MICROSTRUCTURE AND SURFACE

INTEGRITY OF MONEL K-500(SUPER

ALLOY) BY ABRASIVE WATER JET
MACHINING
A PROJECT REPORT
submitted by
SELVA KUMAR R 710716114082
SENTHIL KUMARAN K R 710716114083
RANJITH M 710716114317

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

Dr.N.G.P. INSTITUTE OF TECHNOLOGY, COIMBATORE – 641 048

ANNA UNIVERSITY: CHENNAI 600 025

SEPTEMBER 2020

1
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “​MICROSTRUCTURE AND

SURFACE INTEGRITY OF MONEL K-500(SUPER ALLOY) BY
ABRASIVE WATER JET MACHINING” ​is the bonafide work of
“SELVA KUMAR R,​ ​SENTHIL KUMARAN K R , RANJITH M ​” who
carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr.S.NANDHAKUMAR Mr V.P.PRADEEP
HEAD OF THEDEPARTMENT​, SUPERVISOR,
Professor, Professor,
Department of Mechanical Engineering, Department of Mechanical
Engineering,
Dr.N.G.P. Institute of Technology, Dr.N.G.P. Institute of
Technology,
Coimbatore–641048 Coimbatore–641048

Submitted for the University Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

2
 ACKNOWLEDGEMENT

We express our deepest gratitude to our Management, for providing us

with an environment to complete our Design and Fabrication Project
successfully.

We are very grateful ​to Dr.K.Porkumaran, Principal, for his valuable

guidance and blessings.

We would also like to thank ​Dr.S.Nandhakumar, Professor and Head,

Department of Mechanical Engineering for his unwavering support during the
entire course of the project work who modeled us both technically and morally
for achieving greater success in this project work.

We thank our Project coordinator ​Mr V.P.PRADEEP​, Professor,

Department of Mechanical Engineering for his help and innovative ideas in
making this project a successful one.

We express our sincere thanks to our Supervisor ​Dr.S.Nandhakumar,

Assistant Professor, and Department of Mechanical Engineering for his constant
encouragement and support throughout our course, especially for the useful
suggestions given during the course of the project period and being instrumental
in the completion of our project with his complete guidance.

We also thank our Faculty and lab technicians, Department of

Mechanical Engineering for their assistance in completing the project work.

Finally, we take this opportunity to extend our deep appreciation to our

family and friends, for all that they meant to us during the crucial times of the
completion of our project.

3
 ABSTRACT

Abrasive water jet machining (AWJM) process is one of the

non-conventional machining processes for difficult to cut brittle, hard and thin
materials. The process parameters which mainly influence the quality of
machining in AWJM are water pressure, stand of distance, nozzle diameter,
Transverse speed, abrasive flow rate, and abrasive size. This is an environment
friendly and relatively inexpensive cause with reasonably high MRR. The
quality parameters considered in AWJM are kerf characteristics, surface
roughness, MRR, nozzle wear and depth of cut. Various mathematical models
and modern approaches are applied to optimize the process parameter thereby
improving the performance of the characteristics. The roughness change of
machining parameters in this paper presents an approach to the determination of
optimal cutting parameters with the help of AWJM method to create high
surface finish in the cutting of MONEL K-500.

