Investigations on mechanical features and mechanical performance of rotary friction welded Al-Cu joint at optimized conditions Bakkiyaraj Murugesan, U Elaiyarasan, Jambulingam Ananth, Parasumanna Krishnamurthy Nagarajan Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2026 In this experimental investigation, rotary friction welding (RFW) was employed to fabricate dissimilar Al-Cu joints, and the RFW variables were rotated against the ultimate tensile strength (UTS) in an effort to strengthen the dissimilar AA1100 and pure copper (Al-Cu) joint using response surface methodology (RSM) with a three-factorial design. Following this, micro-hardness, metallurgical characterization, and fatigue properties studies were done on the dissimilar joints fabricated under the optimized conditions. As a result of this investigation, the UTS of 208 MPa was attained as a maximum as the rotation speed was set at 1800 rpm, the friction time was 10 s, and the forging load was 5 kN. The dissimilar joint exhibits a better fatigue strength of 98.5 MPa when compared to the AA1100 base metal. At optimized conditions, the feature of the fracture image was found to be brittle due to the development of new compounds in the weld interface. A significant dip in micro hardness (52 Hv) was noticed in the region that connects TMAZ and HAZ of the AA1100 side of the dissimilar joint, which was concluded to be the weakest zone as the dissimilar joints were fractured in the same location during the tensile test. The observed results benefit the automotive sector, especially when fabricating components that require effective thermal management and weight reduction, like electrical connectors, heat dissipation systems, and radiators. For heat exchanger applications, improved fatigue strength in dissimilar Al-Cu joints is important because it guarantees longer structural integrity and improved durability.
An integrated RSM-ANN approach for predicting mechanical properties in bobbin tool friction stir welded dissimilar AA5052 and AA6061 alloys Sathish Kumar M, Gopi S, Elaiyarasan U Phosphorus Sulfur and Silicon and the Related Elements, 2026 This investigation employs response surface methodology (RSM) and artificial neural network (ANN) model to develop an integrated optimization and prediction for the mechanical characteristics of bobbin tool friction stir welded dissimilar AA5052-H32 and AA6061-T6 alloys. The effects of rotational speed (Rs: 450–650 rpm), travel speed (Ts: 80–100 mm/min), and tool shoulder diameter (Td: 6–8 mm) on ultimate tensile strength (UTS) and microhardness (MH) were investigated through central composite design. The quadratic regression models developed using RSM exhibited excellent accuracy, with R2 values of 99.96% for UTS and 99.97% for MH. The parameters Rs: 650 rpm, Ts: 80 mm/min, and Td: 8 mm produced maximum UTS of 219.12 MPa and MH of 122.12 HV, attributed to enhanced frictional heat, grain refinement, and dynamic recrystallization within the stir zone. ANN modeling further validated the framework, showing strong correlations (R = 0.983) between experimental and predicted values. Microstructural examination under optimal conditions confirmed improved metallurgical bonding, lamellar material flow, and homogeneous precipitate redistribution. Overall, the integrated RSM–ANN framework provides robust tool for process optimization, enabling the defect-free joining of dissimilar alloys with excellent performance for automotive, maritime, and aerospace fields.
Evaluating the effect of discarded tube light particle filler on the mechanical performance of epoxy/novel crown root fiber bio-composites Baranitharan Paramasivam, Elaiyarasan Uthirapathi, Sriariyanun Malinee, Balaji Narayanasamy Shanmugam Materials Science and Technology United Kingdom, 2026 This study examines the mechanical performance of epoxy bio-composites reinforced with crown root fiber (CRF) and embedded with waste tube light particles (WTP) using a Taguchi L27 orthogonal design. The composites were fabricated by compression molding with varying fiber length (20, 35, 50 mm), fiber content (40, 50, 60 wt.%), and filler content (3, 6, 9 wt.%). Mechanical characteristics were assessed in accordance with ASTM standards, and regression models combined with analysis of variance (ANOVA) were applied to analyse parameter significance. The results revealed that flexural strength attained a maximum of 38 MPa under the optimized reinforcing conditions, while tensile strength, impact strength peaked at 32.5 MPa and 47.5 J/m, respectively for fiber length of 35 mm, fiber weight fraction of 50 wt% and filler content of 6 wt.%. The study demonstrates the potential of integrating e-waste fillers and agricultural residues into epoxy composites, thereby improving mechanical performance while contributing to sustainable and eco-friendly materials development for structural applications. The developed composites are useful for low-load structural components, car interiors, construction panels, packing, and other lightweight structural applications. They can also be used as economical material solutions by substituting waste materials for traditional fillers.
