Browsing by Author "Sathiya, P"

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    A REVIEW OF FRICTION WELDING RESEARCH ADDRESSING THE INFLUENCE, DEVELOPMENT, SIMILAR & DISSIMILAR WELDING
    (Galati University Press, 2023-12-28) Murugan, S. Senthil.; Sathiya, P
    This review paper discusses the recent research work carried out in the frictional joining of dissimilar and similar alloys through the friction welding (FW) process with various parameters and modifications. It includes further the latest developments and advances in the research on FW and the influences of FW’s process parameters on the quality of joints and their properties. The specimens’ faying surfaces can also influence the joint properties as the surface modifications stimulate or change the metal joints’ bonding according to the welding parameters selected during FW. Though the rise of friction pressure (FP) during FW improves the strength of the joints, the improper selection of parameters leads to metal damage. It feels better if the axial shortening is less than 30 mm for FW of soft metals. The axial shortening values are less than 25 mm for the hemispherical bowl-type faying surfaces under 18 bar FP and it is noted that the bevel-type tapered faying surfaces increase the shortening. FW provided very narrow weld interfaces with around 5-10 µm width. With a low FP, it was possible to obtain a maximum of 100 % efficiency by modifying their faying surfaces. The small-diameter soft material needs less FP and friction time. The microstructure modification is possible and the weld joint is shown as U and V shapes for the bowl and tapered faying surfaces. It further increases the contact area and thus increases strength.
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    An experimental study of thermal fatigue on ASTM A 213 grade T-23 steel tube
    (Hindawi Limited, 2009-08-31) Jinu, G.R.; Sathiya, P; Ravichandran, G; Rathinam, A
    Super heater tubes are subjected to alternate heating and cooling in power plants causes crack and eventually fail. This phenomenon is termed as thermal fatigue. In this paper, a laboratory simulation for reproducing thermal fatigue phenomenon is developed to determine the number of cycles of failure occurs in super heater tubes. Thermal fatigue tests are conducted in Non-Destructive Tested T23 base and SMAW welded tubes separately. The tubes are subjected to thermal cycles from 800∘C (accelerated temperature) to room temperature (28∘C). In this work 800∘C is selected in order to achieve the crack much earlier. The selected temperature is just below the Ac1 temperature. The tubes are subjected to heat by Oxy-acetylene flame and subsequently quenched with water. The tests are carried out until open cracks are identified. Surface cracks are identified in the base and weld tubes after 120 and 80 cycles respectively. The tubes are then sectioned and subjected to optical microscopy. The causes of failures are thoroughly investigated using Scanning Electron Microscope (SEM). This study reveals that localised heating and cooling causes thermal fatigue which initiates cracks in the tubes.
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    Artificial neural network modeling studies to predict the friction welding process parameters of Incoloy 800H joints
    (Elsevier B.V., 2015-02-26) Anand, K; Barik, Birendra Kumar; Tamilmannan, K; Sathiya, P
    The present study focuses on friction welding process parameter optimization using a hybrid technique of ANN and different optimization algorithms. This optimization techniques are not only for the effective process modelling, but also to illustrate the correlation between the input and output responses of the friction welding of Incoloy 800H. In addition the focus is also to obtain optimal strength and hardness of joints with minimum burn off length. ANN based approaches could model this welding process of INCOLOY 800H in both forward and reverse directions efficiently, which are required for the automation of the same. Five different training algorithms were used to train ANN for both forward and reverse mapping and ANN tuned force approach was used for optimization. The paper makes a robust comparison of the performances of the five algorithms employing standard statistical indices. The results showed that GANN with 4-9-3 for forward and 4-7-3 for reverse mapping arrangement could outperform the other four approaches in most of the cases but not in all. Experiments on tensile strength (TS), microhardness (H) and burn off length (BOL) of the joints were performed with optimised parameter. It is concluded that this ANN model with genetic algorithm may provide good ability to predict the friction welding process parameters to weld Incoloy 800H. © 2015 Karabuk University
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    Numerical investigation of corrosion phenomena in heat-treated Mg-1Er-1Yb alloy via multiphysics modeling
