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    A comparative study on mechanical and ballistic performance of functionally graded Al6061 composites reinforced with B4C, SiC, and Al2O3
    (Elsevier, 2023) Karabulut, Sener; Karakoc, Halil; Bilgin, Musa; Canpolat, Hakan; Krolczyk, Grzegorz M.; Sarikaya, Murat
    In the present study, functionally graded Al6061 composites reinforced with boron carbide (B4C), silicon carbide (SiC), and alumina (Al2O3) were prepared using the stir and centrifugal casting techniques. Arc-shaped functionally graded metal (FGM) specimens were treated with a hot-rolling process to enhance their mechanical properties and obtain laminated plates. Then, the impacts of ceramic reinforcements on the density, microhardness, tensile strength, and ballistic resistance of FGMs were studied. Moreover, the microstructural properties of the specimens were analyzed to elucidate the particle gradient from the inner to the outer surface. As a result, the microstructure observations revealed that the ceramic particles are dispersed from the inner to the outer periphery of the FGMs with centrifugal acceleration. A more homogeneous particle distribution was obtained in B4C-reinforced FGM compared to those of SiC and Al2O3. The hot-rolled FGM specimen reinforced with B4C offered the lowest density. The microhardness was improved by 32% and 30.4% in the inner to outer regions of the SiC-and Al2O3-reinforced FGMs, respectively, while it was improved by 22.6% in B4C-reinforced FGM. On the other hand, the tensile strength and elongation of the B4C-reinforced FGM specimen were better than those of the SiC-and Al2O3-reinforced FGMs. In addition, the highest ballistic protection was achieved with B4C-reinforced laminated FGM at an impact speed of 664.25 m/s with a penetration depth of 14 mm, while the impact speeds of SiC-and Al2O3-reinforced FGMs were 500.88 and 435.23 m/s, respectively.(c) 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
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    A review on aluminum alloys produced by wire arc additive manufacturing (WAAM): Applications, benefits, challenges and future trends
    (Elsevier, 2024) Sarikaya, Murat; Onler, Dilara Basil; Dagli, Salih; Hartomacioglu, Selim; Gunay, Mustafa; Krolczyk, Grzegorz M.
    Metal additive manufacturing is advancing with increasing momentum and attracting great attention. The Wire Arc Additive Manufacturing (WAAM) process, one of the metal additive manufacturing methods, involves melting a filler wire with an electric arc and depositing metal droplets layer by layer along the planned path. Aluminum alloys produced by the WAAM process have been in high demand in the industry, especially in the last decade. The WAAM process stands out as a suitable method for many industries due to its low investment cost, high deposition rates and the advantages of creating relatively complex parts. Key application areas of aluminum alloys produced using WAAM include aerospace, automotive, marine, and energy sectors, where lightweight structures, corrosion resistance, and high strength are critical. Much research has been done and innovative applications, including hybrid systems, have been developed to prevent defects such as residual stresses, cracks, porosity and delamination. This review article provides a comprehensive overview of the use of the WAAM process in aluminum alloys over the past decade. In the article, firstly, aluminum alloys, the WAAM technique and its types are introduced. In the following section, the methods used to improve mechanical properties and optimize the microstructure are examined in detail. In the next section, the difficulties encountered when using aluminum alloys in WAAM applications are discussed in detail. In the discussion section, current developments are evaluated, and in the last section, suggestions for future studies and inferences obtained from this study are presented. As a result, WAAM-CMT and hybrid systems were found to be effective in reducing defects such as porosity, distortion and residual stress. In addition, post-processing heat treatments and surface treatment methods are also crucial for improving mechanical properties. Finally, more research is needed in the areas of 7xxx series alloys, repair applications and environmental sustainability.
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    Cutting forces and temperature measurements in cryogenic assisted turning of AA2024-T351 alloy: An experimentally validated simulation approach
    (Elsevier Sci Ltd, 2022) Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Sarikaya, Murat; Krolczyk, Grzegorz M.; Gunay, Mustafa; Wojciechowski, Szymon
    Aluminium alloys are widely used in modern engineering applications such as automobile, aerospace etc because of its characteristics. The machining of aluminium alloys are also considered as difficult because of its sticky and soft nature, low thermal conductivity, strain hardening effect etc. The cooling conditions employed at cutting zone improved the machining performance but the resources, material consumption, skilled labor etc. are also required for performing the machining experiments. Therefore, the simulation of process parameters with the help of Finite Element Modelling (FEM) during machining is highly researched topic these days. In this work, a new practice from measurement science i.e., FEM simulation was performed with AdvantEdge software and the prediction models were developed for evaluating the cutting forces and cutting temperature while machining AA2024-T351 alloy under dry, liquid nitrogen (LN2) and carbon dioxide (CO2) conditions. Initially, the 3D turning model was developed and the results were compared with experimental findings. The results obtained from simulation model are very close with experimental results with minimum standard value of 0.67 (5.7%) for cutting forces and 4.58 (6.16%) for cutting temperature. Thus, it is worthy to mention that the 3D FE model is efficient and effective to predict and measurement results with minimum error.
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    Environmental, technological and economical aspects of cryogenic assisted hard machining operation of inconel 718: A step towards green manufacturing
    (Elsevier Sci Ltd, 2022) Danish, Mohd; Gupta, Munish Kumar; Rubaiee, Saeed; Ahmed, Anas; Sarikaya, Murat; Krolczyk, Grzegorz M.