Optimization and performance evaluation of PET-SiO2 polymer-modified geopolymer concrete employing integrated RSM-ANN approach Prabha G., Elaiyarasan U., Visagan A., Senthilkumar P., Senthilkumar N. Phosphorus Sulfur and Silicon and the Related Elements, 2026 This research investigated the optimization and prediction analysis of mechanical characteristics of PET-SiO2 polymer-modified geopolymer concrete (GPC) using response surface methodology (RSM) integrated with artificial neural network (ANN). The mixture effects of PET-SiO2 volume (Vp), ratio of activator (Ra), and curing period (Cp) on compressive strength (CS) and flexural strength (FS) have been studied using RSM-based Box–Behnken design. The developed mathematical model for CS and FS exhibited strong predictive accuracy with R2 value of 99.87% and 99.67%, respectively. The composite desirability optimization results revealed that the identified optimal parameters of 5.7 g, 1.995, and 7.02 days attained the maximum CS of 40.33 MPa and FS of 4.93 MPa, which was close to the RSM values with a minimal error of 2.21% and 1.45%, respectively. Additionally, validation iteration was carried out to confirm the reliability and robustness of the developed model. The feedforward backpropagation-based ANN was proposed to train, test, and validate the model of CS and FS. The ANN results revealed the correlation coefficient of 0.9881 which was close to the RSM regression model, demonstrating its excellent predictive capability. The findings concluded that addition of PET- SiO2 polymer acted as effective strategy to enhance the mechanical properties and matrix densification.
Investigation on microstructural evolution and surface integrity of Ti-6Al-4V alloy machined using WC nanoparticle-enhanced powder-suspended EDM Elaiyarasan Uthirapathi, Shanthos Kumar Ganesan, Visagan Arjunan, Elangovan Theerthamalai, Putti Venkata Siva Teja Metallurgical Research and Technology, 2026 Ti-6Al-4V paly crucial role in biomedical, automobile, and aerospace sectors; however, its high chemical reactivity and low thermal conductivity poses serious challenges during traditional machining. Electrical discharge machining (EDM) has demonstrated significant potential in improving surface characteristics; however, the integration of powder-suspended EDM (PS-EDM) further enhances machining performance. This study investigates the effects of tungsten carbide (WC) nanoparticle-enriched dielectric fluid on the material removal rate (MRR), microhardness (MH), surface roughness (SR), and microstructural characteristics of Ti-6Al-4V alloy. WC nanoparticles were introduced into the dielectric fluid at varying concentration of 0, 1, 3 and 5 g/L, with continuous mechanical stirring. The controlled EDM parameters included discharge current (I) of 4 A, 6 A, 8 A and pulse on time (T on ) of 30 μs, 50 μs, 70 μs. The results revealed that an optimal WC concentration of 3 g/L, coupled with increasing ‘I’ and ‘T on ’, led to enhanced MRR, MH, while reducing SR. The maximum MRR (0.0223 g/min) and MH (515 HV) were achieved at 3 g/L, 8 A, 70 μs, whereas the lowest SR (2.85 μm) was observed at 3 g/L, 6 A, 50 μs. MH improved by 63.4% compared to the base alloy. Scanning electron microscope (SEM) analysis confirmed a refined surface with minimal defects at 6 A, 50 μs, 3 g/L, whereas deep crater, and nanoparticle agglomeration were evident at 8A, 70 μs, and 5 g/L. This study establishes that WC concentration, ‘I’ and ‘T on ’ significantly influence machining performance and surface integrity during EDM of Ti-6Al-4V alloy. Future research could explore the dispersion of hybrid nanoparticle in bio-based dielectric fluids to optimize machining efficiency and surface characteristics.