4
 TABLE OF CONTENTS

CHAPTER
TITLE PAGE NO.
NO.
ABSTRACT 4

1. INTRODUCTION 9

1.1.Introduction of water jet 9

1.2.History of abrasive water jet 9

1.2.1.Abrasive water jet 10

1.2.2.Water jet control 11

1.2.3.components required in AWJM 12

1.3.Process parameters 12

1.3.1.Working principle 15

1.3.2.Advantages 15

1.3.3.Application 16

1.3.4.Limitation 16

1.4 Objective 17

2. LITERATURE REVIEW 18

2.1.Literature survey 18

2.2.Summary 22

5
CHAPTER
TITLE PAGE NO.
NO.
3. EXPERIMENTAL METHODOLOGY 23

3.1.Flow chart of methodology 23

3.2.Material requirements 24

3.3.Experimental setup 24

3.3.1 The working tank 25

3.3.2 Air compressor unit 25

3.3.3 Abrasive water jet cutting head 26

3.3.4 Work holding and cutting head holding

26
arrangement

3.3.5 pressure hose 27

3.3.6 Storage tank 27

3.4 Experimental procedure 28

3.5 Mechanical testing process 30

3.5.1 X-Ray diffraction test 30

3.5.2. Scanning Electron Microscope 31

6
 3.5.3 Properties of monel k-500 33

3.5.4 Heat Treatment 34

3.5.5 Machining 35

3.5.6 Standard Inventory Specifications 36

3.5.7 Characteristics of monel k-500 37

3.5.8 Physical properties of monel k-500 38

4. RESULT AND DISCUSSION 39

4.1 Sem Analysis Result 40

4.2 XRD – Test 43

5. CONCLUSION 47

5​.1.1 Future scope of project 47

REFERENCE 48

LIST OF FIGURES

FIGURE.
TITLE PAGE NO.
NO
1.1 Working Principle 15

3.1 Air Compressor Unit 25

3.2 Abrasive Water Jet Cutting Head 26

7
 Schematic diagram of Abrasive Water Jet
3.3 27
Machining.
3.4 Experimental Procedure 29

3.5 X-Ray diffraction setup 31

3.6 Process of scanning electron microscope 32

4.1 SEM analysis results 39

4.2.1 XRD SAMPLE TEST A 43

4.2.2 XRD SAMPLE TEST B 44

4.2.3 XRD SAMPLE TEST C 45

4.2.4 XRD SAMPLE TEST D 46

LIST OF TABLES

1.3.1 Process parameters of AWJM (A) 12

1.3.2 Process parameters of AWJM (B) 13

3.1 chemical composition of Monel K-500 24

8
 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION TO WATER JET

A Water jet cutter is also known as a water jet, is an industrial tool

capable of cutting a wide variety of materials using a very high pressure jet of
water, or a mixture of water and abrasive substance. The term abrasive jet refers
specifically to the use of a mixture of water and abrasive to cut hard materials
such as metals or granite, while the terms of pure water jet and water only
cutting refer to water jet cutting without the use of added abrasives, often used
for softer materials such as wood or rubber. Water jet cutting is often used
during fabrication of machine parts. It is the preferred method when the
materials being cut are sensitive to the high temperatures generated by other
methods. Water jet cutting is used in various industries, including mining and
aerospace, for cutting, shaping and reaming.

1.1. HISTORY OF ABRASIVE WATER JET

The first use of water jets can be traced back over 100 years when they
were originally developed for the use in the mining of gravel and clay deposits
to the blast material from the quarry face. However, the development of water
jet systems, as we know them today, did not truly begin in earnest until the early
1960’s, and it wasn’t until the 1970’s that the usable systems began to appear.
In 1971 the very first commercially usable water jet cutting system was installed
for the alton box board company, a cardboard box manufacturing facility.
Known as the “Fluid Jet Cutting System”, it eliminated that use of commercial
saws and was designed for the contour cutting of furniture packing forms foe
the paper tube division in Jackson, TN ,USA.

9
1.1.1. Abrasive water jet

While cutting with water is possible for soft materials, the addition of an
abrasive turned the water jet into a modern machining tool for all materials.
This began in 1935 when the idea of adding an abrasive to the water stream was
developed by Elmo Smith for the liquid abrasive blasting smith’s design was
further refined by Leslie Tirrell of the Hydroblast corporation in 1937, resulting
in a nozzle design that creates a mix of high pressure water and abrasive foe the
purpose of wet blasting.

The first publication on the modern abrasive water jet (AWJ) cutting was
published by Dr. Mohammed Hashish in the 1982 BHR proceedings showed for
the first time that water jet relatively small amounts of abrasives are capable for
cutting hard materials such as steel and concrete. The march 1984 issue of the
Mechanical engineering magazine showed more details and materials cut with
AWJ such as aluminum, titanium, glass and stone.

A most critical development was creating a durable mixing tube that could
withstand the power of the high pressure AWJ, and it was Boride products
developments of their ROCTEC line of ceramic tungsten carbide composite
tubes that significantly increased the operational life of the AWJ nozzle. Current
work on AWJ nozzles is on micro abrasive water jets so cutting with jets
smaller than 0.015 inches in diameter can be commercialized.

Working with Ingersoll-Rand water jet systems, Michael Dixon implemented

the first production practical means of cutting titanium sheets, an abrasive water
jet system very similar to those in widespread use today. By January, 1985 that
system was being run 24 hours a day producing titanium parts for the B-1B
largely at Rockwell’s North American Aviation facility in New York.

10
1.1.2. Water jet control

As water jet cutting moved into traditional manufacturing shops,

controlling the cutter reliably and accurately was essential. Early water jet
cutting systems adapted traditional systems such as mechanical pantographs and
CNC systems based on John Parson’s 1952 NC milling machine and running
G-code, as accuracy depends on varying the speed of the nozzle as it approaches
corners and details. Creating motion system control to incorporate those
variables became a major innovation for leading water jet manufacture.

1.1.3. Components requires in AWJM

In Abrasive water jet machining is a mechanical based nontraditional

machining process used to cut and machine soft and non metallic materials. It
involves the use of a high velocity water jet smoothly cutting a soft work piece.
In AWJM high velocity of water jet is allowed to strike a given work piece.
During this process its kinetic energy is converted into pressure energy. This
induces a stress on the work piece. When this induced stress is high enough,
unwanted particles of the workpiece are automatically removed. The apparatus
of Abrasive water jet machining consists of the following components:

Reservoir: ​It is used for storing water that is to be used in the machining
operation.
Mixing chamber: ​It is used to mix the abrasive particles into the water. Mixing
the abrasive particles and water is called slurry. This slurry used to machine the
workpiece.
Pumps: ​A pump is a device that moves fluids or sometimes slurries, by
mechanical action. Pumps can be classified into three major groups according to
the method they use to move the fluid: direct lift, displacement and gravity
pumps
11
 It pumps the water from the reservoir. High pressure intensifier pumps
are used to pressurize the water as high as 55000 psi. For the abrasive water jet,
the operating pressure ranges from 31000 to 37000 psi. At this high pressure the
flow rate of the water is reduced greatly.
Intensifier: ​It is connected to the pump, It pressurizes the water acquired from
the pump to a desired level.
Nozzle: ​It renders the pressurized water as a water jet at high velocity. Once the
water is pressurized, it is forced through a sapphire nozzle which is composed
of the natural sapphire stone due to the strength of the stone. The diameter of
the nozzle can be varied depending on the application for which the water jet is
being used. A damaged nozzle leads to poor cohesion of the stream, thereby
reducing the cutting ability greatly. The nozzle typically lasts 100 to 200 hours
before it needs to be replaced.
Catchers: After the cut has been made, the water abrasive material is collected
in a catcher. In a field situation there are still problems catching the waste
material. Often catchers need to be custom designed for a specific job.
1.2. PROCESS PARAMETERS

These process parameters with respect to the 0.76mm constant nozzle diameter.