    It is critical in today's modern manufacturing era to have a machining system that is both environmentally and economically beneficial. It is therefore necessary in many ways to illustrate a relationship between technological, economic and sustainability measures in the machining of Inconel 718. In present investigation, the experimental studies are incorporated by the use of the dry and MQL (minimum quantity lubrication) environments, as well as cryogenic-LN2 and cryogenic-CO2 environments. In terms of technological, sustainability, and economic metrics, the results show that cryogenic-LN2 performed better, followed by cryogenic-CO2, MQL, and dry conditions. As turning Inconel 718, LN2 assisted machining reduce total machining costs and energy usage considerably when compared to dry, MQL, cryogenic-CO2 environments. In addition, the LN2 cooling environment has been shown to significantly reduce machining outputs such as cutting force, tool wear, and surface roughness. LN2 conditions was found to be most promising as it has decreased the cutting force by 32.1%, tool flank wear by 33.33% and total energy consumption by 18% compared to dry machining conditions. It's worth noting that modern lubricooling technologies help the aerospace sector be more sustainable by decreasing resource consumption, enhancing environmental advantages, and improving machining features.
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    In-process detection of cutting forces and cutting temperature signals in cryogenic assisted turning of titanium alloys: An analytical approach and experimental study
    (Academic Press Ltd- Elsevier Science Ltd, 2022) Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Sarikaya, Murat; Krolczyk, Grzegorz M.; Guenay, Mustafa
    In-process detection of cutting forces, temperature, roughness, wear etc. during machining of titanium alloys are very important. The Finite element (FE) analysis plays an important role in monitoring and detection of machining responses. It offers a high accuracy in modeling of dry cutting processes and its performance in modeling of cryogenic machining process is a matter of interest. In this context, current investigation focuses on the dry turning and LN2/CO2 cooling assisted turning process of commonly used Ti6Al4V alloy. It is very useful material in the biomedical sector, and the simulation of cutting forces and cutting temperature via finite element method (FEM) has been performed. In addition, the simulation results are validated with experimental work. The results show that the deviations between FE modeling and experimental results for the cutting temperature are the average of 5.54%, 5.18% and 8.42% for the dry, LN2 and CO2 cooling conditions, respectively. On the other hand, the deviations from FE modeling and cutting force test results were 3.74%, 3.358%, and 3.03% under dry, LN2 and CO2 cooling conditions, respectively.
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    Performance and wear analysis in machining of Co-based Haynes 25/L605 superalloy using sustainable cooling/lubrication agencies
    (Elsevier, 2025) Sarikaya, Murat; Yildirim, cagri Vakkas; Sirin, Senol; Kara, Muhammed Ikbal; Sirin, Emine; Kivak, Turgay; Krolczyk, Grzegorz M.
    The cobalt-based Haynes 25 superalloy is a key material in sectors such as aerospace, medical, and energy, known for its outstanding high-temperature strength, wear and corrosion resistance. However, its low thermal conductivity and rapid work hardening rate make it inherently difficult to machine, highlighting the need for new cooling and lubrication methods. This work investigates the machinability of Haynes 25 under various sustainable cooling and lubrication techniques, including dry conditions, minimum quantity lubrication (MQL), nanofluids, and cryogenic COQ. Additionally, hybrid systems combining cryogenic COQ with nanofluids are also being investigated. The effectiveness of these approaches was ascertained by thorough investigations of surface roughness, cutting temperature, tool wear, and its mechanisms, and power consumption. Experimental results show that hybrid cooling systems especially those including nanofluids and cryogenic COQ significantly improve machining performance. Compared to dry machining, these methods minimized tool wear by 38 % and achieved up to a 44 % reduction in cutting temperature and a 32 % reduction in power usage. These results were a result of the enhanced thermal and tribological characteristics of nanofluids along with COQ's fast cooling capacity. This work provides a route toward sustainable and high-performance manufacture of challenging-to-machine materials by highlighting the possibilities of hybrid cooling strategies to maximize machining efficiency, extend tool life, and lower environmental impact.
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    Resource savings by sustainability assessment and energy modelling methods in mechanical machining process: A critical review
    (Elsevier Sci Ltd, 2022) Sarikaya, Murat; Gupta, Munish Kumar; Tomaz, Italo; Krolczyk, Grzegorz M.; Khanna, Navneet; Karabulut, Sener; Prakash, Chander
    In machining processes, there are contradictions between high efficiency and environmentally-friendly machining. This indicated that there is a major potential for sustainable machining to both increase efficiency and protect ecological balance. For this, the employment of effective methods has become imperative to reduce resource use. In this way, the use of analysis and optimization tools to select the tool material, cutting parameters, cooling/lubrication conditions, etc., will be a benefit for minimizing waste without sacrificing efficiency. In the literature, researchers have used various methods to reveal the requirements of sustainability. However, reaching the concept of sustainable machining by using one more than technique confuses the readers. Therefore, it was deemed necessary to present and discuss the current methods, models and analyzes in a comprehensive review paper. In this context, this paper reviewed the previously published works, especially focusing on sustainability and energy consumption modeling methods in machining operations. At the end of the study, it was seen that LCA provides a systematic and quantitative view of the system and thus can act as a decision support tool. Moreover, it can give an idea to the manufacturers about the improvement of the process and the areas of innovation. However, the method has several disadvantages such as relatively expensive and specific software, obtaining inventory data, impractical to use, time-consuming and requires large amounts of data. Various mathematical models and algorithms have been developed to deal with the complex situations and offer a more practical use compared to LCA. However, it is difficult to state that clear results have been achieved thanks to these models. It was seen that in complex machining processes, only approximate results can be found with models, which leads to questioning the reliability of the models.