Flyash poses a great threat to humans and the environment (groundwater contamination). Hence, waste management is one of the major challenges of coal-powered thermal power plants in India. The project aims at the fabrication of flyash based ceramic tiles by liquid phase sintering technology for industrial and household applications. In this work, the technology for liquid phase sintering of flyash based ceramic tiles is demonstrated. Also, the glazing methodology for flyash based ceramic tiles is optimized. The results indicate that the fabricated flyash based ceramic tiles possess perfect ceramic matrix and glazed surface.

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2021

P. P Sai, Balu, T. M. B. Roshan, Vaira Vignesh R., Sastry, C. Vikram Bha, and Padmanaban, R., “Artificial neural network models for predicting the corrosion behavior of friction stir processed AA5083”, Materials Today: Proceedings, 2021.[Abstract]


Aluminum alloy 5083 has good corrosion resistance in marine environments and consists of a primary phase of α-Al and a secondary phase of β-Mg2Al3. AA5083 was subjected to friction stir processing (FSP. AA5083 was friction stir processed by varying the tool rotation speed, tool traverse speed, and tool shoulder diameters as per face-centered central composite design. The specimens were subjected to a potentiodynamic polarization test in an artificial seawater solution to estimate the corrosion potential and corrosion rate of the alloy at three different temperatures. In this work, a feed-forward backpropagation network with the Levenberg–Marquardt training algorithm was developed to predict the corrosion potential and corrosion rate of the specimens as a function of the friction stir processing process parameters. The model predictions were in good agreement with the experimental results. The correlation coefficient of the models was approximately equal to unity, demonstrating the high prediction efficiency of the developed models.

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2021

V. Pamula, Kalyan, K. Pavan, Vaira Vignesh R., and Dr. Govindaraj M., “Development and characterization of aluminum matrix composite reinforced with continuous stainless-steel fibers”, Materials Today: Proceedings, 2021.[Abstract]


Driven by energy conservation and environmental protection, present-day engineering applications focus on the effective usage of fossil fuels. Hence, industrial sectors perform extensive research on light-weighting of structures to improve efficiency. In this study, the aluminum matrix composite (AMC) is fabricated by reinforcing continuous stainless-steel (SS 304) fibers. The fabricated AMC is examined for its mechanical, metallurgical, and tribological properties. The results indicate a 6% enhancement in ultimate tensile strength, a 73% enhancement in hardness, and a 33% enhancement of wear resistance in developed AMC.

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2021

N. Udayan, Srinivasan, M. V., Vaira Vignesh R., and Dr. Govindaraj M., “Elimination of casting defects induced by cold box cores”, Materials Today: Proceedings, 2021.[Abstract]


One of the challenges of foundry industries is rejection of casting caused by porosity defects. Of the many factors, proper selection of core manufacturing process has higher impact on the reduction of porosity defects in castings. Cold box core making processes widely used by foundry industries to produce cores because of its good productivity and ability to produce complex designed cores. However, the probability of porosity defect in castings produced using cold box cores is higher than that of other processes. Globally, research is being carried out to solve the porosity defects in castings. However, complexity of the process and involvement of more process variables necessitate identification of root causes of the defects. This work aims at resolving the porosity defect in castings, when cold box core is used. Cores produced by furan core making process, which rarely results in porosity defects, was set as standard for testing the effectiveness of cores produced by cold box core making process. The results indicate that considerably high nitrogen content in the charge raw material in secondary iron making foundries enables reaction of metal with core (binder). Consequently, porosity arises in castings. The remedial measures to control the nitrogen content ensured casting rejections less than 7% in the foundry.

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2021

Vaira Vignesh R., R. Kumar, A., Srirangarajalu, N., and Dr. Padmanaban R., “Investigations on the Mechanical, Corrosion, and Tribological Behavior of Friction Stir Welded Aluminum Alloy AA8011”, Transactions on Maritime Science (Accepted) , 2021.

2021

P. Kalyan Kota, Dr. Govindaraj M., and Vaira Vignesh R., “Metallurgical Characterization and Mechanical Properties of Solid-Liquid Compound Casting of Aluminum Alloy – Steel Bimetallic Materials”, Metals and Materials International (Accepted), 2021.

