Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V
Adding Al and Al 2 O 3 powder creates electrical discharge machining (EDM) in a significant machining gap with stable condition. Practically, it is almost impossible to distribute powder particles evenly into the plasma channel. This study investigates the intermolecular process while the plasma cha...
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| Veröffentlicht in: | International journal of advanced manufacturing technology 2021-09, Vol.116 (5-6), p.1763-1782 |
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| creator | Ilani, Mohsen Asghari Khoshnevisan, Mohammad |
| description | Adding Al and Al
2
O
3
powder creates electrical discharge machining (EDM) in a significant machining gap with stable condition. Practically, it is almost impossible to distribute powder particles evenly into the plasma channel. This study investigates the intermolecular process while the plasma channel’s pressure and temperature are changed. In our research, surfactant Tween 80® and its effects on intermolecular forces (IMF) through the plasma channel were investigated to evaluate surface quality. In the first phase of our research, output parameters ran at three experimental blocks (without surfactant, with 21.81 g/l of surfactant, and 43.3512 g/l of surfactant) in 17 runs while adding Al and Al
2
O
3
powders with the design of experience (DOE) method by Design Expert software. Decomposition phenomena (DP), adhesion phenomena (AP), and nonuniform distribution (NUD) of Al and Al
2
O
3
powders demonstrated how new molecules (aluminum trihydride, aluminic acid, methyl(methylene)aluminum, hydroxy(methyl)aluminum hydride, hydroxy(methylene)aluminum, and methyl(oxo)aluminum) were created on the surface element composition. In our experiment, powders’ even distribution when we decomposed Al and Al
2
O
3
created a more stable plasma channel. Consequently, it led to a more balanced heat transfer on the electrodes’ surface. We used scanning of surface quality by field emission-scanning electron microscopy (FE-SEM), electron dispersive spectrum (EDS), and mapping and have shown how to improve the surface defects (hole, crack, and globule). In the second phase of our research, we investigated the intermolecular forces (IMF) on Al–O bond and Al–Al bond. The percentage of elements obtained by mapping analysis of cross-section illustrated that oxygen and aluminum had increased notably when we used Al powder. Considering physical, chemical, metallurgical, and machining time management (MTM) of PM-EDM, we demonstrated that the fine finishing surface improved by 217.7% at Ip = 15 A and Ton = 50 μs and Cp = 5 g/l when the surfactant was added. We compared the best-optimized points in the final phase of our work and measured the recast layer thickness (RLT) after adding Al and Al
2
O
3
. As a result, the RTL was removed entirely when Al was added to the dielectric. We have shown that MRR (g/h) and TWR (g/h) were decreased by 5.23 and 113.36%, and SR (Ra) and machining time were increased by 21.75 and 50.84%, respectively. We note that high strength-to-weight ratio and corro |
| doi_str_mv | 10.1007/s00170-021-07569-3 |
| format | Article |
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2
O
3
powder creates electrical discharge machining (EDM) in a significant machining gap with stable condition. Practically, it is almost impossible to distribute powder particles evenly into the plasma channel. This study investigates the intermolecular process while the plasma channel’s pressure and temperature are changed. In our research, surfactant Tween 80® and its effects on intermolecular forces (IMF) through the plasma channel were investigated to evaluate surface quality. In the first phase of our research, output parameters ran at three experimental blocks (without surfactant, with 21.81 g/l of surfactant, and 43.3512 g/l of surfactant) in 17 runs while adding Al and Al
2
O
3
powders with the design of experience (DOE) method by Design Expert software. Decomposition phenomena (DP), adhesion phenomena (AP), and nonuniform distribution (NUD) of Al and Al
2
O
3
powders demonstrated how new molecules (aluminum trihydride, aluminic acid, methyl(methylene)aluminum, hydroxy(methyl)aluminum hydride, hydroxy(methylene)aluminum, and methyl(oxo)aluminum) were created on the surface element composition. In our experiment, powders’ even distribution when we decomposed Al and Al
2
O
3
