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Study of the effect of process factors on the wear rate and surface integrity in incremental point forming of AA6061 aluminum alloy

Mughir Walaa Amer, Jasim Hussein Hatem

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 3

84--95

Incremental point forming is a contemporary method employed in sheet metal forming to achieve great flexibility in fabrication of intricate forms, eliminating the requirement for specific mold. According to its exceptional mechanical characteristics and low weight, this method is particularly employed in the production of aluminium alloys. The essential aim of this research is to examine the deformation mechanisms and discuss the mechanical properties of aluminium during the incremental forming process. The aim was to examine how various process parameters influence the surface properties, hardness, and wear resistance of the workpieces using aluminium alloy type AA6061. The parameters under investigation are increment step down size, feed rate, and spindle rotational speed. Furthermore, the impact of these factors on the forming process was investigated using several methodologies, including the Taguchi method for parameter optimization and surface analysis. The findings of this study demonstrate that spindle rotation speed exerted a substantial influence on both surface roughness and hardness, accounting for 63.41% for hardness and 52.19% for roughness. In terms of wear rate, the step size had the most significant impact, accounting for 48.53%.

Improving Wear Resistance of Mechanical Seal Using NI-P Electroless Coating

Jasim Hussein Hatem, Mughir Walaa Amer, AbidAli Abdulraheem

Advances in Science and Technology. Research Journal

2024

Vol. 18, no. 8

375--384

Electroless nickel phosphor coating is an important technology in the field of industrial coatings which is widely used in many technical applications. The electroless nickel phosphorus layer has high hardness and corrosion resistance, making it ideal for multiple applications for example, automotive, aerospace and electronics industries. Sulfuric acid is an essential agent in many industrial processes. The corrosive and abrasive nature of sulfuric acid results in rapid wear of mechanical parts, resulting in frequent replacement, increased maintenance costs, and may cause environmental and safety issues. This work employed electroless Ni-P coating, which was effectively assigned to mechanical seal models. The Taguchi design array L9 was used to conduct the experimental work. Mechanical properties such as Vickers hardness and wear rate were measured at different heat treatment temperature, coating time and coating bath temperature. The coating thickness was measured using an optical microscope. The results showed that the hardness increased reaching peak as 653 HV at 400C° and coating time 4 hours. As for wear resistance, it was recorded the lowest value as 0.00060 under same conditions. Through SEM and XRD, the formation of NiP and Ni3P were found. ANOVA demonstrated that heat treatment temperature was the most effected factor that contributed to enhance both hardness and wear resistance, followed by coating time.