2021

S. G Priyadharshini, T. Satish Kumar, Anbuchezhian, N., Vaira Vignesh R., Subramanian, R., Velmurugan, T., and K Basha, K., “Influence of tool traverse speed on microstructure and mechanical properties of CuNi/B4C surface composites”, Transactions of the IMF, vol. 99, no. 1, pp. 38–45, 2021.[Abstract]


The study presents an analysis specifically on the effect of tool traverse speed (one of the most influential process parameters of friction stir processing) on the microstructural evolution, microhardness, tensile behaviour, and tribological characteristics of CuNi/B4C surface composite. The friction stir processing trials were performed at the following tool traverse speeds: 20, 25, 30, 35, and 40 mm min−1. The microstructural analysis confirmed the homogeneous dispersion/agglomeration of B4C particles in the specimens that are friction stir processed at low/high traverse speed. The results indicate that friction stir processing of specimens beyond tool traverse speed of 30 mm min−1 results in undesirable microhardness, tensile strength, and wear resistance. A comprehensive correlation of microstructural evolution with the mechanical properties, fracture mechanism, and tribological characteristics of the fabricated surface composites is presented.

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2020

A. K. Raghav, Vaira Vignesh R., Kalyan, K. Pavan, and Dr. Govindaraj M., “Friction Welding of Cast Iron and Phosphor Bronze”, Journal of The Institution of Engineers (India): Series C, vol. 101, no. 2, pp. 347–354, 2020.[Abstract]


There is sometimes a need to fabricate machine parts that have the best properties of multiple materials while being economical at the same time. A prime example of such a scenario is with gears. Gears made out of cast iron are a poor choice because cast iron has poor impact resistance and is vulnerable to corrosion. The addition of phosphor bronze as an annulus to the cast iron hub in a composite gear provides the gear with those valuable resistances along with a superior intermeshing with mated gears. However, joining dissimilar materials such as cast iron to phosphor bronze is challenging when conventional welding techniques are employed. To overcome it, applying friction welding to join cast iron to phosphor bronze is focused in this thesis. The obtained results are analyzed and optimized for this particular combination of materials to facilitate their use in gears. The results show that there is an increased accumulation of graphite at the weld joints between cast iron and phosphor bronze for trials at higher (rotational) welding speeds, which leads to less favorable mechanical properties. At lower welding speeds, sound joints with acceptable mechanical and metallurgical properties were obtained.

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2020

M. Abdul Hadi Baig, Vaira Vignesh R., Dr. Padmanaban R., and Dr. Govindaraj M., “Characterization of AA5052-ZrO2 and AA5052-SiO2 Surface Composites Fabricated by Friction Stir Processing”, Songklanakarin Journal of Science and Technology. (Accepted) , 2020.

2020

R. K. Kannan, Vaira Vignesh R., and Dr. Govindaraj M., “Development and Tribological Characterization of Fly Ash Reinforced Iron based Functionally Gradient Friction Materials”, Engineering Review. (Accepted), 2020.

2020

M. B Bharathi, Vaira Vignesh R., Dr. Padmanaban R., and Dr. Govindaraj M., “Effect of friction stir processing and heat treatment on the corrosion properties of AZ31 alloy”, Australian Journal of Mechanical Engineering, pp. 1–10, 2020.[Abstract]


Magnesium alloys are widely used to lightweight the components in the automobile, aerospace, and electronics industries because of their low density and high specific strength. However, factors like low ductility, low mechanical strength, and high corrosion rate restrict the extensive use of the material. To utilise the alloy with improved mechanical and corrosion properties, friction stir processing followed by heat treatment was performed. The study explored the effect of ageing temperature and ageing time on the microstructure, mechanical and corrosion properties of friction stir processed AZ31 alloy. The results indicate that friction stir processing at TRS of 1200 rpm and TTS of 60 mm/min, followed by heat treatment augments the corrosion resistance of AZ31 alloy.

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2020

V. Shrinaath, Vaira Vignesh R., and Dr. Padmanaban R., “Parametric Study on the Spring-Back Effect in AA5052 Alloy in the Course of Three-Point Roll Bending Process”, Acta Mechanica et Automatica, vol. 14, no. 3, pp. 128-134, 2020.[Abstract]


Three-point roll bending is one of the most common forming processes employed to obtain the desired radius of curvature in the sheet metal operations. Upon the removal of the forming load, the sheet metal deforms to a lesser extent than that of the required dimension. This phenomenon is termed as spring-back and is considered the most challenging areas of research in three-point roll bending of sheet metals. This study aims to develop a numerical model using HyperWorks and Radioss solver to understand the influence of load, the distance between the forming rollers, and its thickness on the spring-back effect in the course of three-point roll bending of sheet metal (AA5052). The results of the numerical model are validated with the results of the experimental trials. Besides, a statistical model is developed to relate the amount of spring-back with the three-point roll bending process parameters.