Table no 1.3.1Process parameters of AWJM (A)

Input Parameter Output

Nozzle
Speed Abrasive
S.No SOD Diameter MRR
Rate size
(Constant)
1 2 90 200 0.76 34.48
2 2 110 400 0.76 37.04
3 2 130 600 0.76 43.30
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 4 2.5 90 400 0.76 35.71
5 2.5 110 600 0.76 37.08
6 2.5 130 200 0.76 34.55
7 3 90 600 0.76 30.32
8 3 110 200 0.76 32.25
9 3 130 400 0.76 34.66
These process parameters with respect to the 1.1 mm constant nozzle
diameter.

Table no 1.3.2 process parameters of AWJM (B)

Input Parameter Output

Speed Nozzle Diameter
S.No. SOD Abrasive size MRR
Rate (Constant)
10 2 90 200 1.1 33.28
11 2 110 400 1.1 34.65
12 2 130 600 1.1 43.47
13 2.5 90 400 1.1 40.00
14 2.5 110 600 1.1 38.46
15 2.5 130 200 1.1 37.06
16 3 90 600 1.1 31.25
17 3 110 200 1.1 35.71
18 3 130 400 1.1 38.46

The following are some of the important process parameters of abrasive jet
machining.

13
Abrasive mass flowrate:​Mass flow rate of the abrasive particles is a major

process parameter that influences the metal removal rate in abrasive jet
machining. Due to this fact, when continuously increasing the abrasive mass
flow rate, Metal removal rate first increases to an optimum value and then
decreases. However, the mixing ratio is kept constant, Meta removal rate
uniformly increases in abrasive mass flow rate.
Stand of distance: ​It is the gap provided between the nozzle tip and the
workpiece. Upon a certain limit , MRR remains constant to some extent and
then decreases. In addition to metal removal rate , stand of distance influences
the shape of diameter of cut.
Gas pressure: gas pressure has a direct impact on MRR. In abrasive jet
machining MRR is directly proportional to gas pressure.
Velocity of abrasive particles: Whenever the velocity of abrasive particles is
increased, the speed at which the abrasive particles hit the workpiece is
increased. Because of this reason, in abrasive jet machining, metal removal rate
increases with the increase of velocity of abrasive particles.
Mixing ratio: ​In this ratio determines the quality of the air-abrasive mixture in
abrasive water jet machining. It is the ratio between the mass flow rate of the
abrasive particles to the mass flow rate of the air. When the mixing ratio is
increased continuously, metal removal rate first increases to some extent and
then decreases.
Abrasive grain size: Size of the particle determines the speed at which metal is
removed. If smooth and fine surface finish is to be obtained, an abrasive particle
with small grain size is used. If the metal is removed rapidly, an abrasive
particle with a large grain size is used.

14
1.3.1 Working principle

It is based on the principle of water erosion. When a high velocity jet of

water strikes the surface, the removal of material takes place. Pure water jet is
used to machine the softer material. But to cut the harder materials, some
abrasive particles mix with the water for machining and it is called AWJM.

Figure no. 1.1

1.3.2 Advantages
Make all sorts of shapes with only one tool.
No heat generated.
Leaves a smooth finish, thus reducing secondary operations.
Modern systems are very easy to learn and safe.
Unlike machining or grinding, cutting does not produce any dust or
particles that are harmful if inhaled.
It can be easily used to produce prototype parts very efficiently

15
1.3.3.Application

Paint removal.

Aerospace industry.

Textile industry.

Pocket milling.

Mining industry.

Leather industry.

Nuclear plant disaster.

1.3.4.Limitations

The material removal rate is low.

The abrasive powder cannot be reused.

High chances of stray cutting. Tapering may occur during drilling.

It is not suited for soft materials because the abrasive may get embedded

in the work material.

Nozzle life is low and short standoff distance causes frequent damage on

the nozzle.

16
1.4 Objective

To study mechanical properties such as hardness and tensile strength.

To study the metallurgical (Scanning Electron Microscopy) properties of AMCs

after Friction Stir Processing.

17
 CHAPTER 2

LITERATURE REVIEW

2.1. Literature survey

Sudhakar., andpravinkubade et al.,(2013)​Found that,materials which

are cut by AWJM steels, Non-ferrous alloys, super alloys. Demand for product
accuracy and surface finish can be solved through AWJM

Shah et al.,(2012)​Revealed that,AWJM Is a non-conventional machining

process where material is removed by impact erosion of high pressure high
velocity of water and entrained high velocity of grit abrasives on a work piece.
Extremely fast set-up and programming, Very low side forces during the
machining. Machine thick plates.

Pravin Kubade et al.,(2016)​Found that,material removal rate[MRR] and

surface roughness [Ra] of Inconel 718. By varying water pressure[WP], traverse
speed[TR] , abrasive flow rate [AFR] and stand of distance[SOD].Water
pressure is the most influencing process parameter for MRR.