Surface integrity and microstructure analysis of the AZ31B magnesium alloy machined by sustainable EDM with a B4C-enriched bio-dielectric fluid T. Elangovan, J. Ajith, G. V. Hariharan, S. Dinesh Kumar, M. Manickam, U. Elaiyarasan Canadian Metallurgical Quarterly, 2026 Owing to their high work-hardening tendency and low thermal conductivity, machining magnesium alloys is challenging. This study investigated the machining of AZ31B magnesium alloy using sustainable electrical discharge machining (EDM) with boron carbide (B4C) nanoparticles suspended in waste vegetable oil (WVO) as a dielectric fluid under reverse polarity. The effects of current (I), pulse-on time (Ton) and B4C concentration (PC) on particle removal rate (PRR) and machined surface roughness (MSR) were analyzed. The maximum PRR of 0.0271 g/min and minimum MSR of 3.15 μm were achieved. PRR and MSR increased with I, Ton, PC, but PRR declined at higher levels. Optimal conditions (6A, 50 μs, 10 g/L) enhanced PRR and MSR. ANOVA identified ‘I’ as the most influential parameter, contributing 11.57% to PRR and 18.57% to MSR. Scanning electron microscope (SEM) revealed surface defects at 6A, 50μs, 15 g/L. The study highlights WVO-based bio-dielectric potential for sustainable EDM applications.
Effect of discharge parameters on surface integrity and microstructure in electro discharge layering of Ni–Cr composite coating on AA2024 aluminium alloy C. Asokan, U. Elaiyarasan, Malinee Sriariyanun, P. Baranitharan, S. R. Kalaivani Discover Materials, 2025 In the present research, an attempt was made to create a nickel–chromium (Ni–Cr) composite layer on AA2024 aluminum alloy using electrical discharge layering (EDL). The electrode was fabricated with a composition of Ni50:Cr50 under a compaction pressure of 400 MPa using the powder metallurgy method. During the EDL process, various parameters such as discharge current (I) − 3 A, 5 A, 7 A; pulse-on time (T on ) − 25 µs, 50 µs, 75 µs; and pulse-off time (T off ) − 4 µs, 6 µs, 8 µs, were regulated to improve the deposition rate (DR) and surface roughness (SR). The microstructure and elemental composition of the Ni–Cr coating were analyzed using a scanning electron microscope (SEM) and energy-dispersive spectroscopy (EDS), respectively. The results revealed that the DR increased with higher levels of I, T on , and T off . The highest DR of 0.435 g/min was achieved at 7 A, 75 µs, and 6 µs, while the lowest SR of 3.59 µm was recorded. SR increased with rising Ton and Toff values but decreased with increasing I. SEM analysis indicated the formation of larger craters at 7 A due to higher energy sparking. At a Ton of 25 µs, shallow craters were observed, whereas, at 75 µs, globular structures were formed, attributed to enhanced energy absorption. EDS analysis confirmed the presence of elements from both the AA2024 alloy and the electrode. The percentages of electrode elements in the coating were 34.32% Ni and 28.64% Cr. This study concluded that the composite electrode and optimal parametric settings play a crucial role in enhancing DR and SR.