    (Sciendo, 2026-03-03) Pranesh, B; Kanagaraj, M; Vaira Vignesh, R; Sathiya, P
    This study examines the galvanic corrosion behaviour of a Mg-1Er-1Yb alloy when coupled with 316L stainless steel, with particular emphasis on the influence of artificial aging. The alloy was solution-treated and aged at 200 °C for 5 h (HT5), 10 h (HT10) and 15 h (HT15), and compared with the base metal. Electrochemical characterization was performed in 3.5 wt.% NaCl using a three-electrode cell, with potentiodynamic scans conducted from −250 mV to +250 mV versus OCP at a scan rate of 1 mV s⁻¹. The Tafel parameters (βₐ, βc), corrosion potential (Ecorr), and corrosion current density (icorr) were extracted for both the Mg alloy (anode) and 316L stainless steel (cathode), enabling a quantitative assessment of galvanic interaction. Among all conditions, HT10 exhibited the most favourable performance, with a significantly reduced icorr (1.22 × 10⁻⁵ A cm⁻²) and the lowest corrosion rate (12.9 mm year⁻¹), compared to 22.8 mm year⁻¹ for the base metal. These experimental findings were incorporated into a COMSOL Multi- physics model using the Arbitrary Lagrangian Eulerian (ALE) method to dynamically track corrosion front movement under galvanic coupling. The simulated electrolyte potential fields, local current density profiles, pit morphology and thickness loss showed strong agreement with immersion and polarization results, with deviations below 7%. The study demonstrates that controlled aging at 200 °C for 10 h leads to a refined microstructure and improved galvanic compatibility with 316L stainless steel. The integrated experimental numerical approach provides a reliable framework for designing rare-earth- -based Mg alloys for sacrificial anode applications. © 2026 B. Pranesh et al., published by Association of Czech and Slovak Corrosion Engineers.
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    Simulation of weld bead geometry in gta welded duplex stainless steel(DSS)
    (John Wiley & Sons Ltd, 2009-07-22) Sathiya, P; Jinu, G.R.; Singh, Navjot
    Temperature analysis of GTA welding of Duplex Stainless Steel material (2205) is simulated using ANSYS software by finite element technique taking in account the characteristics and advantage of GTAW than other sources. A travel heat source combined with body loads was designed by analyzing thermal physical parameters, latent heat of fusion of material. Modeling was carried out by using solid modeling and direct generation technique. A residual control method was taken for precise node selection, Simulation was done by varying the parameter of GTA, welding speed. The quasisteady state temperature field of GTA welding was simulated with the FEA softwareANSYS as well as tests. The objective of this work is to compare the experimentally obtained weld bead geometry of DSS material with simulated results from ANSYS software for various weld parameters. The higher the value of joining efficiency is, the less heat energy is spent on unnecessary heating-that is generating a heat affecting zone (HAZ) or distortion. Joining of two metals or alloys is important in every aspect of engineering which leads to welding in an effective manner and carrying out the analysis. The experimental analysis shows that the model is showing good agreement with the experimental results. Comparison of the experimental and simulated results shows the maximum deviation of 1.27 and 10 for calculating bead width and depth of penetration, respectively. Copyright © 2009 P. Sathiya et al.
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    Transient out-of-plane distortion of multi-pass fillet welded tube to pipe T-joints
    (China Ordnance Society, 2016-07-19) Vetriselvan, R.; Devakumaran, K.; Sathiya, P; Ravichandran, G.
    The out-of-plane distortion induced in a multi-pass circumferential fillet welding of tube to pipe under different weld sequences and directions was studied using Finite Element Method (FEM) based Sysweld software and verified experimentally. The FEM analyses consisted of thermal and mechanical analyses. Thermal analysis was validated with experimental transient temperature measurements. In the mechanical analysis, three different weld sequences and directions were considered to understand the mechanism of out-of-plane distortion in the tube to pipe T-joints. It was learnt that the welding direction plays a major role in minimizing the out-of-plane distortion. Further, during circumferential fillet welding of the tube to pipe component, the out-of-plane distortion generated in the x direction was primarily influenced by heat input due to the start and stop points, whereas the distortion in the z direction was influenced by time lag and welding direction. The FEM predicted distortion was compared with experimental measurements and the mechanism of out-of-plane distortion was confirmed.