Korat and Acharya et al.,(2014)​Explained that,high-velocity jet of water

mixed with abrasive particles based on the principle of erosion of the material.
AWJ has advantages such as high machining versatility, small distortion.
AWJM is widely used in the processing of materials such as titanium, steel,
brass, aluminum stone, Inconel and any kind of glass and composites.

Akshay bharate et al.,(2017) ​The orifice is made of sapphire. When water at

such pressure is issued through a suitable orifice(generally of 0.2 – 0.4mm
dia).which yields a high velocity jet.

Deepak doreswamy et al.,(2015)​Explained that,the effect of abrasive impact

angle on machining of ceramic material was investigated by srinivasu

18
Arunet al.,(2016)​Found that,abrasive particles are mixed in a suitable
proportion, which is forced on a workpiece surface through a nozzle.material
removal occurs due to erosion caused by the impact of abrasive particles on the
work surface. AWJM is especially suitable for machining of brittle material like
glass, ceramics and stones as well as for composites materials and ferrous and
non-ferrous material.

Kovacevic et al.,(2015)​Found that,among these processes, abrasive water jet

machining has offered certain unique capability to machine exotic and
difficult-to-machine materials where conventional machining is often
technically or economically not feasible.

Sreekesh et al.,(2014)​Found that,abrasive water jet machining is a mechanical,

non-conventional machining method in which abrasive particles such as silica
sand, Garnet, Aluminum oxide, silicon carbide etc are entrained in high speed
waterjet to erode materials from the surface of material. About 90% of
machining is done by using garnet as an abrasive particle .In AWJM material
removal takes place by erosion induced by the impact of solids.

Venkataniran jankumar et al.,(2018)​Found that abrasive water jet machining

is an unconventional machining process, in which abrasives are used along with
pressurised water for machining of materials. It is used for cutting, drilling and
cleaning of hard materials. It is capable of cutting ceramics, composites and
rock metals.

Kirankumar et al.,(2018)​Found that,a very thin stream of about 0.004 to 0.010

dia. It shows good mechanical properties even at high temperatures.

DEY et al.,(1993)​Found that,alloy containing a substantial amount of copper

together with small amounts of iron, manganese , aluminum, and titanium, Age
hardening in this alloy is caused by the formation of coherent, ordered (Ni (AL,
TI)) Precipitates.
19
DevAnand et al.,(2014)​Found that the cutting parameters are set to the
predefined levels for all the experiments. Forty six experiments were conducted
in this element named copper iron alloy as per the Box-Behnken design
considered.The machine or the equipment used to cut the copper iron alloy was
the abrasive water jet cutting machine which is equipped with kmt ultrahigh
pressure pump with the designed pressure of 4000.

Paktinat et al.,(2014)​Found that the cooling fluid is a mixture of air and oil in
the form of spray that is sprayed to the machining region periodically. Oil small
droplets that are in micron size are sent directly to the tool tip and as a
consequence cooling and lubricating are done.

Mofizulislam et al.,(2017)​Found that the fabrication of composites for an

application requires a suitable secondary process. Among the various processes
available, AWJM is more appropriate for machining CFRP and UD CFRP with
a woven fabric surface, were selected and machined using AWJM.

Vasanth et al.,(2016) ​Revealed that abrasive flow rate and standoff distance are
the most significant role and determining surface quality. Higher abrasive flow
rate and higher standoff process the higher surface roughness owing to large and
random energy distribution.

Appasmuthu et al.,(2017) ​Observed that water pressure has more significance

on kerf with and metal removal rate rather than the abrasive flow rate and stand
of distance.

Akshayhejjaji et al.,(2017) ​Stated that, jet pressure and transverse speed are
the most crucial factors of metal removal rate and jet pressure is the most
influential factor for surface roughness.

Mayur et al.,(2017) ​Found that, with the help of GRA technique, optimum
response value of MRR is 3.9853 g\min and surface roughness is 2.4658

20
micrometer. This result offers the greatest feature of MRR, SR while
,machining on abrasive water jet machining..,,

Jitendrakumar et al.,(2016) ​Concluded that, the help TOPSIS method that

started that speed and feed are the main parameters that affect surface roughness
of the job.

Kaushalkumar et al.,(2018) ​Found that, as the transverse speed increases, the

kerf taper ratio increases. which increases the traverse speed the smooth cutting
region(SCR) depth of samples decreases.

Niranjan et al.,(2018) ​found that pressure remains the dominant parameter in

deciding the depth of penetration and transverse speed is the most significant
factor for surface roughness measurement.

Satyanaraya et al.,(2014) State that, performance characteristic of AWJM

process. From ANNOVA it is found that water jet pressure has the most
significant effect of kerf width and MRR rather than abrasive flow rate and
stand of distance.

Rajeshram et al.,(2015) ​Concluded that, while ANNOVA analysis step over

and transverse speed play the most significant role achieving high depth of cut,
high step over and high transverse speed leads to lower depth of cut.

Alberdi et al.,(2015) ​Stated that, the most significant factors for the taper angle
with respect to the jet pressure and transverse feed rate, in order to minimize the
taper angle and surface roughness to recommended high pressure and lower
transverse speed.

2.2. Summary

21
AWJM Is a non-conventional machining process where material is removed by

impact erosion of high pressure high velocity of water and entrained high
velocity of grit abrasives on a work piece.

Extremely fast set-up and programming, Very low side forces during the

machining. Machine thick plates.