created a more stable plasma channel. Consequently, it led to a more balanced heat transfer on the electrodes’ surface. We used scanning of surface quality by field emission-scanning electron microscopy (FE-SEM), electron dispersive spectrum (EDS), and mapping and have shown how to improve the surface defects (hole, crack, and globule). In the second phase of our research, we investigated the intermolecular forces (IMF) on Al–O bond and Al–Al bond. The percentage of elements obtained by mapping analysis of cross-section illustrated that oxygen and aluminum had increased notably when we used Al powder. Considering physical, chemical, metallurgical, and machining time management (MTM) of PM-EDM, we demonstrated that the fine finishing surface improved by 217.7% at Ip = 15 A and Ton = 50 μs and Cp = 5 g/l when the surfactant was added. We compared the best-optimized points in the final phase of our work and measured the recast layer thickness (RLT) after adding Al and Al
2
O
3
. As a result, the RTL was removed entirely when Al was added to the dielectric. We have shown that MRR (g/h) and TWR (g/h) were decreased by 5.23 and 113.36%, and SR (Ra) and machining time were increased by 21.75 and 50.84%, respectively. We note that high strength-to-weight ratio and corrosion resistance are essential for many industries, particularly aerospace and biomedical industries. We believe that these industries can potentially benefit from our study.</description><identifier>ISSN: 0268-3768</identifier><identifier>EISSN: 1433-3015</identifier><identifier>DOI: 10.1007/s00170-021-07569-3</identifier><language>eng</language><publisher>London: Springer London</publisher><subject>Aerospace industry ; Aluminum hydrides ; Aluminum oxide ; CAE) and Design ; Computer-Aided Engineering (CAD ; Corrosion resistance ; Decomposition ; EDM electrodes ; Electric discharge machining ; Engineering ; Field emission microscopy ; Industrial and Production Engineering ; Intermolecular forces ; Mapping ; Mechanical Engineering ; Media Management ; Metallurgy ; Methylene ; Original Article ; Plasma ; Strength to weight ratio ; Surface defects ; Surface properties ; Surfactants ; Thickness ; Time management ; Titanium base alloys</subject><ispartof>International journal of advanced manufacturing technology, 2021-09, Vol.116 (5-6), p.1763-1782</ispartof><rights>The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2021</rights><rights>The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2021.</rights><lds50>peer_reviewed</lds50><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c249t-976190ca016b5efb7f67771897f3ff5d8733af6fdc76a9f5fd5c2972a7c1a7023</citedby><cites>FETCH-LOGICAL-c249t-976190ca016b5efb7f67771897f3ff5d8733af6fdc76a9f5fd5c2972a7c1a7023</cites><orcidid>0000-0003-0189-6956</orcidid></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktopdf>$$Uhttps://link.springer.com/content/pdf/10.1007/s00170-021-07569-3$$EPDF$$P50$$Gspringer$$H</linktopdf><linktohtml>$$Uhttps://link.springer.com/10.1007/s00170-021-07569-3$$EHTML$$P50$$Gspringer$$H</linktohtml><link.rule.ids>314,776,780,27901,27902,41464,42533,51294</link.rule.ids></links><search><creatorcontrib>Ilani, Mohsen Asghari</creatorcontrib><creatorcontrib>Khoshnevisan, Mohammad</creatorcontrib><title>Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V</title><title>International journal of advanced manufacturing technology</title><addtitle>Int J Adv Manuf Technol</addtitle><description>Adding Al and Al
2
O
3
powder creates electrical discharge machining (EDM) in a significant machining gap with stable condition. Practically, it is almost impossible to distribute powder particles evenly into the plasma channel. This study investigates the intermolecular process while the plasma channel’s pressure and temperature are changed. In our research, surfactant Tween 80® and its effects on intermolecular forces (IMF) through the plasma channel were investigated to evaluate surface quality. In the first phase of our research, output parameters ran at three experimental blocks (without surfactant, with 21.81 g/l of surfactant, and 43.3512 g/l of surfactant) in 17 runs while adding Al and Al
2
O
3
powders with the design of experience (DOE) method by Design Expert software. Decomposition phenomena (DP), adhesion phenomena (AP), and nonuniform distribution (NUD) of Al and Al
2
O
3
powders demonstrated how new molecules (aluminum trihydride, aluminic acid, methyl(methylene)aluminum, hydroxy(methyl)aluminum hydride, hydroxy(methylene)aluminum, and methyl(oxo)aluminum) were created on the surface element composition. In our experiment, powders’ even distribution when we decomposed Al and Al
2
O
3
created a more stable plasma channel. Consequently, it led to a more balanced heat transfer on the electrodes’ surface. We used scanning of surface quality by field emission-scanning electron microscopy (FE-SEM), electron dispersive spectrum (EDS), and mapping and have shown how to improve the surface defects (hole, crack, and globule). In the second phase of our research, we investigated the intermolecular forces (IMF) on Al–O bond and Al–Al bond. The percentage of elements obtained by mapping analysis of cross-section illustrated that oxygen and aluminum had increased notably when we used Al powder. Considering physical, chemical, metallurgical, and machining time management (MTM) of PM-EDM, we demonstrated that the fine finishing surface improved by 217.7% at Ip = 15 A and Ton = 50 μs and Cp = 5 g/l when the surfactant was added. We compared the best-optimized points in the final phase of our work and measured the recast layer thickness (RLT) after adding Al and Al