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2020

J. Han, Paidar, M., Vaira Vignesh R., Mehta, K. P., Heidarzadeh, A., and Ojo, O. O., “Effect of shoulder features during friction spot extrusion welding of 2024-T3 to 6061-T6 aluminium alloys”, Archives of Civil and Mechanical Engineering, vol. 20, pp. 1–17, 2020.

2020

Dr. Govindaraj M., Chakkingal, U., Kalvala, P. Rao, Vaira Vignesh R., and Balasubramanian, K., “Investigations on the Creep behavior of friction-stir-processed magnesium alloy AE42”, Journal of Materials Engineering and Performance, vol. 29, pp. 3172–3182, 2020.[Abstract]


Magnesium alloy AE42 is a candidate material for high-temperature applications. However, as-cast AE42 alloy exhibits poor high-temperature creep properties because of the microstructure that shows a continuous network of b-Mg17Al12 and Al-RE precipitates along the boundaries of coarse a-Mg grains. In the current work, friction stir processing technique was adopted to refine the coarse as-cast structure of the AE42 alloy and break up the continuous network of b-Mg17Al12 and Al-RE precipitates. The creep properties of the parent material and friction-stir-processed specimens were determined by impression creep test at 150, 175, 200, 225 and 250 C. The results demonstrated that the presence of fragmented precipitates and the elimination of continuous network structure improved the creep resistance of the AE42 alloy. The metallurgical analysis revealed that no new precipitates were formed after friction stir processing and creep testing. From the data, it can be concluded that friction stir processing of AE42 alloy can lead to an increase in service temperatures from 150 to 225 C.

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2020

M. Paidar, Vaira Vignesh R., Khorram, A., O Ojo, O., Rasoulpouraghdam, A., and Pustokhina, I., “Dissimilar modified friction stir clinching of AA2024-AA6061 aluminum alloys: Effects of materials positioning”, Journal of Materials Research and Technology, vol. 9, no. 3, pp. 6037–6047, 2020.[Abstract]


Modified friction stir clinching (MFSC) process was employed to joint dissimilar AA2024-T3 and AA6061-T6 Al sheets by interchanging the upper and the lower sheets during the joining process. The material flow, microstructure, tensile strength and fracture behaviors of the MFSC joints were studied. The results reveal that material positioning significantly affects the material flow behavior of the MFSC joint due to the disparity in the properties (flow stress) of the AA2024-T3 and AA6061-T6 Al alloys. The flow-induced hook path and proximity of hook tip to the geometric differential flow-induced defect (at the refilled end of the keyhole) are undesirable in the welded AA6061-T6/AA2024-T3 joint as compared to the AA2024-T3/AA6061-T6 joint. The microstructure (precipitate dispersion, dislocation density, and tangles), hardness distribution, and fracture morphology of the joints are altered by the material positioning-induced flow behavior. Improved tensile strength (97.88 MPa) is obtained in the AA2024-T3/AA6061-T6 joint as compared to the AA6061-T6/AA2024-T3 joint (86.65 MPa).

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2020

Dr. Padmanaban R., Balusamy, V., and Vaira Vignesh R., “Effect of friction stir welding process parameters on the tensile strength of dissimilar aluminum alloy AA2024-T3 and AA7075-T6 joints”, Materialwissenschaft und Werkstofftechnik, vol. 51, no. 1, pp. 17–27, 2020.[Abstract]


This work investigates the influence of friction stir welding parameters on the mechanical properties of the dissimilar joint between AA2024‐T3 and AA7075‐T6. Experiments are conducted consistent with the three‐level face‐centered composite design. Response surface methodology is used to develop the regression model for predicting the tensile strength of the joints. The analysis of variance technique is used to access the adequacy of the developed model. The model is used to study the effect of key operating process parameters namely, tool rotation speed, welding speed and shoulder diameter on the tensile strength of the joints. The results indicate that friction stir welding of aluminum alloys at a tool rotation speed of 1050 min<sup>−1</sup>, welding speed of 40 mm/min and a shoulder diameter of 17.5 mm would produce defect less joint with high tensile strength.

