During micromachining the accuracy of micro-feature is always a major concern. Using laser beam micro-milling (LBMM) the produced size is generally larger than the input design size. Another important drawback of LBMM is the formation of melt spatter around the feature geometry. The spatter adheres within the premises of the machined feature and influences the machining results, especially the geometry of previously machined features by adhering inside or around the feature. Determination of spatter size is very important when the objective is to produce an array of micro-features such as micro-channels. Thus, the minimum distance between two consecutive micro-features is necessary to be known in order to achieve safe geometry for which the size of spatter plays a significant role. The knowledge of spatter scattering and pre-calculated distance of dispersing spatter could certainly assist the machinist in estimating the safe distance between adjacent micro-channels. In this study, the micro-channel size and average spatter size are studied during the micro-milling of Ti-6AL-4V by Nd:YAG laser beam machining (LBM). Response surface methodology (RSM) has been utilized to plan a set of experiments and mathematical models are proposed to pre-calculate the channel size and spatter dispersion. Finally, the models are validated through confirmatory tests showing an acceptable range of error.

Risk appetite is a crucial component that plays a key role in the decision-making process of project risk management. Despite rising scholarly interest in project risk management, risk appetite has received little attention thus far. A well-defined risk appetite ensures that all decisions taken throughout the course of a project are consistent with an organization’s ultimate strategic aim. This research aims to identify the factors affecting the risk appetite of megaproject selection in the construction sector. The study adds to the knowledge of risk appetite in mega construction project selection and qualitatively examines the factors affecting risk appetite. Exploratory research design is used to identify these factors. The factors are identified using semi-structured interviews of 30 practitioners from the top and middle management working on mega construction projects. Thematic analysis was performed using NVIVO academic software. The most highlighted factors are financial attributes, board of directors’ agility, political factors, project location and demographics. The proposed conceptual framework identifies the factors affecting the risk appetite of mega construction project selection. These factors may be utilized as a starting point by construction project organizations to evaluate the risk appetite of a mega construction project. Risk appetite-based project selection will decrease chances of failures, delays, and cost overruns in mega-projects. These factors can be used by researchers as a rationale for developing predictive or descriptive models of project selection based on risk appetite.

Squeeze overcasting has emerged as an attractive option for casting of Al alloys in terms of mechanical properties. The attainment of the desired magnitude of these properties is challenging in overcasting due to the involvement of a number of process parameters. In this study, the effects of insert preheat temperature (T_I) along with pouring temperature (T_P), and squeeze pressure (P_S) on the mechanical properties of squeeze overcast AA2026-AA2026 joint were investigated. Experimental results revealed that the squeeze pressure is the most prominent factor affecting the ultimate tensile strength (UTS) while micro-hardness (MH) is significantly influenced by the pouring temperature. Maximum values of UTS (315 MPa) and MH (130 HV) were achieved at aP_Sof 120 MPa,T_Pof 780 °C, andT_Iof 250 °C. Energy dispersive X-ray (EDX) analysis witnessed thatT_Ihas also a significant role in determining the quality of bond between the substrate and the melt. Scanning electron microscopy (SEM) depicts that the morphology of the fractured surface has a sound influence on both selected responses. Both the strength and hardness are noticed better if the fractured surface possesses the flat-faced morphology. Furthermore, an empirical regression model was developed using response surface methodology (RSM) design and validated through eight confirmatory experiments. RSM integrated multi-objective optimization genetic algorithm (MO-GA) was deployed to optimize the UTS and MH. The comparative results obtained from RSM and MO-GA demonstrated that the deviation in experimental and predicted values is less than 5%.

Among the family of carbides, tungsten carbide (WC) and its variants have extensive use in numerous applications including cutting tools, dies, and many wear resistant parts. Such applications need machining of WC, which is famously considered as challenging due to high tool wear mainly in traditional machining. Sinking electric discharge machining (EDM) can be considered as a suitable alternate but the low machining rate of EDM, with conventional tool design, poses limitations. In this research, the conventional tool design is modified by providing relief angles to the tool electrodes. The relief-angled tool electrodes are first time introduced in this research to machine through holes. The role of the relief angle during EDM has been investigated in terms of six response characteristics, i.e., machining time, hole taper angle, radial overcut at the hole entrance, radial undercut at the hole exit, longitudinal tool wear, and roughness of inside hole surfaces. The performance of the relief-angled electrodes is found to be significantly better than the performance of conventional cylindrical tool. In addition to improvements in other responses, a 49% reduction in the machining time has been realized by the use of relief-angled electrode indicating a worthwhile contribution in the field of electric discharge machining.