2
O
3
. As a result, the RTL was removed entirely when Al was added to the dielectric. We have shown that MRR (g/h) and TWR (g/h) were decreased by 5.23 and 113.36%, and SR (Ra) and machining time were increased by 21.75 and 50.84%, respectively. We note that high strength-to-weight ratio and corrosion resistance are essential for many industries, particularly aerospace and biomedical industries. We believe that these industries can potentially benefit from our study.</description><subject>Aerospace industry</subject><subject>Aluminum hydrides</subject><subject>Aluminum oxide</subject><subject>CAE) and Design</subject><subject>Computer-Aided Engineering (CAD</subject><subject>Corrosion resistance</subject><subject>Decomposition</subject><subject>EDM electrodes</subject><subject>Electric discharge machining</subject><subject>Engineering</subject><subject>Field emission microscopy</subject><subject>Industrial and Production Engineering</subject><subject>Intermolecular forces</subject><subject>Mapping</subject><subject>Mechanical Engineering</subject><subject>Media Management</subject><subject>Metallurgy</subject><subject>Methylene</subject><subject>Original Article</subject><subject>Plasma</subject><subject>Strength to weight ratio</subject><subject>Surface defects</subject><subject>Surface properties</subject><subject>Surfactants</subject><subject>Thickness</subject><subject>Time management</subject><subject>Titanium base alloys</subject><issn>0268-3768</issn><issn>1433-3015</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2021</creationdate><recordtype>article</recordtype><sourceid>BENPR</sourceid><recordid>eNp9kLFOwzAQhi0EEqXwAkyWWNrBYMe1Lxmr0kKlIgYKq-U6dpsqTYqdCCrx8LgEiY3phvv-_04fQteM3jJK4S5QyoASmjBCQciM8BPUYyPOCadMnKIeTWRKOMj0HF2EsI24ZDLtoa-Xps0PuHY4tN5p0-iqwdY5a5qA6woXVWP9ri6taUvtsau9sQEP5k-zYdzhff2RW092xafNsY1U4wujS5wXwWy0X1u802ZTVEW1xoPp_dPweGlZEDkuyejtEp05XQZ79Tv76HU2XU4eyeL5YT4ZL4hJRllDMpAso0bHn1fCuhU4CQAszcBx50SeAufaSZcbkDpzwuXCJBkkGgzTQBPeRzdd797X760NjdrWra_iSZUIARIEFRCppKOMr0Pw1qm9L3baHxSj6mhZdZZVtKx-LCseQ7wLhQhXa-v_qv9JfQOAZ381</recordid><startdate>20210901</startdate><enddate>20210901</enddate><creator>Ilani, Mohsen Asghari</creator><creator>Khoshnevisan, Mohammad</creator><general>Springer London</general><general>Springer Nature B.V</general><scope>AAYXX</scope><scope>CITATION</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>AFKRA</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>L6V</scope><scope>M7S</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>PTHSS</scope><orcidid>https://orcid.org/0000-0003-0189-6956</orcidid></search><sort><creationdate>20210901</creationdate><title>Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V</title><author>Ilani, Mohsen Asghari ; Khoshnevisan, Mohammad</author></sort><facets><frbrtype>5</frbrtype><frbrgroupid>cdi_FETCH-LOGICAL-c249t-976190ca016b5efb7f67771897f3ff5d8733af6fdc76a9f5fd5c2972a7c1a7023</frbrgroupid><rsrctype>articles</rsrctype><prefilter>articles</prefilter><language>eng</language><creationdate>2021</creationdate><topic>Aerospace industry</topic><topic>Aluminum hydrides</topic><topic>Aluminum oxide</topic><topic>CAE) and Design</topic><topic>Computer-Aided Engineering (CAD</topic><topic>Corrosion resistance</topic><topic>Decomposition</topic><topic>EDM electrodes</topic><topic>Electric discharge machining</topic><topic>Engineering</topic><topic>Field emission microscopy</topic><topic>Industrial and Production Engineering</topic><topic>Intermolecular forces</topic><topic>Mapping</topic><topic>Mechanical Engineering</topic><topic>Media Management</topic><topic>Metallurgy</topic><topic>Methylene</topic><topic>Original Article</topic><topic>Plasma</topic><topic>Strength to weight ratio</topic><topic>Surface defects</topic><topic>Surface properties</topic><topic>Surfactants</topic><topic>Thickness</topic><topic>Time management</topic><topic>Titanium base alloys</topic><toplevel>peer_reviewed</toplevel><toplevel>online_resources</toplevel><creatorcontrib>Ilani, Mohsen Asghari</creatorcontrib><creatorcontrib>Khoshnevisan, Mohammad</creatorcontrib><collection>CrossRef</collection><collection>ProQuest SciTech Collection</collection><collection>ProQuest Technology Collection</collection><collection>Materials Science & Engineering Collection</collection><collection>ProQuest Central UK/Ireland</collection><collection>ProQuest Central</collection><collection>Technology Collection</collection><collection>ProQuest One Community College</collection><collection>ProQuest Central Korea</collection><collection>SciTech