The cooling fluid is a mixture of air and oil in the form of spray that is sprayed
to machining region periodically
The machine or the equipment used to cut the copper iron alloy was the abrasive
water jet cutting machine which is equipped with a kmt ultrahigh pressure pump
with the designed pressure of 4000.
The cutting parameters are set to the predefined levels for all the experiments.

Among these process, abrasive water jet machining has offered certain unique

capability to machine exotic and difficult-to-machine materials where

conventional,

machining is often technically or economically not feasible

22
 CHAPTER 3
3.1. Flow Chart of methodology

23
3.2. Material Requirements

Monel k-500 is a nickel – copper alloy with age hardening properties

imparted by alloying additions of aluminum and titanium. Its basic composition
is similar to that of monel k-400 but the alloying additions make it age
hardenable under controlled conditions of temperature and time. This alloy can
be delivered in the annealed, stress equalized, hot finished or age- hardened
conditions.the table 3.1 shows that chemical composition of monel k-500..,

Table 3.1.chemical composition of Monel K-500

Element Ni Mn si Fe AL S C cu
Wt. % 63% 1.50% 0.50 2.00% 2.30% 0.010% 0.18% 27.0%
min max max max - max -
3.15% 33.0%

3.3. Experimental Setup

GENERAL DESCRIPTION OF AWJM

The experimental set-up of Abrasive Water Jet Machining consists of a main

cylindrical tank with a hemispherical bottom, a storage tank, an air compressor,
abrasive water jet cutting head and work holding arrangements.
The working tank has provision for slurry inlet and outlet and also for
high-pressure air inlet. The cutting head with a nozzle is mounted on a
stationary worktable. The stand-off-distance is adjusted by the vertical
movement of the cutting head and is measured by the graduatescalefitted to the
cutting head. The cutting head has a provision to accommodate nozzles of
different orifice diameters.

24
3.3.1 The Working Tank

The working tank is a cylindrical tank made up of mild steel. The Bottom
end of the tank is made semi-spherical so that abrasive particles that tend to
settle down are lifted up by the pressure of the compressed air coming out of
small holes drilled on the periphery of a small pipe, which is fitted at the
bottom. A circular lid made up of mild steel is fastened to the top end of the
working tank using bolts and nuts.A pressure gauge is fitted to the working tank
so that pressure inside the tank can be recorded. A pressure relief valve is fitted
at the center of the lid to release excess pressure.It also consists of two control
valves to control the inflow of air and outflow of slurry. A slurry inlet is made
near the top of the tank.
3.3.2 Air Compressor Unit

The air compressor used has a maximum rated capacity of delivering air
at a pressure of 10kgf/cm^2. The compressed air from the air compressor flows
into the slurry tank through a pneumatic pressure hose.

Figure no 3.1
25
3.3.3 Abrasive Water Jet Cutting Head

It consists of a convergent nozzle fitted to a galvanized iron pipe.Since

nozzles are subjected to a great degree of abrasion wear, they are made up of
hard materials such as tungsten carbide, synthetic sapphire(ceramics) to reduce
the wear rate. Nozzles made up of tungsten carbide have an average life of 10 to
20 hours, while nozzles of sapphire lost ab>out300 hours of operation when
used with 27pm abrasive powder.The nozzle materials that are used In the
present experimentation work are EN 31. The AWJ nozzle Inside diameter
varies from 1 to 3mm.Dimensional details of nozzle are shown In Figure 4.1.

Figure 3.2
3.3.4 Work Holding and Cutting Head Holding Arrangement
It consists of base, column, table, clamping an arrangement for holding
the cutting head and a transparent hood as shown In Figure 4.1The work piece
Is held on table with the help of C-clamp. The table can be moved up and down
with the help of a pair of rack & pinion. Andalso the table can be swung about
the column. The abrasive water jet cutting head can be moved vertically up and
down with the help of another pair of rack & pinion, which facilitates the
adjustment of stand-off-distance.A transparent hood Is placed at the machining

26
zone as shown inFigure 4.2. This Is provided to avoid the spilling of slurry
around the machining zone during the machining operation.A collector Is placed
at the bottom of the table to collect the abrasive slurry during machining
operation.

3.3.5 Pressure Hose

A flexible high pressure hose made up of fibre reinforced rubber having

capacity to withstand pressure up to 15kgf/cm^ is made use to transfer abrasive
slurry from abrasive tank to cutting head.

3.3.6. Storage Tank

It is used to store the slurry before passing into the working tank. It is
made up of a mild steel cylinder, sealed at bottom and with a slurry outlet.

Figure 3.3 Schematic diagram of Abrasive Water Jet Machining.

27
3.4 Experimental Procedure

The abrasive is mixed with water in a suitable proportion in the slurry

tank and stirring should be done continuously till all the slurry from the slurry
tank is passed to the working tank. After passing the slurry mixture into the
working tank,compressed air is also being passed into the working tank. This
compressed air pressurizes the slurry mixture and avoids the settlement of
abrasive particles in the slurry. The pressurized sl7 is supplied to the cutting
head through a pressure hose and the nozzle and then is made to impinge on the
work surface.The impact of high-pressure abrasive particles on the work surface
lead to erosion of the work material and thereby the material removal takes
place.Abrasive water jet machining with pressurized slurry is essentially an
erosion process which involves two distinct mechanisms depending upon
whether the eroded material is brittle or ductile in nature.
Ductile erosion is defined as a process in which the abrasive particles
progressively cut the eroded materials, eventually causing volumetric material
removal.
Brittle erosion is described as a cracking process in which the material is
removed by the propagation and intersection of cracks.To begin with the
experiments, initial experimentation was done to choose optimum nozzle
diameter, stand-off-distance, slurry concentration, and abrasive grit size.Initially
nozzle diameters of 1mm, 1.5mm, 2mm, 2.5mm & 3mm were tried to identify
the optimum nozzle diameter with varied parameters. Nozzle diameter of 2mm
was identified to be the appropriate nozzle diameter and hence in the present
investigation nozzle diameter of 2mm only has been used.The
stand-off-distance of 1mm, 2mm, 3mm, 4mm & 5mm were tried to identify the
optimum value with varied parameters. It was observed that 3mm is appropriate
and hence for further experimentation 3mm stand-off-distance has been used.