Strategic SWOT and RSM Analysis on Performance Assessment of WC/Cu Powder Metallurgy Electrode in EDM of AISI-D2 Tool Steel S Mathiazhagan, V Arjunan, E Uthirapathi, V Bareedu International Journal of Industrial Engineering: Theory, Applications and … , 2026 2026
Evaluating the effect of discarded tube light particle filler on the mechanical performance of epoxy/novel crown root fiber bio-composites B Paramasivam, E Uthirapathi, S Malinee, B Narayanasamy Shanmugam Materials Science and Technology, 02670836261444116 , 2026 2026
Development of empirical model and surface integrity enhancement of electro-discharge alloyed AA2024 aluminium substrate using a sintered P/M electrode C Asokan, U Elaiyarasan, G Kavitha, P Govindhan, M Shalini Canadian Metallurgical Quarterly, 1-15 , 2026 2026
Optimization and performance evaluation of PET-SiO2 polymer-modified geopolymer concrete employing integrated RSM-ANN approach G Prabha, U Elaiyarasan, A Visagan, P Senthilkumar, N Senthilkumar Phosphorus, Sulfur, and Silicon and the Related Elements , 2026 2026
An integrated RSM-ANN approach for predicting mechanical properties in bobbin tool friction stir welded dissimilar AA5052 and AA6061 alloys S Gopi, U Elaiyarasan Phosphorus, Sulfur, and Silicon and the Related Elements , 2026 2026
Investigations on mechanical features and mechanical performance of rotary friction welded Al-Cu joint at optimized conditions B Murugesan, U Elaiyarasan, J Ananth, PK Nagarajan Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2026 2026 Citations: 1
Surface integrity and microstructure analysis of the AZ31B magnesium alloy machined by sustainable EDM with a B 4 C-enriched bio-dielectric fluid T Elangovan, J Ajith, GV Hariharan, S Dinesh Kumar, M Manickam, ... Canadian Metallurgical Quarterly 65 (1), 88-98 , 2026 2026 Citations: 10
Investigation on microstructural evolution and surface integrity of Ti-6Al-4V alloy machined using WC nanoparticle-enhanced powder-suspended EDM E Uthirapathi, SK Ganesan, V Arjunan, E Theerthamalai, ... Metallurgical Research & Technology 123 (1), 115 , 2026 2026
Investigation of kinetic and thermodynamic attributes of co-pyrolysis of chemically treated wood apple seed and clinical medical waste for energy recovery B Paramasivam, U Elaiyarasan, M Sriariyanun, S Venkatesh Energy Sources, Part A: Recovery, Utilization, and Environmental Effects 47 … , 2025 2025
Parametric optimization of electro discharge machining for A356/TiB 2 composite using neem oil dielectric: Machining performance and surface morphology analysis C Rajaravi, U Elaiyarasan Phosphorus, Sulfur, and Silicon and the Related Elements 200 (12), 905-914 , 2025 2025 Citations: 3
Enhancing surface integrity and mechanical characteristics of AZ91D magnesium alloy using Cr–Cu electrode assisted electro-discharge deposition P Shanmugapriya, U Elaiyarasan, S Ravi, G Kavitha Canadian Metallurgical Quarterly, 1-16 , 2025 2025
Wear behaviour and coating performance of WC–Cu composite electrodes on ZE41A magnesium alloy using electrospark deposition U Elaiyarasan, P Baranitharan, V Satheeshkumar, C Senthilkumar, ... Canadian Metallurgical Quarterly 64 (4), 2114-2127 , 2025 2025 Citations: 11
Utilization of stone apple seed biomass and discarded X-ray film blend for kinetic and thermodynamic attribute analysis for efficient energy refinery P Baranitharan, U Elaiyarasan, M Sriariyanun Biomass Conversion and Biorefinery 15 (18), 25023-25033 , 2025 2025 Citations: 1