Premium Collection</collection><collection>ProQuest Engineering Collection</collection><collection>Engineering Database</collection><collection>ProQuest One Academic Eastern Edition (DO NOT USE)</collection><collection>ProQuest One Academic</collection><collection>ProQuest One Academic UKI Edition</collection><collection>ProQuest Central China</collection><collection>Engineering Collection</collection><jtitle>International journal of advanced manufacturing technology</jtitle></facets><delivery><delcategory>Remote Search Resource</delcategory><fulltext>fulltext</fulltext></delivery><addata><au>Ilani, Mohsen Asghari</au><au>Khoshnevisan, Mohammad</au><format>journal</format><genre>article</genre><ristype>JOUR</ristype><atitle>Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V</atitle><jtitle>International journal of advanced manufacturing technology</jtitle><stitle>Int J Adv Manuf Technol</stitle><date>2021-09-01</date><risdate>2021</risdate><volume>116</volume><issue>5-6</issue><spage>1763</spage><epage>1782</epage><pages>1763-1782</pages><issn>0268-3768</issn><eissn>1433-3015</eissn><abstract>Adding Al and Al
2
O
3
powder creates electrical discharge machining (EDM) in a significant machining gap with stable condition. Practically, it is almost impossible to distribute powder particles evenly into the plasma channel. This study investigates the intermolecular process while the plasma channel’s pressure and temperature are changed. In our research, surfactant Tween 80® and its effects on intermolecular forces (IMF) through the plasma channel were investigated to evaluate surface quality. In the first phase of our research, output parameters ran at three experimental blocks (without surfactant, with 21.81 g/l of surfactant, and 43.3512 g/l of surfactant) in 17 runs while adding Al and Al
2
O
3
powders with the design of experience (DOE) method by Design Expert software. Decomposition phenomena (DP), adhesion phenomena (AP), and nonuniform distribution (NUD) of Al and Al
2
O
3
powders demonstrated how new molecules (aluminum trihydride, aluminic acid, methyl(methylene)aluminum, hydroxy(methyl)aluminum hydride, hydroxy(methylene)aluminum, and methyl(oxo)aluminum) were created on the surface element composition. In our experiment, powders’ even distribution when we decomposed Al and Al
2
O
3
created a more stable plasma channel. Consequently, it led to a more balanced heat transfer on the electrodes’ surface. We used scanning of surface quality by field emission-scanning electron microscopy (FE-SEM), electron dispersive spectrum (EDS), and mapping and have shown how to improve the surface defects (hole, crack, and globule). In the second phase of our research, we investigated the intermolecular forces (IMF) on Al–O bond and Al–Al bond. The percentage of elements obtained by mapping analysis of cross-section illustrated that oxygen and aluminum had increased notably when we used Al powder. Considering physical, chemical, metallurgical, and machining time management (MTM) of PM-EDM, we demonstrated that the fine finishing surface improved by 217.7% at Ip = 15 A and Ton = 50 μs and Cp = 5 g/l when the surfactant was added. We compared the best-optimized points in the final phase of our work and measured the recast layer thickness (RLT) after adding Al and Al
2
O
3
. As a result, the RTL was removed entirely when Al was added to the dielectric. We have shown that MRR (g/h) and TWR (g/h) were decreased by 5.23 and 113.36%, and SR (Ra) and machining time were increased by 21.75 and 50.84%, respectively. We note that high strength-to-weight ratio and corrosion resistance are essential for many industries, particularly aerospace and biomedical industries. We believe that these industries can potentially benefit from our study.</abstract><cop>London</cop><pub>Springer London</pub><doi>10.1007/s00170-021-07569-3</doi><tpages>20</tpages><orcidid>https://orcid.org/0000-0003-0189-6956</orcidid></addata></record> |
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| ispartof | International journal of advanced manufacturing technology, 2021-09, Vol.116 (5-6), p.1763-1782 |
| issn | 0268-3768 1433-3015 |
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| source | SpringerLink Journals - AutoHoldings |
| subjects | Aerospace industry Aluminum hydrides Aluminum oxide CAE) and Design Computer-Aided Engineering (CAD Corrosion resistance Decomposition EDM electrodes Electric discharge machining Engineering Field emission microscopy Industrial and Production Engineering Intermolecular forces Mapping Mechanical Engineering Media Management Metallurgy Methylene Original Article Plasma Strength to weight ratio Surface defects Surface properties Surfactants Thickness Time management Titanium base alloys |
| title | Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V |
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