28
 The slurry concentration of 1:6, 1:8, 1:10, 1:12, &1:14 were tried to
identify the optimum slurry concentration with varied parameters. It was
observed that 1:8slurry concentration is the appropriate slurry concentration and
hence in the present investigation slurry concentration of 1:8 only has been
used.
The abrasive grit sizes of 180, 220, 280, 320, & 400 were tried to identify
the influence of these abrasive grits on material removal. Amongst these,
180abrasive grit sizes had shown highest material removal in comparison with
the other grit sizes. As the other grit sizes were small in dimension & assumed
to behave less sharp edges, to make an effective impact on work material
showed less material removal and hence the abrasive grit size of 180 was being
used as the optimum grit size in the present investigation.
The experiments were conducted by mixing pure water with acetone,
purewater with phosphoric acid, pure water with polymer.

Figure 3.4

29
3.5 Mechanical Testing Process

3.5.1 X-Ray diffraction test

Powder ​x-ray diffraction (XRD) uses x-rays to investigate and quantify

the crystalline nature of materials by measuring the diffraction of x-rays from
the planes of atoms within the material. It is sensitive to both the type of and
relative position of atoms in the material as well as the length scale over which
the crystalline order persists. It can, therefore, be used to measure the crystalline
content of materials; identify the crystalline phases present (including the
quantification of mixtures in favourable cases); determine the spacing between
lattice planes and the length scales over which they persist; and to study
preferential ordering and epitaxial growth of crystallites. In essence it probes
length scales from approximately sub angstroms to a few nm and is sensitive to
ordering over tens of nanometres.

The samples for analysis are typically in the form of finely divided
powders, but diffraction can also be obtained from surfaces, provided they are
relatively flat and not too rough. Moreover the material can be of a vast array of
types, including inorganic, organic, polymers, metals or composites and the
potential applications cover almost all research fields, e.g. metallurgy,
pharmaceuticals, earth sciences and composites, microelectronics and
nanotechnology. Powder XRD can also be applied to study the pseudo
crystalline structure.

30
 Figure 3.5 X-Ray diffraction setup

3.5.2.Scanning Electron Microscope

The SEM instrument is made up of two main components, the electronic

Console and the electron column. The electronic console provides control knobs
and switches that allow for instrument adjustments such as filament current, and
accelerating voltage, focus, magnification, brightness and contrast. The FEI
Quanta 200 is a state of the art electron microscope that uses a computer system
in conjunction with the electronic console making it unnecessary to have a
bulky console that houses control knobs, CRTs, and an image capture device.
All of the primary controls are accessed through the computer system using the
mouse and keyboard. The user need only be familiar with the GUI or software
that controls the instrument rather than control knobs and switches typically
found on older style scanning electron microscopes. The image that is produced
by the SEM is usually viewed on CRTs located on the electronic console but,

31
instead with FEI. Images that are captured can be saved in digital format or
printed directly.

Figure3.6 Process of scanning electron microscope

3.5.3 Properties of monel k-500

Alloy K500 is a precipitation-hardenable nickel-copper alloy which is also

known as Monel K500 (Monel® is Special Metals Corporation’s trademark for

a family of Nickel-Copper alloys). Although Langley Alloys supply Alloy
K500 in all conditions, we predominantly supply material in the hot worked and
precipitation treated condition. Both forms offer the optimum combination of
high strength and ductility across the size range. The increased properties are
obtained by adding aluminium and titanium to the nickel-copper base, and by
heating under controlled conditions so that particles of ‘ϒ’ Ni3 (Ti, Al) are
precipitated through the matrix. The thermal processing used to effect
precipitation is commonly called age hardening or ageing.

32
This alloy provides excellent corrosion resistance in a range of environments

including sea water, hydrofluoric acid, sulphuric acid and alkalis. It has been
found to be resistant to a sour-gas environment and is listed within NACE
MR1075. The combination of very low corrosion rates in high-velocity sea
water and high strength make it well-suited for marine shafts in stagnant or
slow-moving sea water, fouling may occur followed by pitting but this pitting
slows down after a fairly rapid initial attack.

Alloy K500 is refined by Electro Slag Refining (ESR), ensuring the cleanest and

highest quality of material is supplied. This increased alloy purity limits the
likelihood of hard non-metallic inclusion that can increase machining difficulty,
processing times and ultimately part failures. It also has low permeability and is
nonmagnetic to temperatures as low as -150°F (-101°C).