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2020

Dr. Govindaraj M., Megalingam, A., Murugasan, J., Vaira Vignesh R., Kota, P. Kalyan, A Ram, S., Lakshana, P., and V Kumar, N., “Investigations on the tribological behavior of functionally gradient iron-based brake pad material”, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, vol. 234, no. 12, pp. 2474–2486, 2020.[Abstract]


In this study, a functionally gradient iron-based brake pad material was developed and the tribological behavior was studied. The functionally gradient specimen had more copper near the base plate and more abrasives towards the top, which provides excellent joint strength and serves the purpose of braking, respectively. The layers had a hybrid composition of metallic materials (Fe, Cu), and abrasives (silicon carbide and aluminum oxide) to improve the strength, wear resistance, and toughness. Graphite was added to stabilize the specimen's thermal and friction characteristics at high temperature. The microstructure, wear rate, and friction coefficient of the functionally gradient specimen and the conventionally sintered specimen were evaluated. The results indicate that the wear resistance of the functionally gradient specimen is higher than the wear resistance of conventional specimen.

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2020

M. Paidar, Vaira Vignesh R., Moharrami, A., Ojo, O. O., Jafari, A., and Sadreddini, S., “Development and characterization of dissimilar joint between AA2024-T3 and AA6061-T6 by modified friction stir clinching process”, Vacuum, vol. 176, p. 109298, 2020.[Abstract]


Friction stir spot welding (FSSW) is one of the effective solid-state welding strategies to achieve good joint efficiency between dissimilar aluminum alloys. However, the formation of tool-induced keyhole (a stress raiser) is inevitable during the FSSW process. This study explores the possibility of eliminating keyhole with the aim of improving the properties of the joint by Modified Friction Stir Clinching (MFSC) process. The tensile-shear and cross-tension strengths of the MFSC joints are 83% and 50% higher than that of the specimens joined by FSSW. The article presents a comprehensive analysis of the material flow characteristics, microstructural evolution, and tensile properties of the dissimilar joints between AA2024-T3 and AA6061-T6 that was enabled by the MFSC process. More »»

2020

M. Muralimanokar, Vaira Vignesh R., Govindaraju, M., and Dr. Padmanaban R., “Characterization of AZ31-NbC Surface Composite Fabricated by Friction stir Processing”, Koroze a ochrana materiálu, vol. 64, pp. 29-37., 2020.[Abstract]


AZ31D magnesium alloy is widely used in automotive, aircraft, and aerospace applications because of its high strength to weight ratio. However, the softness of the alloy results in higher wear rate and the high activity results in higher corrosion rate. With an aim of reducing the wear rate and corrosion rate of AZ31 alloy, surface composite of AZ31 alloy is fabricated by reinforcing niobium carbide (NbC) by friction stir processing. The microstructure and dispersion of the reinforcements in AZ31-NbC surface composite is analysed by optical microscopy. In addition, the microhardness and tribological characteristics of the developed AZ31-NbC surface composite are investigated. The results demonstrated an increase in microhardness (23.2 %) and the decrease in wear rate (15.6 % for a normal load of 2 kg) in the developed AZ31-NbC surface composite with respect to the base material. The immersion corrosion test was performed to analyse the corrosion rate of the developed AZ31-NbC surface composite in simulated sea water environment (3.5 wt % NaCl solution). The results indicate that the corrosion rate of the developed AZ31-NbC surface composite is higher than that of base material. A comprehensive analysis on the wear and corrosion mechanism of the developed AZ31-NbC surface composite is presented.

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2020

Vaira Vignesh R., Dr. Padmanaban R., Kovukkal, M. D., and Dr. Govindaraj M., “Research and Development in Magnesium Alloys for Industrial and Biomedical Applications: A Review”, Metals and Materials International, vol. vol. 26, pp. 409-430, 2020.[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.

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2020

Vaira Vignesh R., Dr. Padmanaban R., and Dr. Govindaraj M., “Synthesis and Characterization of Magnesium Alloy Surface Composite (AZ91D - SiO2) by Friction Stir Processing for Bioimplants”, Silicon, vol. 12, 2020.[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.

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2019

A. Aravind, Vaira Vignesh R., Dr. Padmanaban R., and Dr. Govindaraj 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.

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2019

Vaira Vignesh R., Dr. Padmanaban R., Dr. Govindaraj 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.

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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, vol. 43, no. 8, pp. 1-12, 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.

