Preface xvii 1 Aluminum and Its Different Graded Alloys 1G. Avinash, V. V. N. Sarath and A. Yeswanth 1.1 Introduction 1 1.2 Other Aluminum Materials 7 1.3 Applications 12 1.4 Conclusion 12 1.5 Future Scope 13 2 Cold Spray Additive Manufacturing 21Jagadeesha T., Arun Prakash J., Avinash Malladi and Seeniappan Kaliappan 2.1 Introduction 21 2.2 Phenomena and Factors Behind CSAM 25 2.3 Different CSAM Techniques 26 2.4 Advantages of CSAM 27 2.5 Disadvantages of CSAM 28 2.6 Numerical Simulation of CSAM of Ti6Al4V Pellets on Ti6Al4V Substrate 30 2.7 Conclusion 32 2.8 Future Scope 32 3 Optimization of Gas Metal Arc Welding (GMAW) Cladding Parameters for Enhanced Weld Integrity in Low-Carbon Steel Plates (EN30) 35Vivek Singh, Amit Kumar Singh, Akash Deep, Som Ashutosh, M. Chandrasekaran and Bishub Choudhary 3.1 Introduction 36 3.2 Experimental Work 39 3.3 Parametric Study 42 3.4 Taguchi Optimization 46 3.5 Conclusions 53 4 Design and Development of Brake Pedal by Topology Optimization Approach 57Sivashankar N., Jagadeesha T., Mothilal T. and Natrayan L. 4.1 Introduction 58 4.2 Structure Optimization 60 4.3 Topology Optimization 62 4.4 Optimization Results 63 4.5 Conclusion 68 5 Enhancing Resistance Spot Welding Weld Quality: A Comprehensive Analysis of Influencing Factors and the Role of Modeling and Optimization for Improved Quality 71Kaushal Jha, Santosh Kumar Tamang, Rajeev Kumar and Bishub Choudhury 5.1 Introduction 72 5.2 Influence of Welding Current and Time 74 5.3 Influence of Resistivity, Surface Preparation, and Cleanliness 78 5.4 Effect of Electrode Force and Electrode Tip Geometry 82 5.5 Modeling and Optimization of RSW Parameters 85 5.6 Conclusion 89 6 Shot-Peening Influence on Corrosion Behavior of SiC Particle Reinforced Aluminum Composite 95J. Venumurali and S. Rambabu 6.1 Introduction 96 6.2 Experimental Procedure 100 6.3 Results and Discussion 104 6.4 Residual Stress 108 6.5 Hardness Variation 110 6.6 Surface Roughness 111 6.7 Corrosion Behavior 112 6.8 Conclusion 117 7 3D Printing: Fundamentals, Applications, and Future Prospects 123Sonali Nag, Partha Pratim Borah and Kankan Kishore Pathak 7.1 Introduction 124 7.2 Materials for 3D Printing 125 7.3 Future Prospects of 3D Printing Technology 133 7.4 Conclusions 134 8 Cutting Zone Temperature and Cutting Force in 3D-Milling Operations Using ABAQUS 139Jagadeesha T., R. Thanigaivelan, Avinash Malladi and Natrayan L. 8.1 Introduction 140 8.2 Literature Review 141 8.3 Objectives 142 8.4 Methodology 142 8.5 Simulation 144 8.6 Milling Conditions 147 8.7 Result and Discussion 149 8.8 Conclusion 153 9 A Rare Ferroelectric Material: Fresnoite (Ba2TiSi2O8) 157Shiv K. Barbar 9.1 Introduction 158 9.2 Experimental 160 9.3 Characterization Details 161 9.4 Result and Discussion 162 9.5 Conclusion 181 10 Research Progress and Developments in GTAW Process Using Visual Sensing and Weld Penetration Estimation 187M. Soundarrajan, R. Prakash, D. Deepa, R.Thanigaivelan and P. Suresh 10.1 Introduction 188 10.2 GTAW Process 188 10.3 Sensing Technologies in Welding 190 10.4 Online Vision Inspection 193 10.5 3 Dimensional Image Processing of Weld Pool Geometry Using Dot Matrix 196 10.6 Real-Time Three-Dimensional Measurement of Topside and Backside Width of Weldment 197 10.7 Dynamic Estimation of Weld Pool Geometry 200 10.8 Visual Sensing Based on Supervised Machine Learning Technique 201 10.9 Hybrid Network Model Using Convolutional Neural Network and Long Short-Term Memory 202 10.10 Conclusion 203 11 Simulation of Sulfur Recovery Unit Using Aspen Plus 207Krati Hardya, V. K. Chandaliya, Pratik Swarup Dash, Barun Kumar Nandi, Deepak Kumar, Bishub Choudhury and Vishnu Kuntal 11.1 Introduction 208 11.2 Process Description 210 11.3 Methodologies 211 11.4 Results and Discussion 215 11.5 Conclusion 222 12 Fabrication of Magnesium Metal Matrix Nanocomposites Using Ultrasonic-Assisted Stir-Casting Method 227Parthiban K., Balaji E., Durairaj S. and Ashok Kumar R. 12.1 Introduction 228 12.2 Effect of Ultrasound on Magnesium Alloys 234 12.3 Conclusion 242 13 Friction Stir Welding of Dissimilar Magnesium Alloys: Analytical Modeling, Simulation, and Experimental Validation 247Biswajit Mallick, Jagadeesha T., Mothilal.T. and Seeniappan Kaliappan 13.1 Introduction 248 13.2 Analytical Modeling 250 13.3 Heat Input Modeling 251 13.4 Experimental Detail 260 13.5 Experimental Setup 260 13.6 Experimental Results 262 13.7 Conclusion 265 14 Advancements in Welding Techniques: Surface and Mechanical Property Insights 269Jagadeesha T., Manoj Nikam, T. Mothilal and M.D. Raj Kamal 14.1 Introduction 270 14.2 Resistance Welding 277 14.3 Hybrid Welding 281 14.4 Rotary Friction Welding 282 14.5 Friction Stir Welding 282 