3.5.4 Heat treatment

Annealing is performed both for softening of the matrix after working and for
solutioning of the age-hardening phase. Adequate softening may be achieved
with temperatures as low as 1400-1600°F, but heating at 1800°F for hot-finished
products and 1900°F for cold-drawn products is recommended for optimum
response to subsequent age hardening. Grain growth becomes fairly rapid above
1800°F, and if a fine-grained structure is desired heating time should be kept to
a minimum at these higher temperatures.
For optimum aging response and maximum softness, it is important to obtain an
effective water quench from the heating temperature without delay. A delay in
quenching or a slow quench can result in partial precipitation of the
age-hardening phase and subsequent impairment of the aging response. Addition
of about 2% by volume of alcohol to the water will minimize oxidation and
facilitate pickling.

33
The following age-hardening procedures are recommended for achievement of
maximum properties.

1.Soft material (140-180 Brinell, 75-90 RB). Hold for 16 hrs at 1100 to 1125°F
followed by furnace cooling at the rate of 15 to 25°F per hr to 900°F. Cooling
from 900°F to room temperature may be carried out by furnace or air cooling, or
by quenching, without regard for cooling rate. This procedure is suitable for
as-forged and quenched or annealing forgings, for annealed or hot-rolled rods
and large cold-drawn rods (over 1-1/2" diameter) and for soft -temper wire and
strip.

2. Moderately cold-worked material (175-250 Brinell, 8-25 RB). Hold for 8 hrs
or longer at 1100 to 1125°F, followed by cooling to 900°F at a rate not to
exceed 15 to 25°F per hr. Higher hardnesses can be obtained by holding for as
long as 16 hrs at temperature, particularly if the material has been cold-worked
only slightly. As a general rule, material with an initial hardness of 175-200
Brinell should be held the full 16 hrs. Material close to the top figure of 250
Brinell (25Rc) should attain full hardness in 8 hrs. These procedures are
applicable to cold-drawn rods, haft-hard strips, cold-upset pieces and
intermediate-temper wire.

3. Fully cold-worked material (260-325 Brinell, 25-35 Rc). Hold for 6 hrs or
longer at 980 to 1000°F followed by cooling to 900°F at a rate not exceeding 15
to 25°F per hour. In some instances slightly higher hardnesses may be obtained
(particularly with material near the lower end of the hardness range) by holding
8 to 10 hrs at temperature. This procedure is suitable for spring-temper strips,
spring wire or heavily cold-worked pieces such as small, cold-formed balls.
Cooling may be done in steps of 100°F, holding the furnace 4 to 6 hrs at each
step. For example, procedure 1 could be 16 hrs at 1100°F + 4 to 6hrs at 1000°F
+ 4 to 6 hrs at 900°F. Procedures described under 1,2, and 3, however, will

34
usually give higher properties.
In some instances it may be desired to decrease heat-treating time, either for
cost saving or for obtaining intermediate properties. It is difficult to make
specific recommendations which would cover the full range of possibilities. The
best procedure is to make pilot tests on specimens which duplicate the cross
section of the material to be hardened.

Material which has been heated for any appreciable length of time in the
temperature range 1100°F to time and temperature of exposure. Overaged
material will have lower mechanical properties than properly aged metal, and
the properties cannot be raised by subsequent aging treatments. In order to
strengthen overaged material, it must be solution-annealed (1800-1900°F) to
redissolve the age-hardening constituents, and then re-aged. All benefits of cold
work are lost in annealing. The highest strength obtainable is that corresponding
to the annealed and aged condition.
Material that has been age-hardened to produce maximum hardness will not
show an appreciable change in properties if again heated to or held at any
temperature up to that at which the original heat treatment was carried out.
There may be a small increase in properties if the rate of cooling in the original
heat treatment was too rapid between 1050 and 800°F. If the hardened material
is subsequently heated above 1100°F and then cooled, there will be a decrease
in properties. Hardened Monel alloy K-500 has been subjected to long
continued heating at 800°F. A further slow aging occurred during the first
month of exposure, but continued heating caused no further significant change
in properties.

3.5.5 Machinin​g
Heavy machining of alloy K-500 is best accomplished when the material is in
the annealed condition or hot-worked and quenched condition. Age-hardened
material, however, can be finish-machined to close tolerances and fine finished.

35
 The recommended practice, therefore, is to machine slightly oversize,
age-harden, then finish to size. During aging, a slight permanent contraction
(about 0.0002 in/in) takes place, but little warpage occurs because of the low
temperatures and slow cooling rates involved.

3.5.6 Standard Inventory Specifications

● QQ-N-286 - Form 1
● UNS N05500
3.5.7 Characteristics of Alloy K500:

● Excellent corrosion resistance in an extensive range of natural and Chemical

environments
● Excellent resistance to chloride-ion stress-corrosion cracking
● Very high strength and hardness
After age-hardening Monel® K500 alloy has:

● Approximately 2 to 3 times higher mechanical properties than Nickel-copper

Monel © 400
● High tensile properties up to about 650°C (1200°F)
● Good fatigue and corrosion fatigue resistance
● Low permeability; non-magnetic down to -135°C (-210°F)
Metallurgical Structure

● Monel® K-500 alloy has a face-centered cubic structure. In the

age-hardened Condition a Ni3Al phase is formed with similar structure.
Inventory Size Range

● K500 Round Bar is supplied in : 0.500" - 1.750"

Please contact us for more details.

The technical data provided is for information only and not for design purposes.
It is not warranted or guaranteed.

36
 * MONEL is a trademark of the Special Metals Corporation group of
companies.