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2019

Dr. Govindaraj M., Vaira Vignesh R., and Dr. 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, 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.

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2019

Vaira Vignesh R., Dr. Padmanaban R., Dr. Govindaraj 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.

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2019

Vaira Vignesh R., Dr. Padmanaban R., and Dr. Govindaraj 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.

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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.

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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&nbsp;°C for 90&nbsp;min, followed by air quenching/water quenching. The specimens are artificially aged at different temperatures (500&nbsp;°C, 550&nbsp;°C, and 600&nbsp;°C) and time (1&nbsp;h, 2&nbsp;h, and 3&nbsp;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&nbsp;N and sliding velocity between 0.8 to 2.2&nbsp;m/s for a sliding distance of 1000&nbsp;m and 1500&nbsp;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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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

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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).

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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.

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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: Book Chapter

Year of Publication Title

2021

A. Naidu, Dr. Padmanaban R., and Vaira Vignesh R., “Optimizing the Conveyor Belt Speed of a Bright Annealing Furnace”, in Advances in Electromechanical Technologies, Lecture Notes in Mechanical Engineering, Springer, 2021, pp. 13-20.[Abstract]


A company’s growth is determined by an increase in its sales numbers and by a decrease in its expenditures. By doing this, the company attains a more significant profit (bottom line). In almost all manufacturing industries, annealing furnaces play a significant role. In this paper, an improvement in the operation of an annealing furnace used in a press shop is attempted. The press shop performs forging of watch cases, and annealing is performed in between every forging stage. This project focuses on increasing the productivity of the furnace by optimizing its conveyor belt speed. Experiments are conducted, and several annealed samples were collected for analysis. Furthermore, hardness and metallographic properties were also studied. With the help of regression plots of hardness and belt speed, and with the help of microstructures, an optimized belt speed was selected. The optimized belt speed is almost 42% more than the original speed used for production, hence increasing productivity.

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2021

Vaira Vignesh R., Dr. Padmanaban R., Dr. Govindaraj M., 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, 2021.[Abstract]


Friction stir processing is applied to fabricate magnesium alloy AZ91D surface composite reinforced with nanophase Al2O3 particles. The refined microstructure in the developed surface composite is induced by nanophase Al2O3 particles and recovery–recrystallization phenomenon by friction stir processing. The results of electrochemical corrosion test and immersion corrosion test reveal that the corrosion rate of the developed surface composite decreased in simulated body fluids. The study originally reports that the homogeneous dispersion of nanophase Al2O3 particles and formation of an adherent layer of corrosion products (calcium hydroxyapatite and calcium-magnesium phosphate) in the developed surface composite decrease the corrosion rate. Besides, the formation of these corrosion products that mimic the bone matrix would support bone growth and promote integration of implant bone.

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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.

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2018

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, 2018, 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.

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2018

Dr. Ilangovan S., Vaira Vignesh R., Dr. Padmanaban R., and Dr. Gokulachandran J., “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.

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Publication Type: Conference Proceedings

Year of Publication Title

2021

G. Ghongade, Kalyan, K. Pavan, Vaira Vignesh R., and Govindaraju, M., “Design, Fabrication, and Analysis of Cost Effective Steel Honeycomb Structures”, Materials Today: Proceedings . Elsevier, 2021.[Abstract]


Lightweight honeycomb structures helps in considerable weight reduction in industrial applications. The study investigates the effect of reinforcement on the circular core honeycomb structure under axial compression behavior. The numerical analysis for load carrying capacity is performed using Abaqus-CAE. For experimental validation, steel honeycomb panels (with and without reinforcements) are fabricated by furnace-brazing technology in a continuous furnace. Though the reinforcements increased the panel weight, a substantial increase in the load carrying capacity (44%)) is observed. The results indicate that reinforced honeycomb structure with cell diameter of 10 mm has the highest load carrying capacity. The experimental results validate the developed numerical model.