Effect of discharge parameters on surface integrity and microstructure in electro discharge layering of Ni–Cr composite coating on AA2024 aluminium alloy C Asokan, U Elaiyarasan, M Sriariyanun, P Baranitharan, SR Kalaivani Discover Materials 5 (1), 103 , 2025 2025 Citations: 6
An integrated biorefinery of wood apple kernel for bio-oil and bio-diesel production: optimization of engine attributes using Taguchi, RSM, and CRITIC-COCOSO hybrid techniques M Sriariyanun, E Uthirapathi, S Rajamohan, B Paramasivam, A Tawai, ... International Journal of Environmental Research 19 (3), 67 , 2025 2025 Citations: 3
Experimental study on parametric effect of wire electric discharge machining of titanium grade 2 alloy using cryogenic treated wire U Elaiyarasan, C Nandakumar, T Arunkumar Journal of Materials Engineering and Performance 34 (12), 12098-12106 , 2025 2025 Citations: 5
Energy out of waste: kinetics and thermolysis of co-pyrolysis of biomass and municipal plastic waste P Baranitharan, U Elaiyarasan, R Sakthivel, M Sriariyanun, ... Biomass Conversion and Biorefinery 15 (10), 15341-15359 , 2025 2025 Citations: 12
Evaluation on Tribological Performance of Ti-6Al-4V Alloy Modified Using Powder Composite Electrode-Assisted Electrical Discharge Coating: Elaiyarasan, Baranitharan … U Elaiyarasan, P Baranitharan, V Satheeshkumar, C Senthilkumar, ... JOM 77 (4), 1834-1843 , 2025 2025 Citations: 9
Investigating the Impact of Parameters on Electrical Discharge Treatment of ZE41A Magnesium Alloy Utilizing a WC/Ni Powder Composite Electrode PS Kumar, U Elaiyarasan, V Satheeshkumar, CS Kumar Advances in Composite and Advanced Materials Machining, 109-122 , 2025 2025
Enhancing microhardness and surface integrity of Ti–6Al–4V alloy using WC–Cu composite electrode aided electrical discharge coating U Elaiyarasan, V Satheeshkumar, C Senthilkumar, T Arunkumar Journal of Adhesion Science and Technology 39 (4), 596-614 , 2025 2025 Citations: 9
MOST CITED SCHOLAR PUBLICATIONS
Experimental analysis of electrical discharge coating characteristics of magnesium alloy using response surface methodology U Elaiyarasan, V Satheeshkumar, C Senthilkumar Materials Research Express 5 (8), 086501 , 2018 2018 Citations: 27
Chemical treatments and mechanical characterisation of natural fibre reinforced composite materials-a review V Vinoth, S Sathiyamurthy, N Ananthi, U Elaiyarasan International Journal of Materials Engineering Innovation 13 (3), 208-221 , 2022 2022 Citations: 25
Response surface methodology study on electrical discharge deposition of AZ31B magnesium alloy with powder composite electrode U Elaiyarasan, B Vinod, K Nallathambi International Journal on Interactive Design and Manufacturing (IJIDeM) 17 (1 … , 2023 2023 Citations: 21
A study on wear behaviour of electrical discharge-coated magnesium alloy U Elaiyarasan, V Satheeshkumar, C Senthilkumar Journal of Bio-and Tribo-Corrosion 5 (1), 30 , 2019 2019 Citations: 20
Effect of sintered electrode on microhardness and microstructure in electro discharge deposition of magnesium alloy U Elaiyarasan, V Satheeshkumar, C Senthilkumar Journal of the Mechanical Behavior of Materials 29 (1), 69-76 , 2020 2020 Citations: 19
Surface modification of a magnesium alloy by electrical discharge coating with a powder metallurgy electrode U Elaiyarasan, V Satheeshkumar, C Senthilkumar Materials Testing 63 (4), 360-367 , 2021 2021 Citations: 18