Element Percent By Weight

Monel K500
Ni Nickel 63% min
Mn Manganese 1.50% max
Si Silicon 0.50% max
Fe Iron 2.00% max
Al Aluminum 2.30% - 3.15%
S Sulfur 0.010% max
C Carbon 0.18% max
Cu Copper 27.0% - 33.0%
Alloy K500 Chemical Composition

Common Applications

Monel® K-500 alloy finds wide applications in the marine, chemical,

petrochemical and shipbuilding industries. Typical applications include:

● Valve seals, pump sleeves and wear rings in marine environments - high
strength and resistance to seawater

● Pump shafts for fire-fighting pumps - high strength (resulting in smaller

diameter shafts) and resistance to flowing seawater

● Propeller shafts - high strength (resulting in smaller diameter shafts and thus
smaller bearings) and resistance to seawater
● Fasteners e.g. bolts, used in marine atmospheres and tidal waters - resistance to
chloride - containing environments
● Doctor blades and scrapers
● Towing cable armoring - high strength, non-magnetic properties and resistance
to seawater
● Springs - resistance to a variety of corrosive media

37
● Oil well drilling equipment such as non-magnetic drill collars, valves and
instrumentation sleeves - resistance to chloride-containing media and sour gas
environments

● Aviation instrument components - non-magnetic properties

3.5.8.Physical Properties and Corrosion Resistance

● In general the corrosion resistance of Monel® K-500 alloy is similar to that of
Monel®400. Excellent resistance is shown to a wide range of media from pure
water to mineral acids, salts and alkalis. This alloy is virtually immune
to Chloride-ion stress corrosion cracking. In the aged condition, the grade may
be susceptible to stress-corrosion cracking in moist, aerated hydrofluoric

● Acid vapor at stresses near the yield strength. In high velocity seawater and in
marine atmospheres, good resistance is shown but, in slow moving or stagnant
seawater, pitting may occur. Monel K500 also shows good resistance in
sour-gas environments.

Mechanical Properties

● The following properties are applicable to Monel® K-500 alloy in the stated
conditions and forms as well as the indicated size range (according to
QQ-N-286). Specified properties of material outside these ranges are subject to
special inquiry.

Tensile Data

38
 CHAPTER 4

RESULT AND DISCUSSION

4.1. SEM analysis results

The below four images are taken from the same piece of material but only
change the parameters which are used in the SEM test. i.e.,

(A) (B)

(C) (D)
Figure4.1.1 A,B,C,D
Nozzle dia ;1.1mm
MRR ; Maximum
Sample no ;12
Description: ​This is the SEM analysis for 1.1mm nozzle with maximum SOD
and minimum speed rate here the crack formation is more and deviations are
igh.

39
 (A) (B)

(C) (D)

(C) (D)

Figure 4.1.2 A,B,C,D

Nozzle dia: 1.1mm

MRR: maximum

Sample no ; 16

Description: ​This is the SEM analysis for 1.1mm nozzle with minimum SOD
and maximum speed rate here the crack formation is less and deviations are
low.

Nozzle dia: 0.76mm

MRR ; Maximum

Sample no; 03

40
 (A) (B)

(C) (D)

Figure 4.1.3A, B, C, D

Description: This is the SEM analysis for 0.76mm nozzle with minimum SOD
and maximum speed rate. The crack formation is high and the deformations are
more

Nozzle dia: 1.1mm

MRR:minimum
Sample no:07

41
 (A) (B)

(C)(D)

Figure 4.1.4 A, B, C,D

Description: ​This is the SEM analysis for 0.76mm nozzle with maximum SOD
and minimum speed rate. The crack formation is little low when compared to
previous analysis and the deformation is medium.

4.2 XRD-TEST

Nozzle dia: 1.1mm

MRR: minimum
Sample no: 16

42
 Figure4.2.1 XRD Test sample(A)
Nozzle dia: 1.1mm
MRR: maximum
Sample no: 12

43
 Figure4.2.2XRDTestsample(B)

Nozzle dia: 0.76mm

MRR: maximum
Sample no: 03

44
 Figure4.2.3 XRD Test sample(C)

Nozzle dia: 0.76mm

MRR: minimum

45
Sample no: 07

Figure4.3.4 XRD Test sample(D)

46
 CHAPTER 5

CONCLUSION

The influence of input parameters on Material Removal Rate(MRR) and surface

roughness in AWJM of Monel K-500 was presented. It was observed that the
Material Removal Rate is high in nozzles with higher diameter with minimum
standoff distance and maximum speed rate from SEM Test it is cleared that for
higher material removal rate the surface cracks are less and in lower Material
removal rate the surface cracks are more. Lesser the standoff distance more the
material removal rate and vice versa Nozzle diameter, standoff distance and
speed rate are the dominant parameters while deciding material removal rate No
fire hazards and ignition of chips where observed during cutting. Overall it can
be concluded that AWJM is the viable risk free technology for processing.

5.1.1 FUTURE SCOPE OF THE PROJECT

The Characteristics Process Parameters in AWJM are XRD,SEM, MRR. These

parameters will be analysed using Orthogonal Array Parameter Design and then
with different input process parameters corresponding to the different process
parameters attaining higher machining efficiency by acquiring a higher Cutting
Speed, MRR then the results are predicted and then compared with the actual
results. Therefore by the predicted results any machines specifications could be
changed easily for the users desires.

47
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49
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50