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2021

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 (Published Online). Elsevier, 2021.[Abstract]


Need for joining similar and dissimilar materials with various thickness and geometry increasing rapidly, inferable from their bit of leeway of light-weighting in the automobile and aviation industries. Brazing is such method expanding quickly with the approach of reasonable high-temperature furnaces incorporated with high vacuum systems. Negligible distortion and restraint of thermal stresses with steady heating and cooling rates make this procedure amiable for joining materials of different size and thickness. In the present study, mild steel brazing was carried out in butt and lap joint configurations using a foil composed of CuSil eutectic (72%Ag28%Cu) to check for reliability in piping and automotive components. Brazing process was performed with varying overlap for lap joints, and butt joint at a constant temperature of 835 °C in a vacuum furnace. Microstructure and elemental composition of the joints were examined using Optical microscope, SEM and EDS. Mechanical properties were investigated at the joint region using micro hardness and tensile strength at room temperature. Results showed that microstructure composed of eutectic Ag and Cu microstructure with no signs of porosity and cracks in the brazed joint. The average hardness of 95 HV in the brazed region is less when compared to the base metal of average hardness 135 HV. It has been found that due to more brazing area, failure occurred away from joints in lap joint configuration, and in brazing joint in case of butt configuration due to micropores and voids.

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2021

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. Elsevier, 2021.

2020

R. K. Kannan, Dr. Govindaraj M., and Vaira Vignesh R., “Development of Fly Ash based Friction Material for Wind Turbines by Liquid Phase Sintering Technology”, Journal of Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology (Published Online). 2020.[Abstract]


Fly ash based sintered materials are identified as potential brake pad materials for wind turbines. However, fly ash based friction materials fabricated through conventional techniques results in more porosity and undesirable tribological properties. This study attempts to develop liquid phase sintering technology for fly ash using Cu as a liquid phase sintering agent. The study presents a comprehensive analysis of the evolution of microstructure, microhardness, and tribological performance of the specimens sintered in Argon and Air environment.

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2020

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 (2nd International Conference on Materials Manufacturing and Modelling, ICMMM – 2019), vol. 22. Elsevier, pp. 3340-3346, 2020.[Abstract]


Aluminium alloy AA5052 has excellent strength to weight ratio, which makes it best suited for marine applications. The study explores the effect of heat treatment on the mechanical, corrosion and tribological properties of friction stir processed aluminium alloy AA5052. The micro hardness, tensile strength and wear rate of the base material, friction stir processed and the annealed specimens were analyzed. The results indicate that the FSP followed by annealing increases hardness, tensile strength and resistance to wear of AA5052 alloy

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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

P. Kesava Sai Srujan, Kaka, H. Krishna, Vaira Vignesh R., Kalyan, K. Pavan, Dr. Padmanaban R., and Dr. Govindaraj 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.

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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.

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2019

R. K Kannan, Vaira Vignesh R., Kalyan, K. Pavan, Murugesan, J., Megalingam, A., Dr. Padmanaban R., and Dr. Govindaraj 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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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 (International conference on advances in Materials and Manufacturing Applications(ICONAMMA 2016)), 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.

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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.

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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.

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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.

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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.

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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: 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 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.

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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.

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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.

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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.

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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.

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2012

Vaira Vignesh R., “Analysis of Impurities in Molten Metal Using Nano Sensor”, in National Conference on Innovations in Manufacturing Technology and Management Arena., 2012.

Patents

  • Hybrid Black Toner
    • Application Number: 5071/CHE/2013
    • Applicants & Inventors: Vaira Vignesh and G. Gnanakumar
    • Official Journal of the Patent Office, India, Issue: 26/2016, June 24, 2016
  • 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, Vaira Vignesh, Maheshkumar
    • Status: Submitted to The Patent OfficeIndia by December 2019

List of Ph. D. Students

Current

  • Co-Advisor Mr. K. Srinivasan (CB.EN.D*MEE19006-PT)

Conferences/Workshops/Short-term courses (Organized)

  • Organized One day National level Conference on “Processing and Characterization of Materials - NCPC 2018” on 11th May 2018.
  • Organized One day National level Workshop on Advanced Materials and Joining Processes, on 6th May 2016.

Professional Activities

Member of Board of Studies

  • Department of Mechanical Engineering, Karpagam College of Engineering (Autonomous), Affiliated to Anna University, India (2019)
  • Department of Automobile Engineering, Karpagam College of Engineering (Autonomous), Affiliated to Anna University, India (2019)

International Research Collaborators

  • Asia
    Dr. Moslem Paidar, Department of Material Engineering, South Tehran Branch, Islamic Azad University, Tehran, Iran 
  • Africa
    Dr. O. Ojo, Department of Industrial and Production Engineering, Federal University of Technology Akure, Akure, Nigeria

Technical Society Membership

Life Member

  • The Indian Institute of Metals, India
  • Indian Welding Society, 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.
  • Vacuum, Elsevier.

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.

 

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