Effect of parameters on microstructure of electrical discharge coated ZE41A magnesium alloy with tungsten carbide-copper composite electrode U Elaiyarasan, V Satheeshkumar, C Senthilkumar Surface Topography: Metrology and Properties 9 (2), 025006 , 2021 2021 Citations: 16
An examination on dry sliding wear behaviour of AA7075 aluminium alloy modified with FA/Cu electro-discharge coating E Uthirapathi, S Chinnamuthu, N Kaliyamoorthi Journal of Bio-and Tribo-Corrosion 10 (2), 25 , 2024 2024 Citations: 15
Modeling and optimization of electro discharge coating parameters for coating of aluminum alloy using WC/Ni electrode S Srikanth, C Senthilkumar, U Elaiyarasan CIRP Journal of Manufacturing Science and Technology 41, 465-476 , 2023 2023 Citations: 15
Surface roughness and microstructure analysis on drilling of titanium diboride in-situ aluminium metal matrix composite C Rajaravi, U Elaiyarasan, B Gobalakrishnan, R Ganapathy Srinivasan Surface Topography: Metrology and Properties 10 (2), 025034 , 2022 2022 Citations: 13
Energy out of waste: kinetics and thermolysis of co-pyrolysis of biomass and municipal plastic waste P Baranitharan, U Elaiyarasan, R Sakthivel, M Sriariyanun, ... Biomass Conversion and Biorefinery 15 (10), 15341-15359 , 2025 2025 Citations: 12
An investigation on electrical discharge metal matrix coating of ZE41A magnesium alloy U Elaiyarasan, V Satheeshkumar, C Senthilkumar Metallurgical Research & Technology 118 (3), 314 , 2021 2021 Citations: 12
Wear behaviour and coating performance of WC–Cu composite electrodes on ZE41A magnesium alloy using electrospark deposition U Elaiyarasan, P Baranitharan, V Satheeshkumar, C Senthilkumar, ... Canadian Metallurgical Quarterly 64 (4), 2114-2127 , 2025 2025 Citations: 11
Parametric effect on electrical discharge treatment of magnesium alloy with powder composite electrode U Elaiyarasan, V Satheeshkumar, C Senthilkumar SN Applied Sciences 2 (3), 390 , 2020 2020 Citations: 11
Microstructure study on electro discharge deposited magnesium alloy with semi sintered and sintered electrode U Elaiyarasan, V Satheeshkumar, C Senthilkumar Materials Research Express 6 (12), 126533 , 2019 2019 Citations: 11
Surface modification of ZE41A magnesium alloy using electrical discharge coating with semi sintered electrode U Elaiyarasan, V Satheeshkumar, C Senthilkumar International Journal of Machining and Machinability of Materials 21 (5-6 … , 2019 2019 Citations: 11
Surface integrity and microstructure analysis of the AZ31B magnesium alloy machined by sustainable EDM with a B 4 C-enriched bio-dielectric fluid T Elangovan, J Ajith, GV Hariharan, S Dinesh Kumar, M Manickam, ... Canadian Metallurgical Quarterly 65 (1), 88-98 , 2026 2026 Citations: 10
Deposition rate and microhardness analysis on electrical discharge coating of AA7075 using response surface methodology K Nallathambi, C Senthilkumar, U Elaiyarasan International Journal on Interactive Design and Manufacturing (IJIDeM) 18 (4 … , 2024 2024 Citations: 10
Evaluation on Tribological Performance of Ti-6Al-4V Alloy Modified Using Powder Composite Electrode-Assisted Electrical Discharge Coating: Elaiyarasan, Baranitharan … U Elaiyarasan, P Baranitharan, V Satheeshkumar, C Senthilkumar, ... JOM 77 (4), 1834-1843 , 2025 2025 Citations: 9
Enhancing microhardness and surface integrity of Ti–6Al–4V alloy using WC–Cu composite electrode aided electrical discharge coating U Elaiyarasan, V Satheeshkumar, C Senthilkumar, T Arunkumar Journal of Adhesion Science and Technology 39 (4), 596-614 , 2025 2025 Citations: 9
