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    Effect of particle volume fraction on wear behavior in Al-SiC MMC coated on DIN AlZnMgCu1.5 alloy
    (Walter De Gruyter Gmbh, 2024) Ballikaya, Hasan
    In this study, DIN AlZnMgCu1.5 alloy surface (Al + SiC) was coated with metal matrix composite (MMC) by using hot press sintering method (HPSM). Al was used as matrix material and SiC powders were used as reinforcing material in the coating process on DIN AlZnMgCu1.5 alloy surface. Al/SiC MMC coating was produced at 600 C-degrees under 120 MPa pressure and with varying SiC content (5, 10 and 15 vol.%). Optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used to examine the microstructure, elemental analysis and phase structure of both the coating zone and the transition zone between the substrate and the coating. The hardness was measured and a dry sliding linear reciprocating wear test was run to determine the mechanical properties of the coating layer. Consequently, the coefficient of friction (COF) and wear volume were determined. OM and SEM images showed a homogeneous distribution of SiC particles and a less porous structure. The hardness of the MMC coating increased with increasing SiC content. Also, the numerical analysis of the wear test simulation was done based on Archard's law. The results of both wear tests showed that the volume loss values were consistent with each other and the amount of wear significantly reduced by increasing the rate of SiC reinforcement.
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    The limit drawing ratio in die angled hydromechanical deep drawing method
    (Springer London Ltd, 2020) Ballikaya, Hasan; Savas, Vedat; Ozay, Cetin
    In the study, the effect of die angle, die radius, die punch, blank holder force, and chamber pressure parameters on the limit drawing ratio (LDR) in die angled hydromechanical deep drawing process was investigated by using Taguchi experimental design method. The effects of the parameters on the limit drawing ratio were numerically examined and compared experimentally using ANSYS packaged software. Also, the data were statistically analyzed by using the ANOVA analysis of variance in order to determine the effects of the parameters on the limit drawing ratio. The results indicated that the chamber pressure value was lower and the limit drawing ratio was higher than the values reported in the literature.
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    A New Optimization Technique in Examining the Machinability of Sverker 21 Steel: Gray Relational Analysis-Based Genetic Algorithm
    (Springer Heidelberg, 2021) Ozay, Cetin; Altug, Mehmet; Ballikaya, Hasan
    In this study, to determine the optimum parameters of the WEDM method, Taguchi experiment design, gray relational analysis (GRA) and gray relational analysis-based genetic algorithm (GRABGA) methods were used. In experimental studies, first, microstructure, microhardness and conductivity examinations of, both commercial and heat treated, Sverker 21 cold tool steel were performed. Then, the commercial and heat-treated Sverker 21 cold tool steel was processed with the WEDM method at the determined parameters. The effects of processing parameters on average surface roughness (Ra), kerf, and vibration were evaluated separately using Taguchi test design, GRA and GRABGA methods. It was determined that the homogeneous distribution of the carbides increased, the microhardness increased and the conductivity increased in the microstructure of the heat-treated sample compared to the commercial sample. In the processing of materials with WEDM, while the Taguchi test design method was used to evaluate the effects of processing parameters on the results were evaluated separately, GRA method was used to determine the grade of relationship between the results. In addition, the GRABGA method enabled the optimum values of the processing parameters to be determined not only on the basis of the level, but also on the intermediate values. It was found that the GRA relationship value was 0.8564 whereas the GRABGA relationship value was 0.8977. It was concluded that the GRABGA method provided better results than the GRA method in the correlation analysis of the results obtained in processing D2 cold tool steel with the WEMD method.