14.6 Properties of Friction Welding 284 14.7 Future Research Opportunities and Conclusions 284 15 Advanced 3D Printing for Industrial Components: Welded Joint Analysis and Strength Assessment 287Jagadeesha T., Amith Kumar Gajakosh, Avinash Malladi and Natrayan L. 15.1 Introduction 288 15.2 Material Used for SLM Technology 289 15.3 SLM Technology 3D Component 289 15.4 TIG Welding Method for Joining 290 15.5 ABS and PLA 3D Component Material 291 15.5.1 Fused Deposition Modeling 291 15.6 Welding Method Used for ABS and PLA 292 15.7 Characterisation Techniques 293 15.8 Challenges Faced in the Development Process 294 15.9 Conclusion 295 16 Advancements in Electrochemical Surface Coatings: Innovations, Applications, and Future Prospects 299Jagadeesha T., Soundarrajan M., Seeniappan Kaliappan and M.D. Raj Kamal 16.1 Introduction 300 16.2 Fundamentals of Electrochemical Process 301 16.3 Types of Electrochemical Surface Coatings 303 16.4 Overview of Surface Preparation Methods 305 16.5 Characterization of Electrochemically Coated Surface 308 16.6 Applications of Electrochemical Surface Coating in Various Fields 308 16.7 Challenges and Limitations of Electrochemical Surface Coating Methods 311 16.8 Conclusions 312 16.9 Future Trends 313 17 Process Variable Impact Analysis in Unconventional Machining: Enhancing MRR, Accuracy, and Surface Quality 317Jagadeesha T., Manoj Nikam, Seeniappan Kaliappan and Natrayan L. 17.1 Introduction 318 17.2 Nontraditional Machining Processes 319 17.3 Electrochemical Machining 321 17.4 Ultrasonic Machining 323 17.5 Laser Beam Machining (LBM) 328 17.6 Conclusion 330 17.7 Future Research Opportunities 331 18 Pulsed Power Supplies for Surface Coating Applications: Methods, Materials, and Case Studies 335Jagadeesha T., Amith Kumar Gajakosh, Seeniappan Kaliappan and S. Socrates 18.1 Introduction 336 18.2 Different Coating Materials 338 18.3 Magnetron Sputtering 338 18.4 Ceramic Coatings 339 18.5 Plasma Electrolysis Oxidation 341 18.6 Case Study 1: Aluminum Oxide Coatings by Unbalanced Sputtering 343 18.7 Case Study 2: Power Supply Mode in Plasma Electrolysis Oxidation (Micro-Arc Oxidation Coating) in Magnesium Alloy 345 18.8 Conclusions 346 19 Fabrication and Water Absorption Testing of Banana Fiber-Reinforced Composite 351Larikynti Massar, Rohan Sarkar, Nako Komo and Nabam Teyi 19.1 Introduction 352 19.2 Materials 354 19.3 Material Preparation 355 19.4 Fabrication Process 356 19.5 Water Absorption Testing 362 19.6 Results and Discussions 363 19.7 Conclusion 365 20 Multi-Objective Optimization of Fusion Welding Parameters Using Non-Dominated Sorting Genetic Algorithm II 369Monoj Kanti Chakraborty, Arun Jyoti Kalita, Deepty Pandey, Nirsanametla Yadaiah, Md. S. Mujaheed Khan and Nabam Teyi 20.1 Introduction 370 20.2 The Suggested Methodology 372 20.3 Results and Discussions 375 20.4 Conclusion 385 Declaration of Competing Interest 386 References 386 Index 389

The book focuses on multiple areas of manufacturing, including cutting-edge material processing technologies, custom-made materials, metallic and non-metallic materials, new engineering experiments, contemporary machining, joining, surface modification, and process optimization techniques. Readers will find in this volume an extensive exploration of various advanced manufacturing and material engineering topics. It includes a detailed examination of aluminum grades and their applications, an overview of cold spray additive manufacturing, and a discussion on Gas Metal Arc Welding (GMAW) for cladding low-carbon steel plates. The volume also presents innovative approaches to brake pedal design using topology optimization, analysis of resistance-spot welding quality, and the impact of shot peening on the corrosion behavior of SiC Particle Reinforced Aluminum Composite. It highlights crucial factors in 3D printed component strength, reviews 3D milling operations with ABAQUS, and delves into the rare ferroelectric material Fresnoite. The book surveys visual sensing technologies for weld pool analysis, simulates Claus Sulfur Recovery Units with Aspen Plus, and discusses ultrasonic-assisted stir casting for metal matrix nanocomposites. It also covers the joining of dissimilar magnesium alloys, advancements in electrochemical surface coatings, unconventional machining techniques, surface coating processes using pulsed power systems, natural fiber-reinforced composite fabrication, and process parameter optimization in laser beam welding using NSGA-II. Audience The book will interest researchers in academia and industry engineers in advanced manufacturing, materials science, surface science, adhesion and coatings, production engineering, civil engineering, and welding.