Casting and forming of nano hard aluminum oxide film on the modified 6061 Al alloys for NARSSCube satellite structure

Abstract

This research focuses on metal additive manufacturing (MAM) and examines the impact of alloying materials on the anodized produced layer, placing particular emphasis on its use in the construction of the NARSSCube satellite's frame. To enhance the AA6061-T6 Al alloy's mechanical and physical qualities, Mg, Mn, Si, and Cr concentrations were changed. As a result, seven different alloys were cast, and their mechanical and physical characteristics were assessed. It is essential to anodize aluminum alloy AA6061-T6 in H2SO4 solution in order to produce an aluminum oxide film (AOF) that increases corrosion and wear resistance. This study looked into how the chemical composition of the AA6061-T6 aluminum alloy, particularly Mn, affected the production of the nano hard aluminum oxide film (NHAOF) at fixed anodization conditions of 4 °C and 20 V. Calculations were made on the thickness variation at various operating voltages throughout the anodizing process. The differences in NHAOF thickness were investigated using optical and scanning electron microscopes. Finally, anodizing the alloy with low Mn Wt.% (0.005 wt% S6) at 4 °C, 20 V, and a duration period of 120 min in a 10 % H2SO4 solution produced the oxide coating with the highest thickness (53 μm) and high-performance attributes. An increase in the hardness ratio, resistance to plastic indentation, and elastic recovery are all results of the surface's harder (5.86 Gpa) than the un-anodized sample's (1.18 Gpa) surface.